IR 05000458/1989023
| ML20247R433 | |
| Person / Time | |
|---|---|
| Site: | River Bend  |
| Issue date: | 05/25/1989 |
| From: | Boardman J, Stetka T NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20247R427 | List: |
| References | |
| 50-458-89-23, IEIN-86-053, IEIN-86-53, NUDOCS 8906070229 | |
| Download: ML20247R433 (10) | |
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APPENDIX U.S. NUCLEAR REGULATORY COMMISSION
REGION IV
NRC Inspection Report:
50-458/89-23 Operating License:
NPF-47 Docket:
50-458 Licensee: Gulf States ~ Utilities Company (GSU)
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P.O. Box 220 St. Francisville, LA 70775 Facility Name: River Bend Station (RBS)
Inspection At:
RBS, St. Francisville, LA Inspection Conducted: May 1-5, 1989
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Inspector:
f/1 fl J. R.
drdman, Reactor Inspector, Plant Date Syst Section, Division of Reactor Safety Approved:
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4M24Ae N2MA9
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F.~ 5tetka, Chief Plants Systems Section Da te '
Division of Reactor Safety Inspection Summary Inspection Conducted May 1-5, 1989 (Report 50-458/89-23)
Areas Inspected:
Routine, announced inspection of the RBS programs for station design changes and modifications, and for installation of Raychem electrical splices.
Results:
In the area of the licensee's program for station design changes and modifications, weaknesses were noted in the licensee's closure of modification packages after work completion, and in the incorporation of modifications in the Updated Safety Analysis Report (USAR). Additionally, certain modification packages did not contain all needed documentation to evaluate the modification.
In the area of installation of Raychem electrical splices, the licensee's p
program appears to be adequate.
No violations or deviations were identified.
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sy DETAILS P
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Persons Contacted 1.
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GSU
- T..F. Plunkett. Plant Manager.
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- M. F. Sankovich, Manager,' Engineering Departments
- T. L.s Crouse Manager, Quality Assurance (QA):
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- K. - F.; Suhrke, Manager, Project Management
- J.- E. Booker, Manager, River Bend Oversight
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-*L. - A. England,. Director; Licensing
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- W. H. Odell, Manager, Administration
- J.: W. Cook, Environment ~ Analyst -' Licensing
- D.: R. Derbonne, Assistant Plant Manager, Maintenance
- J. P. Shippert, Assistant' Plant Manager, Operations 1-
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- G. K.- Henry, Director.- Quality Operations
- I.'M. Malik Supervisor Quality Systems
- C.'L. Miller, Senior-Compliance Analyst
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{ *W. J. llountain.' Senior QA Engineer
- C. A. Rohrmann; Training System Coordinator
- C. Mernigas Project. Engineering Coordinator.
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D. Thomas, Supervisor, Engineering Administration
A.1Soni, Supervisor Equipment Qualifications and Specifications J. Langley,: Supervisor, Nuclear Steam Systems Design-
'J.. Mead, Supervisor, Electrical and Special Projects -
T. Davey, Senior Instrumentation and Control Engineer
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J. Amburgey, Senior Nuclear Engineer.
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J.. Thompson, Senior Nuclear Engineer B. Fichtenkort,. Senior Mechanical Engineer..
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D. Sandlin, Construction Engineer,~ Instrumentation B. Hey, Nuclear Engineer R. Cole, Senior Systems Engineer
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A. Bysfield,' Control Systems Engineer
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V. Bacanskas, Senior Area Coordinator, Equipment Qualification
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Cajun Electric Cooperative'.
- W. L. Curran, Site Representative NRC
- D. D. Chamberlain, Section Chief, Region IV
- E. J. Ford, Senior ~ Resident Inspector
- W. B. Jones, Resident Inspector
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- Denotes attendance at exit interview conducted on May 5,1989.
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Design, Design Changes, and Modifketions (37700)
The NRC inspector reviewed the licensee's program for design changes and modifications, change control for instrument setpoints, and control of temporary electrical and mechanical ' jumpers. To determine program effectiveness, the NFC inspector reviewed the licensee's procedures and modification requests (MRs) listed below. The listed MRs we m selected as being significant to plant operational safety and.were reviewed for the l
following attributes as appropriate:
Control'and implementation of the design process by approved
procedures;
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Formal design verification of changes;<
The effect of selected design' changes on operational safety;
Functional testing for operability;
Review and approval.in accordance with technical specifications; and
Procedural controls for temporary modifications.
- The procedures reviewed included the following:
Quality Assurance Directive (QAD)-3, Revision 5, " Design Control,"
approved October 14, 1987.
QAD-17, Revision 4 " Quality Assurance Records," effective August 6
1986.
