ML20203B563

Insp Repts 50-424/86-45 & 50-425/86-22 on 860519-23. Violation Noted:Failure to Accomplish Corrective Action Prescribed in Deviation Rept PP-12074

ML20203B563
Person / Time
Site:	Vogtle
Issue date:	06/27/1986
From:	Conlon T, Gibbons T NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
To:
Shared Package
ML20203B546	List: ML20203B540 ML20203B554 ML20203B563
References
50-424-86-45, 50-425-86-22, NUDOCS 8607180251
Download: ML20203B563 (9)

See also: IR 05000424/1986045

Text

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NUCLEAR REGULATORY COMMisslON <

[ g REGION 11

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j 101 MARIETTA STREET, N.W.

g ATLANTA, GEORGI A 30323

'+4 . . . . . $

Report Nos.: 50-424/86-45 and 50-425/86-22

Licensee: Georgia Power Company

P. O. Box 4545

Atlanta, GA 30302

Docket Nos.: 50-424 and 50-425 License Nos.: CPPR-108 and CPPR-109

Facility Name: Vogtle Units 1 and 2

Inspection Conducted: May 19-23, 1986

Inspector: (r hdher.4 6 b7!f4

T. D. Gib~ bons Date Signed

Accompanying Person 1: D C. Ford

Approved by: . .

T. E. Conlon, Section M4eV

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[- 22- [d

Date Signed

Engineering Branch

Division of Reactor Safety

SUMMARY

Scope: This routine, unannounced inspection involved the areas of licensee

ider.tified items, instrumentation components and systems.

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Results: One violation was identified - Failure to accomplish the corrective

action prescribed in deviation report PP-12074.

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8607180251

DR 860707

ADOCK 05000424

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REPORT DETAILS

1. Persons Contacted

Licensee Employees

• P. D. Rice, Vice President - Engir.eering

• E. D. Groover, QA Site Manager

• G. A. McCarley, Project Compliance Supervisor

• D. H. Day, Instrumentation and Controls Section Supervisor

• B. C. Harbin, Manager Quality Control

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• D. O. Foster, Vice President Project Support

Other Organizations

• R. Urick, Controls Engineer, Bechtel Power Corporation (BPC)

• D. W. Strohman, Project QA Engineer BPC

• S. Pietroyk, Assistant Project Engineer BPC

D. Scheyer, Engineering Group Supervisor BPC

NRC Resident Inspector

• R. J. Schepens, Resident Inspector

• Attended exit interview.

2. Exit Interview

The inspection scope and findings were sumarized on May 23, 1986, with

those persons indicated in paragraph 1 above. The inspector described the

areas inspected and discussed in detail the inspection findings listed -

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below. No dissenting comments were received from the licensee,

a. Violation 424/86-45-01, Failure to accomplish the corrective actions

prescribed in Deviation Report PP-12074, paragraph 5.

b. Unresolved Item 424/86-45-01, Separation of tubing originating from a

common component pipe tap, paragraph 5.

c. Inspector Followup Item 424/86-45-03, Qualified replacement for pres-

sure transmitters IPT-0934, IPT-0935, IPT-0936, and IPT-0937, paragraph

5.

The licensee did not identHy as proprietary any of the materials provided

to or reviewed by the inspector during this inspection.

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3. Licensee Action on Previous Enforcement Matters

(Closed) Unresolved Item 424/86-14-01, Review the Retrievability of QA

Records for Installation of Equipment Released for Startup Testing.

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The inspector examined the records for emergency diesel generator control

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panels 1-2403-PS-DG3'and 1-2403-P5-DG4. The licensee produced the receiving

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inspections, installation inspection, and the tubing installation on panel

1-2403-P5-DG4. The inspector has no further questions.

4 4. Unresolved Items

Unresolved items are matters about which more information is ' required to

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determine whether they are acceptable or may involve violations or devia-

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tions. One unresolved item was identified during this inspection and is

discussed in paragraph 5.

