ML20137K745

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QA Audit of Turkey Point Design Control,Including Production Engineering Group
ML20137K745
Person / Time
Site: Turkey Point  NextEra Energy icon.png
Issue date: 02/08/1994
From: Canazaro D, Symes R
FLORIDA POWER & LIGHT CO.
To:
Shared Package
ML17354B293 List:
References
FOIA-96-485 QAS-JPN-93-4, NUDOCS 9704070089
Download: ML20137K745 (31)
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A REPORT OF OUALITY ASSURANCE DEPARTMENT AUDIT 1

Audit No:

OAS-JPN 93 4 Location of Audit:

Juno Beach, Turkey Point Plant 4

Date of l

Audit:

November 5,1993 - January 11,1994 Audit Scone:

Turkey Point Design Control including Production Engineering Group (PEG) and site engineering i

Audit Summary:

Based on the activities and objective evidence audited, it was determined that the requiremeiits of the Turkey Point Engineering OA Program were adequately addressed by procedures and the implementation of those procedures was effective. The finding in this report identifies an area where improvement in implementation was needed.

2 The audit team evaluated the following Turkey Point Engineering Packages, Minor Engineering Packages, and their associated calculations:

PC/M 92-034 " Unit 4 Emergency Bus Load Sequencer Modification"; 93 020,

  • RCP 4A Motor Refurbishment / Upgrade";92-097," Unit 4 Alternate Safety injection Thermal Relief Valve Modification";93-051, " Unit 3 Hot Leg injection Cross-Tie isolation Valve"; 93 072, " Unit 4 Hot Leg injection Cross-Tie isolation Valve";93-125, " Modify and Repair Unit 3 Intake Structure Beam";93-005, " Unit 3 Turbine Runback Elimination";92-079, " Modify and Repair Unit 4 Intake Structure Beam";

and 92-181," Elimination of Unit 4 Turbine Runback Switch."

In addition to tha audit finding identified below, four concerns were identified.

These are as foibys:

Specification CNJ,1.28 section 3.7.2 revisiori

  • dated 12/3/91 states that, "lCW 1.

bays scheduled for inspection do not require pumps removal but it is desirable for all detailed inspections after the f.'Wt 3 EDG/ Cycle 13 outage "

4 Subsequent outages have not remo,ed the pumps. A revision to the specification needs to explain why itis nQ1 desirable to remove the pumps based on previous modifications.

2.

Design Basis Documents (DBD) are being used fora reference on each PC/M with updates only required every year. DBDs should be updated as changes are made. The FPL approval and review of the verification for the DBDs a

prepared by contractors should also be maintained as retrievable documents.

1 of 6 9704070089 970325 PDR FOIA BINDER 96-485 PDR

7 cs Mp REPORT OF QUALITY ASSURANCE, DEPARTMENT AUDIT Audit No:

OAS-JPN-93-4 3.

The RPS Wire List drawing 5610-M-430-168 was recognded as a " Category 5" drawing not subject to updating. Since this drawing and others like it, previously considered to be Category 5 drawings, contain safety related information they should be reviewed for updating or voiding.

l 4.

Drawing 5610-M-T D 14, Sheet 1, revision 9 was the latest revision in the PTN Engineering / Tech Staff library. The correct revision should have been revision

11. Tirnely updating of these documents should be addressed and engineers need to be alert that these documents are uncontrolled.

Satisfactory Areas:

Engineering Packages

. Minor Engineering Packcges Design and Safety Analyses Calculations

[

In addition to the above satisfactory areas, the following strengths were noted 3

during the conduct of the audit.

1.

Review of the Condition Reports and their associated corrective actions over the past six months by the audit team revealed a concern for the accuracy of the PTN Fuse List. Engineering had already initiated a project to correct these deficiencies (was due to finish 12/31/93) and the responsible engineer was knowledgeable of the outstanding CRs.

2.

The responsible engineer for the Unit 3 Turbine Runback Elimination (PC/M 93-005) was careful to ensure that wiring options available for his design were identicalto those installed as part of the Unit 4 modification. Having both units identical aids not only in installation and testing but also in all future I&C maintenance activities.

3.

