IR 05000272/1986025

Insp Repts 50-272/86-25 & 50-311/86-25 on 860908-12. Deviations Noted:Administrative Controls to Designate & Assure Quality of Bolt Matl Lubricants Did Not Meet Requirements of IE Bulletin 82-02

ML20215M722
Person / Time
Site:	Salem
Issue date:	10/15/1986
From:	Gray E, Wiggins J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I)
To:
Shared Package
ML18092B338	List: IR 05000272/1986025
References
50-272-86-25, 50-311-86-25, IEB-82-02, NUDOCS 8611030198
Download: ML20215M722 (6)

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U.S. NUCLEAR REGULATORY COMMISSION

REGION I

50-272/86-25 Report N __50-311/86-25 50-272 Docket N DPR-70 License N DPR-75 Licensee: Public Service Electric and Gas Company P.O. Box 236 Hancocks Bridge, New Jersey 08038 Facility Name: Salem Nuclear Generating Station Units 1 and 2 Inspection At: Hancocks Bridge, New Jersey Inspection Conducted: September 8-12, 1986 Inspectors: , Uf E.H. Gray, Lead React A ngineer

/4/6/85 date Approved by: Shj,_ /o //bdf5 J f.' Wiggin/lfChiefMaterialsand ' date'

P cesses S'ection, EB, DRS Inspection Summary: Inspection on September 8-12, 1986 (Combined Report Nos. 50-272/86-25 and 50-311/86-2 Areas Inspected: Routine, unannounced inspection by one region based inspector of licensee actions taken in response to the IE Bulletin 82-02 to prevent degradation of threaded fasteners in the reactor coolant pressure boundary of PWR plants. During the inspection, licensee plans to minimize service water system leakage by changes of selective materials were reviewed. A sample of high temperature bolting was obtained for independent analysis and comparison to the bolt material test repor Results: Two deviations were identified in the administrative controls to designate and assure the quality of bolt material lubricants as related to actions required by IE Bulletin 82-02.

i 8611030198 861021 PDR O ADOCK 05000272 PDR

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DETAILS 1) Persons Contacted Public Service Electric & GAS Co. (PSE&G)

R. Antonow, Sr. Engineer Maintenance Staff R. Audette, Sr. Installation Engineer

E. Browder, Quality Assurance Supervisor M. Danak, Senior Engineer J. Eggenhofer, Sr. Boiler Repair Supervisor

L. Miller, Ast. General Manager-Salem Operations

J. Morrison, Maintenance Engineer

R. Patwell, Licensing D. Perkins, Manager, Station QA R. Stanley, Manager, System Engineering W. Treston, ISI Supervisor

P. White, Maintenance Manager NRC

T. Kenny, Senior Resident Inspector

K. Gibson, Resident Inspector

• Indicates presence at exit meeting of September 12, 198 ) Licensee Action on Previously Identified Item (0 pen) IE Bulletin (IEB 82-02) Degradation of Threaded Fasteners in the Reactor Coolant Pressure Boundary of PWR Plant Field verification of actions taken to respond to IEB 82-02 were not co, plate as discussed in part 3 of this repor In particular, QA measures to confirm the absence of halogens and sulfides in bolting lubricants were not in plac ) Inspection of Licensee's Actions in Response To IE Bulletin 82-02 (IEB 82-02)

IEB 82-02 outlines actions to be taken by PWR licensees to improve reactor coolant pressure boundary bolting (threaded fasteners) practices. These actions include the development and implementation of bolting maintenance procedures; quality assurance requirements for proper selection, procurement and use of fastener lubricants; and inspection of bolting per the ASME Code Section XI before reuse. The Bulletin also specifies that the licensee develop controls for the selection and application of injection sealant material _ _

