ML20138Q618
| ML20138Q618 | |
| Person / Time | |
|---|---|
| Site: | Catawba  |
| Issue date: | 12/12/1985 |
| From: | Dance H, Skinner P, Van Doorn P NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML20138Q595 | List: |
| References | |
| 50-413-85-48, 50-414-85-56, NUDOCS 8512270320 | |
| Download: ML20138Q618 (8) | |
See also: IR 05000413/1985048
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UNITED STATES
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NUCLEAR REGULA7ORY COMMISSION
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101 MARIETTA STREET, N.W.
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ATLANTA, GEORGI A 30323
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Report Nos.: -50-413/85-48 and 50-414/85-56
Licensee: Duke Power Company
422 South Church Street
Charlotte, NC 28242
Docket Nos.:
50-413 and 50-414
License Nos.:
NPF-35 and CPPR-117
Facility Name:
Catawba 1 and 2
Inspection Conducted:
October 26 - November 25, 1985
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Inspectors:
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Approved by:
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C. Da'nce', Section Chief
Dat'e Signed
Division of Reactor Projects
SUMMARY
Scope: This routine, unannounced inspection involved 109 inspector-hours on site
in the areas of followup of licensee and NRC identified items (Units I and 2);
management meeting (Units 1 and 2); plant operations (Unit 1); surveillance
observation (Unit 1); maintenance observation (Unit 1); preoperational test
program implementation (Unit 2); observation of ' modifications for human
engineering discrepancies (unit 2); and review of nonconforming items (Unit 2).
Results:
Two violations were identified
Failure to follow Technical
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Specification 3.0.4 for changing plant modes; and, Failure to follow procedure
for nonconforming items.
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8512270320 851216
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REPORT DETAILS
1.
Persons Contacted
Licensee Employees
H. B. Tucker,.Vice President, Nuclear Production
G. R. Vaughn, General Manager, Nuclear Stations
- J._W. Hampton, Station Manager
E. M. Couch, Project Manager
- H. L. Atkins, QA Engineering Supervisor
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H. B. Barron, Operations Superintendent
- W. F. Beaver, Performance Engineer
W. H. Bradley, QA Surveillance
- H. D. Brandes, Analytical Engineer
- T. B. Bright, Construction Engineering Manager
B. F. Caldwell, Station Services Superintendent
- J. W. Cox, Superintendent, Technical Services
T. E. Crawford, Operations Engineer
L. R. Davidson, Project QA l.ianager
J. R. Ferguson, Assistant Operating Engineer
- *C. L. Hartzell, Licensing and Projects Engineer
R. A.' Jones, Test Engineer
C. S. Kelly, Instrumentatio1/ Electrical Technical Support
R. D. Kindard,.HP Coordinator
- J. Knuti, Operating Engineer
- P. G. LeRoy, Licensing Engineer
W. R. McCullum, Superintendent, Integrated Scheduling
R. L. Medlin, QA Technical Services
C. E. Muse, Operating Engineer
T. D. Mills, Construction Engineer, Electrical
D. B. O'Brien, Administrative Methods Supervisor
C. L. Ray, Principal Design Engineer
T. Robertson, Construction Engineer
G. Robinson, QA~ Engineer, Operations
F. P. Schiffley, II, Licensing Engineer
- G. T. Smith, Maintenance Superintendent
D. Tower, Operating Engineer
- E. G. Williams, Project QA Technician
- J. W. Willis, Senior QA Engineer, Operations
Other licensee employees contacted included construction craftsmen,
technicians, operators, mechanics, security force members, and office
personnel.
- Attended exit interview
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2.
Exit Interview
The inspection scope and findings were summarized on November 24, 1985, with
those persons indicated in paragraph 1 above. The violations and unresolved
items described in paragraphs 3, 5, 8 and 9 were discussed in detail. The
licensee acknowledged the findings and had no dissenting comments.
The
licensee did not identify as proprietary any of the materials provided to or
reviewed by the inspectors during this inspection.
3.
Licensee Action on Previous Enforcement Matters
a.
(0 pen) Unresolved Item 414/85-43-01:
Fillet Weld Leg Size for Joint
Geometry Configuration With 1/16 to 3/16-inch Gap Not Considered at
Final Weld Inspection. The inspector met with licensee representatives
to discuss this issue and also reviewed licensee documentation of their
position relative to this issue. The licensee considers that they have
met AWS code requirements and have had adequate surveillance
inspections and audits to verify that fillet weld sizes were increased
relative to fitup gap as required by the code. The licensee documenta-
tion was forwarded to NRC:RII for further review.
