ML20052B602
| ML20052B602 | |
| Person / Time | |
|---|---|
| Site: | Hatch, Wolf Creek, Grand Gulf, Turkey Point, Callaway, Farley, 05000000 |
| Issue date: | 04/02/1982 |
| From: | Ang W, Costello J, Hale C NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II), NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20052B578 | List: |
| References | |
| REF-QA-99900519 IEB-79-02, IEB-79-14, IEB-79-2, NUDOCS 8205030361 | |
| Download: ML20052B602 (21) | |
Text
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ORGANIZAT10N:
BECHTEL POWER CORPORATION GAITHERSBURG POWER DIVISION GAITHERSBURG, MARYLAND REPORT INSPECTION 1/25-29/82 INSPECTION NO.:
99900519/82-01 DATE(S) 2/22-26/82 ON-SITE HOURS: 63 CORRESPONDENCE ADDRESS:
Bechtel Power Corporation Gaithersburg Power Division ATTN:
Mr. J. M. Komes, Vice President and General Manager 15740 Shady Grove Road Gaithersburg, MD 20760 ORGANIZATIONAL CONTACT:
Mr. D. C. Kansal, QA Manager TELEPHONE NUMBER:
(301) 258-3776 PRINCIPAL PRODUCT: Architect Engineering Services NUCLEAR INDUSTRY ACTIVITY: The Gaithersburg Power Division has a total of 2,755 employees of which 2,017 or 73% are assigned to nuclear projects.
Major projects include Callaway Unit 1, Wolf Creek Unit 1, and Grand Gulf Units 1 and 2.
There are also modification / repair / service contracts on 14 additional reactor units.
ASSIGNED INSPECTOR:
- h. k. bbM-4/2/7z J
. Costello, Reactor Systems Section (RSS)
D a'te' OTHER INSPECTOR (S): W. P. Ang, Region II APPROVED BY:
~77./e/.B g/;z./g C. J. Hale, Chie RSS Da'te ~
INSPECTION BASES AND SCOPE:
A.
BASES:
10 CFR Part 50, Appendix B, and SNUPPS PSAR, Chapter 17 B.
SCOPE:
Implementation inspection of Bechtel's commitments in the areas of compliance with NRC IE Bulletins 79-14 and 79-02, design corrective action, and a 10 CFR Part 50.55(e) report and a potential construction deficiency report which covered the following:
(1) valve chatter in RHR heat exchanger vent valves (Grand Gulf 1 and 2); and (2) incorrect sized cable which resulted in a failure of the control rods to scram (Grand Gulf 1 and 2).
PLANT SITE APPLICABILITY:
The contents of this report relate to the following dockets: 50-416, 50-482, 50-483, 50-321, 50-366, 50-250, 50-251, 50-348, and 50-364.
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ORGANIZ TION:
BECHTEL POWER CORPORATION GAITHERSBURG POWER DIVISION GAITHERSBURG, MARYLAND
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REPORT ihaPEGilON NO.:
99900519/82-01 RESULTS:
PAGE 2 of 5 A.
VIOLATIONS:
None B.
NONCONFORMANCES:
None C.
UNRESOLVED ITEMS:
None D.
OTHER FINDINGS OR COMMENTS:
1.
Design Corrective Action - SNUPPS PSAR Chapter 17, Engineering Depart-ment and Engineering Project Procedures were examined to deterr 'ne quality assurance program commitments.
To verify implementatiors of these commitments, the following documents were examined: QA program management corrective action log, project open items list, three management corrective action reports, five open items, six nonconfor-mance reports (NCRs), four deficiency / noncompliance reports, three revised drawings, and three revised calculations.
Relative to the documents examined, all quality assurance program commitments were being properly implemented.
2.
Potential Construction Deficiency Report - Valve chatter in RHR Heat Exchanger Vent Valves (Grand Gulf).
Mississippi Power and Light Company (MP&L) reported to Region II that the RHR heat exchanger vent valves, manufactured by Yarway, open and close intermittently due to a worm gear in the valve operator which is not self-locking.
The purpose of this inspection was to determine if this was a generic problem, and if there was a breakdown in the AE's quality program.
The problem was discovered by Bechtel during testing operations at the construction site prior to turnover to MP&L and was, therefore, not reportable under 10 CFR Part 21, but was reportable under 10 CFR Part 50.55(e).
The problem was corrected by rewiring the control circuit to actuate the position switch which opens at full close or full travel of the valve and thus prevents reenergizing the circuit.
This position switch is in the switch compartment furnished with the Limitorque actuator and is available for customer use, if necessary.
- Normally,
ORGANIZA' TION:
BECHTEL POWER CORPORATION GAITHERSBURG POWER DIVISION GAITHERSBURG, MARYLAND NtFURI indecciiua NO.:
99900519/82-01 RESULTS:
PAGE 3 of 5 the Limitorque valve actuator has a self-locking capability and it is not necessary to use the position switch lockout.
- However, in a few cases it is not possible to achieve self-locking capability and at the same time satisfy specification requirements of quick close operation at reduced voltage and high differential pressure.
This is what happened at Grand Gulf and affected 20 valve actuators out of a total of approximately 160.
The condition is difficult to predict prior to final test operation, but can be corrected by rewiring the control circuit on those valve actuators to achieve the self-locking capability.
No similar problems were found in other nuclear plants being designed by Bechtel/Gaithersburg.
