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                                    U.S. NUCLEAR REGULATORY COMMISSION
.
                                                  REGION II
.
            Docket Nos:       50-413. 50-414
.
            License Nos:     NPF-35 NPF-52
4
            Report Nos.:     50-413/97-03, 50-414/97-03
U.S. NUCLEAR REGULATORY COMMISSION
            Licensee:         Duke Power Company
REGION II
            Facility:         Catawba Nuclear Station Units 1 and 2
Docket Nos:
            Location:         422 South Church Street                                     I
50-413. 50-414
                              Charlotte, NC 28242                                         l
License Nos:
            Dates:           January 12 - February 15, 1997
NPF-35 NPF-52
            Inspectors:       R. J. Freudenberger. Senior Resident Inspector
Report Nos.:
                              P. A. Balmain. Resident Inspector
50-413/97-03, 50-414/97-03
                              R. L. Franovich, Resident Inspector                         l
Licensee:
                              E. H. Girard, Reactor Inspector (Sections E1.3 & E8.8-12)
Duke Power Company
                              P. J. Kellogg. Reactor Inspector (Sections E2.2 & E7.2)
Facility:
                              R. L. Moore. Reactor Inspector (Sections E2.1 & E7.1)
Catawba Nuclear Station Units 1 and 2
                              C. W. Rap). Senior Reactor Inspector (Sections E8.1-7)
Location:
                              J. W. Yorc, Reactor Inspector (Sections E1.1-2)
422 South Church Street
            Approved by:     C. A. Casto Chief
Charlotte, NC 28242
                              Reactor Projects Branch 1
Dates:
                              Division of Reactor Projects
January 12 - February 15, 1997
  ,
Inspectors:
R. J. Freudenberger. Senior Resident Inspector
P. A. Balmain. Resident Inspector
R. L. Franovich, Resident Inspector
l
E. H. Girard, Reactor Inspector (Sections E1.3 & E8.8-12)
P. J. Kellogg. Reactor Inspector (Sections E2.2 & E7.2)
R. L. Moore. Reactor Inspector (Sections E2.1 & E7.1)
C. W. Rap). Senior Reactor Inspector (Sections E8.1-7)
J. W. Yorc, Reactor Inspector (Sections E1.1-2)
Approved by:
C. A. Casto Chief
Reactor Projects Branch 1
Division of Reactor Projects
,
i
i
f
f
                                                                                Enclosure 2
Enclosure 2
1
1
          9704010094 970317
9704010094 970317
          PDR
PDR
          G      ADOCK 05000413
ADOCK 05000413
                            PDR
G
PDR


      .
.
  -
-
        .
.
    .
.
                                          EXECUTIVE SUMMARY
EXECUTIVE SUMMARY
                                Catawba Nuclear Station. Units 1 & 2
Catawba Nuclear Station. Units 1 & 2
                          NRC Inspection Report 50-413/97-03. 50-414/97-03
NRC Inspection Report 50-413/97-03. 50-414/97-03
          This integrated inspection included aspects of licensee operations,
This integrated inspection included aspects of licensee operations,
          maintenance, engineering and plant support. The report covers a 6-week
maintenance, engineering and plant support.
          period of resident ins)ection: in addition, it includes the results of
The report covers a 6-week
          announced inspections ay regional reactor safety inspectors.
period of resident ins)ection: in addition, it includes the results of
          Doerations
announced inspections ay regional reactor safety inspectors.
                                                                                          i
Doerations
          .
i
                Emergency Core Cooling System valve stem leakage flow alarm panels         i
Emergency Core Cooling System valve stem leakage flow alarm panels
                provided in the auxiliary building, although not required by the Final     l
.
                Safety Analysis Report, were not being maintained as a reliable means of   i
i
                locating potential reactor coolant system leakage sources (Section
provided in the auxiliary building, although not required by the Final
                01.1).
Safety Analysis Report, were not being maintained as a reliable means of
          Maintenance
i
          .
locating potential reactor coolant system leakage sources (Section
                The time allowed by Technical Specifications for reactor trip breaker
01.1).
                testing was exceeded because procedural changes to incorporate             !
Maintenance
                additional tasks were not evaluated to verify that those changes would
The time allowed by Technical Specifications for reactor trip breaker
                not extend the time to perform the test beyond the time allowed (Section
.
                M1.1).
testing was exceeded because procedural changes to incorporate
          *    The inspector identified that material condition and housekeeping in the
additional tasks were not evaluated to verify that those changes would
                Unit 2 Residual Heat Removal / Containment Spray Heat Exchanger Rooms was
not extend the time to perform the test beyond the time allowed (Section
                poor (Section M2.1).
M1.1).
          .    A non-cited violation was identified for failure to follow procedures
The inspector identified that material condition and housekeeping in the
                that resulted in mispositioned nitrogen backup supply valves that         i
*
                degraded the function of two steam generator power operated relief
Unit 2 Residual Heat Removal / Containment Spray Heat Exchanger Rooms was
                valves (Section M8.1).
poor (Section M2.1).
          Enaineerina
A non-cited violation was identified for failure to follow procedures
.
that resulted in mispositioned nitrogen backup supply valves that
i
degraded the function of two steam generator power operated relief
valves (Section M8.1).