The process in place at the site for minimum quorum review several weeks in advance of the issuance of a PC/M allows all affected parties adequate time to consider impacts of the change. The comments noted were judged to be pertinent and evidence of carefulconsideration.

4 The contractor technical specialist on the audit team observed that the FPL PC/M process was wellstructured and that FPL has a strong engineering staff in comparison to other utilities he has visited.

FindInas:

PC/M Post Modification Testing inadequate 2 of 6

$ $ l?P REPORT OF QUALITY ASSURANCE DEPARTMENT AUDIT Audit No:

OAS-JPN-93-4 Details:

Finding 1 - PC/M Post Mooification Testing inadequate Criteria:

10CFR50 Appendix B Criteria 111. " Design Control-JPN-Ol 3.13, Rev. 8, pape 10, states in part, "Specify any post-modification acceptance testing Gohed... Acceptance criteria or references to acceptance criteria shall be provided as required to ensure design adequacy."

Findina:

Post modification testing on Unit 4 PC/M 92-181 was inadequate. A work order to install a jumper wire, which activated circuits previously untested during insta of the PC/M, only checked continuity of the wire installed and did not ensure the circuits would activate.

Discussion:

The affected circuits activate turbine runback. The oversight of not installing t wire was identified by the responsible engineer for the Unit 3 ider.:ical modification and Condition Report 93 740 was wntten. This deficiency was brought to engineering and tech staff's attention upon discovery (11/15/93).

The Unit 3 PC/M does specify adequate post modification testing requirements.

Recommendation:

A Plant Manager Action item (PMAl 94-01-038) has been opened to conduct the turbine runback test.

The system engineering and nuclear engineering quality instructions (TDI-SE 007 rand JPN-OI 3.1) have been revised to require more engineering involvement in and review of post modification testing.No other actions are required. This finding is closed.

~

i 3 of 6

Ib ct-I REPORT OF i

QUALITY ASSURANCE DEPARTMENT AUDIT Audit No:

OAS JPN-93-4 i

l Audit Particinants:

Name Denartment/ Group A

jil Q

l W. W. Woodard JNA JB X

X X

R.A.Symes JNA JB X

X X

R. F. Renuart JPN JB X

X J. B. Perkins JNA JB X

X X

D. J. Canazaro JNA JB X

X D. A. Brown JPN JB X

X S. G. Brain JPN JB X

X i

J.T. Luke JPN JB X

X X

J. C. Gallagher JNA JB X

X X

J. S. Fields Gasser Assoc.

X X

R. S. Kundakar PTN JPN X

X*

C.R. Bible PTN JPN X

J. J. Nknas PTN JPN X

S. P. Chaviano PTN JPN X

K. W. Frehafer PTN JPN X

P. Roney PTN OC X

i R. L Henry PTN JPN X

R. Verges PTN JPN X

P. M. Banaszak PTN TS X

M. K. Adside PTN TS X

M. S. King PTN TS X

E. L. Anderson JPN ESI X

A. Castaldi JPN JB X

T. M. Sweeney JPN JB X

D. Becker JPN JB X

R. S. Custis JPN JB

~

X S. Kozlin JDC JB X

M. E. Dixon JPN JB X

L. D. Richardson JDC JB X

P. D. Savine JPN JB X

S Trepanier JDC JB X

D. Gkn JPN JB X

L.1. Kennedy JPN JB X

Contacted by phone 1/11/93 4 Sf 6 l

1 l

\\D REPORT OF QUALITY ASSURANCE DEPARTMENT AUDIT Audit No:

OAS-JPN-93-4 1

Kiy.:

i A - Pre-Audit Conference B - Interviewed or Contacted During Audit C - Attended Post-Audit Conference i

References:

10 CFR 50, Appendix B TOR 3.0 OP 2.15, 3.2, 3.4. 3.6 JPN Of 3.1, 3.1 -3, 3.1-6, 3.2, 3.14, 6.5 Pre-Audit Conference:

Post-Audit Conference:

Location:

Juno Beach Location:

Juno Beach Date:

November 5,1993 Date:

December 14,1993 January 11,1994 (telecon w/R. Kundalkar)

Summary of Post-Audit Conference:

The results of the audit were presented to the auditee. Discussion were held relative to obtaining corTective action to the audit finding and concerns. It was agreed that the audit finding would be closed with the issuance of the Plant Manager Action item and the revised engineering instructions. It was i

further agreed that JPN would provide a separate response to the concems identified in this audit report,j l

5 of 6 i

NN 1

,i REPORT OF QUALITY ASSURANCE DEPARTMENT AUDIT

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Audit No:

QAS-JPN-93-4 Aud tor:

Y W. W. Woodard Date Performance Assessment Juno Beach Accompanying

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f J. B. Perkins Date Performance Assessment' Juno 86ach JwJh1 l-E4'-9'I

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Date Technical Specialist Gasser Assoc.

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Instl MFG #2 FIP FISCHER $ PORTER CO.

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PROCESS RANGE W1 0-12 N/A ENGINEERING PROCESS UNITS $1 GPM N/A ENGINEERING SIGNAL INPUT 81 4-20 N/A ENGINEERING INPUT UNITS #1 MA DC N/A ENGINEERING SIGNAL OtJTPW #1 N/A OUTPUT UNITS #1 N/A SCALE RANGE #1 N/A j

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ELECTRONIC TRANSMITTERS Gentlemen:

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chaser's Identification No. FLO-8770.138, Revision 8,. dated April.24,1975,.+. fi.

entitled " Electronic Transmitters & Hiscellaseous', Electronic, Instruments"..,$20'-

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. ' '9 ITEM QTY ITEM l QTY ITEM QTY ITEM. OTY IMM QTY BTEM QTY 3UBBLER. SYSTEM AT REACTOR CAVITY 2

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SEE B770-B-258 % M-j seAsco senwcas wecompostArvo FIDRIDA POURER & LIGHT CoefMW '8770

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INSTALLATION OF BUB 8LER WT R2 PCM 320-i8g

... iz -a -n ? - g --- 7 SYSTEM AT REACTOR CAvlTY SUMP e

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Facility: PSL Unit: 01 LMDi l Componenti LT-07-12 l

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1 I I I

TOTAL EQUIPMENT CATA BASE SHEET EQ Tag N/A EQ Rev N/A EQ Doc Pact N/A System: 07 CONTAINMENT SPRAY Seismic: 1 Safety Class SR Eng Ref Q Group: N/A EQ Sury Note: N/A EQ Speeri N/A RG197: N EQ Related: N EQ Scews N/A RG197 Cat _

Q Basist ____ EQ Remarks: N/A RG197 Type,

Comp Type IX Sub Types T Kafety Channe.'

NS Pem Name: LEVEL TRANSMITTE.- FOR REACTOR CAVITY SUMP LEAK CETECTION i

Loen Codes RCB/0/N-O/W-25 Startup System: 039 Locn Desc Instl MFG W.: NAS NATIONAL SONICS Engineering Verified: Y Instl Model 3005/320 Revs 000 Orig Pos NY-422370 Comp Group: L-07-12 NPRDS Y Acet No: 530 P3 iab:

Insulation Rmvli Train:

Scaffold Req:. Critical Compi, Control Room Comp:,

Work Groupe IST Reqdi N RWP Reqd: Y M2 int Pgms: _ _ _ _ _ _ _ _ _

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TOTAL EQUIPMENT DATA BASE SHEET l

Drrwing Sheets Coordinates 8770-8152 8770-B-231 07-11 8770-B-327 576 6770-G-088 (K-16) 8770-G 226 1

Tsch Manuals:

2398-14281 Proctdures:

Nottas SEE PROCEDURE 1&C 1 1400154 TKM 9-1-96 1

Approved Alternate I

Mfg Description Modeli Rev. Inst 1. Eng Ver.