5. Instrumentation Components And Systems - Work Observation (52053)

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1 The inspector selected the following systems, process variables and compo-

nents for examination:

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j Engineering Safety Features Actuation System (ESFAS)

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Variable Devices

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Primary Containment Pressure Pressure Transmitter IPT-0934

Pressure Transmitter IPT-0937

1 Pressure Indicator 1PT-0934

Pressure Indicator IPT-0937

Pressure Transmitter 2PT-0937

Pressure Transmitter 2PT-0936

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ReactorProtectionSystem(RPS)

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Pressurizer High Pressure Trip Pressure Transmitter IPT-0457

Pressure Transmitter IPT-0458

Pressure Indicator IPI-0457

1 Pressure Indicator IPI-0457a

l Pressure Indicator IPI-0458

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Level Transmitter ILT-0461 '

! Level Transmitter ILT-0462

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Safety-Related Display Instrument (SRDI)

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! Reactor Coolant Pressure Pressure Transmitter IPT-0403

Pressure Indicator

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IPI-0403

Pressure Indicator IPI-0403a

Flow Transmitter 1FT-0414

Flow Transmitter 1FT-0415

j . Flow Transmitter 1FT-0416

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The following documents provided the basic acceptance criteria for this

inspection:

a. General Documents

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Bechtel Power Corporation, Plant Design and Instrumentation Construc-

tion Specification, X4AZ01, " Instrumentation - Installation of Instru-

i ment Piping, Tubing and Instrument Hook-up, " Revision 14, April 10,

1986.

Georgia Power Company, Generating Plant Construction Procedure,

GD-T-22, " Installation of Instrumentation," Revision 2, April 25,1985.

Pullman Power Products, Vogtle Project Procedure, X-26, " Instrument

System Closeout and Final Inspection," Revision 6/20/84.

l Pullman Power Products, Vogtle Project Procedure, IX-40, "Instrumenta-

tion Installation Inspection and Testing" Revision 9/9/85

b. System Dccuments

ESFAS - (Primary Containment Pressure)

Bechtel Drawing - IX4DB131, Revision 14

Bechtel Drawing - 1X5DS3D01, Revision 8

j Bechtel Drawing - IX5DS3D02, Revision 11

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Bechtel Drawing - IX5DS4004, Revision 6

Bechtel Drawing - IX5DS4A07, Revision 14

Bechtel Drawing - 1X50Y00937B, Revision 0

Bechtel Drawing - 1X50Y009348, Revision 0

Westinghouse - 7244D42, Revision 6

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Bechtel Drawing - CX5DF3002, Revision 3

RPS - (PressurizerHighPressureTrip)

i Bechtel Drawing - IX4DB112, Revision 19

Bechtel Drawing - IX50Y00457A, Revision 1

Bechtel Drawing - 1X5DY00a57B, Revision 1

Bechtel Drawing - IX50Y00458A, Revision 1

Bechtel Drawing - IX5DY00461A, Revision 1

Bechtel Drawing - 1X5DY00462A, Revision 1

Bechtel Drawing - CX5DP6009, Revision 4

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SRDI - (ReactorCoolantPressure)

Bechtel Drawing - 1X4DB111, Revision 14

Bechtel Drawing - IX5DY00404A, Revision 2

Bechtel Drawing - 1X5DY00403B, Revision 0

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Bechtel Drawing - 1X5DY00414A, Revision 1

Bechtel Drawing - IX50Y004148 Revision 0

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Bechtel Drawing - IX5DY00415A, Revision 1

, Bechtel Drawing - 1X5DY00415B, Revision 0

i Bechtel Drawing --1X5DY00416A, Revision 1

i Bechtel Drawing - 1X50Y00416B, Revision 0

i Bechtel Drawing - IX4DL4A17, Revision 18 '