Enaineerina
~
~
          .    A review of station Problem Identification Process (PIP) reports and
A review of station Problem Identification Process (PIP) reports and
                associated corrective actions revealed that the licensee's threshold for
.
                problem identification was at an appropriately low level and that the
associated corrective actions revealed that the licensee's threshold for
                Nuclear Safety Review Board had a positive impact on the licensee's
problem identification was at an appropriately low level and that the
                corrective action process. For the PIPS reviewed the licensee had not
Nuclear Safety Review Board had a positive impact on the licensee's
                failed to identify any unreviewed safety questions (Section E1.1).
corrective action process.
          .    A review of modification packages revealed that the licensee properly
For the PIPS reviewed the licensee had not
                screened and performed the safety evaluations for modifications and test
failed to identify any unreviewed safety questions (Section E1.1).
                procedure changes and that no unreviewed safety questions existed
A review of modification packages revealed that the licensee properly
                (Section E1.2).
.
          .    The licensee met the intent of Generic Letter (GL) 89-10 in verifying
screened and performed the safety evaluations for modifications and test
                the design-basis capabilities of their motor-operated valves (MOVs).
procedure changes and that no unreviewed safety questions existed
                Several weaknesses were identified. Of these, the more important were
(Section E1.2).
                the limited data that was used to establish the capabilities of several
The licensee met the intent of Generic Letter (GL) 89-10 in verifying
                groups of MOVs.and the marginal capabilities of several groups of MOVs.
.
                                                                              Enclosure 2
the design-basis capabilities of their motor-operated valves (MOVs).
Several weaknesses were identified. Of these, the more important were
the limited data that was used to establish the capabilities of several
groups of MOVs.and the marginal capabilities of several groups of MOVs.
Enclosure 2


        .
.
    .
.
          .
.
      4
4
                                                    2
2
l
l
                  An Inspector Followup Item was identified to track the completion of
An Inspector Followup Item was identified to track the completion of
                  licensee initiated corrective actions. Strengths were identified which
licensee initiated corrective actions.
                  included: knowledgeable personnel who recognized and addressed the
Strengths were identified which
l                problems identified, strong
included: knowledgeable personnel who recognized and addressed the
                  state of the art technology. plant   and corporate
problems identified, strong
                                                leadership          support,
state of the art technology. plant and corporate support, application of
                                                            in addressing       application
l
                                                                          industry problems,of
leadership in addressing industry problems,
                  and the detailed thrust / torque requirement calculations that were
and the detailed thrust / torque requirement calculations that were
                  developed for each valve group. Based on the NP,C staff's review of the     !
developed for each valve group.
                  Catawba GL 89-10 program and its implementation, and the corrective
Based on the NP,C staff's review of the
                  actions initiated by the licensee, the NRC is closing its review of the
Catawba GL 89-10 program and its implementation, and the corrective
                  GL 89-10 program at Catawba.     The completion of these licensee actions   ;
actions initiated by the licensee, the NRC is closing its review of the
                  will be assessed as part of the NRC staff's monitoring of the licensee's     )
GL 89-10 program at Catawba.
                  long-term MOV program (Section E1.3).                                       j
The completion of these licensee actions
            .
will be assessed as part of the NRC staff's monitoring of the licensee's
                  Procurement Engineering performance related to identification, upgrade
long-term MOV program (Section E1.3).
                  and validation of safety-related replacement parts was generally good.
j
                  A violation was identified for failure to follow procedures for the
Procurement Engineering performance related to identification, upgrade
                  storage and control of the spare parts diesel generator (Section E2.1).
.
            .    The engineering department was providing aggressive and effective
and validation of safety-related replacement parts was generally good.
                  support to the operations, maintenance, and modification departments:
A violation was identified for failure to follow procedures for the
                  the number of open items was at an acceptably low level; and the Top
storage and control of the spare parts diesel generator (Section E2.1).
                  Equipment Problem Resolution Process was a strength (Section E2.2).
The engineering department was providing aggressive and effective
            .
.
                  The scope of the procurement self-assessments was adequate to evaluate
support to the operations, maintenance, and modification departments:
                  performance of the activity under review. Findings were appropriately
the number of open items was at an acceptably low level; and the Top
                  documented and tracked for resolution (Section E7.1).
Equipment Problem Resolution Process was a strength (Section E2.2).
            .
The scope of the procurement self-assessments was adequate to evaluate
                  Engineering was aggressively pursuing identified equipment problems and
.
                  self-assessments were effective in identifying areas for improvement in
performance of the activity under review.
                  the engineering department (Section E7.2).
Findings were appropriately
            .    The monthly flushing program was effective in controlling clam
documented and tracked for resolution (Section E7.1).
                  population in service water piping (Section E8.1).
Engineering was aggressively pursuing identified equipment problems and
            Plant Stocort
.
  '
self-assessments were effective in identifying areas for improvement in
            .    The licensee had existing radiation monitoring systems in the new fuel
the engineering department (Section E7.2).
                  unloading and storage areas that were capable of alarming should an
The monthly flushing program was effective in controlling clam
                  accidental criticality occur. A violation for failure to implement
.
                  criticality accident emergency procedures and failure to conduct
population in service water piping (Section E8.1).
                  evacuation drills was identified (Section R2.1).
