ML19309D891
| ML19309D891 | |
| Person / Time | |
|---|---|
| Site: | Arkansas Nuclear  |
| Issue date: | 06/01/1973 |
| From: | Brownlee V, Crossman W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML19309D855 | List: |
| References | |
| 50-313-73-06, 50-313-73-6, NUDOCS 8004110726 | |
| Download: ML19309D891 (11) | |
See also: IR 05000313/1973006
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UNITED STATES
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ATOMIC ENERGY COMMISSION
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DIRECTORATE OF REGULATORY OPERATIONS
REGION 11 - Suet E 818
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RO Inspection Report No. 50-313/73-6.
Licensee: Arkansas Power and Light Company
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Sixth and Pine Streets
Pine Bluff, Arkansas
71601
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Facility Name:
Arkansas Nuclear One, Unit 1
Docket No.:
50-313
License No.:
CPPR-57
Category:
A3/B1
Location: Russellville, Arkansas
Type of Licensee: B&W, PWR-2568 Mwt, 880 Mwe
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Type of Inspection: Routine, Unannounced
Dates of Inspection: May 9-11, 1973
Dates of Previous Inspection: March 6-9, 1973, and March 20-21, 1973
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Principal Inspector:
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V. L. Brownlee, Reactor inspector
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Facilities Section
Facilities Construction Branch
Accompanying Inspectors: None
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Other Accompanying Personnel: None
Reviewed By:
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W. A. Crossman, Senior Inspector
Facilities Section
Facilities Construction Branch
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R0 Report No. 50-313/73-6
SIDefARY OF FINDINGS
I.
Enfore.ement Action
A.
Violations
,,
Certain items appear to be in violation of 10 CFR 50,
Appendix B, " Quality Assurance Criteria for Nuclear Power
Plants," as indicated below:
73-6-Al Lack of Documentation and Effecting Followup of Corrective
Action Regarding Possible Nonconforming Mate-ials, Parts or
Components
Contrary to Criteria XV and XVI, the inspection revealed
that AP&L's program for handling of significant construction
deficiencies failed to document and effect followup evalua-
tion of an apparent significant construction deficiency re-
garding the control rod drive trip breaker undervoltage trip
assembly problem identified at the Oconee nuclear facility.
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(Details I, paragraph 4)
73-6-A2 Documentation of Nonconforming Materials, Parts or Components
Contrary to Criterion XV, the inspection revealed that AP&L's
constructor, Bechtel, has been lax in implementing in a timely
manner nonconformance reports for the purpose of reporting,
controlling, processing and documenting resolution of noncon-
formances identified during inspection. This was evidenced
by the several months sr in between identifying the mechanical
,
interlock problems associated with the Allis-Chalmers motor
control centers and initiating the nonconformance report.
(Details I, paragraph 5)
B.
Safety Items
None
II.
Licensee Action on Previously Identified Enforcement Matters
A.
Violations
None
B.
Safety Items
None
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III. New Unresolved Items
None
IV.
Status of Previously Reported Unresolved Items
72-4/2 Cable Routing (Region II Letter, July 27, 1972, Item 2)
The routing of cables under the control room removable
floor may not meer safeguards and reactor protection systems
separations and loading criteria.
It is our understanding
that the licensee will evaluate this item and corrective
measures will be initiated as may become necessary. This
item remains open.
72-4/3 Cable Routing (Region II Letter, July 27, 1972, Item 2)
The separation of safety channel wiring inside the B&W
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supplied panels may not meet the requirements of the
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safeguarG1 and reactor protection systems separations
and loading requirements. It is our underscanding that
the licensee will evaluate this item and corrective
meascres will be initiated as may become necessary.
This item remains open.
72-4/4 Control Rod Drive Motor Tube Defect Analysis (Region II
Letter, July 27, 1972, Item 3)
Upon arrival of documentation onsite, AP&L will audit the
NDT records to verify that tubes meet acceptance criteria
of BAW 10047, Rev. 1, and identify physical location of
installed minimum wall tubes.
AP&L has documented acceptable tubes by serial number and
physical location. This item is closed.
(Details I,
paragraph 3)
72-7/1 Pressurizer Safety and Relief Valve Mounting and Connecting
Piping (Region II Letter, August 21, 1972, Item 1)
It is our understanding that the licensee will evaluate the
pressurizer safety and relief valve mountings and connecting
piping to assure that these have been analyzed for dynamic
reaction forces during blowdown. This item remains open.
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72-11/1 Paddle-Type Flow Switches (Region II f atter, December 19,
1972 Item 1)
AP&L has determined that those paddle type flow switches
to be used do not' represent a safety problem. This item
is closed.- (Details I, paragraph 6)
72-11/2 B&W Safety cabinets - Internal Panel Wiring (Region II
Letter. December 19, 1972, Item 2) (See Item 72-4/3.)
It is our understanding that the licensee will require that
B&W perform an engineering evaluation of all safety cabinets
regarding conformance to the separations criteria for internal
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cabinet wiring. This item remains open.