Bechtel Drawing - CX5DP1013, Revision 0

Components which comprise portions of the Engineered Safety Features

i Actuation System, and which monitor primary containment pressure, were

examined to determine whether receiving inspection activities had been

i controlled and accomplished in- accordance with approved procedures. ,

The inspector verified that component attributes such as identifica-

, tion, physical condition, and associated quality documentation were as

! specified by procedural requirements. For the systems listed above,

the inspector verified that Unit 1 components had been installed in the

, plant and stored in place pending plant startup. Additionally, the

Unit 2 pressure transmitters listed were examined to determine whether

the proper storage activities had been accomplished. . The warehouse

storage level, component identification, storage environment, and ,

j associated licensee inspection activities were determined by the

inspector to be in accordance with applicable requirements. With

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i regard to the installation of instrumentation components, the inspector

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verified that the ' proper procedures and drawings had been used for

installation, that specified materials were used, and that the compo-

l nents were properly located and mounted. Component identification was

clear and in accordance with approved design documents,

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! During the examination of components which monitor reactor coolant

i pressure, the inspector identified a deficiency 'in the routing of '

l instrument sensing lines from the flow elements in the reactor coolant

leg (loop 1) to associated flow transmitters. Design documents indi-

cate that sensing lines should be installed from valve 1-1201-X4048 to

flow transmitter 1-FT-416, and from valve 1-1201-X4050 to flow trans-

! mitter 1-FT-414. However, the as-installed configuration of these

components exhibits a deficiency in that the sensing lines from these

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valves are routed to the opposite flow transmitter. 'This issue was

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discussed with . licensee personnel who subsequently produced Deviation

Report (DR) PP-12074 - dated Octobe" 19, 1985. .This DR details the

subject deviation and provides a "use-as-is" disposition with instruc-

{ tions to revise the Isometric drawing and other installation documen-

j tation to reflect the as lastalled configuration. 'In reviewing the DR

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the inspector noted a " Work Complete" and "QC Acceptance" sign off as

of October 23, 1985. However, a review of the applicable Instrumenta-

tioh Isometric and Piping and Instrumentation Drawing (P&ID) disclosed

that these documents have not been revised to reflect the as-installed  ;

j. configuration. This is a violation identified as 424/86-45-01, Failure 1

to accomplish the corrective - actions prescribed in Deviation Report

PP-12074.

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! The inspector identified several plant locations in which redundant

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instrument sensing lines had been routed. from a common pipe tap. ,

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Examples include, a) the high pressure side of the reactor coolant

loop legs, where a single tube is routed from a common tap for approxi-

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mately 15 feet and then split for routing to individual flow transmit-

ters, b) the high pressure tap to the pressurizer vessel where a single

tube is routed from a common tap for approximately 200 feet before <

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splitting to individual pressure transmitters. The inspector expressed

concern regarding the adequacy of these installations as they relate to

-Regulatory Guide 1.75 requirements and " Single Failure" criteria.

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This issue and the application of project design criteria was discussed

1 with licensee personnel and will be considered an unresolved item

t pending further evaluation and analysis by the licensee. This Unre-

solved Item is identified as 424/86-45-02, Separation of tubing

originating from a common component pipe tap.

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, The examination of components which monitor primary containment pres-

j sure disclosed that the licensee had previously identified a deficiency

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in the area of environmental qualification for several pressure trans-

. mitters used in this system. This deficiency was the result of a

! determination that pre-manufactured capillary tubing provided with the

! instruments was not of sufficient length to allow for installation of'

j originally designed barriers. Consequently, relative to temperature

i effects for pressure transmitters IPT-0935 and 1PT-0937, and radio-

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logical effects for pressure transmitters 1PT-0934 and 1PT-0936 the

) installed instruments would not be qualified for use. Discussions with

licensee personnel indicated that qualified replacement instruments ,

l have been ordered and will be installed prior to full loading. This

j issue is considered an inspector followup item pending further licensee

action. This Inspector Followup Item is identified as 424/86-45-03,

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" Qualified Replacements for pressure transmitters IPT-0934,1PT-0935,

IPT-0936 and 1PT-0937.