Plant Stocort
'
The licensee had existing radiation monitoring systems in the new fuel
.
unloading and storage areas that were capable of alarming should an
accidental criticality occur. A violation for failure to implement
criticality accident emergency procedures and failure to conduct
evacuation drills was identified (Section R2.1).
1
1
                                                                                Enclosure 2
Enclosure 2


        __     .   .__             _ _ _ _ _ _ _ _ _ _ _ . _ _ _ .               __ _ _ .   ._     ._ . _ _
__
          .
.
    .
.__
            .
_ _ _ _ _ _ _ _ _ _ _ . _ _ _ .
      .
__
!                                                                   Report Details
_ _ .
                Summary of Plant Status
._
                Unit 1 began the period operating at 100% power and operated at that power
._
                level until February 14, when power was decreased to 59% so that a failed
. _ _
                speed sensor (one of two) associated with the IB main feedwater pump turbine
.
                could be replaced. The specd sensor was replaced, and the unit returned to
.
                full power on February 15.
.
                                                                                                                '
.
                                                                                                                !
!
                Unit 2 began the Jeriod operating at 100% power and operated at essentially
Report Details
                full power througlout the inspection period.
Summary of Plant Status
!               Review of Vodated Final Safety Analysis Reoort (UFSAR) Commitment.s
Unit 1 began the period operating at 100% power and operated at that power
                                                                                                                l
level until February 14, when power was decreased to 59% so that a failed
                While performing inspections discussed in this report, the inspectors reviewed
speed sensor (one of two) associated with the IB main feedwater pump turbine
                the applicable portions of the UFSAR that were related to the areas inspected.
could be replaced. The specd sensor was replaced, and the unit returned to
              The inspectors verified that the UFSAR wording was consistent with the
full power on February 15.
                observed plant practices, procedures, and/or parameters.
Unit 2 began the Jeriod operating at 100% power and operated at essentially
                                                                    I. Doerations
'
                                                                                                                I
full power througlout the inspection period.
!
Review of Vodated Final Safety Analysis Reoort (UFSAR) Commitment.s
l
While performing inspections discussed in this report, the inspectors reviewed
the applicable portions of the UFSAR that were related to the areas inspected.
The inspectors verified that the UFSAR wording was consistent with the
observed plant practices, procedures, and/or parameters.
I. Doerations
,
,
l              01      Conduct of Operations                                                                    1
              01.1 Valve Stem Leakoff Flow Monitorina Indication
l
l
l                 a.   Insoection Scone (71707, 40500)
01
Conduct of Operations
01.1 Valve Stem Leakoff Flow Monitorina Indication
l
l
a.
Insoection Scone (71707, 40500)
l
l
l
l                      The resident inspector noted that annunciator panels located in the
The resident inspector noted that annunciator panels located in the
l                       auxiliary building, designed to provide flow indication from valve stem
l
l                       leakoff lines, had numerous indications of valve stem leakoff. The
auxiliary building, designed to provide flow indication from valve stem
                        inspector questioned the alarm status of these leakoff lines and
l
                        referred to pertinent design basis documents to determine the function
leakoff lines, had numerous indications of valve stem leakoff. The
                        of the annunciator panels.
inspector questioned the alarm status of these leakoff lines and
l                 b.   Observations and Findinas
referred to pertinent design basis documents to determine the function
of the annunciator panels.
l
b.
Observations and Findinas
i
i
  '
During a routine tour of the auxiliary building on January 29. the
                        During a routine tour of the auxiliary building on January 29. the                       l
                        resident inspector identified a number of flow alarms associated with                  i
                        Emergency Core Cooling System (ECCS) valve stem leakoff flow monitoring.
                        The inspector questioned operations personnel about the alarms and
                        determined that the annunciator panel indications were not considered
                        reliable and, therefore. the alarms were not attended to. The inspector
                        also noted that annunciator response procedures were not available to
j                      provide guidance in response to the alarms.
'
'
                        The licensee generated station Problem Investigation Process (PIP)
resident inspector identified a number of flow alarms associated with
                        report 0-C97-0265 to document the alarm status on these annunciator
i
                        panels. According to the PIP. the reliability 3roblems associated with
Emergency Core Cooling System (ECCS) valve stem leakoff flow monitoring.
                        the flow alarms has been an ongoing 3roblem. T1e 3rocedure for
The inspector questioned operations personnel about the alarms and
determined that the annunciator panel indications were not considered
reliable and, therefore. the alarms were not attended to.
The inspector
also noted that annunciator response procedures were not available to
j
provide guidance in response to the alarms.
The licensee generated station Problem Investigation Process (PIP)
'
'
                        identifying Reactor Coolant System (RCS) leakage. )T/1&2/B/4150/01E.
report 0-C97-0265 to document the alarm status on these annunciator
                        Identifying Reactor Coolant System Leakage, provides guidance for using
panels.
                                                                                            Enclosure 2
According to the PIP. the reliability 3roblems associated with
the flow alarms has been an ongoing 3roblem.
T1e 3rocedure for
'
identifying Reactor Coolant System (RCS) leakage.
)T/1&2/B/4150/01E.
Identifying Reactor Coolant System Leakage, provides guidance for using
Enclosure 2


      .                   .                                     .     .   .   _- -.
.
    .
.
        .
.
      .
.
r                                                   2                                   ;
.
l                                                                                         :
_-
-.
.