P2remater N213:

Value UOM:

Verfied By:

SENSING LINE QGROUP

-N/A IMPULSE LINE NO N/A TUBE TRACF NO N/A RANGk DESCR #1 N/A PROCESS RANGE #1 N/A SENSING LINE QGROUP B N/A ENGINEERING IMPULSE LINE NO N/A N/A ENGINEERING TUBE TRACK NO N/A N/A ENGINEERING PROCESS RANGE #1 N/A PROCESS UNITS #3 N/A SIGNAL INPUT #1 N/A INPUT UNITS #1 N/A SIGNAL OUTPUT #1 N/A OtfTPUT UNITS #1 N/A SCALE RANGE #1 N/A SCALE UNITS #1 N/A

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j l l Component: LS-07-12 l l l Associate:

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TOTAL EQUIPMENT CATA BASE SHEET Drawing:

Sheet Coordinates 8770-B 327 576 9770-G 088 IX-15) 5770-8153 8770-6154 Tech Manuals:

2958-14281 1

Procedures:

. 1400154 1400065 Notes:

Approved Alternate Mfg

==

Description:==

Model:

Rev. Inst). Eng Ver.

Persmater Nicas Value:

UOM:

Verfied By:

FROCESS RANGE #1 N/A PROCESS UNITS #1 N/A SIGNAL INFUT #1 N/A INPUT UNITS #1 N/A SIGNAL OUTPUT #1 N/A OUTPUT UNITS #1 N/A SCALE RANGE #1 N/A SCALE UNITS #1 N/A CONTROL CLASS #1-1 N/A ACTION #1-1 INCREASING N/A ENGINEERING FUNCTION #1 1 HI A N/A ENGINEERING PROCESS SETPT #1 1 1

N/A ENGINEERING FROCESS RESET #1-1 N/A FROCESS UNITS #1-1 GFM N/A ENGINEERING ACTUATION SETPT #1-1 __

N/A ACTUATICN RESET #1-1 N/A ACTUATION UNITS #1'-1 N/A

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( lPage of l

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TOTAL EQUIPMENT DATA BASE SHEET EQ Tag: N/A EQ Revs N/A EQ Doc Face N/A Systemi 07 CONTAINMENT SPRAY j

Seismic N Safety Class NNS Eng Ref Q Group: N/A EQ Sury Note: N/A EQ Speer: N/A RG197s N EQ Relateds N EQ Scews N/A RG197 Cat:,

Q Basist EQ Remarks: N/A RG197 Type:,

Comp Type: IB Sub Types B1 Safety Channel: NS Pem:

Names LEVEL SWITCH FOR REACTOR CAVITY SUMP LEAK HIGH DETECTION Locn Code: RCB/23/N O/W-25 Startup System: 039 Locn Dese:

l Instl MFG si NAS NATIONAL SONICS Engineering Verified: Y Instl Model: 300C Rev: 000 Orig Pos NY-422237 Comp Groupr L-07-12sANN N-46 WPRDS: Y Acet No 530*

EQ Tabs,,, Insulation Rmvli, Train,

Scaffold Regi. Critical Comp:, Control Room Comps,

Work Group IST Reqd: N RWP Reqd Y Maint Pgms:,,,,,,,,,

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'I

't Purchance'n Ideittficatfon No. PLO-8770.323 II

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JUL 10 HIS 1

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EBASCO SPECIFICATION..,

ULTRASONIC L1Qt!LO LEVEL SWIYCIICS

l

~

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PURCilASER Florida Power & Light Companv i

STATION St T,ucie Plant PROJECT 1975-890 M1 installation UNIT NO.

1 LOCATION liutchinson Island, Florida SELLER National Sonics m m D.. " V [S.

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Issue No._

Dato e

All Originni 3/28/75 R Daverto N tlallach R1 4/10/75 R Daverio N ',Jallach A'Id. 11 Add. C R2 5/27/75 R Daverio

- N 11allach 6/24/75 11 Daverio N tlallach Add. C R3

l i

k l'u r c h.u.c r ' - bicutiffc.iti.m F,llASCO SPF.CI FICATlo:1 No. Fl.0 - t.17 7 0. 32 3 !!'

ULT!!ASO:11C.1.1Qtli D !.E'.*1:1. SUITCl!KS CONTENTS Paragrapit l'acc 1

Sd0PE...............................................

1 1

2 PR0 JECT.............................................

1 CENERAL............................................

2 4

STANDARDS...........................................

1 2

5 DESIGN AND CONSTRUCTION.............................

i i

4 6

DRAWING DATA........................................

1 4

7 CLEANING.....:.......................................

5

)

8 PAINTING.............................................

I 5

9 LA11ELS..............................................

5 lo S tr.C Int. T00 tS.......................................

