ML20054J387
| ML20054J387 | |
| Person / Time | |
|---|---|
| Issue date: | 06/07/1982 |
| From: | Chamberlain D, Hale C NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20054J378 | List: |
| References | |
| REF-QA-99900509 NUDOCS 8206280563 | |
| Download: ML20054J387 (28) | |
Text
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ORGANIZATION:
STONE AND WEBSTER ENGINEERING CORPORATION BOSTON, MASSACHUSETTS HtPUNI INSPECTION IriSPECTION NO.
99900509/82-01 DATE(S) 3/8-12/82 & 3/22-26/8J ON-SITE HOURS: 111 CORRESPONDENCE ADDRESS:
Stone and Webster Engineering Corporation ATTN:
Mr. R. B. Kelly Vice President, Quality Assurance P. O. Box 2325 Boston, MA 02107 ORGANIZATIONAL CONTACT:
Mr. F. B. Baldwin, Assistant QA Manager TELEPHONE NUMBER:
(617) 973-6566 PRINCIPAL PRODUCT:
Architect Engineering Services NUCLEAR INDUSTRY ACTIVITY: Major projects include Beaver Valley 2, River Bend 1 and 2, Shoreham, Nine Mile Point 2, Millstona 3, North Anna 3, New Haven 1 and 2, Montague 1 and 2, and Jamesport 1 and 2.
In addition, there are 44 modification / repair / service contracts.
The aforementioned contracts cover work performed in the Boston, Cherry Hill, New York, and Denver offices.
bk
_!D b/7/b ASSIGNED INSPECTOR:
D. O. 6%mberlain, Rea/fo~r Systems Section (RSS)
Datd 0THER INSPECTOR (S): A. L. Smith, Equipment Qualification Section J. I. Tapia, Engineering Secticr APPROVED BY:
O/
h Il C. J@Te, Chiet RSS Bate-INSPECTION BASES AND SCOPE:
A.
BASES:
10 CFR Part 50, Appendix B and Topical Report SWSQAP 1-74A.
B.
SCOPE:
Status of previous inspection findings (Boston and Cherry Hill of fices), design process management (follow up on concern identified in 81-03 report at Boston office), high energy line ruptures in fluid systems outside containment (Boston office), safe shutdown following pipe rupture outside containment (Cherry Hill office), and an (cont. on next page)
PLANT SITE APPLICABILITY:
Docket Numbers 50-404, 50-334, 50-412, 50-458, 50-459, 50-410, and 50-423.
des 1G3g ED ORIG U
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8206200563 820610 PDR GA999 EECSWE 99900509 PDR
ORGANIZATION:
STONE AND WEBSTER ENGINEERING CORPORATION BOSTON, MASSSACHUSETTS REPORT INSPECTION NO.:
99900509/82-01 RESULTS:
PAGE 2 of 7 SCOPE:
(Cont.)
inspection conducted as a result of the following 10 CFR Part 50.55(e) reports:
(1) 10 CFR Part 50.55(e) Report (North Anna 3) - Pressurizer safety valve inlet piping design with large pressure drop could lead to valve chatter (Boston office); (2) 10 CFR Part 50.55(e) Report (River Bend 1 and 2) - Heat loads provided by General Electric to Stone and Webster (5&W) for sizing HVAC in the High Pressure Coolant System (HPCS) diesel generator room were about one-third of the expected valve (Cherry Hill office); and (3) 10 CFR Part 50.55(e) Report (Beaver Valley 2) - Structural calculations for control room extension contained errors (Boston office).
A.
VIOLATIONS:
None B.
NONCONFORMANCES:
1.
Contrary to Criterion V of 10 CFR Part 50, Appendix B and Engi-neering Department Memorandum No. 82-3, all required experience records for designers in the electrical and the engineering mechanics division (Boston office) were not prepared or updated by March 1, 1982, as committed to the NRC.
2.
Contrary to Criterion V of 10 CFR Part 50, Appendix B and Engi-neering Assurance Procedure 5.3, an assumption made in calculation No. 12179-US(B)-221 was not confirmed and the assumption was not identified as an assumption that required confirmation at a later date (Millstone 3 project).