River Bend Nuclear Procedure (RBNP)-010, Revision 3 " Design and
Modification Control," effective January 13, 1987.
Quality Assurance Instruction (QAI)-2.6, Revision 2, "QA Review of
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Design Changes and Plant Modifications," effective January 1,1989.
Engineering (ENG)-3-006, Revisinn 5 (including Interim Procedure
Change (IPC) 3-006-5-3, " River Bend Station Design and Modification Request Control Plan," effective April 7,1989.
ENG-3-004, Revision 0, " Safety and Environmental Evaluations,"
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including IPC-3-004-0-1, effective November 3, 1987.
ENG-3-007, Revision 1 Instructions and Requirements for Use of the
River Bend Q-List," effective November 15, 1988.
ENG-3-017, Revision 0, " System / Equipment Designation," effective
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February 15, 1989.
Engineering Department Procedure (EDP)-AA-20. Revision 7
" Engineering Calculations," dated July 25, 1988.
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EDP-AA-21 Revision 3,, " Control Room Document. Redline and Review
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Process," dated March 23,'1989.
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EDP-AA-22, Revision 1. " Design Activities for Engineering.Prograrr,s,
Droductior.' Draings and Vendor Drawing Revisions," dated July '18,.,
,1988.
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EDP-AA-23, Revision 0, "Beaunont Drawing and' Change Document -
Interface," dated June 9, 1987.
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EDP-AA-24, Revision 0, " Preparation and Revision of Piping and
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Instrumentation Diagrams (P&ID's)," dated July 28, 1987.
EDP-AA-26, Revision 1. " Document Change Notices," dated March 23,
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Nucle'ar-Plant Engineering (NuPE)-AA-40. Revision 2, " Preparation of
Equipment Specifications and. Review of Bids," dated April 22, 1986.
EDP-AA-55, Revision l','" Design Walkdowns," dated March 9, 1987.
EDP-AA-58,' Revision 1. " Design Verification," dated March 10. 1988.
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EDP-AA-59,.Revisici 1, " Tracking, Distributing, anct Incorporating,
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Design Change Documents,"' dated March 11, 1988.
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NuPE-AA-62. Revision 2. " Training Requirements for Preparers and Approvers'of Unreviewed Safety / Environmental Question Determinations," dated November 18, 1985.
NuPE-AA-72 Revision 2. " Quality Classification of Items and '
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Services," dated July 30, 1986.
EDP-AA-74, Revision 1. " Computer Program Qualification for Design
Calculations," dated, August 20, 1987.
EDP-EE-11, Revision 0, "Contrcl and Maintenance of Instrumentation
Colorbanding," dated April 3,1989.
EDP-EE-12, Revision 0, "Setpoint Change Cont ol," dated Ncvember 14,
1988.
EDP-E0-10, Revision 1,' " Control and Maintenance of t% F,ver Bend
Q-List," dated Octcber 6, 1988.
General Maintenance Procedure (GMP)-0042, Revision 7. " Circuit
Testing and lifted Leads and Jumpers," effective April 18, 1989.
'From approximately 4480 MRs initially reviewed. the NRC inspector selected
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a sample of'56 safety-related MRs based upon their apparent affect on
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These MR's are discussed below and were closed except as noted.
MR 88-0118 - This MK revised electricai installations to separate
signal grounds from power grounds to prevent spurious reactor trips resulting from trips of Rosemount transmitters. Such events were documented in Condition Reports (CRs) 88-0043 and 0052. CR 88-0043 identifies six similar CRs dating back to 1986. The MR appeared to be te '...ically acceptable. Work was completed on this MR, but it was not closed.
Discussions with the licensee's engineering organization identified
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that the CR 88-0043 was still open for determination of generic corrective action.
Further discussions with the licensee's engineering personnel determined that the cross-connection of the signal and power grounds violated the RBS design basis as set.forth in General Electric Specification 22A2736. Revision 8. Sheet 35, Section 4.12.2.8.
Generic action on this problem will be included in the licensee's closure of CR 88-0043.
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Inspector Followup Item (458/8923-01): Review the licensee's generic.
corrective action for elimination of common grounds for instrumentation signals.
MR 85-0001 - This was the first MR issued by the licensee and is
still open. The MR deals with design changes to increase the keepwarm temperature of the standby diesel generator jacket water.
The scope of the MR had changed several times. The NRC inspector, based on documents contained in the MR package and in discussions with licensee engineering, determined that failure to complete this MR promptly did not result in an operational safety concern. Work was completed, but the MR was not closed.
MR 88-0054 - This MR approved an alternate gasket material for the
water jacket of the standby diesel generators. The documentation in the design change package supported the use of the alternate material.