This item remains
open pending further review by NRC.
b.
(Closed) Unresolved Item 413/85-31-02:
Failed Containment Spray Pipe
Support.
This item involved a Containment Spray System (NS) pipe
support 2-R-NS-0080 discovered by an NRC inspector to be partially
pulled out of the wall.
The licensee conducted further evaluation at
the request of the inspector and discovered that the damage to the
hanger was caused by a water hammer which occurred in April 1985. The
licensee further indicated that a Nonconforming Item Report (NCI) was
not issued at the time of the occurrence and only a partial system
walkdown which did not include the damaged, hanger had been conducted to
evaluate the effect of the water hammer.
The licensee has now
completed a total walkdown and is also conducting further evaluation of
the NS heat exchanger at the request of engineering personnel. These
evaluations are being documented on NCI Nos. 19890 and 19956.
Construction QA Procedure Q1, Revision 24, Control of Nonconforming
Items, requires licensee personnel to initiate an NCI for items which
do not meet design requirements. Since a water hammer is an occurrence
which has a high potential for damaging piping systems, this situation
should have been documented on an NCI.
Therefore, this item is
considered to be a violation of 10 CFR 50, Appendix B, Criterion V
which requires that activities affecting quality be performed in
accordance
with
established
procedures.
This
is
violation
414/85-56-01:
Failure to Follow Procedure for Control of Nonconforming
Items - Water Hammer in Containment Spray System.
c.
(0 pen) Unresolved Items 413/85-20-01, 414/85-16-01:
Verification of
Adequate
Installation of Instrumentation.
The
inspector held
discussion with licensee personnel and reviewed documentation relative
to this item. Licensee's seismic analysis has shown that transmitters
for the instrument loops questioned, Refueling Water Storage Tank
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Level, are adequately mounted.
In addition, the licensee has
reinsulated heat traced Loop No. 1FWLT5000. Therefore, no questions of
operability remain for the questiened instrument loops.
The inspector
requested the licensee 'to evaluate why the seismic analysis had not
been performed prior to being questioned by the NRC and why the
insulation was found to be missing from Loop No. IFWLT5000. This item
remains open pending this additional licensee evaluation.
No violations or deviations, except as described in paragraph 3.b., were
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identified.
~4.
Unresolved Items *
New unresolved items are identified in paragraphs 8 and 9.
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5.
Plant Operations Review (Unit 1) (71707 and 71710)
a.
The inspectors reviewed plant operations throughout the reporting
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period to verify conformance with regulatory requirements, Technical
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Specifications (TS), and administrative controls.
Control room logs,
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danger tag outs, Technical Specification Action Item Log, and the
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removal and restoration log were routinely reviewed.
Shift turnovers
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were observed to verify that they were conducted in accordance with
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approved procedures.
The . inspectors verified by observation and interviews, that measures
taken to assure physical protectior, of the facility met current
requirements.
Areas ' inspected included the security organization, the
establishment and maintenances of gates, doors, and isolation zones in
the proper condition, that access control and badging were proper and
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procedures followed.
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In addition to the areas discussed above, the areas toured were
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observed for fire prevention and protection activities. These included
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such things ~ as combustible material control, fire protection systems
and materials, and fire protection associated with maintenance and
construction activities.
b.
The inspector reviewed Operations Division Nonconforming Item Reports
(NCIs) to determine if documentation was clear and complete and whether
appropriate resolution and corrective action was specified.
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- An Unresolved Item is a matter about which more information is required to
determine whether it is acceptable or may involve a violation or deviation.
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c.
The licensee informed the NRC on September 22, 1985, that reanalysis
for their McGuire Nuclear Station had shown that containment peak
pressures would exceed the previously assumed design value of 15 psig
by 0.8 psig. The inspector requested information as to whether this
reanalysis also affected the Catawba plant. The licensee informed the
inspector that analysis for Catawba indicated that pressure would be
reduced from 14.68 psig to 13.3 psig and also forwarded a copy of the
proposed Rev. 14 to the FSAR.
Licensee actions appear acceptable.
d.