.
.
r
2
;
l
:
I
I
                  these annunciator panels to identify sources of RCS leakage. The
these annunciator panels to identify sources of RCS leakage.
                  inspector obtained a copy of the procedure, approved July 16,1996, and
The
                  reviewed Enclosure 13.3 Valve Stem Leakoffs to the Recycle Holdup Tank.
inspector obtained a copy of the procedure, approved July 16,1996, and
                Although the enclosure lists the ECCS valves that are represented on the
reviewed Enclosure 13.3 Valve Stem Leakoffs to the Recycle Holdup Tank.
                  annunciator panels, using this method to identify RCS leakage is not
Although the enclosure lists the ECCS valves that are represented on the
                  required and is implemented at the discretion of the Operations Shift
annunciator panels, using this method to identify RCS leakage is not
                . Supervisor.
required and is implemented at the discretion of the Operations Shift
                The inspector consulted the FSAR in an effort to determine the design
. Supervisor.
                basis of the valve stem leakoff flow indications. Although ECCS valve
The inspector consulted the FSAR in an effort to determine the design
                stem leakoff collection was briefly discussed, a discussion of flow       i
basis of the valve stem leakoff flow indications. Although ECCS valve
                monitoring of the leakoff was not provided in the context of reactor
stem leakoff collection was briefly discussed, a discussion of flow
                coolant system leakage detection or auxiliary building radiological
i
                activity limits.
monitoring of the leakoff was not provided in the context of reactor
            c. Conclusions
coolant system leakage detection or auxiliary building radiological
                                                                                          '
activity limits.
                The inspector concluded that the ECCS valve stem leakage flow alarms
c.
                that were not being maintained as a means of locating potential reactor   I
Conclusions
                coolant system leakage sources. Although no safety basis for the flow     i
'
                indication could be identified in the FSAR, an evaluation is appropriate i
The inspector concluded that the ECCS valve stem leakage flow alarms
                to determine whether the equipment should be available and maintained in J
that were not being maintained as a means of locating potential reactor
                good working condition or should be abandoned.
coolant system leakage sources. Although no safety basis for the flow
                                            II. Maintenance
i
                                                                                          l
indication could be identified in the FSAR, an evaluation is appropriate
          M1    Conduct of Maintenance                                                   '
i
          M1.1 Reactor Trio Breaker Surveillance Testina
to determine whether the equipment should be available and maintained in
            a. Jnsoection Scooe (61726)
J
                On February 6. the licensee determined that the time allowed for Unit 2
good working condition or should be abandoned.
                reactor trip breaker (RTB) testing was exceeded, and RTB inoperability
l
                had exceeded the 2-hour limit specified in Technical Specification (TS)
II. Maintenance
  '              3.3.1. Item 18. Action 9. The inspector reviewed station PIP 2-C97-
M1
                0341, reviewed associated testing procedures, and discussed the issue
Conduct of Maintenance
                with licensee personnel.
'
            b. Observations and Findinas
M1.1 Reactor Trio Breaker Surveillance Testina
                The licensee conducted RTB testing concurrent with Solid State
a.
                Protection System testing on February 6. According to TS 3.3.1. Item
Jnsoection Scooe (61726)
                18. Action 9. one RTB channel may be bypassed (inoperable) for up to two
On February 6. the licensee determined that the time allowed for Unit 2
                hours for surveillance testing per TS Surveillance Requirement 4.3.1.1.
reactor trip breaker (RTB) testing was exceeded, and RTB inoperability
                provided that the other RTB channel is operable. The work associated
had exceeded the 2-hour limit specified in Technical Specification (TS)
                with the surveillance testing was completed within the allowed 2-hour
3.3.1. Item 18. Action 9.
                time )eriod; however, paper work to clear the work order and declare the
The inspector reviewed station PIP 2-C97-
                RTB clannel operable was not completed until after the allowed time       ;
'
                period had elapsed by 20 minutes. As a result. RTB testing required       i
0341, reviewed associated testing procedures, and discussed the issue
                                                                                          1
with licensee personnel.
                                                                              Enclosure 2   l
b.
                                                                                            l
Observations and Findinas
                                                                                          l
The licensee conducted RTB testing concurrent with Solid State
Protection System testing on February 6.
According to TS 3.3.1. Item
18. Action 9. one RTB channel may be bypassed (inoperable) for up to two
hours for surveillance testing per TS Surveillance Requirement 4.3.1.1.
provided that the other RTB channel is operable. The work associated
with the surveillance testing was completed within the allowed 2-hour
time )eriod; however, paper work to clear the work order and declare the
RTB clannel operable was not completed until after the allowed time
period had elapsed by 20 minutes. As a result. RTB testing required
Enclosure 2


                                  . --   _       -_             .     -     -       .   ..-.
.
                                                                                                  i
--
        .
_
    *
-_
          s
.
      .                                                                                         l
-
                                                      3
-
.
..-.
i
.
*
s
.
l
l
                  entry into the 6 hour shutdown action of TS 3.3.1. Item 18. Action 9.         I
3
                                                                                                  I
entry into the 6 hour shutdown action of TS 3.3.1. Item 18. Action 9.