MR 87-0110 - This MR was issued to determine a replacement grease for
use in the planetary gears of the high pressure core spray (HPCS)
system diesel generator air start rator. Subsequently, the component manufacturer identified the grease specified by part number in the technical manual (Ingersoll-Rand Lubricant #28) by its conunercial designation (Beacon 325) obviating the need for the modification request.
MRs 86-1726 and 87-310 - These MRs dealt with alternate methods of
ascertaining the water level in the standby diesel generator jacket water standpipe. The MRs stated that the normal method was difficult to read. MR 86-1726 proposed the use of a tygon tube attached to a valved (normally closed) open-ended line. The valve would only be
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opened to take a reading of water level. MR 87-310 provided for a L
permanent sight glass, but has been cancelled.
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MR 86-0456 - This modification rendered inoperative the subsection of
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the Electro-hydraulic Control (EHC) system which controls reactor power as a function of required electrical load. Use of this subsystem is~ prohibited. Such use could have permitted an unlicensed person,in-
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the remote load control system to have.de facto control of reactor power; however subsequent' review indicated that such operation was y
b" not possible. No work had been performed on this MR.
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MR 85-0700. This 4 year old MR was still open. The basis for this
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- MR was identified as an improperly sized orifice in the air supply to the lube oil sump level indicators for the standby diesel generators.
This MR was to replace the oversized orifices with smaller orifices, or with a constant pressure regulator..The basis indicated that the oversized orifice resulted in oil level readings " pegging.high" unless the isolation valves were throttled.
It further indicated that these valves ~were not designed for.this type of throttling.
Subsequent discussions with the licensee's engineering personnel indicated that the valves provided adequate throttling, and that the modification'would be accomplished. The licensee further stated that the valve position adjustment was visually verified as providing the proper reading of sump lube oil level.
MR 88-150 - This MR covered the installation of additional structural braces on the hydraulic control units (HCOs) installed in the control rod drive system (CRDS).
Initial review of documentation in the MR package indicated that the installation of these braces was a condition of the plant operating license. Subsequent documentation-indicated that this requirement recently had been rescinded by NRR.
This MR will be cancelled.
MR 85-0414 - This MR was written in response to notification from the
Limitorque corporation of the potential for failure of the worm shaft gear on size 2 actuators of types'SB, SMB, and SBD. This problem was first identified at the Calloway and Wolf Creek nuclear plants.
Limitorque notified the NRC by letter dated August 13, 1985. Based on subsequent inspections of the four applicable actuators at RBS and the technical rationale of the Limitorque letter, the licensee's e
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engineering personnel determined that no modification of the installed actuators was required. This MR was cancelled.
MR 88-0007 - This MR dealt with a modification to prevent spurious
downshifting of the reactor recirculation pumps.- Though these pumps are not safety-related. they perform safety-related functions, such as the Anticipated Transient Without Scram (ATWS) response. The NRC inspector reviewed this modification and its basis to determine if there were identifiable implications for operational safety; none
.were identified.
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r MR 88-0339 - This MR dealt with resetting the time-current relay
curve checkpoints for two trip devices in the 480 volt safety-related electrical distribution system from 120 and 240 volts to 240 and 480 volts to permit required trip times at specified ampacity values.
MR 87-0805 - This MR dealt with correcting a reported problem of
cable separation of safety-related and nonsafety-related power cables. Further review of documentation indicated that the original condition did not exist. The reported violation was a nonsafety conduit for which the cable had been deleted. This MR was cancelled.
MR 87-0367 - This MR dealt with certf fication of replacement parts
for safety-related Crane-Deming pumps which were purchased to the requirements of the ASME Class III quality assurance program.
Discussions with the licensee's engineering personnel indicated that these parts only required a 10 CFR 50, Appendix B quality program; the ASME program was specified as a convenience. The licensee's personnel indicated that the parts were acceptable based on certified material test reports supplied with the parts.
MR 85-1099 - This MR dealt with the incorrect termination of the
backup scram valves. Discussions with the licensee's engineering personnel indicated that the problem was that a certain drawing was incorrectly revised, but that the terminations were correct. This MR showed work completed on April 29, 1986, but the MR had not been closed at the time of this inspection.
MR 86-1667 - This MR dealt with correction of reported excessive
overheating of a safety-related inverter. The MR stated that there was incorrect clearance around the air intake and exhaust. This MR was subsequently cancelled without action. Documentation and discussions with the licensee's engineering personnel indicated that General Electric (GE) had performed an evaluation of this condition.
GE's findings were that the increase in air flow would be of little or no benefit, and that there was no apparent identified problem.
Based on this determination, the licensee cancelled the MR.
