IR 05000317/1992032
| ML20138D642 | |
| Person / Time | |
|---|---|
| Site: | Calvert Cliffs  |
| Issue date: | 01/29/1993 |
| From: | Gray E, Lohmeier A NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML20138D640 | List: |
| References | |
| 50-317-92-32, 50-318-92-32, NUDOCS 9302230028 | |
| Download: ML20138D642 (3) | |
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U.S. NUCLEAR REGULATORY COMMISSION
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REGIONI REPORT / DOCKET NOS. 50-317/92 32 50-318/92-32 LICENSE NOS.
DPR-53 DPR49 LICENSEE:
Baltimore Gas & Electric Company FACILITY NAME:
Calvert Cliffs Nuclear Power Plant Units 1 & 2 INSPECTION AT:
Lusby, Maryland INSPECTION DATES:
November 30 - Dece.nber 3,1992 f)
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f3 INSPECTOR:
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e A. Lohrifeier, Sr. Reactor Engineer, Date '
Materials Section, EB, DRS
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9b APPROVED BY:
E. Harold Gray, Chief,' Materials Section, Date Engineering Branch, DRS Areas Insoected: The scope of this inspection included the assessment of engineering organization personnel changes, design engineering and plant engineering performance, fatigue cycle monitoring program, emergency diesel generator anti-missile door bolting adequacy, POSRC activity, modification package review, welding program control, and the 10 CFR 50.59 screening process.
Results: Management cross functiona' transfers has the potential for improved effectiveness of engineering organizations. The engineering performance measurement system provides a comprehensive me.ans to direct engineering efforts. The fatigue cycle monitoring program is used to demonstrate that fatigue will not affect the operability of the site components during operation up to and beyond the current license operating period. The boinag of the heavily reinforced diesel generator doors was not accomplished at a level of workmanship commensurate with a nuclear power generation facility. By-pass valve modification package reviewed was comprehensive and consistent with regulatory requiremets and good engineering review practice. The licensee is implementing a corrective action program to focus on the education of welding supervisors and coordinators to improve welding performance.
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9302230028 930211-PDR ADOCK 03000317 O
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1,0 SCOPE OF INSPECTION The scope of this inspection included the assessment of engineering organization personnel changes, design engineering and plant engineering performance, fatigue cycle monitoring program, emergency diesel generator anti-missile door bolting adequacy, POSRC activity, modification package review, welding program control, and 10 CFR 50.59 screening process.
2.0 FINDINGS 2.1 Engineering Organization Personnel Changes The licensee apprised the inspector of recent personnel changes in key plant engineering positions. The former plant general manager is vice president of the nuclear energy division and is replaced by the fortaer manager of nuclear engineering. The former technical support superintendent is manager of nuclear engineering. The new technical support superintencent is the former strategic engineering director.
The inspector noted that the transfer of nuclear engineering management to plant engineering functions, and visa versa, provides for engineering management experience in both functions.
This has the potential to improve the effectiveness of both engineering organizations. The format of the nuclear engineering and plant engineering organizations was unchanged.
2.2 Assessn ent of Engineering Performance Drsign Encineerine Section The inspector reviewed the November '92 Monthly Report of Performance Indicators for the design engineering section. The report covers progress made by the design engineering section toward meeting CCNPP goals related to safety and quality, generation of 11 million MWH of electricity, self assessments, and nuclear operation and maintenance expenses, The inspector noted safety and quality goal accomplishments included improved QA surveillance of 10 CFR 50.59 screening, study of de loading data, and consideration of means to stop auxiliary feedwater feed line check valve leakage. A weakness has been identified by the licensee in the make-up capability of safety-related (SR) system water norage to prov Je make-up for the service water system (SRW) because of excessive isol: tion valve leakage. Other concerns included adequacy of the design engineering specification enhancement project, and Unit 2 Cooling Water Project schedule integration.
The identification of these accomplishments and concerns were the result of evaluation performance data against established goals. In this manner, engineering adjusts its resouices towards correction of programs not meeting the established goals.
