IR 05000364/1978014

IE Inspec Rept 50-364/78-14 on 780912-15 During Which 2 Items of Noncompliance Were noted:2 Valves Were Vulnerable to Dirt & Cables & Trays Were Improperly Designed & Had Been Walked on

ML20148U374
Person / Time
Site:	Farley
Issue date:	10/19/1978
From:	Bryant J, Hunt M, Vallish E NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
To:
Shared Package
ML20071F942	List: IR 05000364/1978014 ML20148U354 ML20148U357
References
50-364-78-14, NUDOCS 7812070030
Download: ML20148U374 (9)

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l UNITED STATES O Raoug NUCLEAR REGULATORY COMMISSION

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Report No.: 50-364/78-14 Docket No.: 50-364 ,

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License No.: CPPR-86 Category: A2 Licensee: Alabama Power Company 600 North 18th Street P. O. Box 2641 Birmingham, Alabama 35291 Facility Name: J. M. Farley Unit 2 Inspection at: Ashford, Alabama Inspection conducted: September 12-15, 1978 Inspectors: M. D. Hunt

D. K. Walters I

E. J. Vallish A. B. Ruff (Ins ector in training)

Reviewedby:kth m, o fi 78 Date J. C. Bryant, phief j Engineering Support Section No. 1 Reactor Construction and Engineering Support Branch Inspection Summary lospection on September 12-15, 1978 (Report No. 50-364/78-14)

Areas Inspected: Reactor pressure vessel installation and records, emergency l

I diesel fuel return line replacement, pipe snubber installation on pressurizer relief valve piping and on steam generator upper lateral supports, containment building vendor weather covers, reactor in-core neutron monitoring system mechanical installation and records, electrical penetration assembly installa-tion, electrical motor operated valves, 125V DC inverter and distribution panel. This inspection consisted of 81 hours9.375e-4 days <br />0.0225 hours <br />1.339286e-4 weeks <br />3.08205e-5 months <br /> on site by three NRC inspector Results: Of the ten areas inspected, no apparent items of noncompliance or deviation were identified in eight areas. Two apparent items of noncompliance were identified in two area , (364/78-14-01)

(Infraction - Failure to follov QC procedures, Details I, par , (364/78-14-02).)

(Infraction - Failure to follow procedures, Details II, par ,

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RII Rpt. No. 50-364/78-14 I-1 Prepared by:

/d' /2 -77 DETAILS I Date E. J. Vallish, Mechanical Engineer

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Engineering Support Section No. 1 Reactor Construction and Engineering

. * Support Branch Dates'of Inspection: September 12-15, 1978 Reviewed by: c , t0 14 ~78 Date

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J. C. Bryant, Chief %

Engineering Support Section No. 1 Reactor Construction and Engineerig Support Branch

' Persons Contacted Alabama Power Company (APCO)

• R. E. Hollands, QA Supervisory Engineer

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• J. C. Payson, QA Staff Engineer

• R. S. Fucich, QA Engineer

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D. Morey, Maintenance Superintendent (Operations)

Daniel Construction Company (DCC) I

• D. L. Garrison, QA Manager

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H. Cooper, Senior Hanger Engineer )

L. C. Easterwood, QC Manager

• Denotes those present at the exit intervie . Licensee Actions on Previous Inspection Findings Licensee actions on previous inspection findings were not reviewed during this inspectio . Unresolved Items l No unresolved items were identified during this inspectio l Independent Inspection Effort l l

This inspection effort _ included observation of installation of two mechanical snubbers on the pressurizer relief valve piping and Under inspection of those which were already installed in that are the snubber' work area on the pressurizer vessel, two root valves were i

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O RII Rpt. No. 50-364/78-14 I-2 observed to have unprotected openings to the valve internals and which were oriented in the .csardposition. The work of installing snubbers over these valves intiaded doncrete chipping, welding and grindin Criterion V, " Instructions, Procedure, and Drawings", of Appendix B to 10 CFR 50 requires that activities affecting quality be prescribed and accomplished by documented procedure Farley Nuclear Plant QC Procedure 5.4.2.1 paragraph 5.7.6.4 implements this requirement by requiring the plugs or caps in openings be sealed to prevent " dirt, weld sptater, grinding dust, etc," from enterin This observed condition is an apparent noncompliance with Criterion V of the infraction severity level (364/78-14-01, Failure to follow QC I l

Procedure). The licensee took Lumediate action to have the two valves protected, and to prevent reoccurence, the piping manager issued an inter-office communication, dated September 14, 1978, to the piping ]

superintendents to address this serious problem thru the general ;

formen, the formen and the craf tsman levels. Since these two valves were the only openings observed during this inspection, that should i have been closed that were not closed and since the licensee took timely corrective action and adequate action to prevent reoccurrence, a reply to this noncompliance is not require !