3.
Contrary to Criterion V of 10 CFR Part 50, Appendix B and Engi-neering Assurance Procedure 5.3, HVAC calculation PB-196 for control building cooling load contained input information that was not confirmed and "Yes" was not checked to indicate confirmation was required at a later date.
C.
UNRESOLVED ITEMS:
None l
ORGANIZATION:
STONE AND WEBSTER ENGINEERING CORPORATION BOSTON, MASSACHUSETTS REPORT INSPECTION NO.:
99900509/82-01 RESULTS:
PAGE 3 of 7 D.
STATUS OF PREVIOUS INSPECTION FINDINGS:
1.
(Closed) Unresolved Item (81-03):
It was not always apparent that the ANSI N.45.2.12 requirements and the S&W procedural requirements for holding a postaudit conference and identify-ing persons attending the postaudit conference are being followed.
The NRC inspector examined a random sample of nine audits and verified that all reports contained documentation of both a postaudit conference and a list of attendees.
It is concluded from this review that S&W is meeting these requirements of ANSI N45.2.12.
2Property "ANSI code" (as page type) with input value "ANSI N45.2.12.</br></br>2" contains invalid characters or is incomplete and therefore can cause unexpected results during a query or annotation process..
(0 pen) Nonconformance (81-04):
Experience Records were not being updated on a yearly basis as required.
S&W management had committed to having all required Experience i
Records updated by March 1, 1982.
The NRC inspector examined a total of 46 experience records for both engineers and designers in the Boston and Cherry Hill offices.
It was determined that the electrical and engineering mechanics divisions in the Boston office l
had not completed the update of all experience records for designers l
as committed.
This item will remain open at the Boston office and l
a nonconformance (B.1 above) was issued for the failure to meet a commitment to the NRC.
E.
OTHER FINDINGS OR COMMENTS:
l 1.
Design Process Management (Follow up on concern identified in 81-03 I
report) - During the 81-03 NRC inspection, a discrepancy was identi-fied on the Millstone 3 project relating to an instrument set point calculation for the component cooling water system.
The calculation I
was a " trial" calculation for a new instrument set point calculation system that was being developed.
A procedure for this system was issued on March 8, 1982, and a small number of calculations have been completed.
From the review of this area, it was determined that the new set point calculation system is being implemented and should provide good control in the future.
2.
High Energy Line Ruptures in Fluid Systems Outside Containment (Boston office) - The applicable SAR sections, procedures, and criteria for high energy line (HEL) rupture analysis were examined
ORGANIZATION:
STONE AND WEBSTER ENGINEERING CORPORATION BOSTON, MASSACHUSETTS REPORT INSPECTION NO.:
99900509/82-01 RESULTS:
PAGE 4 of 7 to determine program requirements.
The following design documents for the Millstone 3 project were examined to verify implementation of program requirements:
eight design drawings, nine analysis cal-culations, and one specification.
From this area of inspection, it was determined that the guidance provided in Branch Technical Positions MEB 3-1 and APCSB 3-1 are being followed for selecting pipe rupture locations, rupture sizes and geometry.
A noncon-formance was identified (B.2 above) regarding confirmation of assumptions in a pressure / temperature analysis calculation.
The assumption stated that all areas sealed with weather-stripped doors are not exposed to high energy line breaks from adjacent areas.
This assumption was not identified as an assumption that must be confirmed and there was no confirmation made to assure that the doors specified would withstand the pressures generated in adjacent compartments.
Due to the incomplete status of the HEL analysis for the Millstone 3 project by S&W, our inspection effort in this area could not be completed during this inspection.
3.
Safe Shutdown Following Pipe Rupture Outside Containment (Cherry Hill office) - Ihe review of HEL documentation on the River Bend project indicated that the break criteria contained in Branch Technical Positions APCSB 3-1 and MEB 3-1 were used as the basis for postu-lating pipe rupture conditions.
