ML20033C838
| ML20033C838 | |
| Person / Time | |
|---|---|
| Site: | Clinton  |
| Issue date: | 11/17/1981 |
| From: | Gardner R, Hawkins F, Richard Lee NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML20033C833 | List: |
| References | |
| 50-461-81-27, NUDOCS 8112040369 | |
| Download: ML20033C838 (7) | |
See also: IR 05000461/1981027
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U.S. NUCLEAR REGULATORY COMMISSION
REGION III
Report No. 50-461/81-27
Docket No. 50-461
License No. CPPR-137
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Licensee:
Illinois Power Company
500 South 27th Street
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Decatur, IL 62525
Facility Name: Clinton Nuclear Power Station, Unit 1
Inspection At: Clinton Site, Clinton, IL
Inspection Conducted: October 20-23, 1981
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Inspectors:
R. N. Gardner
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R. L. Lee
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Approved By:
F. C. Hawkins, Acting Chief
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Plant Systems Section
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Inspection Summary
Inspection on October 20-23, 1981 (Report No. 50-461/81-27)
Areas Inspected: Followup of previously identified inspection findings,
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observation of electrical cable installation activities, observation of
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electrical component installation activities, observation of electrical
cable termination activities, and review of records. This inspection
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involved a total of 54 inspector-hours onsite by two NRC inspectors.
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Results: Of the five areas inspected, no items of noncompliance or
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deviations were identified in four areas; one apparent item of noncom-
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pliance was identified in one area (Criterion III - two examples of
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failure to translate design criteria into drawings, procedures, and
instructions - Sections 1.c and 1.d).
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8112040369 811124
PDR ADOCK 05000461
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DETAILS
Persons Contacted
Illinois Power Company
- W.
C. Gerstner, Executive Vice President
- J. O. McHood, Vice President, Project Manager
- A. J. Budnick, Director - QA
- E. E. Connon, Director - Compliance
- R. F. Plunkett, Plant Menager
- J.
S. Spencer, Director - Design Engineering
- W.
L. Calhoun, Electrical Construction
- M. C. Hollan, Supervisor - QA
Baldwin Associates
- J. E. Findley, Resident Engineer
- L. A. Gelbert, Manag
r - QC
- D. Murphy, Senior Electrical Engineer
- J. W. Smart, Manager - QA
- H. R. Swift, Project Engineer
- J. C. Wilson, Assistant Manager - QC
Other licensee personnel were routinely contacted during this inspection.
- Denotes those present at the exit interview.
Licensee Actions on Previously Identified Items
(Closed) Noncompliance (50-461/81-05-16): Failure to incorporate the
latest changes and revisions into electrical installation drawings. The
licensee has implemented a document control system audit program. During
this inspection, the Region III inspectors determined that the subject
audit program is effective in eliminating document control errors.
(Closed) Unresolved Item (50-461/81-09-07):
General Electric drawings
identified as " status two" by the Architect Engineer. The licensee stated
that the Foreign Vendor Drawing List will identify any vendor drawing which
is categorized as other than Status 1.
The General Electric Action Required
list (GEAR) wil! identify priority items which require completion. A monthly
meeting is held to discuss the items identified on the GEAR list.
(Closed) Unresolved Item (50-461/81-01-02): Measures were not clearly
established to ensure that future design changes were reviewed and incorpor-
ated into the appropriate construction documents. The Region III inspector
reviewed Baldwin Associates Job Instruction E-008, Revision 0, " Electrical
Drawing System." This instruction, "... delineates responsibilities for the
review of new and revised design documents and for ensuring the incorporation
of any changes into travelers or similar documents as necessary."
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(0 pen) Unresolved Item (50-461/81-20-04):
Inspections performed by a Level I
inspector were not being evaluated by a Level II or Level III inspector. The
Region Ill inspector reviewed Technical Services Procedure TSI-VI-2,
Revision 0, " Welding Inspectors Responsibilities." Paragraph 4.1 of the
subject procedure states in part, "Only personnel certified as Level / Grade II
welding inspectors perform inspections required herein." The inspectors also
questioned the licensee concerning the implementation of QCI-102 which requires
the evaluation of Level I inspections by Senior Quality Control Engineers. The
licensee stated that all inspection checklists had been revised to reflect the
requirements of QCI-102 except for the cable tray checklist. This item will
remain open until the subject checklist has been revised.
Functional or Program Areas Inspected
1.
Obeervation of Electrical Cable Installation Activities
a.
The Region III inspectors observed the in-process installation of
Class IE control cables in the Control and Auxiliary Buildings.