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This item is close :

Also inspected was the progress of installation of the hydraulic snubbers on the steam generator upper lateral supports, the reactor in-core neutron monitoring system mechanical hardware the containment building's tendon weather covers and the ultimate beat sink pond are Other than the one stated above no other items of noncompliance were identifie . Reactor Vessel Installation - Work Observation The FSAR Section 4 and 6.2 were reviewed prior to this inspection to determine licensee commitments in this area. The following items were selected and inspected in detail to assure that the installation and inspections were performed in accordance with the specifications and drawings. These items were located on the reactor pressure vessel's 205' and 325* nozzle leg ,

1 Support shoe Hold down out Guide pin Bottom sbia Hold down pin Bulkhead (nozzle restraint) ;

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RII Rpt. No. 50-364/78-14 I-3 Side shim ,

b. Cavity liner plate floo'r The following drawings werecreviewed and used to verify orientation, configuration, location and installation requirements: 1 " Reactor Vessel Supports", y drawing Il82F5 " Reactor Vessel Support Hardware Details and Ass'y", y drawing 1095E7 " Reactor Cavity Liner Plate Floor and Misc 1. Steel Plate

. Additions", Bechtel drawings D-206279R4 and D-206277R ll The reactor vessel ope:ning was observed to be completely covered with a special steel plate cover. The personnel access doors to the inside were padlocked. The licensee's representative stated that there would be no more scaffolding or platforms installed in the vessel. All hot and cold legs were welded into the primary loop hence the vessel nozzles are protected from 6amag No items of noncompliance were ,dentifie . Reactor Vessel Installation - Quality Record Review QC inspection records of the installed reactor vessel were reviewed covering the time period from January 24, 1978,thru August 28, 1978.

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These inspections were preformed in accordance with QCP 5.2.4 which includes provisions for access control and cleanlines APC0 QA audits of January 27, 1978, titled, " Installation of Mechanical Equipment" and of April 7, 1978, titled, " Storage and Handling" (Housekeeping) were reviewed. Dispositions were adequate and timely accomplishe No items of noncompliance were identifie . Part 21 Report Follovup(Closed)(78-14-03): Emergency Diesel Fuel

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Returns Lines A possible generic condition concerning the Unit 2 emergency diesel generator's fuel return line was inspected. This condition cause fuel leakage at another site because of cracking of the fuel line material induced by a poorly made. flare in the connection fitting. The following documents were reviewed and used to determine the status of the work performed:

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RII Rpt. No. 50-364/78- 4 I-4

. Colt Industries - Fairbanks Morse Engine Divison drawing P12610262, " Fuel Pipe Inspection".

. " Inspection of Colt Model 12PC-2V Diesel Engine Skid Mounted Fuel Piping Flares FKP '78-0963".

The Unit 2 diesel was inspected and the newly installed fuel lines were observed. The flares which were removedywere inspected and only surf ace irregularties were observed. All flared fuel line ends were replaced to assure qualit This Part 21 has an identification number of 78-058-000 and was reported orignally to another IE Regio There are no further questions on this item for this license . Exit Interview A meeting was held at the end of this inspection with the licensee's representatives identified in paragraph 1 and others, to discuss the results of this inspect 4on. Items discussed included the reactor vessel installation and records, progress of installation of snubbers, reactor in-core neutron monitoring system mechancial hardware, the tendon weather covers,the apparent noncompliance regarding Criterion V and the open root valve parts on the pressurizer., the ultimate heat sink pond area and the fuel return line change on the emergency diescl. The licensee acknowledged these findings, i

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. RII Report No. 50-364/78-14 11-1 DETAILS II Prepared by: , , N#m_ b, lo a v f'/ g M. D. Hunt , EleR't'rical Eng@ nee r Da t'e Engineering Support Section No. 1 Rpactor Construction and Engineering

' Support Branch

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. Waltars, Electrical Engineer IC/t7l?E Date Engineering Support Section No. 1 Reactor Construction and Engineering Support Branch Dates of Inspection

September 12-15, 1978 Reviewed by: 2 k .( t-u J. C. Bryant, Cliief  ;

lo[l9 f 78 4)ath Engineering Support Section Reactor Construction and Engineering Support Branch Persons Contacted Alabama Power Company (APCO)

• R. E. Hollands, Jr., QA Supervisor

• C. R. Kualheim, QA Engineer

• A. W. Hankins, QA Engineer

• J. C. Payson, QA Engineer Contractor Organizations (1) Daniel Construction Company of Alabama (DCCA)

• C. C. Wagoner, Project Manager (2) Diversified Electrical Contractors (DELCON)

• J. C. Weaver, Project Engineer

• Denotes those present at exit intervie . Licensee Action on Previous Inspection Findings (Closed) Unresolved Item 364/78-11-01, Installation of metallic tape as a separation barrier. The inspector reviewed an instruction sheet issued to supplement DCCA QC Procedure 5.4.3.1, " Cable Terminations".