MR 86-1452 - This MR dealt with a reported problem with a differential pressure instrument in the HPCS system being " pegged high" because one side was connected downstream of a check valve which was a boundary between high and low pressure. The high differential pressure caused the instrument to peg high. The MR was to relocate the instrument connection upstream of the check valve.
This MR had been cancelled. The licensee's engineering personnel indicated that cancellation was based on the following factors:
The instrument and instrument lines were designed for the higher
pressure,
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The instrument was used in connection with the HPCS " keep fill"
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pump surveillance.
During this surveillance the instrument measures pump differential pressure and operates as designed.
The instrument root valves are administratively closed to
prevent the high differential pressure when the. instrument is not in use.
During the surveillance, additional temporary differential
pressure gauges are connected that are redundant to this instrument.
Review of the Licensee's Last Audit of Design Control The NRC inspector reviewed the licensee's last audit of the RBS design control program. This audit was No. 88-12-I-DCON and was performed November 17, 1988, through January 20, 1989. The report of this audit, contained 14 Quality Assurance Finding dated February)17, 1989, Reports (QAFRs requiring responses, 9 condition reports requiring evaluation,'and 11 concerns, 6 of which required responses. Several of these findir.gs could have safety significance, either specifically or generically. An example was the reported Control Room HVAC dampers that failed closed on loss of air. The NRC inspector identified no licensee audit findings that appeared to affect plant operational safety during the refueling outage, and responses to the findings were required prior to plant startup. One specific finding in the audit that was also found by the NRC inspector was lengthy delays between work completion and closure of the modification packages. The NRC inspector identified delays in excess of 36 months. Also identified in the licensee's audit, was that the licensee is adding modifications to the USAR based on closure of the modification package and not on the installation of the modification in the plant. The USAR is supposed to reflect the condition of the plant.
The licensee was working on-the corrective action to resolve this self-identified problem.
Another weakness, identified by the NRC inspector, was that all documentation needed to evaluate modifications was not contained in certain modification packages. The missing documentation was that required to verify the design changes and to evaluate the effect of the changes on pla9t operational safety.
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Inspector Followup Item (458/8923-02): Review the licensee's corrective actions relating to NRC review of design controls that were identified in 0A Audit 88-12-I-DCON.
Summa ry Though there were weaknesses in the licensee's program for design changes and modifications, such as those identified in the licensee's audit and above, the program was adequate to support plant operational safety.
No violations or deviations were identified.
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Review of the Licensee's Procram for the Installation of Raychem Heat Shrinkable Tubing Splices Based on Temporary Instruction (T/I) 2500/17
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The NRC inspector began a review of the. licensee's program for installation of Raychem heat shrinkable tubing based upon Ni-i, T/I 2500/17..
I Background l
NRC Information Notice 86-53 was issued on June 26, 1986. This notice
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dealt with potentially generic problems with.the installation of heat L
shrinkable splices for electrical terminations. Specific concerns were with installed Raychem splices. T/I 2500/17.was issued September 22, 1986, to provide guidance for regional review of the licensees'7 programs for installation of Raychem splices.
NRC Inspection Report 50-458/88-03, Section 2.b.(5)(g), stated that the licensee had identified on January 7,'1986, potentially nonconforming.
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.Raychem splices in Condition Report (CR)86-035. This CR was initiated to
. document an engineering review of all splices made by RBS since initial-
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installations. ' Included in this review was the review of Raychem splices'.
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At the time of that inspection, evaluation of this CR was not complete.
During the present inspection, the licensee stated that evaluation of the CR would be complete by the end of the present outage.
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Inspection to T/I 2500/17 Inspection performed to T/I 2500/17 indicated the following:
Documentation of specific splices is contained in the specific
applicable initial installation, maintenance work: order, or n
documentation package.
Bulk splicing material was used for making splices. The licensee had
no specific instructions for determination.of splicing components and
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sizing.
The licensee had no documented qualification requirements for
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installation and inspection personnel, however evidence of'such qualification existed.
The licensee had no documented training for installation'and
inspection personnel, however evidence of such training existed.
Summary The licensee's program for installation of Raychem splices' appears to be adequate. The licensee is conducting a thorough review of the issues identified in CR 86-035.
During this inspection, there was no evidence of plant operability issues relating to this CR. This TI will remain open pending NRC review of the CR 86-035 evaluation and visual examination of selected installed Raychem splices by the NRC.
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Exit In't'erview-
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The NRC inspector met'with the licensee representatives denoted in:
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paragraph '1 on May 5,1989. and:sumarized 'the inspection scope and-findings.. No information was presented to the NRC inspector that was
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identified by.the licensee as; proprietary.
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