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The inspector reviewed the licensee's initial response to IEB 82-02 dated July 29, 1982 and NIS-1 data reports required by ASME XI for reference to examination of threaded fasteners. Maintenance procedures of both the Salem staff and contractors were reviewed to determine how bolt torque practices and bolt lubricants are specified and controlled. The purchase orders and receiving inspection practice for Felpro N5000 and Neolube 2 noted in the response to IEB 82-02 as used on reactor coolant pressure boundary (RCPB) bolting were reviewed. In addition, work packages of completed bolted joints were examined for conformance to procedure requirements and traceability of the bolting lubricant The Salem IEB response of July 29, 1982 identified Neolube No. 2 and Felpro #5000 (N5000) as the two types of thread lubricant in use at the Salem Generating Station on RCPB boltin Neolube was found to be identified by folio number 99-0066 in maintenance procedure M8C-3 for use on the Reactor Pressure Vessel (RPV) flange stud holes. At Salem, the folio number is a tracking number used by maintenance, purchasing and QA to identify materials. The inspector determined that the folio number for Neolube had been subsequently changed by the licensee and Neolube is currently classified under folio 97-0783. However, in the maintenance storeroom the inspector noted that the latter folio number was assigned to both Neolube #1 and Neolube #2. Based on phone conversation with the Neolube vendor it was determined that the difference between Neolube #1 and #2 is that #1 is certifiable with respect to halogen content per Mil Standard 24131 B while #2 is no The inspector noted that the NSSS procedure used in the 1986 outage for RPV head stud installation as well as the 1982 IEB response specified the use the Neolube type (#2) which does not have certification for halogen conten Further review of recent purchase order P2-151717 indicated that current practice is to order Neolube only as " Lubricant-Dry Film Conductive" without reference to the product name or type. The purchase order indicates this lubricant is "not safety related" and does not require certification of chemistry that would indicate halogen or sulfide conten In fact, no certification of chemistry was included with any Neolube stored in the maintenance are The QA department could find no instance of Neolube 1 or 2 having been sampled by the site for chemical residuals such as those identified in IEB 82-02 as potential contributors to Stress Corrosion Cracking (SCC).

Receiving QA inspection documentation for folio 99-0066 consisted of verification of the number of Neolube containers. The inspector questioned why the Neolube #2 would be specified for RCPB bolting when its chemistry is not certifie The inspector concluded that the lack of administrative controls to select the required Neolube type, lack of definition of the material on the purchase order and designation of the material as not safety related without imposition of alternate QA measures is a deviation from the requirements of IEB 82-0 . - .- . _ .

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Felpro N5000 is the primary bolt and stud lubricant or anti-seize material used on RCPB bolting. For RPV head installation it is used on the vessel head to flange stud The plant maintenance procedures and contractor work packages for bolting up of RCPB items including steam generator manway covers, pressurizer pressure relief valves, RPV studs, and torque values were reviewe Felpro N5000 was identified as the bolt lubricant in these procedures and work packages. The actual bolt torque values and torquing methods were shown in these procedures for RPV studs, steam generator and pressurizer manway studs and for the pressurizer valve reinstallation. Maintenance procedures do not, however, specify the bolt torque value required for valve bonnet bolting. The maintenance procedures and work packages do not provide for assuring that an acceptable product is used. For instance, the procedures / packages do not call for recording the lot or batch number of Felpro N5000 used or for further checks to verify that the product used meets quality requirements. For example CWP No. MT-943622-0901, sheet 24 indicates the use of Felpro N5000 but does not provide for recording the batch number use In review of purchasing documentation for Felpro N5C00 (P0 P2-091432) the inspector noted that it is ordered as not safety related, and without a requirement for chemical analysis for halogen or sulfur. Receiving inspection by QA indicated only a count of the number of cans receive The inspector observed that containers from batch number 287 in the main-tenance storeroom were accompanied by a certificate of compliance that indicated low levels of halogens, sulfur, lead, zinc, tin, cadmium, mercury and copper. However, the inspector could find no documentation that the chemistry certificate had been reviewed by the licensee for conformance to designated maximum levels of elements that could contribute to SCC of bolt materials. QA had ne record of Felpro N5000 having been sampled for independent analysis of potentially detrimental elements or compound The PSE&G Engineering and Construction Department memorandum EDD-7 Form 1, Revision 0 dated May 18, 1982 states that Molykote Z, Felpro-CSA and Felpro N1000 are not suitable for reactor vessel stud lubrication. Review of the preliminary work package for RCPB stud installation for the Salem 2 fall 1986 outage indicates the field option of using either Felpro N-1000 or N5000 in conflict with the May 18, 1982 memorandu The procedure GM8-EMP-011, paragraph 9.2.2 describes the Engineering and Plant Betterment Department (E&PB) activities in regard to the required engineering review and justification required when a safety related item is to be purchased as non-safety related. In the cases of Neolube 1 or 2 and Felpro N5000, the inspector was not provided with documentation that this type of review had been performe Overall, the inspector concluded that the licensee had not conducted the review or established purchasing controls or Quality Assurance measures for proper selection and procurement of Felpro N5000. This is a deviation from the requirements of the IEB 82-02 and is similar to the deviation in regards to practices involving Neolube #2. (50/272/86-25-01; 50-311/86-25-01).