The attempted review of documenta-tion containing the plant transient analyses that support the posi-tion that the plant can~be safely shutdown in the event of any pipe rupture indicated that the SAR Chapter 15 accident analyses are viewed as the bounding analyses as long as the safe shutdown systems are protected from the effects of pipe rupture.
This area will be inspected further during subsequent inspections.
4.
High Pressure Coolant System (HPCS) Diesel Generator Room Heat Loads - This area of inspection resulted from a 10 CFR Part 50.55(e) report (River Bend 1 and 2) which stated that the heat loads provided by General Electric (GE) to S&W for sizing the heating, ventilation, and air conditioning (HVAC) in the HPCS diesel generator room were about one third of the expected value.
S&W had questioned the heat load values provided by GE because they were significantly lower, per kilowatt, than the values being used for the main plant diesels.
GE is presently evaluating this item and S&W has not officially been
l ORGANIZATION:
STONE AND WEBSTER ENGINEERING CORPORATION BOSTON, MASSACHUSETTS REPORT INSPECTION N0.:
99900509/82-01 RESULTS:
PAGE 5 of 7 provided with new values.
However, S&W evaluation has convinced them that the values are low and S&W has decided to revise the HVAC design to provide ventilation for the HPCS diesel generator room that equals the main diesel generator room capacity.
S&W also had responsibility for design of HVAC for the Nine Mile Point (NMP) 2 project HPCS diesel generator room but the original design called for HVAC capacity equal to the main diesel generator room, therefore the design is adequate for NMP-2.
An examination of the HPCS diesel generator room HVAC calculations revealed that S&W program require-ments were implemented.
The HVAC calculation for the Control Building Cooling Load (PB-196) was also examined to determine the source of heat load data and the required confirmation of input data used.
A nonconformance was identified (B.3 above) regarding confirmation of input data.
The inputs noted that require confir-mation were GE supplied information that was identified as preli-minary and heat load information for computer equipment.
The specific nonconformance was corrected during this inspection by revising the calculation to indicate confirmation was required.
It was also noted that S&W had performed an internal audit during March 1982, which identified similar concerns with HVAC calcu-lations. However, S&W had not determined corrective actions and preventive measures for the internal audit finding, therefore, a response to the NRC nonconformance will be required.
The HPCS diesel generator heat load item will remain open pending the completion of the GE evaluation and possible generic implications at other Architect Engineers.
S&W actions for affected projects is adequate and no further review will be required at S&W.
5.
Potential CDR Pressurizer Safety Valve Problem at North Anna, Unit 3 -
The Electric Power Research Institute (EPRI) is currently performing a study of pressurizer safety relief valves and piping systems.
The original study's intent was to qualify individual safety relief valves by testing various sizes and piping arrangements for safety relief valves representative of all reactors in operation or under construction.
The original intent has had to be revised since representative safety relief valves have been found to interact with piping configurations (in particular the characteristics of piping upstream of the valve).
EPRI contacted utilities to determine plant
ORGANIZATION:
STONE AND WEBSTER ENGINEERING CORPORATION BOSTON, MASSACHUSETTS REPORT INSPECTION N0.:
99900509/82-01 RESULTS:
PAGE 6 of 7 specific safety relief valve inlet pipe configurations and performed a preliminary analysis using computer modeling to predict safety relief valve performance for the various configurations.
The pre-liminary calculations performed under this study indicate that valve chatter (as a result of the pressure drop in the inlet piping) is expected on the North Anna, Unit 3, system.
Virginia Electric and Power Company (VEPCO) had their A/E (Stone & Webster) review the EPRI calculations.
The review performed by S&W indicated no inconsistencies in the EPRI calculation, hence, VEPC0 notified Region II of a potential deficiency under the provisions of 10 CFR 50.55(e) and has instructed S&W to revise the design of the inlet piping to permit satisfactory valve operation.
S&W has entered this problein into their problem reporting system and VEPC0 was informed that (a) the stress analysis of the pressurizer safety relief valve inlet piping has not been performed, (b) when performed the detailed stress analysis will consider the response of the piping system due to a valve opening transient condition of the type addressed by EPRI, and (c) if a detailed analysis indicates a degradation of system performance, the appro-priate system component (s) will be redesigned to rectify the potential problem.