On November 19, 1985, the licensee identified that they were in violation
of Technical Specification (TS) 3.0.4 in that they entered into Mode 4
and subsequent higher modes with one train of the containment air
return system (VX) inoperable. TS 3.6.5.6. requires both trains of the
containment air return system to be operable.
A review of this occurrence
identified that a work request had been written on November 4,1985 to
repair a failed damper in the VX system. Through errors in the raview
process, this work request had not been identified as TS related work
and therefore mode dependent. Jpon identification of this problem, the
licensee took prompt action as specified by the TS. This is the second
similar occurrence of this type,
i.e.,
entering into a mode without
satisfying all operability requiremants, within the rast 12 months.
The other example is discussed in Inspection Report 50-413/84-106.
It appears that the corrective actions for the previous violation may
not have been sufficient to preclude other occurrences of this nature.
This is identified as Violation 50-413/85-48-01; Failure to meet
TS 3.0.4 requirements for changing operating modes.
6.
Surveillance Observation (61726) (Unit 1)
During the inspection period, the inspector verified plant operations were
in compliance with various TS requirements.
Typical of these requirements
were confirmation of compliance with the TS for reactor coolant chemistry,
refueling water tank, emergency power systems, safety injection, emergency
safeguards systems, control room ventilation, and direct current electrical
power sources.
The inspector verified that surveillance testing was
performed in accordance with the approved written procedures, test
instrumentation was calibrated, limiting conditions for operation were met,
appropriate removal
and restoration of the affected equipment was
accomplished test results met requirements and were reviewed by personnel
other than the individual directing the test, and that any deficiencies
identified during the testing were properly reviewed and resolved by
appropriate management personnel.
Typical of the surveillance items that were witnessed in part or in full
were various calibrations of the nuclear instrumentation radiation
monitoring systems instrumentation, battery testing, auxiliary feedwater
system testing, and heat removal system testing.
No violctions or deviations were ident*fied.
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7.
Maintenance Observations (62703) (Unit 1)
Station maintenance activities of selected systems and components were
observed / reviewed to ascertain that they were conducted in accordance with
the requirements.
The inspector verified licensee conformance to the
requirements in the following areas of inspection:
the activities were
accomplished using approved procedures, and functional testing and/or
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calibrations were performed prior to returning components or systems to
service; quality control records were maintained; activities performed were
accomplished by qualified personnel; and parts and materials used were
properly ~ certified.
Work requests were reviewed to determine status of
-outstanding jobs and to assure that priority is assigned to safety related
equipment maintenance which may effect system performance.
No violations or deviations were identified.
8.
Licensee Identified Items 50.55(e) (Unit 2) (99020)
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a.
The inspector reviewed the licensee's evaluation of a potentially
reportable item involving plastic melted onto stainless steel piping
systems.
This problem .was referenced in NRC Report Nos. 413/85-43,
414/85-46. The licensee found no detrimental effects on the piping and
therefore informed the NRC that this item was not reportable. Licensee
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actions are acceptable.
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b.
The inspector also held discussions with licensee personnel relative to
a potentially reportalle item involving cold springing of safety-
related piping.
The NRC was informed of this issue as potentially
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reportable on November 8,
1985.
This issue involves a concern
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expressed by a licensee employee in a licensee conducted interview that
a craft pipefitter foreman had allowed cold springing of safety-related
piping in order to accomplish weld joint fitup. This is prohibited by
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licensee QA procedures unless design analysis is accomplished.
The
licensee has formed a task force which has interviewed 21 craftsmen,
two inspectors, two technicians, and the accused foreman.
Three
instances of possible cold spring have been identified. One situation
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was apparently corrected at the time it occurred and two others are
being evaluated by the licensee.
The licensee is documenting each
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interview and intends to prepare a report on their investigation and
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evaluation.
Preliminary indications are that this situation is
isolated to a particular crew and time frame and that the cold sprung
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piping will be acceptable for its intended service.
However, further
evaluation by the licensee and NRC is necessary and therefore, this is
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Unresolved Item 414/85-56-02:
Evaluation of Cold Spring in Safety-
Related Piping.
No violations or deviations were identified.
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9.
Preoperational Test Program Implementation (Unit 2) (71302)
The inspector conducted tours to verify that turned over equipment was
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' adequately protected and controlled. This review included observation
of construction activities, observation for fire hazards and observa-
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tion of security boundaries.
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b.
The inspector observed conduct of portions of the preoperational test
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program.
