IR 05000285/2006006
| ML070890472 | |
| Person / Time | |
|---|---|
| Site: | Fort Calhoun  |
| Issue date: | 03/28/2007 |
| From: | William Jones Division of Reactor Safety IV |
| To: | Ridenoure R Omaha Public Power District |
| References | |
| IR-06-006 | |
| Download: ML070890472 (24) | |
Text
rch 28, 2007
SUBJECT:
FORT CALHOUN STATION - NRC INSPECTION REPORT 05000285/2006006
Dear Mr. Ridenoure:
On February 12, 2007, the U.S. Nuclear Regulatory Commission (NRC) completed aninspection at your Fort Calhoun Station. The enclosed report documents the inspection findings, which were discussed on February 12, 2007, with Mr. Reinhart and other members of your staff.The inspection examined activities conducted under your license as they relate to safety andcompliance with the Commission's rules and regulations and with the conditions of your license.
Within these areas, the inspection consisted of selected examination of procedures and representative records, observations of activities, and interviews with personnel. This inspection covers steam generator, pressurizer and reactor vessel head replacement activities.Based on the results of this inspection, no findings of significance were identified.
In accordance with 10 CFR 2.390 of the NRC's "Rules of Practice," a copy of this letter, itsenclosure, and your response (if any) will be made available electronically for public inspection in the NRC Public Document Room or from the Publicly Available Records (PARS) component of NRC's document system (ADAMS). ADAMS is accessible from the NRC Web site at http://www.nrc.gov/reading-rm/adams.html (the Public Electronic Reading Room).
Sincerely,
/RA/William B. Jones, ChiefEngineering Branch 1 Division of Reactor Safety-2-Docket: 50-285License: DPR-40
Enclosure:
NRC Inspection Report 05000285/2006006 w/Attachments:1. Supplemental Information2. Official Use Only - Security-Related Information
REGION IVDocket:50-285 License:DPR-40 Report:05000285/2006006 Licensee:Omaha Public Power District Facility:Fort Calhoun Station Location:Fort Calhoun Station FC-2-4 Adm.P.O. Box 399, Highway 75 - North of Fort Calhoun Fort Calhoun, Nebraska Dates:March 6, 2006, through February 12, 2007 Inspectors:J. Adams, Reactor Inspector, Engineering Branch 1B. Baca, Health Physicist, Plant Support Branch G. George, Reactor Inspector, Engineering Branch 1 S. Graves, Reactor Inspector (NSPDP)
J. Groom, Reactor Inspector (NSPDP)
J. Hanna, Senior Resident Inspector, Projects Branch E D. Holman, Senior Physical Security Inspector, Plant Support Branch T. Nazerio, Project Engineer, Reactor Projects Branch 6, Region II D. Stearns, Health Physicist, Plant Support Branch L. Willoughby, Resident Inspector, Projects Branch EApproved By:William B. Jones, ChiefEngineering Branch 1 Division of Reactor Safety Enclosure ii
SUMMARY OF FINDINGS
IR 05000285/2006006; 3/6/06 - 2/12/07; Fort Calhoun Station; Integrated Resident andRegional Report of Steam Generator, Pressurizer and Reactor Vessel Closure Head
Replacement Activities.This report covered a 11-month period of inspections by ten resident and regional inspectors. No findings of significance were identified. The significance of most findings is indicated bytheir color (Green, White, Yellow, or Red) using Inspection Manual Chapter 0609, "Significance Determination Process." Findings for which the significance determination process does not apply may be Green or be assigned a severity level after NRC management's review. The NRC's program for overseeing the safe operation of commercial nuclear power reactors is described in NUREG-1649, "Reactor Oversight Process," Revision 3, dated July 2000.A.
NRC-Identified and Self-Revealing Findings
No findings of significance were identified.
B.Licensee-Identified Violations
None.
1
REPORT DETAILS
4OA5Other Activities.1Steam Generator, Pressurizer and Reactor Vessel Head Replacement Projects (50001,50003, 71007)
a. Inspection Scope
This inspection report discusses NRC inspection activities related to the Fort Calhounsteam generator, reactor vessel head, and pressurizer replacement projects.