The inspectors witnessed the cables being pulled from the NSSS PGCC
termination cabinet 1H13-P701A in the control room to division one
480 vcit motor control center IAP73E in the Auxiliary building.
Cables were identified as Low Pressure Core Spray valve F001
control cable ILP03C; RHR Heat Exchanger 1A outboard vent valve
F074A control caole IRH44C; and 3D1 pump 1A suction valve F004A
control cable IRH09E.
The Region III inspectors verified that the cables were routed in
accordance with the cable pull cards. The size and type of cable
pulled was as specified on the cable pull cards and had no apparent
damage. The raceways were clean, properly identified and undamaged.
Craftsmen were stationed at sufficient intervals and were preventing
damage to the cable. Cables were measured, cut to length, and
noted on the pull cards. The pull crew foreman and QC inspector
verified that the proper cable was selected, that the cable came
_ rom reels marked as containing safety related cable, verified cable
ro? ting, and entered the information on their respective copies of
the pull cards.
The cable installation was observed to be installed in accordance
with Baldwin Associates cable installation Procedure BAP 3.3.2,
Revision 9, dated October 15, 1981.
A quality control inspector was observing all stages of the cable
pulling work and recorded the cable pulling data on a Baldwin
Associates cable installation checklist. The checklist included
appropriate attributes and acceptance criteria.
Discussion with
the QC inspector, providing quality control coverage of this in-
stallation, indicated that he was knowledgeable in the inspection
of this activity and had the required documents on hand.
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b.
The Region III inspectors verified that the following Class 1E
cables, installed in the Control and Auxiliary Buildings, were
routed in accordance with the applicable cable pull cards:
Main Steam Isolation Valve F003A control cable IIS10C from
PGCC termination cabinet 1H13-P715E in the control room to
division one 480 volt motor control center IAP73E in the
Auxiliary Building.
Battery IB load instrumentation cable 1DC03G from PGCC
termination cabinet 1H13-P732E in the control room to
division two 125 volt DC motor control cercer IDC14E in
the Auxiliary Building.
The inspectors observed that the raceway internals were free of
hazardous debris and sharp edges, conduit bushings were installed
as required, and cables and raceway were properly identified.
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c.
The Region III inspectors observed eight instances, at elevation
781 in the Control Building, where the vertical separation between
Class IE cable trays and non-Class IE cable trays was less than the
required three foot vertical separation. Pcragraph 8.3.1.4.2.2.3 of
the Clinton Power Station PSAR requires either three foot vertical
separation or installation of fire resistant barriers. The inspec-
tors noted that the applicable Sargent & Lundy (S&L) cable tray
installation drawings did not indicate fire resistant barriers.
The licensee stated that it was the design intent to install fire
protection barriers in accordance with PSAR requirements.
Class IE
cable trays, vithout the required separation, were identified as
1H13-P701A, lu 3-P70?A, 1H13-P702B, 1H13-P714A, 1H13-P715E, 1H13-P715F,
1H13-P730E and 1H13-P741E. The licensee had not previously identified
these nonconforming conditions.
This failure to translate physical separation requirements into
drawings, procedures and instructions is considered an item of
noncompliance with 10 CFR 50, Appendix B, Criterion III as
described in Appendix A of the report transmittal letter.
(461/81-27-01)
d.
The Region III inspectors observed two instances, at elevation
781 in the Control Building, where installed Class IE instru-
mentation cable trays 1H13-P714A and 1H13-P715F were of the open
ladder type instead of the non-ventilated solid trays required by
Paragraph 8.3.1.4.4.3.4 of the Clinton Power Station PSAR. Neither
S&L drawings nor other documents specified the use of solid trays.
The licensee had not previously identified this nonconforming
condition.
This failure to translate the physical separation requirements
into drawings, procedures and instructions is a further example
of noncompliance as cite ' in Paragraph 1.c above.
(461/81-27-01)
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e.
The Region III inspectors observed that a small Class IE instru-
mentation cable, identified as IDC03G, had been pulled over 200
feet through Auxiliary Building conduit IC6931 and Control
Building vertical cable tray 1H13-P732E. The cable pull card
specified a maximum pulling tension of 21 pounds. No devices,
such as tension links, had been required or utilized by the
craftsmen to ensure that the 21 pound maximum pulling tension
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had not been exceeded. Cable test data indicates that one man
may exceed 125 pounds tension when hand pulling a cable.
Adequacy of the licensee's control to prevent damage to Class IE
cable with very low allowable pulling tension will be reviewed
during a subsequent Region III inspection. This item is con-
sidered open.