'                  The licensee initiated P75 2-C97-0341 to document the issue. The               i
I
                    inspector reviewed the 'T and discussed the occurrence with licensee         i
The licensee initiated P75 2-C97-0341 to document the issue. The
                  personnel. The cause of the time delay was attributed to multiple
'
                  changes to the test ?rocedure that required the performance of
inspector reviewed the 'T and discussed the occurrence with licensee
i
personnel.
The cause of the time delay was attributed to multiple
changes to the test ?rocedure that required the performance of
additional tasks. T1e licensee did not attemat a walkthrough
,
,
                  additional tasks. T1e licensee did not attemat a walkthrough                  !
verification to ensure that these procedure c1anges did not
                  verification to ensure that these procedure c1anges did not                   i
significantly impact the time necessary to cc.oplete testing. Corrective
                  significantly impact the time necessary to cc.oplete testing. Corrective
actions proposed in the PIP include procedural changes to enhance the
                  actions proposed in the PIP include procedural changes to enhance the
efficient use of time in conducting the test.
                  efficient use of time in conducting the test.                                 l
I
I                                                                                                 l
l
              c.   _ Conclusions                                                                 !
c.
'
_ Conclusions
                  The inspector concluded that exceeding the time allowed by TS for RTB
The inspector concluded that exceeding the time allowed by TS for RTB
                  testing because of outstanding papenvork did not adversely impact plant       1
'
testing because of outstanding papenvork did not adversely impact plant
1
safety. However, the procedural changes to incorporate additional tasks
-
-
                  safety. However, the procedural changes to incorporate additional tasks
were not evaluated to verify that those changes would not extend the
                  were not evaluated to verify that those changes would not extend the
time to perform th.e test beyond the time allowed by TS, without entering
4
4
                  time to perform th.e test beyond the time allowed by TS, without entering
a shutdown TS action.
;                  a shutdown TS action.
;
1
1
            M2 Maintenance and Material Condition of Facilities and Equipment
M2 Maintenance and Material Condition of Facilities and Equipment
;
M2.1 Unit 2 Containment Soray and RHR Heat Exchanger Room Observations
            M2.1 Unit 2 Containment Soray and RHR Heat Exchanger Room Observations
;
:             a.   Insoection Scooe (62707, 61726, 40500)
:
i
a.
                  The inspector observed portions of the following surveillance activities       l
Insoection Scooe (62707, 61726, 40500)
                  performed on the 2B containment spray pump:
i
                  -
The inspector observed portions of the following surveillance activities
                          PT/2/A/4200/09A, Auxiliary Safeguards Test Cabinet Periodic Test
l
                  -
performed on the 2B containment spray pump:
                        -PT/2/A/4200/04C, Containment Spray Pump 2B Performance Test
-
                  -
PT/2/A/4200/09A, Auxiliary Safeguards Test Cabinet Periodic Test
                          PT/2/A/4203/03. Leak Rate Determination for NS System Outside of
-
; ,
-PT/2/A/4200/04C, Containment Spray Pump 2B Performance Test
                          Containment
-
                  During the performance of these tests, the inspector observed poor             ,
PT/2/A/4203/03. Leak Rate Determination for NS System Outside of
                  housekeepino and material conditions in the Unit 2 Residual Heat Removal       i
;
;                 (RHR)/ Containment Spray heat exchanger rooms.                                 l
,
Containment
During the performance of these tests, the inspector observed poor
housekeepino and material conditions in the Unit 2 Residual Heat Removal
;
(RHR)/ Containment Spray heat exchanger rooms.
.
b.
Observations and Findinas
4
4
.
Surveillance Test PT/2/A/4203/03, Leak Rate Determination for NS System
              b.  Observations and Findinas
Outside of Containment, is performed within six months of each refueling
                  Surveillance Test PT/2/A/4203/03, Leak Rate Determination for NS System
outage and consists of a walkdown of containment spray system piping and
                  Outside of Containment, is performed within six months of each refueling
i
                  outage and consists of a walkdown of containment spray system piping and       i
;
;                 components located outside of the reactor containment while the system
components located outside of the reactor containment while the system
,
is pressurized.
                  is pressurized. Components with evidence of leakage are identified for
Components with evidence of leakage are identified for
j                 repair. During the portion of the walkdown performed in the 2B
,
j
repair.
During the portion of the walkdown performed in the 2B
1
1
                  RHR/Contaiu,,ent Spray heat exchanger room the inspector and the licensee
RHR/Contaiu,,ent Spray heat exchanger room the inspector and the licensee
                                                                                Enclosure 2
Enclosure 2
:
:


          -_     .             - -             ._     --- - _ .-- -       -- __.               - -.
-_
            .
.
      .
- -
              .
._
        .
--- - _ .-- -
                                                              4
-- __.
                      technician observed an uncontained leak spraying from a containment             ;
-
                      saray system vent located above the containment spray heat exchanger.
-.
                      T1e inspector investigated areas in the lower part of the room and
.
                      identified that a significant amount of boric acid had accumulated on
.
                      safety-related components in this area, including the heat exchanger
.
                      hold down bolts and supporting structure. The accumulation of boric
.
                      acid indicated that this leakage source had existed previously and would
4
                      occur when the system was in operation and pressurized.     The inspector
technician observed an uncontained leak spraying from a containment
                      found similar boric acid accumulation in the A train heat exchanger
saray system vent located above the containment spray heat exchanger.
                      room.