72-11/3 Cable Installation in control Room and Computer Room False
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Floor and Floor of Main Control Panels (Region II Letter,
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December 19, 1972, Item 3) (See Item 72-4/2.)
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It is our understanding that the licensee will require
Bechtel to evaluate cable installation under the control
room and computer room false floor regarding separations,
loading and quality workmanship criteria. This item
remains open.
72-12/2 Valve Wall Thickness Verification (Region II Imtter,
_ June 30,1972)
It is our understanding that AP&L will develop and implement
a verifiertion program when AEC defines the requirements
regarding their letter of exception, July 28, 1972. This
item remains open.
73-2/2 Lack of Material Control Weld Filler Material (RO Inquiry
Report No. 50-313/73-lQ/CDR)
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This item is being evaluated by Headquarters staff. This
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item remaina open.
73-4/1 Faulty Overcurrent Trip Delay Device on Circuit Breakers
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For Engineered Safety Systems (RO Bulletin 73-1. RO:II
Letter, Dated February 12, 1973)
B&W and Bechtel report that no circuit Breakers of the
type identified in the R0 Bulletin are used. This item
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is closed.
(Details I, paragraph 7)
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73-4/2 Limitorque Valve Operators (Region II Letter,
December 4, 1972)
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AP&L has identified the defective units and are in the
process of changing out the torque switches. This
item-is closed.
(Details I, partgraph 8)
73-6/1 Motor Control Center - Reversing Starters (R0 Inquiry Report
No. 50-313/73-20)
.
AP&L has identified the defective units and are in the process
of changing out the units. This item is closed.
(Details I,
paragraph 5)
V.
Design Changes
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Core Flood Modifications. .(Details I, paragraph 2)
VI. Unusual Occurrences
None
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VII. Other Significant Findf_ags
A.
Project Status
See Details I, paragraph 2, " General."
B.
Personnel or Organizational Changes
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None
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C.
Inquiry Reports
None
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VIII. Management Interview
. Arkansas Power and Light Company (AP&L)
N. A. Moore - Chief QA Coordinator
A. C. Bland - QA Engineer (Civil)
C. L. Bean - QA Engineer (Mechanical)
E. Quattlebaum - QA Engineer (Electrical)
L. W. Humphrey - QA Engineer (General)
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Bechtel Engineering Corporation (Bechtel)
C. G. Beckham - Lead QA Engineer (Mechanical)
P. W. Sly - QC Engineer (Records)
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The inspectors apprised the attendees of the general areas of
inspection and findings.
The enforcement action items identified above were discussed.
The licensee was informed that RO:II had no further questions
regarding previously identified unresolved items 72-4/4, 72-11/1,
73-4/1, 73-4/2 and 73-6/1.
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R0 Report No. 50-313/73-6
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DETAILS I
Prepared By: ' L-
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V. L. Brownlee, Reactor
Date
Inspector, Facilities
Section, Facilities
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Construction Branch
Dates of Inspection: May 9-11, 1973,,
Reviewed By: hd
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W. A. Crossman, Senior
Date
Inspector, Facilities
Section, Facilities
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Construction Branch
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1.
Individuals Contacted
a.
Arkansas Power and Light Company -(AP&L)
,
N. A. Moore - Chief QA Coordinator
A. C. Bland - QC Inspector (Civil)
V
C. L. Bean - QC Inspector (Mechanical)
E. Quattlebaum - QC Inspector (Electrical)
L. Humphrey - QC Inspector (General)
,
H. G. Petty - Senior Plant Electrician
b.
Contractor Organizations
Bechtel Engineering Corporation (Bechtel)
.
W. T. Stubblefield - Project Superintendent
C. G. Beckham - Lead QA Engineer
P. W. Sly - QC Engineer
F. Plutchak - QA Supervisor (San Francisco)
G. Richey - Electrical Engineer
2.
General
.
Progress of Construction: Physical construction is estimated to be
97% complete. Piping systems installation is considered 99% complete.
Electrical systems installation is estimated to be 98% complete.
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Bechtel personnel onsite for Unit 1 is 296. AP&L personnel is 92
including 5 QA. Labor problems, none.
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R0 Report No. 50-313/73-6
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Work Summary and Schedule
All systems have been released to operations for startup and
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testing except the reactor coolant loop. Bechtel is reported
to have completed original scope of work and have remaining some
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work on scope changes and rework. The ECCS modification is not
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completed; however, the system has been turned over to operations
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and will be released back to construction for piping modification
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later.
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3.
Control Rod Drive Motor Tube Defect Analysis
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AP&L has qualified the inspection results with regard to the
acceptance limits as prescribed in Topical Report BAW-10047.
AP&L has received thrity-five units that were qualified to meet
the minimal wall thickness acceptance limits. These units are
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identified by serial number and physical installation is mapped.
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Region II has no further questions regarding this item.
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4.
Control Rod Drive Trip Breakers
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AP&L was questioned regarding the undervoltage trip assembly
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problems identified at the Oconee facilitics. It became
apparent that AP&L personnel were aware of the problem as
indicated by correspondence (onsite), dated April 11, 1973.