These three inspection procedures are presented together because, in most instances, the inspection procedures required the same inspection tasks and there was considerable overlap between the inspections. In the few instances where different component specific inspections were performed, they are provided later under the "Component Specific Inspections." These three inspection activities are not part of the normal baseline inspection programbut are performed on an as-needed basis. Therefore, no sample size is specified. The inspectors completed the entire procedure for each project, with the exception of the disposal radiological plans. This inspection will be performed at a later date.Inspection Activities Common to All Three Projects:A significant portion of these inspection efforts were completed and documented in priorNRC inspection reports. Each of the following past inspections were related to all three projects: *50.59 and modification inspections as well as emergenct work risk assessments,NRC Inspection Report 05000285/2006004, Sections 1R02, 1R13, and 1R17 respectively*Radiation protection program controls, NRC Inspection Reports05000285/2006004 and 05000285/2006005, Sections 2OS1 and 2OS2 (both reports)*Storage radiological safety plans, NRC Inspection Reports 05000285/2006004and 05000285/2006005, Sections 2OS1 and 2OS2 (both reports)*Welding and nondestructive (NDE) examinations, NRC Inspection Report05000285/2006005, Sections 1R08 and 1R22*Outage operating conditions, NRC Inspection Reports 05000285/2006004 and05000285/2006005, Sections 1R20, 2OS1, and 2OS2 (all sections in both reports)*Surveillance and postmaintenance testing, NRC Inspection Report05000285/2006005, Sections 1R19 and 1R22 2*Fire protection and mitigation, NRC Inspection Report 05000/2006005,Section 1R05In addition to the above, as part of this current inspection effort, the inspectors reviewedadditional activities to ensure proper
- (1) design and planning;
- (2) removal and replacement; and
- (3) post-installation verification and testing of the projects, as provided below:Engineering and Technical Support. The inspectors reviewed engineering and technicalsupport activities prior to, and during, the replacement outage. The inspectors reviewed the following temporary modifications:*Temporary Outage Transformer*Temporary Power to the Containment Palfinger Crane
- The temporary containment opening modification.The inspectors verified the technical adequacy of the temporary modifications, including10 CFR 50.59 related documents.Lifting and Rigging. The inspectors reviewed engineering design and analysisassociated with major component lifting and rigging projects. This included:
- (1) crane and rigging equipment,
- (2) steam generator, pressurizer, and reactor vessel head component drop analysis,
- (3) safe load paths, and
- (4) load lay-down areas. The inspectors verified that the licensee had properly evaluated the potential impact of load handling on the reactor core and spent fuel, including cooling and support systems.
This review also included the potential impact to underground electrical lines and fluid piping that were traversed by the heavy haul route.The inspectors conducted reviews of the preparations and procedures for:
- (1) crane andrigging inspections;
- (2) testing;
- (3) equipment modifications;
- (3) lay-down area preparations; and
- (4) training. The related activities and equipment included:*Area preparation for the outside systems
- Outside lift system
- Hatch transfer system
- Reactor cavity decking
- Inside lifting device
- Upending device
- Steam generator, pressurizer, and reactor vessel head removal, placement ofnew components, and transport of the old units to the storage facility 3The inspectors directly observed the movement of the installed Steam Generator A outof containment, as well as transfer of the replacement Steam Generator A into containment. The inspectors also observed portions of Steam Generator B movement.
In addition, the inspectors observed the removal of the "old" reactor vessel upper head, and the insertion into containment of the new reactor vessel head. The inspectors observed a sample of various other activities including the initial lifts, heavy haul routes, and use of the transfer equipment. Radiation Protection Program Controls. The inspectors reviewed the followingadditional areas as part of this inspection:
- (1) contamination controls,
- (2) emergency contingencies, and
- (3) project staffing and training plans. The inspectors used the requirements in 10 CFR Part 20 and the licensee's technical specifications and procedures as criteria for determining compliance. Disposal Radiological Safety Plans. Disposal activities will be addressed in a futureNRC inspection report, under Inspection Procedures 71122.02, "Radioactive Material Processing and Transportation," and 71122.03, "Radiological Environmental Monitoring Program (REMP) and Radioactive Material Control Program." Security Related Activities. Additional activities performed are documented inAttachment 2, which is designated and marked as "Official Use Only - Security-Related Information."Major Structural Modifications. The inspectors reviewed documentation related tostructural modifications to facilitate steam generator, pressurizer and reactor vessel head replacement, including the structural supports for the steam generators and pressurizer, the temporary reactor coolant system piping structural supports, and all attached piping during all phases of removal and installation. The inspectors reviewed the major structural modification to reroute the 161kVtransmission lines to allow clearance for the major components to move through the temporary equipment penetration made in containment. The inspectors also completed a review of modifications to the reactor coolant gas system piping inside containment. Containment Access and Integrity. The inspectors reviewed the following activities:*The licensee's evaluation of containment concrete voiding issues, found duringthe temporary equipment opening excavation *The licensee's actions associated with a liner plate weld repair and thesubsequent retest*Procedures for installing reinforcing steel, Cadweld splices, and control ofconcrete placement *Concrete pours