T1e inspector investigated areas in the lower part of the room and
                      In contrast to the conditions in the 2B heat exchanger room, a previous
identified that a significant amount of boric acid had accumulated on
                      atte.nn D contain leakage was obvious in the A train heat exchanger
safety-related components in this area, including the heat exchanger
                      room as evidenced by a drip bag installed on the heat exchanger vent
hold down bolts and supporting structure. The accumulation of boric
                      piping. The inspector discussed the licensee's leak containment                 I
acid indicated that this leakage source had existed previously and would
                      practices for these rooms with radiation protection management. The             ,
occur when the system was in operation and pressurized.
                      inspector found that the heat exchanger rooms were classified as                !
The inspector
                      nonrecoverable from a radiological contamination standpoint because of
found similar boric acid accumulation in the A train heat exchanger
room.
In contrast to the conditions in the 2B heat exchanger room, a previous
atte.nn D contain leakage was obvious in the A train heat exchanger
room as evidenced by a drip bag installed on the heat exchanger vent
piping.
The inspector discussed the licensee's leak containment
practices for these rooms with radiation protection management.
The
,
,
inspector found that the heat exchanger rooms were classified as
nonrecoverable from a radiological contamination standpoint because of
the chronic leakage sources which make the rooms difficult to maintain
,
decontaminated.
From the dicussions, the inspector discerned that the
'
'
                      the chronic leakage sources which make the rooms difficult to maintain
licensee did not routinely install drip bags or leak containments in
                      decontaminated. From the dicussions, the inspector discerned that the          ;
areas which are considered " nonrecoverable."
                      licensee did not routinely install drip bags or leak containments in
The inspector performed additional inspections in these rooms and
                      areas which are considered " nonrecoverable."
identified a substantial amount of debris left in the heat exchanger
                      The inspector performed additional inspections in these rooms and
rooms, including discarded scaffold tie down wires, several ropes tied
                      identified a substantial amount of debris left in the heat exchanger
,
,                    rooms, including discarded scaffold tie down wires, several ropes tied
to instrument air lines and safety-related valves, sections of unsecured
'
'
                      to instrument air lines and safety-related valves, sections of unsecured        1
1
                      insulation left on valve actuators, damaged flexible electrical conduit,
insulation left on valve actuators, damaged flexible electrical conduit,
                      trash, and discarded rubber gloves.
trash, and discarded rubber gloves.
                      Following identification of these issues the licensee developed a plan
Following identification of these issues the licensee developed a plan
                      to repair the leaks and correct housekeeping issues. The licensee
to repair the leaks and correct housekeeping issues.
  ,
The licensee
                      tightened the 2B heat exchanger pipe cap and the associated vent valves
,
  l                   which stopped the leak, Vent valves associated with the 2A heat
tightened the 2B heat exchanger pipe cap and the associated vent valves
                      exchanger were also tightened and no leakage was observed when the pump
l
    '
which stopped the leak,
                      was subsequently operated (PIP 2-C97-0349). Station management
Vent valves associated with the 2A heat
exchanger were also tightened and no leakage was observed when the pump
'
was subsequently operated (PIP 2-C97-0349). Station management
.
.
requested a root cause evaluation be performed by the safety review
'
'
                      requested a root cause evaluation be performed by the safety review
group to determine how conditions were allowed to degrade in the heat
                      group to determine how conditions were allowed to degrade in the heat
exchanger rooms and to assess how ioentified leaks are addressed on all
                      exchanger rooms and to assess how ioentified leaks are addressed on all
ECCS components.
                      ECCS components. The licensee oIso performed walkdowns of other
The licensee oIso performed walkdowns of other
;                     infrequently entered areas and found additional instances of where
;
                      material condition or housekeeping were substandard, but not as poor as
infrequently entered areas and found additional instances of where
l                     conditions in the Unit 2 RHR/ containment spray heat exchanger rooms.
material condition or housekeeping were substandard, but not as poor as
l
conditions in the Unit 2 RHR/ containment spray heat exchanger rooms.
!
!
l
l
                  c. Conclusions
c.
                      The ins'ector
Conclusions
                              >      identified that material condition and housekeeping in the
The ins'ector identified that material condition and housekeeping in the
                      Unit 2 Residual Heat Removal / Containment Spray Heat Exchanger Rooms was
>
;                     poor. Poor conditions resulted in part because of uncaptured
Unit 2 Residual Heat Removal / Containment Spray Heat Exchanger Rooms was
                      containment spray system leakage that resulted in accumulation of boric
;
                                                                                    Enclosure 2
poor.
Poor conditions resulted in part because of uncaptured
containment spray system leakage that resulted in accumulation of boric
Enclosure 2
;
;
,
,


      __ _   _ ._ .       __           __ _         _ _ _ _ _ _ . _ . _ _ _ _                 _ _ _
__
          .                                                                                           1
_
j   *       s
_ ._ .
__
__ _
_ _ _ _ _ _ . _ . _ _ _ _
_ _ _
1
.
j
*
s
.,
.,
;
;
                                                              4
4
i                     technician observed an uncontained leak spraying from a containment               '
i
                      s) ray system vent located above the containment spray heat exchanger.
technician observed an uncontained leak spraying from a containment
                      Tie inspector investigated areas in the lower part of the room and
'
s) ray system vent located above the containment spray heat exchanger.