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Power generation related accompshments noted by the inspector include continued saltwater piping replacement, maintenance of containment filter units, diesel generator project improvement, reactor cavity seal replacement, and neutron shield design.
q The inspector noted that improvements through self, INPO, and NRC assessments include improved 10 CFR 50.59 training, and equipment operability task fece site-wide procedure j
development. Meteorological tower installation, reduction of field cic.nge requests, field l
change request library renovation, improving maintenance engineering library equipment i
descriptions, review of the safety tag out process, computer aided design drafting (CADD)
strategy development, and assessment of the integrated performance assessment team (IPAT)
inspection weakness related to 10 CFR 50.59 screening process projects are being. addressed by engineering.
Review of performance charts by the inspector indicated a comprehensive program of l
engineering management oversight of design engineering section performance toward meeting established Nuclear Division goals. Accomplishments and concerns are discussed in periodic management reports together with corrective action plans to alleviate the concerns.
Plant Engineering Section The inspector reviewed the plant engineering section performance monitoring charts. Thesc included temporary modifications, commitments, plant operations safety review committec
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action items, non-conformance repart action items, audit findings, facility change requests, l
minor modifications, vendor manual review, maintenance orders on engineering delay, engineering assistance requests, and safety audits.
The inspector noted that outstanding facility change requests and temporary modifications are being reduced. Auxiliary feedwater pump and site emergency diesel generator unavailability were within 1992 goals. High pressure safety injection (HPSI) system availability for Unit I was within the 1992 goal, while that for Unit 2 was above the 1992 goal.
l The inspector noted the 12 month average of thermal performance index (TPI) for Unit 1 l
was 98.7%, with the November Monthly Index at 100%. For Unit 2, however, the TPI was
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approumately 97.7% on a monthly and 12 month average basis. The TPI goal is 99%.
Steps are being taken to improve thermal performance of Unit 2.
Review of the CCNPP plant engineering performance measurement system by the inspector indicates a comprehensive means to overview plant engineering effectiveness.
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2.3 Fatigue Cycle Monitoring Program The inspector reviewed the licensee's Fatigue Cycle Monitoring program. Long Term Goal Number 1 of CCNPP is to operate safely up to and beyond the current l license operating period.- The program of cycle counting is a strategic approach to demonstrate that fatigue will not affect the operability of the site during the license renewal period.
Calvert Cliffs Instruction (CCI) 513 provides for the recording of transients / operating cycles.
Implementation of these instructions are reflected in the Mechanical Discipline Training given at CCNPP. This program is consistent with, and goes beyond, the requirements of Technical Specification Section 6.10 requiring retention of transient operation records for the duration of the operating life of the facility.
Using a program developed by Combustion Engineering.to evaluate fatigue damage in pressure boundary components, the licensee has evaluated the status of fatigue usage for critical primary system components. Results of this evaluation identify the fatigue-limiting -
components, the monitored transients, the maximum allowable number of cycles for each transient at each component, the actual number of cycles to-date, and the cumulative usage factor (CUF) for the fatigue limiting component for both CCNPP Units 1 and 2. They are listed as follows as of October 1,1992:
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Fatigue Limiting -
Monitored Max Allow Actual Actual
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Component -
Transient Cycles Cycles Cycle CUF
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U1 U2-UI U2 -
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RV Out Nozzles Plant 500
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.027 Cooldowns Press Spray Sys Initiation 120 149
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.14-Spray RV Closure Studs Plant 500
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.24 Heatups Shut Down Cooling Outlet Plant 500
48
.15
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Nozzles Cooldowns Sai'ety Injection Nozzle Shutdown 500
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.026
.016 Cooling Pressurizer Surge Nozzle Plant 500
48 Cooldown
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.076 Pressun.zer Heat-Ups 500
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S/G Tubesheet RCS Leak 320
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.026
.026-Test Pressurizer Bottom Head Plant 500
48 Support Cooldown
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.221 Reactor Tnp 400 112
S/G Secondary Shell Main FW 15000 149
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S/G FW Nozzle Main FW 15000 No Data Not Initiation Calculated Charging Inlet Nozzle Letdown 1450 134
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reinitiation
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.077
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pg Cooldown 500
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On review of the transient cycle data reported, the inspector noted, with one exception (initiation spray in the pressurizer), that the number of cyclic transients e perienced to7 ate d
remains well within the allowable numbers of cycles projected for operation throughout the-d 40 year plant lifetime. In the case of the initiation spray transient, discussion with the -
licensce indicated that the 149 transients experienced to date were mostly at a temperature.
differential less thar the minimum 200 F for which the 120 cycles were evaluated. The total usage factor calculated for the spray system under those conditions was calculated to be 0.18.