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j 6. Licensee Identified Items

, a. (Closed) Item 424/CDR 82-36, DeLaval Diesel Generator - Piston Skirt

Cracking (10 CFR 50.55(e)).

The final report was submitted on June 11, 1984. The report has been

reviewed and determined to be acceptable. The inspector held discus-

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sions with responsible licensee representatives and reviewed supporting

documentation to verify that the corrective actions identified in the

report have been completed. The licensee has replaced all of the type

AN piston skirts with the new type AE piston skirts. The work was-

documes.ted on Vogtle Electric Generating Plant (VEGP) work orders (WO)

Engine serial number 76021 was documented on WO 1-84-00937 and serial

number 76022 was documented on WO 1-84-00916

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b. (Closed) Item 424/CDR 85-77, Transamerica DeLaval (TDI) Diesel Genera-

{ tor - Crankshaft 011 Plugs (10 CFR 50.55(e))

i The final report was submitted on May 23, 1985. The report has been

'} reviewed and determined to be acceptable. The inspector held discus- j

sions with responsible licensee representatives and reviewed supporting I

4 documentation to verify that the corrective actions identified in the  ;

report have been completed. TDI identified that all 22 gauge oil plugs

were to be replaced with 16 gauge plugs. TDI identified that the 22

1 gauge plugs were only used between March 3,1980 and June 22, 1982.

l The licensee replaced the plugs on both emergency diesel generators i

documenting the replacements on Work Orders 1-85-0829 and 1-85-04384.  !

. The liquid penetrate testing of the installed plugs is documented on

I work orders 1-85-0930, 1-85-04423.  :

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c. (Closed) Item 424/CDR 85-80, Diesel Generator Control Panel Overhearing i

, (10CFR50.55(e)).

i The final report was submitted on August 23, 1985. The report has been

reviewed and determined to be acceptable. The inspector held discus-

j sions with responsible-licensee representatives and reviewed supporting

4 documentation to verify that the corrective action identified in the

i report has been completed. TDI informed the licensee that additional

I cooling was needed in the electrical control panels. The licensee

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issued design change notice (DCN) 13 to drawing IX4DI5103 which modi-

i fied the heating and ventilation ducts to add a duct which increased

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the air flow to the panel. This work is documented on Maintenance W0s-

} 1-85-11954 and 1-85-11399.

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d. (Closed) Item 424/CDR 83-49 TDI - Class IE Electrical Cables (10  !

CFR50.55(e)).

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i- The final report was submitted on November 3,1983. The report has

{ been reviewed and determined to be acceptable. The inspector held

{- discussions with responsible licensee representatives and reviewed

] supporting documentation to verify that the corrective actions identi-

- fled in the report have been completed,

j TDI informed the licensee that several cables on the diesel generator

, were not qualified for their service. The cables were used to connect

j the tachometer to the input of the Woodward governor. The licensee

! replaced the cables using the instructions in TDI Service Information

2 Memo 361 dated October 21, 1982. This work is. documented in mainte-

i nance WO 1-85-07980 which was closed on December 9, 1985.

! e. (Closed) Item 424/CDR 84-71 Cable Separation Discrepancies (10

j CFR50.55(e)).

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l The final report was submitted on May 31, 1985. The report.has been

reviewed and determined to be acceptable. The inspector held discus-

i sions with responsible contractor representatives and reviewed

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supporting documentation to verify that the corrective actions identi-

fled in the report have been completed.

The licensee has corrected the cable separation deficiencies identified

in audit findings reports (AFR) 004 and 686. As a result of the AFRs

further inspections were conducted and the following deviation reports

were issued, 5814, 5885, 5886, 5887, 5888, 5890, 7581 and 7582. The

deviation reports were dispositioned, the necessary corrective actions

completed and accepted by QC. All terminations electricians and

inspections were retrained on the separation criteria. The separation

criteria was emphasized in all applicable procedures.

f. (Closed) Item 424/CDR 83-50 and 425 CDR 83-50, Strut Channel Installa-

tionDiscrepancies(10CFR50.55(e))

The final report was submitted on July 20, 1984. The report has been

reviewed and detemined to be acceptable. The inspector held discus-

sions with responsible licensee representatives and reviewed supporting

documentation to verify that the corrective action identified in the

report has been completed. The inspector examined the evaluation by

Bechtel which included testing by the four strut manufactures and

stress analysis of the data found during the analysis of 301 supports.