This included discussions with the test program director and
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test engineers, general observation of testing and operations in the
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control room and observation of specific tests described below. This
inspection was performed to assess whether the licensee was conducting
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a well organized program, personnel had a good understanding of
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responsibilities and conduct of specific tests, control or organiza-
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tional interfaces was good, procedurcs were properly approved, control
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of test schedule was adequate and current drawings and manuals were
used by the licensee.
The tests observed were as follows:
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TP/2/A/1100/02A, Section 13.11, Diesel Generator consecutive
starts - observed start No. 42 for Diesel Generator 2A. This was
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the tenth valid start of 35 required.
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PT/2/A/4200/09A, Section 12.37, Checkout of auxiliary safeguards
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electrical logic for Containment Spray System Train A.
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The inspector also reviewed Construction Nonconforming item Reports to
verify that appropriate ' documentation and evaluation was acconplished
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for nonconforming conditions on systems being
turned-over
to
operations.
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No violations or deviations were identified.
10.
Special Inspection of Modifications for Human Engineering Discrepancies
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(Unit 2) (70302)
The licensee has conducted a detailed Control Room design review to identify
improvements necessary to correct Human Engineering Discrepancies (HEDs).
These modifications provide for improvements in consistency of labeling,
consistency of status lights, meter scale units, visibility of meters,
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location of switches and meters, etc.
The licensee has committed in their
response to Supplement 1 to NUREG-0737 to complete modifications for 55% of
the HEDs identified prior to fuel load.
The inspector verified through
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discussions with if censee personnel, record review and physical observation
of all or portions of 77 HED modifications that at least 55% of HED
modifications have been implemented. Modifications were observed for HED
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Nos. C-1-51, 84, 87, 91, 98,117,119, 204 (partial), 211, 235, 238, 241,
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244, 255 (partial), 256, 304, 307, 327, 338, 341, 361 (partial), 367, 368,
369 (partial), 387, 390, 395, 399, 400, 402, 403, 405, 408, 411, 417, 423,
467, 509 (partial), 5, 8, 9, 10, 22, 42, 43, 45, 53, 58, 68, 72, 78, 89,
105, 251, 283A, 283E, 301, 324, 332, 344, 345, 350, 353, 354, 357, 358,
392B, 438, 416, 422B, 424B, 426, 467, 468, 4708, 536, and 537.
During this review, apparent discrepancies between the actual installation
and Design Change Authorization requirement were identified.
These
discrepancies include the numbers on I/R Amps meter; Steam Generators B and
C SM Flow meters inconsistent with other similar meters; NS Train B SI and
Containment Ventilation Phase A Isolation push buttons; legends not removed
for valves 2RC*3, 2RC4, 2ND26, and 2ND60; CFPT 2A and 2B T-GR status lights;
and labels for valve 2NV238A, CFPT 2A and 2B, Chill Surge Tank, Steam Dump
Select, Steam Generator Stm Flow Select, and 2YM100 UST Level Ctr1.
The
inspector requested construction personnel to evaluate these discrepancies.
In addition, the inspector requested operations personnel to evaluate an
apparent inconsistency in range markings on the Hot Leg Wide Range Pressure
meters and to reevaluate installation of non glare meter lenses since these
lenses appear to blur the meter images,
e.g., S/R Count Rate and I/R Amps
meter.
These questions are assigned Unresolved Item No. 4154/85-56-03: Evaluation
of Human Engineering Discrepancies in Control Room.
No violations or deviations were identified.
1;.
Previously Identified Inspector Findings (Units 1 and 2) (92701)
(Closed) Inspector Follow'up Item 413/85-41-01, 414/85-40-01: Evaluation of
Testing of PORV NC34A. The inspector held discussions with licensee test
personnel and a vendor representative and reviewed the licensee's pressure
vs. time plot of this valve appears to be adequ' ate.
No violations or deviations were identified.
12. Management Meeting (Units 1 and 2) (30703)
NRC:RII Management (Mssrs. R. D. Walker, J. P. Stohr, V. L. Brownlee, and
H. C. Dance), and NRC Licensing Project Manager, K. N. Jabbour met with
licensee management onsite on November 15, 1985, to assess readiness for
Unit 2 licensing.
Plant tours were conducted and discussions were held
relative to status of construction completion, test status, procedure
status, diesel generator status, staffing, licensing issues, TS, and Unit 1
operating history.