Tie inspector investigated areas in the lower part of the room and
4
4
identified that a significant amount of boric acid had accumulated on
;
;
                      identified that a significant amount of boric acid had accumulated on
safety-related components in this area, including the heat exchanger
                      safety-related components in this area, including the heat exchanger
hold down bolts and supporting structure.
,
The accumulation of boric
                      hold down bolts and supporting structure. The accumulation of boric
,
,
                      acid indicated that this leakage source had existed previously and would
acid indicated that this leakage source had existed previously and would
                      occur when the system was in operation and pressurized. The inspector
,
occur when the system was in operation and pressurized. The inspector
found similar boric acid accumulation in the A train heat exchanger
.
.
                      found similar boric acid accumulation in the A train heat exchanger
room.
,
,
                      room.
I
I
                      In contrast to the conditions in the 2B heat exchanger room, a previous
In contrast to the conditions in the 2B heat exchanger room, a previous
;
;
                      attempt to contain leakage was obvious in the A train heat exchanger
attempt to contain leakage was obvious in the A train heat exchanger
                      room as evidenced by a drip bag installed on the heat exchanger vent
room as evidenced by a drip bag installed on the heat exchanger vent
<
<
#
#
                      piping. The inspector discussed the licensee's leak containment
piping. The inspector discussed the licensee's leak containment
practices for these rooms with radiation protection management.
The
,
,
                      practices for these rooms with radiation protection management. The
inspector found that the heat exchanger rooms were classified as
                      inspector found that the heat exchanger rooms were classified as
nonrecoverable from a radiological contamination standpoint because of
                      nonrecoverable from a radiological contamination standpoint because of
the chronic leakage sources which make the rooms difficult to maintain
,
,
                      the chronic leakage sources which make the rooms difficult to maintain
i
i                    decontaminated. From the dicussions, the inspector discerned that the
decontaminated.
                      licensee did not routinely install drip bags or leak containments in
From the dicussions, the inspector discerned that the
'
licensee did not routinely install drip bags or leak containments in
                      areas which are considered " nonrecoverable."
'
                      The inspector performed additional inspections in these rooms and
areas which are considered " nonrecoverable."
                      identified a substantial amount of debris left in the heat exchanger
The inspector performed additional inspections in these rooms and
                      rocms, including discarded scaffold tie down wires, several ropes tied           ;
identified a substantial amount of debris left in the heat exchanger
                      to instrument air lines and safety-related valves, sections of unsecured         '
rocms, including discarded scaffold tie down wires, several ropes tied
                      insulation left on valve actuators, damaged flexible electrical conduit.           '
;
                      trash, and discarded rubber gloves.                                               i
to instrument air lines and safety-related valves, sections of unsecured
                      Following identification of these issues the licensee developed a plan
'
                      to repair the leaks and correct housekeeping issues. The licensee
insulation left on valve actuators, damaged flexible electrical conduit.
                      tightened the 2B heat exchanger pipe cap and the associated vent valves
'
                      which stopped the leak. Vent valves associated with the 2A heat
trash, and discarded rubber gloves.
                      exchanger were also tightened and no leakage was observed when the pump           i
i
  '                  was subsequently operated (PIP 2-C97-0349). Station management                     l
Following identification of these issues the licensee developed a plan
                      requested a root cause evaluation be performed by the safety review
to repair the leaks and correct housekeeping issues.
                      group to determine how conditions were allowed to degrade in the heat
The licensee
                      exchanger rooms and to assess how identified leaks are addressed on all
tightened the 2B heat exchanger pipe cap and the associated vent valves
                      ECCS components. The licensee also performed walkdowns of other
which stopped the leak.
                      infrequently entered areas and found additional instances of where
Vent valves associated with the 2A heat
                      material condition or housekeeping were substandard, but not as poor as
exchanger were also tightened and no leakage was observed when the pump
                      conditions in the Unit 2 RHR/ containment spray heat exchanger rooms.
i
                  c. Conclusions
was subsequently operated (PIP 2-C97-0349). Station management
                      The inspector identified that material condition and housekeeping in the
'
                      Unit 2 Residual Heat Removal / Containment Spray Heat Exchanger Rooms was
requested a root cause evaluation be performed by the safety review
                      poor. Poor conditions resulted in part because of uncaptured
group to determine how conditions were allowed to degrade in the heat
                      containment spray system leakage that resulted in accumulation of boric
exchanger rooms and to assess how identified leaks are addressed on all
                                                                                    Enclosure 2
ECCS components. The licensee also performed walkdowns of other
                                                                                                      J
infrequently entered areas and found additional instances of where
material condition or housekeeping were substandard, but not as poor as
conditions in the Unit 2 RHR/ containment spray heat exchanger rooms.
c.
Conclusions
The inspector identified that material condition and housekeeping in the
Unit 2 Residual Heat Removal / Containment Spray Heat Exchanger Rooms was
poor.
Poor conditions resulted in part because of uncaptured
containment spray system leakage that resulted in accumulation of boric
Enclosure 2
J


      .
.
    .
.