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RII Report No. 50-364/78-14 Il-2 The inspector was advised that all metallic tape installed would be inspected to verify that the aluminum tape is a minimum of 1" from the barrel of the lug and wrapped with glass tap / Unresolved Items No new unresolved items were identified during this inspectio . Independent Inspection The inspector selected four electrical penetration assemblies (EPA)

which were installed for inspection. The EPA's are identified as B028, B024, B026 and B030. All were pressurized as verified by an attached pressure guage. The storage inspection records for the last eight months were reviewed. The rigging report, which described the method and inspection required for moving the EPA's from the warehouse to the installation location, was reviewed. This report is a require-ment of DCCA QA Procedure 5. Electrical (Cables and Terminations I) Observation of Work and Work Activities The inspector selected the nine 4160V power cables listed below for physical examinatio VBDG04P Component Cooling Water (CCW) Pump 2A 2VBDG09P Residual Heat Removal (RHR) Pump 2B 2VBDGllP Containment Spray (CS) Pump 2B 2VADFilP CS Pump 2A 2VADF09P RHR Pump 2A 2VADF07P Alternate Feed from Bus 2F to Key Lock Switch for swing High Head Safety injection (HHSI) Pump 2VBDG07P Alternate Feed from Bus 2G to Key Lock Switch for swing HHSI Pump 2VADF05P Alternate Feed from Bus 2F to Key Lock Switch for swing CCW pump 2VBDG05P Alternate Feed from Bus 2G to Key lock switch for swing CCW Pump The routing of these cables was verified from the components and breaker panels to the cable trays. The air space between cables in the cable trays appeared adequate. The terminations for all ends of these cables could not be examined due to status of tests in progres The pulling and termination records had been completed in accordance with DCCA FQC Procedures 5.4.3.1, " Cable Pulling," and 5.4.3.lA,

" Cable Terminations". The inspector found evidence that the cable trays had been used to support personnel in the cable spreading room elevation 139' Auxiliary Buildin In cable tray AIE-45, the bottoa

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RII Report No. 50-364/78-14 II-3 of the cable tray was damaged due to it being stepped in. The cables in this tray were conformed to the same distortion. The cables installed in cable tray AHK 27C were g'agging below the rungs of the tray giving evidence of being used as a step to higher elevation. Field QC Procedure 5.2.4, Appendix 1, states " Personnel shall not walk or stand in tray."

The inspector also noted that the power feed (cable 2VBDG06P) for HHSI pump motor 2C was not properly installed in the raceway above the 4160V breaker DG06. The cable was susperled above the raceway for a length of approximately 10 feet. The " Notes and Details" referenced in FQC Procedure 5.2.4 permits only six feet horizontal and four feet vertical unsupported length The above listed cable tray discrepancy and the inproperly installed cable are identified as infraction 364/78-14-02, failure to follow procedure . Electrical (Cables and Terminations I) Review of Quality Records The records for receipt and storage, terminations, installetion and testing were reviewed for the cables listed in paragraph 5. The vendor certifications were compared to the specifications. All table records were traceable to the vendor certification The inspector reviewed the following closed nonconforming reports (NCR) related to cable installation and testing: Q2E-293, 289, 284, 282, 281, 273, 264, 260, 259, 256, 254, 252 and 239. All NCR's reviewed indicated disposition and reinspection after corrective action had been complete Within the areas examined, no items of noncompliance or deviation were identifie . Electrical (Components and Systems II) Observation of Work and Work Activities The installation and in place storage of 7.5 KVA Inverter 2A, Vital AC Distribution Panel 2D and nine safety-related cables associated with inverter 2A input and output power were inspected. Cabling to the components had been terminated and equipment grounds had been installe Using the cable pull and termination cards, termination, routing and separation of the selected cables were checked f rom the 600 volt load center 2D to 7.5 KVA inverter 1A via battery charger 2C and 125 VDC bus 2A. Due to the 600 volt equipment being energized and tagged, terminations for cable 2VCED09Q only to battery charger 2C were examine .

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RII Report No. 50-364/78-14 11-4 The installation and in place storage of the listed safety-related electric valve operators were inspected:

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• Valve Operated Q2E11MOV8809A(V027A) RHR Suction Q2E11MOV8809B(V027B) RHR Suction Q2E11MOV8888A(V023B)

RHR Discharge Q2E11MOV8888B(V023A)

RHR Discharge Q2E21LCV115B(V336A) HHSI Suction HHSI D.!scharge Q2E21LCV115B(V336B)

Cabling to the valve operators had been terminated and grounds had been installe Within the areas inspected, no items of noncompliance or deviations were identifie . Electrical (Components and Systems II) Review of Quality Records Records for the components listed in paragraph 7 were reviewed.

Identification was traceab1'e through all records. Installation records were reviewed for compliance to FQCP 5.4.3.2, " Installation and Inspec-tion of Electrical Equipment." The manufacturer's certifications or quality control releases were examined. Receiving records required by FQCP 5.2.3, " Receiving QC Inspection" were examine Selected noncon-formance reports identified on the receiving reports were also reviewe Within the areas examined, no items or nonconformance or deviations were identifie . Exit Interview The inspectors met with the licensee representatives and others denoted in paragraph 1, at the conclusion of the inspection. The scope and findings of the inspection of electrical penetration assemblies, power cable installation and records, and electrical component installation and records were discusse The infraction 364/78-14-02, failure to follow procedures, was discussed in detai .

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