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Item 4 of IEB 82-02 required a written report to be submitted to the Regional Administrator following completion of the outage when threaded fasteners were cleaned and inspected before reuse, per item 2 of the Bulletin. In regard to this reporting requirement, the inspector noted that the reply of July 29, 1982 addressed IEB 82-02 items 1 and 3 only. No further licensee response to the Bulletin had been provided apparently because the licensee lost the file on IEB 82-02. The inspector noted that recent NIS-1 reports, such as those dated August 23, 1983, October 20, 1983, and August 7, 1986, report results of RCPB bolting removal and inspection. However, the NIS-1 reports did not fulfill the 82-02 part 4 requirement The failure to address Action Item 4 Bulletin is also a deviation (272/86-25-02 and 311/86-25-02).

In the area of control of materials and methods for application of sealants (Furmanite), the inspector reviewed the Engineering and Construction Department procedure S-C-R 200-McD-059 Rev. 1 and Revision 2 and the QA surveillance report for the use of Furmanite on the 11GB4 valve body to bonnet in August 1985. The inspector noted the reporting of the Furmanite chemistry of leachable halogens and sulfides, the documentation of lot number used and QA involvement in the use of Furmanit No deviations from the IEB 82-02 were identified in the use of injected sealant ) Service Water System 2" Piping Leak A recent occurrence of a through-wall corrosion of the 2 inch diameter carbon steel cement lined service water piping to the containment fan cooler motor was examined by the inspector. The leak occurred at the carbon steel pipe to stainless steel dissimilar metal socket weld where weld stresses appear to have damaged the cement lining, permitting corrosion to occur in the carbon stee The inspector noted that PSE&G has initiated an extensive study of the service water system as reported in the June 1986 engineering report titled " Service Water System, Materials Evaluation, Salem Nuclear Generating Station." The report identifies near term and long term corrective actions including evaluation of a high molybdenum stainless steel for resistance to the corrosive effects of the Delaware River water in the vicinity of the Salem Plan No violations were identifie . .

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5) Random Sampling of Bolting For Independent Analysis Unrelated to the IEB 82-02 inspection, the bolt and stud storage and issue practices and documentation were examined. Samples of hex head bolts (SA 193-B7), studs (SA 193-B7) and nuts (SA194), all inch in size, were obtained for future testing by NRC. The documentation for the Hex Head bolts including purchase order requirements and certificates of analysis and test were readily available and reviewed for conformance to the ASME Code,Section III and specification requirement No violations were identifie ) Exit Interview

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The inspector met with licensee management representatives (see Section 1.0 for attendees) on September 12, 1986. The inspector summarized the scope and findings of the inspection at that time. At no time during the inspection were written materials provided to the licensee by the inspector.