ML20198F385
| ML20198F385 | |
| Person / Time | |
|---|---|
| Issue date: | 10/24/1985 |
| From: | Alexander S, Dandini V NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
| To: | |
| Shared Package | |
| ML20198F375 | List: |
| References | |
| REF-QA-99900911 NUDOCS 8511140340 | |
| Download: ML20198F385 (21) | |
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ORGANIZATION: GENERAL ELECTRIC COMPANY VALLEY FORGE, PENNSYLVANIA / SAN JOSE, CALIFORNIA REPORT INSPECTION 6/3-7/85 and INSPECTION NO.- 99900911/85-01 DATE(SI: 6/19-13/85 ON-SITE HOURS: 174 CORRESPONDENCE ADDRESS: General Electric Company Nuclear Energy Business Operations ATTN: Mr. Forest Hatch, Manager, Equipment Qualification 175 Curtner Avenue San Jose, California 95125 ORGANIZATIONAL CONTACT: Noel C. Shirley TELEPHONE NUMBER: (408) 975-1192 PRINCIPAL PRODUCT: Class 1E Equipment Qualification Reports NUCLEAR INDUSTRY ACTIVITY: The GE Nuclear Energy Business Operations (NEB 0)
Equipment Qualification Program is headquartered in the GE San Jose, CA facilities with some engineering staff housed at Valley Forge, PA. They are currently conducting their " Phase III" equipment qualification program for the below listed domestic plants. All testing is conducted at the San Jose facility.
ASSIGNED INSPECTOR: N/ss s_ _
S."D. Alexadddr, Equipment Qualification Shff
'Date Inspection Section (EQIS)
OTHERINSPECTOR(S): G. Hubbard, EQIS V. Dandini, Sandia National Laboratories (SNL)
APPROVED BY: M h U. Potapovs, Chief EQlS
/C-24-K Date INSPECTION BASES AND SCOPE:
A. BASES: 10 CFR Part 21, 10 CFR 50.55(e), 10 CFR Part 50, Appendix B.
B. SCOPE: The inspection, conducted in two parts at the NEB 0 offices in Valley Forge, PA and facilities at San Jose, CA, consisted of technical review and evaluation of recent and in-progress qualification programs.
PLANT SITE APPLICABILITY: River Bend Unit 1(50-458), Nine Mile Point, Unit 2 (50-410), Hope Creek (50-354), Perry Unit 1(50-440),
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ORGANIZATION: GENERAL ELECTRIC COMPANY VALLEY FORGE, PA/ SAN JOSE, CA REPORT INSPECTIOW NO.- 99900911/85-01 RESULTS: PAGE 2 of 7 A. VIOLATIONS:
None.
B. NONCONFORMANCES:
- 1. Contrary to the requirements of Cr.iterion V of Appendix B to 10 CFR Part 50 and Paragraph 4.4.2.4.3 of NEDE-24326-1-P, justi-fications for radiation exposures in Environmental Qualification Reports (EQR) NEDC-30404 (C03) and NEDC-30446 (C59) were not documented in the Product Analysis Reports (PAR).
- 2. Contrary to the requirements of Criterion V.of Appendix B to 10 CFR Part 50 and Paragraph 4.4.8.1 of NEDE-24326-1-P, EQR NEDC-30378 (C11) did not contain a PAR.
C. UNRESOLVED ITEMS:
- 1. Site-issued Field Deviation Disposition Request (FDDR) LD1-3162 conflicted with Engineering Operating Procedure (E0P) No.55-3.00 in that it contained design changes and affected certain design documents such that it should have been issued by the central engineering organization.
GE claimed that this practice was justified based on apparent policy changes prescribed in NEB 0 QA Newsletter #68. However, it was noted that the newsletter was not an authorized vehicle for modifying approved E0Ps.
A formal procedure change was initiated during this inspection.
GE's resolution of this issue along with their reevaluation of their document change control policy and practices remains unre-solved.
- 2. Detailed work procedures in FDDR LD1-3162 for replacing damaged relays also specified adding protective dicdes at the relay outputs.
These diodes, present in other similar circuitry, had been omitted in this application (originally and in the modification design to replace some solenoid operated valves (S0V) for EQ purposes). The diodes proved necessary in view of the resulting damage which necessitated replacing the relays. The reasons and responsibility for the omissions remain to be determined.
I
ORGANIZATION: GENERAL ELECTRIC COMPANY VALLEY FORGE, PA/ SAN JOSE, CA REPORT INSPECTION Hp.- 99900911/85-01 RESULTS: PAGE 3 of 7
- 3. Neither the detailed diode installation procedure in FDDR LD1-3162 nor the QA installation check procedures (Inspection Instructions GA-024 and 026) required any electrical check of the diodes to en-sure they functioned and had been installed correctly. GE stated function of the system would be verified during preoperational testing.