This item will remain open since this was a result of preliminary analysis and S&W prefers to have, in hand, the final EPRI report prior to initiating any redesign.
In addition, a decision concern-ing increasing the height of the pressurizer is pending and any increase in pressurizer height would automatically result in a t
l redesign of the inlet piping configuration.
We will continue to monitor this potential problem for its generic aspects, since the preliminary EPRI findings indicated that several more plants may also experience probable safety relief valve problems, particular for the short valve opening times.
6.
Structural Design Deficiencies at Beaver Valley, Units 1 and 2 -
On August 31, 1981, Duquesne Light Company submitted a 10 CFR Part 50.55(e) report concerning structural design deficienies identified during the review of the design calcula-tions for the Unit 2 control room extension.
As a result of this discovery, S&W conducted a reverification of all calculations I
l
ORGANIZATION:
STONE AND WEBSTER ENGINEERING CORPORATION BOSTON, MASSACHUSETTS l
l REPORT INSPEG110N NO.:
99900509/82-01 RESULTS:
PAGE 7 of 7 performed by the group of engineers involved in the original design.
The reverification program disclosed a discrepancy in the design of the Auxiliary Building floor slab supporting the boron recovery test tanks.
The NRC inspector performed an evaluation of the generic implica-tions of all work performed by the group of engineers responsible f
for the design deficiencies.
The evaluation included a review of the S&W problem report system documentation of the reverification of work.
It was determined that the group of engineers was only involved in a limited scope of work in the Beaver Valley Project.
The original calculations were performed in 1974 and 1975 in the New York office of S&W.
The discrepancies involved failure to include loads due to flooding, failure to check drawings against calculation requirements for accuracy, and a failure to justify an engineering assumption pertaining to load distribution.
The S&W Engineering Assurance Division, in January of 1977, revised Engineering Assurance Procedure No. 5.3, " Control of Computerized and Manual Calculations," to include the requirement in NRC Regula-tory Guide 1.64, " Quality Assurance Requirements for the design of Nuclear Power Plants" for an independent review of design calcula-tions.
The required independent design verification represents a more formalized program than that existing at the time of the discrepancies.
By review of ongoing design activities during this inspection, the NRC inspector found that preventive measures now exist which are intended to preclude similar design deficiencies from being undetected.
4
Inspector D, 6 H k r/)$ g g [ $ l N Report No. _l/ - Of ~
Scop / Module _5TA705 of F86V!OUS DOCUMENTS EXAMINED Page of
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\\MSPECTiod FIHONGS (Bosto n) 1 2
TITLE / SUBJECT 3
4 Nkz b_1_ 3 NEAM-41 ATLACMrnEgT 5
SETPOINT cAinLLATl0NS J
l 2
CA LCVLATt0N 5 P-3CC E - 4 IHSTRVt1\\EHT 3CCf-TS 28 A/B CHARGING PurnPS lfs; 1
i COOLERS 00TL6T TErnPERATVRE ALARrnS 3
SP-3NSs-L isSTeventar s uss-1s22 ncornou sn Eco rana corttr utGn yp/c l
TEMPERATURE ALABM 4
SP-3HSS-2 INSTRornEHT f SNSS-RV 21 A/B HEv7RON SHI6LD TANK C_00).LdL Nz sYS76rn R6 LIEF VALV6s 6
14 (ERSOHNCL EXPERIENc6 RECORDS - ELLC TRICAL DIVISIObl l
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Internal Memo
- 2. Type of Document Procedure 7.
Letter
- 3. Date of Document QA Manual 8.
Other (Specify-if necessary)
- 4. Revision No., if applicable
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Scop / Module }f f(fff Er4E86'( LlW6_RUPTugt$
DOCUMENTS EXAMINED Page l _of IN FLUID SYSTEMS 00TS106 conrAnnmEn7 (805708) 1 2
TITLE / SUBJECT 3
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