At 149 cycles,- therefore, the usage factor would be 0.22 for Unit I under the most conservative assumption of temperature differential assumed. The licensee is presently-evaluating the transients for the spray system to determine more precisely the severity or the thermal transients and the consequent usage factors.
Further review of the licensee data by the inspector indicates that the CUF was not computed for the main feedwater initiator transient. Data for this transient had not been collected over
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the past upcrating history. The licensee is now collecting this data and will trend backwards to a rive at a CUF. Since the allowable cycles are 15,000, the inspector believes the CUF-will be within the analyzed value.
Based on the assumption that the plant will continue to experience the transients at the same frequency as in the past, no fatigue failures of those components tracked by the fatigue cycle monitoring program are anticipated during the remainder of the plant life unless heretofore not considered transients of a significant nature are experienced. The inspector noted that the
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licensee can utilize the monitoring system to identify components where fatigue usage may..
challenge the remaining and extended life of the structures and provide for a basis for.
corrective action wbere racessary.
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~2. 4 Emergency Diesel Gercrator Door Ilolting During a walkdown of the exterior of the turbine building, the inspector noted that the bolting of the heavily reinforced diesel generator doors was not accomplished at a level of workmanship commensurate with a nuclear power generation facility. The inspector found that some bolts were missing and many others showed evidence that the bolt washers were of insufficient thickness. As a consequence of this, the washers were squeezed into the clearance of the enlarged holes on tightening the bolts.. The effectiveness of many of the bolts holding the doors to the diesel generator room are in question by the inspector. _ While the doors have been reinforced to preclude missile penetration, the bolting is necessary to -
sustain the dynamic loadings during carthquake. During the earthquake, the bolts most hold the missile doors. - The inspector questioned the adequacy of the diesel generator door bolting. Justification of the bolting system by the licensee is an unresolved item (URI 50-317/318/92-32-01).
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2.5 Plant Operations Safety Review Committee (POSRC)
The inspector attended a POSRC meeting on December 2,1992. At this meeting, the licensee discussed closure of a POSRC outstanding item related to fatigue failure of a Unit 1 main steam drain weld which caused a forced shut down. Failure was due to interference of the drain line with an adjacent system support. This issue was significant in that it was one of several plant trips and forced outages due to fatigue failure of small diancter pipe or tube.
The POSRC had asked the design engineering section to determine why the design of the Unit 1 main steam drain was inadequate and develop appropriate actions to prevent recurrence. They also requested that design engineering determine why preventative actions ken following previous failures did not prevent this failure and why self assessment failed tv identify an adverse trend related to fatigue failure of small diameter piping.
Design engineering response to POSRC was to conduct a comprehensive study of the related engineering issues and development of a corrective action program toward resolution of these issues. On that basis the POSRC recommended closure.
2.6 Modification Package Review The inspector reviewed the modification package for Unit 1 Main Steam by-pass valves CV 3940/42/44/46. The package related to modification of the actuators to attain a maximum opening time of 3 seconds and closing time of 5 seconds. The present design could not achieve these Bechtel specification stroketimes. Thc package included the project scope document, desi o change request, drawing change notice, letter to POSRC, design approval d
documentation, design input record, design review, cross discipline inpat screening, 10 CFR 50.59 screening, updated fimal safety analysis report (UFSAR) change notification, calculation cover sheets, document list, and facility change request 85-0068. The package indicated a comprehensive modification program, consistent with regulatory requirements and good engineering review practice.
2.7 Welding Program Control-Corrective Action Program The licensee discussed with the inspector the progress made in improving the welding program controls. The General Supervisor of Mechanical Maintenance stated the programs completed included review of recent issue reports to determine welding problems and provide refresher training for Weld Authorization Traveler (WAT) coordinators and Welding Supervisors, and providing overview training regarding the use of WATS, and review of ASME Code related issues with craft personnel. An informal root cause analysis of issue reports associated with the welding program was performed. Training was provided to Quality Assurance personnel in the welding program areas referred to in the issue reports.