On the bases of the above evaluation the licensee no longer considers '

this item reportable. The inspector concurs with the licensee's

evaluation.

g. (Closed) Item 424/CDR 84-74 and 425/CDR 84-74, Undetectable Failure,

Westinghouse ESFAS (10 CFR 50.55(e)).

The final report submitted on April 25, 1985. The report has been

reviewed and determined to be acceptable. The inspector held discus-

sions with responsible licensee representatives and reviewed supporting

documentation to verify that the corrective action identified in the

report has been completed. Westinghouse notified the NRC and the

licensee of a concern relating to an undetectable failure relating to

the P4 permissive. When the breaker is open (Reactor tripped) the P4

permissive permits the operator to block actuation of safety injection

and to enter the recirculation mode.

The original Westinghouse testing procedure required use of jumpers and

portable test equipment. Westinghcuse offered an optional modification

which mounted a meter and a switch to allow testing without entering

the cabinets. This modification was installed at Vogtle by Westing-

house field representatives in accordance with Field Change Notice

(FCN) GAEM-10592. During an evaluation of the optional modification,

Westinghouse identified a possible undetectable failure might remain.

Westinghcuse deleted FCN GAEM 10592 and issued a new FCN GAEM 10636

which corrects the circuitry. The new field change will be installed

in the near future. The licensee has issued procedure 54715-1, dated

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April 2,1986, Reactor Trip System P4 Interlock Test, which will be

used to perform the test every eighteen months as required by the

Technical Specification.

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h. (Closed) Item 424/CDR 82-29 and 425/CDR-82-29, Electrical Raceway

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Hangers and Supports (10 CFR 50.55(e)).

The final report was submitted on September 5,1985. The report has

been eviewed and determined to be acceptable. The inspector held

discussions with responsible licensee representatives and reviewed

supporting documentation. The licensee verified the structural integ-

rity of the electrical raceway hangers and supports by testing hanger

TS-140-66 to destruction. The results of the test indicated the

adequacy of the design. The inspector examined 17 deviation DRs which

documented various hanger or support problems. Each of the DRs was

dispositioned with a calculation that verified the structural integrity

l of the support. The licensee has evaluated the above and no longer

l considers this item reportable. The inspector concurs with the licens-

ee's evaluation.

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, i. (Closed) Item 424/CDR 82-29 and 425/CDR 82-29, Starting Air Valves -

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Diesel Generators (10 CFR 50.55(e)).

l The final report was submitted on August 6, 1982. The report has been

! reviewed and determined to be acceptable. The inspector held discus-

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sions with responsible licensee representatives and reviewed supporting

documentation to verify that the corrective actions identified in the

l report have been completed. TDI has issued Service Memo 360 which

l identifies that the 3 inch studs on the starting valves may bottom out

without sufficiently compressing the gasket. TDI recomended using

2-3/4 inch bolts which will not bottom out. The 32 studs were re-

placed, a new copper gasket installed and all studs torqued to 150 ft

pounds.

j. (Closed) Item 424/CDR 82-33, TDI Generator Drive Coupling (10

CFR50.55(e)).

Tne final report was submitted on December 14, 1986. The report has

l been reviewed and determined to be acceptable. The inspector held

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discussions with responsible licensee representatives and reviewed

supporting documentation to verify that the corrective actions identi-

fled in the report have been completed. TDI informed the licensee that

the generator drive coupling should be replaced. The licensee replaced

the couplings and documented the replacement on Maintenance WO

1-84-01223 for generator A and 1-84-01218 for generator B.

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