However, a management information bulletin was sent out to other Bechtel offices to alert them of the problem.
The potential error in this case appears to be a failure of the valve supplier to alert the user that this condition could occur and could be corrected by rewiring the control circuit.
All modifications have been completed on Unit 1.
Unit 2 modifications will be completed prior to Unit 2 fuel load.
No nonconformances or unresolved items were identified in this area of the inspection.
3.
Potential Construction Deficiency - Incorrect Sized Cable Resulting in Failure of the Control Rods to Scram On August 26, 1981, Mississippi Power & Light Company notified Region II that during control rod testing, 14 scram pilot valves were found stuck in the energized state when both of the solenoids were deenergized.
The purpose of this inspection was to determine if this was a generic problem and if there was a breakdown in the AE's quality program.
The valves that failed did not contain a defect.
They were damaged by being operated with insufficient voltage being supplied to the solenoid coils by the Reactor Protection System (RPS) due to cables of insufficient capacity.
The low voltage caused chattering of the solenoid core internals, resulting in damage and subsequent sticking of the internals, preventing proper operation.
G.E. Specification 22A3899AL CRD Hydraulic Control System, Section 4.3, states that the minimum pick up voltage for the pilot scram valves is 87 VAC.
Bechtel calculations showed the minimum voltage across the most remote solenoid valve to be 96 VAC with the original sized wiring.
ORGANIZATION:
BECHTEL POWER CORPORAT10N GAITHERSBURG POWER DIVISION GAITHERSBURG, MARYLAND REPORT IN5ettstuN NO.:
99900519/82-01 RESULTS:
PAGE 4 of 5 After the problem had been discovered, information supplied by the solenoid manufacturer indicated their solenoids would not operate properly below 105 VAC and that they had been purchased to operate between 105 and 125 VAC The affected Reactor Protection System Supply Cables are being replaced with cables of sufficient capacity and all scram pilot valves are being rebuilt to replace damaged parts.
Two Nuclear projects at Bechtel/Gaithersburg use GE nuclear steam supply systems.
This problem was identified as being unique to the Grand Gulf project and did not affect the Hatch project.
The error appears to be in the GE/Bechtel interface whereby the information supplied by the solenoid manufacturer of a minimum requirement of 105 VAC for proper operation was not transmitted in GE documentation to Bechtel.
A Problem Alert was issued by Bechtel/Gaithersburg to other Bechtel offices on January 6, 1982.
This problem alert warned of the danger of low voltage with this type solenoid.
No nonconformances or unresolved items were identified in this inspection.
However, in future inspections the NSSS/AE interface requirements will be examined in greater detail.
4.
Follow up on IE Bulletins 79-14 and 79 This was a follow-up inspection related to activities performed at the Gaithersburg office of Bechtel Power Corporation which resulted from the issuance of IE Bulletin 79-14 (Seismic Analysis for As-Built Safety Related Piping Systems) and IE Bulletin 79-02 (Pipe Support Base Plate Designs Using Concrete Expansion Anchor Bolts).
The inspection was performed by an inspector from Region II with limited participation from the Region IV inspector.
There were no findings regarding the programmatic aspects of Bechtel's efforts.
The other aspects of this inspection will be reported in Region II Reports 50-416/82-06; 50-321/82-03; 50-366/82-03; 50-348/82-07; 50-364/82-06; 50-250/82-12; and 50-251/82-12.
The highlights of these inspections are as follows:
a.
Grand Gulf, Unit 1, Report No. 50-416/82 To verify imple-mentation of the requirements of IEB 79-02 and 79-14, six stress problems and six baseplate design calculations with their related documents were examined.
Also, the as-built configuration for two pipe anchors was checked.
One unresolved item was
l ORGANIZ T10N:
BECHTEL POWER CORPORATION GAITHERSBURG POWER DIVISION GAITHERSBURG, V.ARYLAND REPORT INdetuiluh NO.:
99900519/82-01 RESULTS:
PAGE 5 of 5 identified to the licensee.
There were no violations or devia-tions.
The unresolved item concerned IEB 79-02 and 79-14 analytical discrepancies of which six were identified.
b.
Hatch, Units 1 and 2, Report Nos. 50-321/82-03 and 50-366/82 To verify implementation of the requirements IEB 79-02 and 79-14, three Licensee Event Reports, seven irawings and one letter were examined.
One unresolved item was identified to the licensee.
There were no violations or deviations.
The unresolved item concerned three unresolved discrepancies involving IEB 79-02 and 79-14.
c.
Joseph M. Farley, Units 1 and 2, Report Nos. 50-348/82-07 and 50-364/82 To verify implementation of the requirements of IEB 79-02 and 79-14, one schematic drawing, one isometric drawing, and one stress problem with their related documentation were examined.
No violations, deviations or unresolved items were identified in the IE 79-02 and 79-14 area.
However, one unresolved item was identified to the licensee concerning the nonsafety-related classification of the diesel generator exhaust piping and pipe supports.
d.
Turkey Point, Units 3 and 4, Report Nos. 50-250/82-12 and 50-251/82 To verify implementation of the requirements of IEB 79-02 and 79-14, two stress problems with their related docu-mentation were examined.
One unresolved item concerning two discrepancies involving IEB 79-14 was identified to the licensee.
Also, another unrelated unresolved item was identified to the licensee concerning the nonsafety-related classification of the diesel generator exhaust piping and pipe supports.
No violations or deviations were identified.
4 e
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