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At the present time, overview training is being conducted to discuss issues and changes in the welding program for all WAT Coordinators. Furthermore, initial training tu new craft personnel and annual refresher training is being given to existing craft personnel regarding the use of WATS.
The licensee is aware of the many problems causing the generation of welding related issue reports and has descloped a corrective action program to focus on the education of welding supervisors and coordinators. This program is being implemented on schedule. The licensee stated that BG&E will move its welding engineering activity from headquarters to be part of the site staff.
2.8 Review of 10 CFR 50.59 Screening Process
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The inspector reviewed the corrective action plan of the licensee resulting from fmdings of the Integrated Performance Assessment Team (IPAT) inspection relating to the 10 CFR 50.59 screening process. The open items from this inspection were closed in
l Inspection Report 92-23. The inspector reviewed the following 10 CFR 50.59 evaluations for completeness and consistency with 10 CFR 50.59 screening procedures:
RDC No. IR9200759 Extraction steam line in FSAR not in existence
.RDC No. IR9200766 CCW system discrepancy between as-built and FSAR MCR No. 92064019 PS Modification of RCS porv block valve circuits
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MCR No. 9204100500 Charging pump tripping P&ID problem MCR No. 9206800300 Debris Cover - Spent Fuel Pool MCR No. 9201203700 Removal of vent line and isolation valve in the 23 Saltwater Pump MCR No. 9204700700 Upgrading of Yarway Indicators The supporting documentation for these items was found to be complete and consistent with
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requirements for 10 CFR 50.59 screening.
3.0 UNRESOLVED ITEAtS Unresolved items are matters for which more information is required to ascertain whether they are acceptable items, violations or deviations. An unresolved item is discussed in Section 2.4 of this report (URI 50-317/318/92-32-01 - Emergency Diesel Generator Door Bolting).
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4.0 CONCLUSIONS Transfer of nuclear engineering management to plant engineering functions, and visa versa, provide for engineering management experience in both functions and has the potential to improve the effectiveness of both engineering organizations.
Nuclear Engineering Section performance charts indicate a comprehensive program is in place giving engineering management good oversight of the design engineering section performance toward meeting established Nuclear Division goals.
The plant engineering performance measurement system provides a comprehensive means to overview plant engineering effectiveness.
The Fatigue Cycle Monitoring program is a strategic approach which is used to demonstrate that fatigue will not affect the operability of the primary system components during operation up to and beyond the current license operating period. The number of cyclic transients experienced to-date remains well within the allowable numbers of cycles projected for
,peration throughout the 40 year plant lifetime.
A review of the adequacy of the heavily reinforced die.sel generator doors is necessary in view of a level of workmanship of the bolting.
The main steam by-pass valve modification package reviewed was comprehensive and consistent with regulatory requirements and good engineering review practice.
The licensee is aware of the many problems identified in the welding related issue reports, and is implementing a corrective action program to focus on the education of welding supervisors and coordinators.
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5.0 MANAGEMENT MEETINGS The inspector met with licensee representatives at the entrance meeting on November 30,1992, and at the exit meeting on December 3,1992 at the Calvert Cliffs Nuclear Power Plant in Lusby, Maryland. The names oflicensee personnel contacted is shown on Attachment 1. Those names having an asterisk attended the exit meeting.
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ATTACIIMENT A l
The following personnel were contacted during the inspection or at the entran management r.iectings (asterisks indicate attendance at the exit meeting).
e Baltimore Gas and Electric P. G. Chabot D. DiBello Technical Support Superintendent B. W. Doroshuk Engineer - Life Cycle Management
S. Loper Principal Engineer - Life Cycle Management Plant Engineerir.g
^1. Milbradt Compliance Engineer
- G. S. Pavis
- R. L. Szoch Director - Strategic Engineering
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L. J. Tucker Principal Engineer - I&C Engineering
D. Vincent General Supervisor - Plant Engineering Section
A. M. Vogel Work Group Leader - Plant Engineering R. H. Waskey Jr.
Asst. Gen. Supervisor - Design Engineering
W. L. Whitaker General Supervisor - Design Engineering General Supervisor - Mechanical Maintenance
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U.S. Nuclear Reculatory Commission P. Wilson
Senior Resident Inspector - CCNPP
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