There appeared to be a lack of management awareness of the
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problea, a lack of documenting and initiating investigative
action to determine if ANO-1 equipment was defective, and failure
to instigate evaluation procedures in accordance with AP&L's
QAP-8, " Handling of Significant Construction Deficiencies,"
to determine if the problem has safety significance and is
an AEC reportable item.
This lack of management knowledge and timely attention to a
known apparent significant deficiency of safety related equipment
is considered a violation of Criteria XV and XVI.
5.
Motor Control Center - Reversing Starters (Inquiry Report No.
50-313/73-2Q, April 23, 1973)
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The reversing starters are required to be equipped with mechanical
interlocks which prevent the simultaneous closure of both sets of
contacts. During routine werk bench tests by field forces, it
became apparent that because of excessive manufacturing tolerances
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RO Report No. 50-313/73-6
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of the mecbanical interlocks, it would be possible to move both
contact assemblies into the closed position. Corrective action
was worked out with Bechtel and Allis-Chalmers. Discussion with
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both AP&L and 'Bect ' .1 personnel and review of records indicate
that all affected
.ts will be corrected by changing out modi-
fled assemblies. L 2/Bechtel reports that there were no problems
found in the electrical interlocks of tbs starters during checkout.
Onsite documentation (October 13, 1972 - April 17, 1973) was
reviewed. The deficiency description and corrective actions were
documented on NCR E-604 dated February 8, 1973. This late date
of the NCR appears to indicate a laxness on the part of Bechtel's
engineers / inspectors to properly inrplement in a timely manner
documentation of inspection findings and rework activities in
accordance with Bechtel's Field Inspection Procedure G-3,
" Processing of Nonconforming Items."
6.
Paddle-Type Flow Switches
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Bechtel has researched the use of paddle-type flow switches
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within the scope of their supply. Their research identified
two items used in the dirty waste filter drains. Analysis of
- their. use (high flow alarm) indicates that the advantages
of having them is offset by the problems they may create and
concluded that deletion of the items is the best solution.
Three vendor supplied items were found in the decay heat
removal coolers and control room emergency unit air filter for
which replacement work is being initiated. Several flow switches
were identified for the penetration room; however, no vendor
information was available at this time and Bechtel proposed to
AP&L that their use would be rejected. Three flow switches were
identified in the fire water systems and evaluation of their use
is not complete. Bechtel identified several flow switches supplied
by B&W associated with auxiliary systems of the reactor coolant
pumps. Bechtel initiated an inquiry to B&W. B&W questioned
Allis-Chalmers regarding the use of padale-type flow switches in
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' the oil systems of the reactor coolant pump motors and their
service esperience. Allis-Chalmers states that they have used
these flow switches on all the reactor coolant pump' motors they
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have manufactured and have not experienced any failures of this
type switch to date. Two switches are used to indicate that the
backstop lube pumps are pumping. These pumps are operated only
for startup and coastdown of the pumps. Capacity of the back-
stop lube pumps is 4.5 gpm at 10 psi. Two switches are in the
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RO Report No. 50-313/73-6
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oil lines which circulate oil through the upper bearing oil coolers
in the event of reverse rotation by the pump motors. Two switches
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are in lines which' carry the flow of oil from the coolers back to
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the oil reservoir. These switches are in continuous service.
Allis-Chalmers analysis is that use of these switches will not
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affect plant safety or availability since the switches are not
in critical services. Since Allis-Chalmers has not previously
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experienced failure and report that secondary indications of
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oil system performance are available and that safety is not a
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factor, they have recommended continued use of these particular
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switches. AF&L concurs.
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7.
Faulty Overcurrent Trip Delay Device on Circuit Breakers for
Engineered Safety Systems (R0 Bulletin 73-1)
B&W's scope of supply does not include any circuit breakers of the
stated type or design. B&W does supply circuit breakers that are
located in the control rod drive central system which are used to
interrupt power to its load. These are General Electric circuit
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breakers and are used in the undervoltage mode. No time delay
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overcurrent trip feature is provided in this design.
Bechtel has surveyed all safety related circuit breakers in their
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scope of supply and report that no circuit breakers referred to in
AEC RO Bulletin 73-1 are being used.
Region II has no further questions regarding this item.
8.
Limitorque Valve Operators
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AP&L has identified seventy-five operators (AP&L letter dated
March 14, 1973) that may contain defective torque switches.
AP&L's electrical personnel and Bechtel construction are in.
the process of changing switches on these identified units.
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Discussion with AP&L and Bechtel personnel and review of work
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lists-and documentation records indicate that this matter is
being resolved in a satisfactory _anner.
Region II has no
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further questions regarding this item.
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Ltr to Arkansas Power and Light Company
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JUN
4 E73
F % cc w/ encl:
. D. Thornburg, RO
RO:HQ (4)
Directorate of Licensing (4)
DR Central Files
- PDR
- Local PDR
- NSIC
- DTIE, OR
- State
- To be dispatched with licensee response.
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