Q UA LI TY C OMPLIA N CE...............*..- r......'..' t '!...~ 5 '

11 ADDENDIRt A Sil 1.

ADDEMDil:1 11 Sil 2,3 ADDENDUlt C Sl! l t

4-l 4

I

_ _._ _._.._. _. _ _.. - _. _ __ _ _____ __ _._. _ _.. _ _ _. _.. _. _ - ~

P.P.ASCO SP!'t:! PICAT!Otl Purcha.c r '- identfiImffon i

l>

IJilll:ASOMIC l.lQUID ' l.P.VCL SUlTCfl!'S No. Pl.0 - H 7 7 0,12 Jll -

SCOPF.

a -

This specification covers performance and const.ruction i

1.

)

It is not the intent features of tiltrasottic of Liquid Level Swiches.

to completely specify all detalla of design and construction, never-in all respects shall comform to hir,h utandarda of the)c.ss, equipacnt

.engineeriny,'deslgn and '.torkmanship.

l PROJECT f

Florida Power & T.f cht Comninty_

2.

' Operating Company _

Station St Lucie Plant Projcet 1975 - 890 000 KU Installatio t nit 1

If Sit.uated at

,_ f1_u t ch i nson f r. l and, Florida

' it' 18 Elevation above cea Icvel Hanufacturer CENERAL Level switches chall be furnished for service conditions 3.1 Addendum A.

cpecified on the attached list, All items shall be suitabic for outdoor service -in a salt 1 mt e n'-~

a

. 2-hurricane winds of 194 mph 1 atmosphere and for condi tions as follows:

tornado winds of 360 mph; torrential rains and high ambient temperature of 135 F and 100 percent humidity.

6 Switches that are an essential part of the Nucicar Safeguard System

.3 design are classified. Class I.. Extra marcin of safety shall be used in their and fabrication to assure reliability under all conditions of operation.

The equipment designated Class I shall be designed to uithstand

.4 scismic acccicrations an represented by the floor responne spectra developed for the different buildfucc-in the plant.

The Sc11er will be required to the equipment wlll-not suf fer loas or change of funct ion substantiate that under the. design acccierations.

~

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1.

a i

EllASCO SPECI FICATION Purchashcr's Identificatio j ULTRASONIC LIQUID 1.1 Vl'.L SWITilCES No. FLO-8770. 32311 j

4 4.

Construction materials shall comply with the latest STANDARDS revision of applicable codes of Araerlean ;;JLional Standards institute Inc; American Society of Mcchanient Enginecru, Instrument' Society of

. America, Inu'titute of Electrical & Electronic Engincet

.nd National Electrical Manu,facturers' Association.

5.

Design and construction of the icvel switches shall,. unicss DESIGN AND otherwise noted on the attached data sheets, be as described herein.

The switch shall be of the ultrasonic type, that is, it shall consist of an ultrasonic sensor and an cicetronic control unit.

The sensor

~

shall be insensitive to variations in viscosity, density, temperature and pressure.

The control unit shall be all solid state components mounted on moisture-proof circuit boards.

The control unit's enclosure shall be made of steel and shall be ahic to uithstand the following environmental conditions:

1) Temp 150 F

2)

Radioactive atmosphere of 1 Rad /IIr for 40 years and a 2 hour2.314815e-5 days <br />5.555556e-4 hours <br />3.306878e-6 weeks <br />7.61e-7 months <br /> emergency condition of 2 x 10 Rad /llr.

)

3) Watertight (NIU1A4)

The sensor shall be made of 316 Stain 1 css Stect and shall be able to withstand the following environraental conditions:

1) Temp 300 F

2)

Pressure 1000 psig 8

3) Radioactive atmosphere of 5 x 10 rads' The coaxial cabic shall be abic to withstand the following enviromental cotiditions :

T Temp.221__ cantip.ucus 1) 8 2)

Radioactive atmosphere of 5 x 10 reds.

R 6

_.. _. _ = _. _.. _.. _ _ _ _ _ _

-m___

"'"'"8 8

EBASCO SPECIFICATION ULTRASONIC LIQUID LEW.L SWITCllES No. FLO-8770.32311 6.