(461/81-27-02)
2.
Observation of Work Activities - Electrical Components
The Region III inspector observed the installation activities pertaining
to the following electrical components:
a.
Residual Heat Removal (RHR) Pump Motors (5KV) 1E12-C002A and
(1) The subject motors were being installed in accordance with
traveler Nos. E12-004, Revision 7 and E12-006, Revision 7.
(2) Receipt inspections were performed and documented on Receipt
Inspection Report No. S-878, dated January 25, 1977.
(3) The RHR motors were withdrawn from the warehouse during
the period of September 4-9, 1981. At that time, the oil
was drained from each motor and the temporary motor heater
connections removed. At the time of this inspection the
heaters were not energized. The inspector observed that
the re-energization of the motor heaters was a traveler
operation which would be completed at a future date.
Through discussions with the licensee, the inspector was
informed that immediate action would be taken to reenergize
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the motor heaters.
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b.
Low Pressure Core Spray (LPCS) Pump Motor (SKV) 1E21-C001.
(1) The subject motor was being installed in accordance with
traveler No. E21-002, Revision 9.
(2) Receipt inspections were performed and documented on Receipt
Inspection Report No. S-870, dated January 24, 1977.
(3) Tne LPCS motor was withdrawn from the warehouse on
September 4, 1981. At that time, the o.1 was drained from
the motor and the temporary motor heater connections removed.
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At the time of this inspection the heaters were not energized.
The inspector observed that the re-energization of the motor
heater was a traveler operation which would be completed at a
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future date.
In discussing this matter with the licensee, the
inspector was informed that immediate action would be taken to
re-energize the motor heater.
c.
Reactor Core Isolation Cooling Water Leg Pump Motor IE51-C003
(1) The subject motor was being installed in accordance with
traveler No. E51-002, Revision 1.
(2) Receipt inspections were performed and documented on Receipt
Inspection Report No. S-5778, dated March 16, 1979.
d.
Motor Operated Valves (MOV) 1E12-F009 and 1E51-F063
(1) MOV IE12-F009 was being installed in accordance with
isometric drawing RH-20, Revision 5A.
MOV IE51-F063 was
being installed in accordance with isometric drawing RI-1,
Revision 7A.
(2) Receipt inspections were performed and properly documented on
Receipt Inspection Reports.
(3) The inspector verified that the MOV heaters were energized
as required.
e.
At the inspector's request, the licensee removed the MOV operator
housing from MOVIG33-F001 to allow inspection of the internal
components. The inspector verified that the internal heater was
energized and that the MOV internal components were free of damage
and corrosian.
3.
Observation of Electrical Work Activities - Terminations
a.
The inspector observed termination activities pertaining to
the following Class IE cables:
Cables
Location
ICC11C
MCC 1A3
1CC11F
MCC 1A3
1CC14G
MCC 1A3
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ICC14J
MCC 1A3
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The terminations were acceptable and in accordance with the
appropriate wiring diagram.
b.
The inspector observed that the use of vinyl self-insulated butt
splices is referenced in Paragraph 6.8 of S&L Standard STD-EA-205
and is also referenced in Table C-1 of Baldwin Associates Quality
Control Instruction (QCI) 408. The licensee stated that vinyl
butt splices have not been used on Class IE cables, nor will they
ever be used on Class 1E cables at the Clinton site. The licensee
further stated that QCI 408 and S&L Standard STD-EA-205 would be
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revised to remove all reference to the use of vinyl butt splices.
Pending review of these revisions, this item is considered open.
(50-461/81-27-03)
4.
Review of Cable Installation Quality Records
The Region III inspectors reviewed QC inspection records and completed
cable pull cards for Class IE cable installations noted in Section 1 of
this repo.t.
Installations were being properly documented on Baldwin
Associates Class 1E cable installation QC inspection checklists. The
records furnished objective evidence that activities affecting quality
were acceptable.
5.
Review of Component Installation Records
The inspectors reviewed the receipt inspection records, storage and
maintenance records, and installation records pertaining to the elec-
trical components identified in Section 2 of this report. The records
were retrievable and acceptable.
Open Items
Open items are matters, not otherwise categorized in the report, that
require followup during a future inspection. Open items identified
during this inspection are discussed in Sections 1.e and 3.b.
Exit Interview
THe inspectors met with licensee representatives (denoted in the Persons
Contacted paragraph) at the conclusion of the inspection on October 23, 1981.
The inspectors summarized the scope and findings of the inspection. The
licensee acknowledged the information.
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