D. STATUS OF PREVIOUS INSPECTION FINDINGS:
None.
E. OTHER FINDINGS AND COMMENTS:
- 1. The NRC inspectors examined dccumentation on qualification of Rosemount 1152 and 1152-T0280 pressure transmitters for Perry-1 and River Ben.;-1. GE originally purchased the 1152 transmitters as nuclear, safety-related equipment and provided them to customers as qualified to IEEE-STD-323-1971 require-ments. The present program is to upgrade qualification of plant installed 1152 and 1152-T0280 transmitters to current
. NRC' requirements. Installed transmitters will be replaced with qualified 11538 transmitters where the 1152s cannot be qualified.
Two problems with the transmitters were identified in a 10 CFR Part 50.55(e) report from River Bend and another during further GE testing: (1) test exposures to radiation were low for some locations, (2) accuracy requirements were not met for some conditions and (3) there were some potentiometer failures at high temperatures. GE prcvided documentation for justification for interim operation to River Bend for certain models pending resolution of the issue. GE evaluated it as a potentially reportable condition (PRC) under 10 CFR Part 21 and determined that it was not reportable. The qualified status of the transmitters and GE's actions on the PRC will be reviewed in a future inspection.
- 2. The inspectors reviewed EQR NEDC-30404 (C03) for Pyco Temper-ature elements at Nine Mile Point-2. The Product Performance Qualification Specification (PPQS) and the Test Plan and Pro-cedure (TP&P) differed with respect to the specified combined normalandaccidentgadiationdose. The PPQS specifies the dose to be 2.23 x 10 rad gamma totalgintegrated dose (TID).
The TP&P specifies a dose of 2.8 x 10 rad gamma TID which envelopes the dose specified
ORGANIZATION: GENERAL ELECTRIC COMPANY VALLEY FORGE, PA/ SAN JOSE, CA REPORT INSPECTION nn.- 99900911/85-01 RESULTS: PAGE 4 of 7 in the PPQS. Noexp1gnationofthedifferencewasfound, although the 2.8 x 10 rad is conservative. Deviations from the specified accuracy of the temperature element were encountered during environmental testing transients in the 250*F-300 F range and the temperature ramps were slow with respect to the step changes indicated in the test profile.
Nonconformance reports (NCR) were issued justifying the anomalies. Failure to justify the radiation exposure to be used resulted in nonconformance identified in paragraph B.1 The Froduct Evaluation Section (PES) of the EQR indicates that three samples were aged, but test results are reported for only two of them. The PES refers to a paragraph within it which is supposed to describe the disposition of all the samples if multiple identical samples are ii volved, but this paragraph is missing. Although not given anywhere in the PES, the disposition of the third sample (it was saved as a spare) is described in the PPQS. This problem will be examined in a future inspection to determine GE's resolution.
. 3. Review of documentation on qualification of an S&K Model 20-9651-8550 flowmeter revealed the following errors:
- a. The compression time calculated as necessary to simulate the post-DBE environment was entered directly onto the PPQS simulation profile. Since the time axis on the profile is for time from the start of the simulation,.the calculated time should have been added to the 6 hour6.944444e-5 days <br />0.00167 hours <br />9.920635e-6 weeks <br />2.283e-6 months <br /> time at which the time compression was to begin.
- b. The manner in which the Arrhenius equation was used to calculate the compression time had the effect of removing the 15 *F margin from the entire simulation profile.
These two errors have the combined effect of putting the sample in a condition which is potentially less degraded than would be the case for the actual 180-day accident profile.
GE agreed with the assessment of the profile, but stated that the PPQS and profile were preliminary versions which had not yet undergone review and were going to change in any case because the customers had changed environmental specifications.
T ORGANIZATION: GENERAL ELECTRIC COMPANY f VALLEY FORGE, PA/ SAN JOSE, CA REPORT INSPECTION NO.- 99900911/85-01 RESULTS: PAGE 5 of 7
- 4. The inspectors reviewed documentation on the qualification of Limitorque SB-3-150 actuators for use in Nine Mile Point-2, Perry-1 and River Bend-1. This actuator is currently undergoing testing at Wyle Labs in Norco, California. The PPQS is.incon-sistent with the PAR on normal operating temperature. The PPQS states that the normal temperature is 135 F for 470 months; whereas, the PAR lists 134 F for the same period. However, the thermal aging was ultimately based on the Nine Mile Point-2 environment which is more severe.