- Material test results (cement, fine and coarse aggregate, water, and admixtures)4*Concrete mix data, to ensure that selected trial mix met concrete design strengthrequirements*Acceptance criteria for the plastic concrete
- Concrete batch plant and mixer inspection results The inspectors verified that the licensee's actions were consistent with the applicableCodes -ACI 318-63, Part IV-B, Building Code Requirements for Reinforced Concrete Institute, 1963; AWS D1.4-98, Structural Welding Code-Reinforcing Steel; and AmericanSociety of Mechanical Engineers (ASME)Section III, Rules for construction of NuclearPower Plant Components, 1968. The inspectors examined the reinforcing steel toensure it was installed in accordance with design requirements, observed the concrete forms to ensure tightness and cleanliness, and that reinforcing steel was clean. The inspectors reviewed activities pertaining to concrete delivery time, free fall, flowdistance, layer thickness and concrete consolidation conformed to industry standards established by the American Concrete Institute. Concrete batch tickets were examined to ensure that the specified concrete mix was being delivered to the site. The inspectors also witnessed testing of the plastic concrete for slump, air, and temperature, unit weight, molding and storage of the concrete cylinders for testing. The inspectors performed reviews to ensure concrete testing was performed and the cylinders were molded in accordance with applicable American Society for Testing and Materials (ASTM) requirements. Finally, the inspectors reviewed activities to ensure that concrete testing was performed by qualified personnel from an independent testing company, and that concrete placement activities were continuously monitored by licensee and contractor quality control and quality assurance personnel.The inspectors verified that concrete batching activities included proper storage and separation of materials, as well as appropriate temperature controls. The inspectors also verified that the contractor's inspection of the trucks and batch plant were performed in accordance with the guidance of the National Ready Mixed Concrete Association and mixer efficiency tests were performed on the truck mixers in accordance with Standard ASTM C-94, Ready-Mixed Concrete. The inspectorsreviewed the concrete mix data to ensure that mix proportions for delivered concrete were selected based on trial concrete mix results, that quality control acceptance criteria for the plastic concrete were based on the trial mixes, and that the trial mix met concrete strength requirements.Additional Post-installation Verification and Testing. The inspectors reviewed: *Implementation of the licensee's post-installation inspections and verificationsprogram, including witnessing the auxiliary feedwater functional test *Pressurizer performance test and the pressurizer heaters resistance and insulation test.
5*Calibration and testing of instrumentation affected by pressurizer replacement -for example, the inspectors reviewed critical functions such as the level control &
actuation setpoints, and validation of pressurizer heater performance *Control element assembly position indication system check and control elementassembly group indicating lights and rod drop testing Note: The inspectorsclosely reviewed the connections of the control element assemblies to the rackextensions once radial misalignments were identified by the licensee. *Reactor vessel seal leakoff monitoring system, and core exit thermocoupleperformance following reactor startup *Post-installation testing of the reactor vessel head. The inspectors also reviewedcritical functions of the replacement reactor vessel head that potentially might be adversely affected either by improper design or during installation activities*Procedures required for equipment performance testing to confirm the designand to establish baseline measurements*Preservice inspection of new steam generator, pressurizer and reactor headwelds The inspectors verified equipment performance was consistent with the proceduralizedacceptance criteria and design requirements.Containment Integrated Leak-Rate Test. The inspectors walked down the installation oftest equipment used to pressurize the containment for performing a containment leak check. The inspectors verified that the actual equipment configuration was consistent with installation and test records. The inspectors also verified that the equipment was operating properly during the test and that instrument calibrations were current.The inspectors verified through observation, records review, and independentcalculations that the containment integrated leak rate test was properly conducted. The inspectors observed the initial pressurization of containment including the communications established for the performance of the test. In addition, the inspectors independently verified the acceptability of the test results. Component Specific Inspections:Pressurizer. Foreign Material Controls. The inspectors directly observed the cuts ofpressurizer piping and the foreign material exclusion boundaries for the remaining reactor coolant system piping. Particular attention was focused on grinding and other debris-generating work in the area and the possibility of introduction of loose material. The inspectors also performed engineering reviews of the foreign material controls.