Sc11er's drawing reproducibics shall include at 1 cast the DRAWING DATA following:

a - Tag numbers.

b - Complete piping and wiring connections.

c - Mounting and space requirement dimensions, d - purchase Order Number l

7. The Seller shall maintain a high standard of cicanliness CLEANING

]

during fabrication and assembly of the instruments to insure accurate j

J and trouble fr2e performance. ' Introduction of foreign materials and l

compounds into the process system by contaminants in instruments is objectionabic. 11alogens in contact with stainicss steels is particu-larly objectionabic.

The parts of any instrument in contact with process fluids shall be thoroughly cicaned of chips, dust, rust, abrasives, scale',

oils and greases.

Stainicss steci and nickel base alloy process-contacting portions of the furnished instruments shall be rinsed with a halogen-free detergent such as Alconox or a solvent such as Acetone or 99.9 percent pure Isolpropyl Alcohol. followed by an appropriate, flushing with water or other solution containing no more than 20 ppm of halogens and then dried with oil-free air.

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0 EBASCO SPECIFICATION Purchascr's Identification ULTRASONIC LIQUID 11Vl:L SUITC11ES No. FLO-8770.32311 8.

All surfaces subject to corrosion shall have at least one PAINTING All

r. hop coat of suitable paint after cleaning, as by wire brush.

assembled equipment shall have a complete permanent exterior finish of the naLure and the color cuctomarily used by the Seller.

LABELS 9.

All cquipment and cystem components shall be identified by the Seller.with metal tag bearing Purchaser's Order No, and Tag i

No. substantially wired to the object.

10.

Sc11er shall furnish all special tools required for the SPECIAL 1

TOOLS installation and carc of the equipment.

11.

Seller shall submit to the Purchaser the following documents QUALITY COMPLIANC for review and acceptance prior to any fabrication on all switches designated Class I.

a - Material Specifications for process contacting portions.

b - C1 caning procedures c - Copics of scismic qualifying data per paragraph 3.4 of this specification.

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EinSCO S1'EC1l'ICATIO:1 Purchaser's idenLiCication ULTI:ASONIC L1QUJD LEVEL SUITCl!ES No. FLO-8770.32311 11.3 Sc11er r. hall submit the following documents to the QUALITY COmW M purchaser prior to fabrication.

(Cont,d) a - lisuufacturer's quality cent rol procedures.

.4 Seller shall submit tuo copien of all test reports to the purchaser.

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QUALITY COMPLlANCE REPORT NY-42237_0 _, _,

l omosa mo.,_

I' lor ida l'ower 1. l.ir.h t 8:orrpeny r.,,,,

suP9 No. _

^"'I' "I

enoircs Natlonal Sonics _

_ usuuractuaea Ultramonic Liquid Level Switches

_ IftLc" __ Final Release FLO-8770-32il nev0

_ E.,,co_

June 18. 1975 spec me.__

Farmingdale. New York t.0c A r#0N _

11587 REF.NO.

June 18._1_975 OATE

~~~

$ HOP NO.

f D* hble - Sales Kggr_y.fintAtive t

TITLC PERSONNEL CON T ACTED &

A CJcioppo - Field Eng F Dicreacio - QC Insp'r 1

ELECTRICAL EQUIPMENT itf*0RT NO.

the i visited the f acilicies of National Sonics in Famingdale, New York today fru

~

purpose of conducting a final examination on the equipment being supplied on functional tests were Upon completion of my examination of the equipment, Test results from crder.

The liquid '.evel switches and associated control perfomed.

and found to be satisfactory.

units are acccitable and are released.

Equipment Examined:

Serial No.

Item No.

Quantity _

Tag No.

Description S, M Idi d odel 3005 Level Sensor with I

1 18" extended length sensor, 200 feet of radiation cable 2

1 LT-06-40 Model 300S Level Sensor with 100 feet of radiation cable 3

1 LT-06-41 Model 300S Level Sensor with 40 feet of radiation cable 75D63 4

3 LS-06-41 Model 300C Controller 10A-75D64 IS lg NEMA 4 enclosure, 75D65 kN@6Eu DPITT relay,115v/60Hz mm-mm I

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