- 5. The inspectors reviewed the file on PRC 85-04 regarding the failure of SB-3-150 Limitorque actuators during qualification testing. Memo: R. L. Gridley to R. J. Brandon,
Subject:
PRC 85-04, Failure of Reliance Class RHAC Motors, dated 3/15/85, outlined requirements for resolution of the PRC.
GE is evaluating the problem with the Reliance motors in the actuators and has concluded that a substantial safety hazard does not exist since all affected valves will have been positioned long before failures are expected to occur.
However, GE and Reliance differ on the cause(s) of the failures and the final determination remains unresolved.
- 6. Three sets of " Functional Performance Requirements" (FPR) were contained in EQR NEDC-30378 (Cll) for Magnetrol level switches for River Bend-1: Scram Discharge Isolation Volume (SDIV) high level alarm and SCRAM switches, reactor core isolation cooling (RCIC) turbine inlet piping drain pot high level alarm and drain valve opening switch, and RCIC turbine drain pot high level alarm and drain valve opening switch. The FPR for the SDIV and RCIC turbine inlet applications were inconsistent with the FPR for the RCIC turbine drain application with respect to acceptability of ground fault failure modes. The electrical interface descriptions for the RCIC turbine inlet and turbine drain switches both specify 125 vDC, Instrument Bus "A" as the supply. This bus is listed as ungrounded in the RCIC' turbine inlet section, thus rendering a single ground fault acceptable; whereas, in the RCIC turbine drain section, the bus is listed as grounded, thus rendering a ground fault unacceptable. GE deter-mined and reported that, in fact, Instrument Bus A is ungrounded and that the error and its cause would be investigated and corrected.
As a result of this review, nonconformance identified in paragraph B.2 was identified.
ORGANIZATION: GENERAL ELECTRIC COMPANY VALLEY FORGE, PA/ SAN JOSE, CA REPORT INSPECTION NA .
QQQnnQ11/85-01 _,. RESULTS: PAGE 6 of 7 ,
- 7. The documentation pertaining to the RCIC turbine drain pots and the SDIV drain pot contained correspondence which reported problems with leakge at the level switch instrument tube-to-float chamber joint noted during hydrostatic testing. The manufacturer's resolution was to increase the torque on the joint union until the leakage was prevented. This torque l (200 ft-lbs) was then made a specification (where there had apparently been none before) and the documents indicated that manufacturer's drawings would be changed accordingly. It was not evident however, that associated GE drawings and specifi-cations, or licensee as-built drawings and maintenance proce-dures would also be changed where appropriate. This concern was raised with GE personnel who agreed to investigate the matter. This item will be reviewed in a future inspection.
- 8. The NRC inspectors reviewed documentation pertaining to PRC No.
ENG 113 concerning arcing and subsequent control circuit damage which had occurred during preoperational testing of replacement backup scram solenoid valves at River Bend-1. (See Unresolved Items C.1, 2, and 3.) A 10 watt, ASCO S0V had been replaced under GE's " Phase III" EQ program with a qualified, 190 watt Valcor 50V. The arcing resulted when originally installed relay contacts could not interrupt the higher current and large inductive kick from deenergizing the Valcor S0V. GE's evaluation of the PRC was that while the problem required immediate corrective action (as specified in FDDR LD1-3162 Rev. 0), it was not a reactor safety concern since (a) the valve performed the backup scram function and (b) the malfunction would occur after the valve had operated. Noting also that River Bend had reported the deficiency to the NRC under 10 CFR Part 50 950.55(e) (as also reported to GE in River Bend's Customer Deficiency Report No. 292),
GE made the determination that they did not need to report the matter to the NRC under 10 CFR Part 21. The NRC inspectors were told that GE was investigating the condition at the other plants affected (Hope Creek, Perry-1, and Nine Mile Point-2) and that, if applicable, a similar disposition would be made in those cases.
GE's corrective actions in this instance and the design control issues they raise will be reviewed during a future inspection.
1
ORGANIZATION: GENERAL ELECTRIC COMPANY '
VALLEY FORGE, PA/ SAN JOSE, CA l
REPORT INSPECTION No - 4Q400911/85-01 RESULTS: PAGE 7 of 7
- 9. Table 2-1 of GE Licensing Topical Report on QA, NED0-11209-04A Rev. 5, dated March 1,1985, comits to Regulatory Guide 1.28 (6/72) and ANSI Standard N45.2-71 whereas effective revisions /
editions are Regulatory Guide 1.28, Rev. 1, 1979 and ANSI Std.
N45.2-77.
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