6Reactor Vessel Head Fabrication Inspections at Licensee Facility. The inspectors performed the following reactor vessel head fabrication inspection activities.Heat Treatment. The inspectors verified that the ASME,Section III,requirements for reactor vessel head forging heat treatment were correctly reflected in the certified design specification, procurement specification, and thefabrication specification. The inspectors also verified that the heat treatment used by the fabrication vendor was performed in accordance with the specifications. The inspectors reviewed the material test report for the reactor vessel head forging and verified that the heat treatment parameters met the applicable procurement specifications and ASME Code requirements. The inspectors also reviewed the material test record for the finished reactor vessel head and verified that the post-weld heat treatments were conducted in accordance with the ASME Code, including furnace temperature and conditions, thermocouple placement, heating and cooling rates, and documentation requirements.Nondestructive Examination. The inspectors reviewed the NDE program for thefabrication vendor, including a review of the NDE technician certifications. Welding. For the cladding, the inspectors reviewed the design specification,design drawings, weld records, NDE records, defect disposition reports, weld procedure specifications, procedure qualification records, welder certifications, and dimensional records and verified that the cladding was performed per specification. For the control element drive mechanism (CEDM) flange-to-nozzle welds, thepenetration nozzle-to-head weld buttering welds, and the CEDM nozzle-to-head J-Groove welds, the inspectors reviewed the certified material test reports, the weld procedure specifications, procedure qualification records, welder certification records, and weld map drawings. The inspectors verified that these welds were performed in accordance with the ASME code and procurement specifications. The inspectors also reviewed the code-required NDE of these welds, including NDE technician certifications, NDE procedures (including NDE solvents for the penetrant testing procedure), and NDE records and verified that these inspections were performed in accordance with authorized procedures and the ASME code.Weld Repairs. The inspectors reviewed selected weld repairs to ensure theywere conducted in accordance with Section IX of the ASME code and procurement specifications. The inspector reviewed the certifications of the welder and NDE technicians, results of the pre- and post-repair NDE examinations, and the records of the repair. The inspectors also reviewed selected nonconformance reports, where reportable indications were found and were dispositioned without repair, to verify that these were performed in accordance with the ASME code and contract requirements. The inspectors concluded that the repairs were done in accordance with applicable codes and specifications.
7Code Reconciliation. The inspectors reviewed supplemental examinations,analysis, and ASME Code documentation reconciliation to ensure that the original ASME Code -Stamp remained valid, and that the replacement head complied with appropriate NRC requirements and applicable industry standards.
The inspectors also ensured that the design specification was reconciled and a design report was prepared for the reconciliation of the replacement head, verifying that they were certified by professional engineers competent in ASME Code requirements.Quality Assurance Program. To the extent practicable, the inspectors ensuredthat machining was carried out under a controlled system of operation, a drawing/document control system was in use in the manufacturing process, and that part identification and traceability was maintained throughout processing and was consistent with the manufacturer's quality assurance program.4OA6Meetings, Including ExitThe inspectors presented the inspection results to Mr. J. Reinhart, Site Director, andother members of the licensee's management staff on February 12, 2007 during a telephonic exit meeting. The licensee acknowledged the information presented. Some proprietary information was reviewed during this inspection but no proprietary information was included in this report.ATTACHMENTS:1. Supplemental Information2. Official Use Only - Security-Related Information 1A1-1
SUPPLEMENTAL INFORMATION
KEY POINTS OF CONTACT
Licensee Personnel
- G. Cavenaugh, Supervisor, Regulatory Compliance
- D. Guinn, Licensing Engineer
- E. Matski, Compliance
- J. Reinhart, Site Director
- J. Cate, Supervisor, System Engineering
- J. Spilker, NSSSRP - Engineering
- R. Short, Manager, NSSSRP
- S. Gambhir, Division Manager, Nuclear Projects
- J. Bednash, Resident Technical Rep. (MHI)
- D. Spear, Mechanical Design Engineer,
- D. Cyboron, Reactor Vessel Head/Pressurizer Components Lead
- P. Ward, Installation Engineering
- D. Pier, Control Room Supervisor
LIST OF DOCUMENTS REVIEWED
In addition to the documents referred to in the inspection report, the following documents wereselected and reviewed by the inspectors to accomplish the objectives and scope of the