                                                5
5
            acid on safety-related components in these rooms. The inspector also
acid on safety-related components in these rooms.
              identified material condition discrepancies. The licensee's subsequent
The inspector also
              inspection of other infrequently accessed areas identified similar       l
identified material condition discrepancies.
            conditions. These observations indicated that areas which are
The licensee's subsequent
            considered " nonrecoverable" from a radiological contamination             1
inspection of other infrequently accessed areas identified similar
            perspective had not received a commensurate level of care as frequently
conditions.
            traveled areas in the plant.
These observations indicated that areas which are
        M8   Miscellaneous Maintenance Issues (92902)
considered " nonrecoverable" from a radiological contamination
        M8.1 LClosed) Unresolved item (URI) 50-414/96-20-01: Mispositioned Nitrogen
perspective had not received a commensurate level of care as frequently
            Backup Supply Valves Result in Degrading the Function of Steam Generator
traveled areas in the plant.
              (SG) Power Operated Relief Valves (PORVs)
M8
            During this inspection period the licensee completed investigation of
Miscellaneous Maintenance Issues (92902)
            this valve mispositioning event. The licensee identified that the
M8.1 LClosed) Unresolved item (URI) 50-414/96-20-01: Mispositioned Nitrogen
            nitrogen supply isolation valves were in the closed position for SG PORV   !
Backup Supply Valves Result in Degrading the Function of Steam Generator
            2SV-1 in response to a low nitrogen pressure alarm received in the main   '
(SG) Power Operated Relief Valves (PORVs)
            control room when a maintenance technician found the valves closed in
During this inspection period the licensee completed investigation of
            the process of changing nitrogen bottles. Additional licensee
this valve mispositioning event.
            inspections identified that nitrogen supply isolation valves for SG PORV
The licensee identified that the
            2SV-13 were also closed. This was the first opportunity to iuentify the   I
nitrogen supply isolation valves were in the closed position for SG PORV
            mispositioned valves.
2SV-1 in response to a low nitrogen pressure alarm received in the main
            The licensee determined that four nitrogen supply isolation valves were
'
            left closed for a period of approximately 13 days following surveillance
control room when a maintenance technician found the valves closed in
            testing performed on SG PORVs 2"V-1 and 2SV-13 on December 22. 1996.
the process of changing nitrogen bottles.
            Two individuals performing the t?st failed to follow a portion of
Additional licensee
            restoration steps in Surveillance Procedure PT/2/A/4200/31A. SG PORV and
inspections identified that nitrogen supply isolation valves for SG PORV
            Block valve D/P Stroke Test. Specifically, two restoration steps were
2SV-13 were also closed. This was the first opportunity to iuentify the
            not completed to open the nitrogen supply isolation valves (Steps
mispositioned valves.
            12.1.21.5 of Enclosures 13.1 and 13.3 for SG PORVs 2SV-1 and 2SV-13.
The licensee determined that four nitrogen supply isolation valves were
            respectively). The licensee determined that a contributing cause was
left closed for a period of approximately 13 days following surveillance
            providing one procedure step to perform multiple actions that were in
testing performed on SG PORVs 2"V-1 and 2SV-13 on December 22. 1996.
            separate areas of the valve room areas.
Two individuals performing the t?st failed to follow a portion of
' '
restoration steps in Surveillance Procedure PT/2/A/4200/31A. SG PORV and
            Failing to follow Procedure PT/2/A/4200/31A restoration steps resulted
Block valve D/P Stroke Test.
            in disabling the safety-related gas su) plies for SG PORVs 2SV-1 and 2SV-
Specifically, two restoration steps were
            13 for a period of time in excess of t1e time allowed by TS 3.7.1.6.
not completed to open the nitrogen supply isolation valves (Steps
            Steam Generator Power Operated Relief Valves. With one less than three
12.1.21.5 of Enclosures 13.1 and 13.3 for SG PORVs 2SV-1 and 2SV-13.
            required operable SG PORVS the licensee is required to restore the
respectively).
i           inoperable SG PORV to operable status within 7 days or take additional
The licensee determined that a contributing cause was
I           actions to shutdown and place RHR inservice. This TS allows one SG PORV
providing one procedure step to perform multiple actions that were in
l           to remain inoperable indefinitely.
separate areas of the valve room areas.
            The purpose of the safety-related backup supply as stated in the TS
'
!           Bases is to mitigate the consequences of a steam generator tube rupture
'
I           accident concurrent with a loss of offsite power (i.e.     loss of
Failing to follow Procedure PT/2/A/4200/31A restoration steps resulted
.            instrument air which normally controls the SG PORVS).     During this
in disabling the safety-related gas su) plies for SG PORVs 2SV-1 and 2SV-
            period, two of the four Unit 2 SG PORVs were fully operable. With the
13 for a period of time in excess of t1e time allowed by TS 3.7.1.6.
Steam Generator Power Operated Relief Valves.
With one less than three
required operable SG PORVS the licensee is required to restore the
i
inoperable SG PORV to operable status within 7 days or take additional
I
actions to shutdown and place RHR inservice.
This TS allows one SG PORV
l
to remain inoperable indefinitely.
The purpose of the safety-related backup supply as stated in the TS
!
Bases is to mitigate the consequences of a steam generator tube rupture
I
accident concurrent with a loss of offsite power (i.e.
loss of
instrument air which normally controls the SG PORVS).
During this
.
period, two of the four Unit 2 SG PORVs were fully operable. With the
4
4
                                                                            Enclosure 2
Enclosure 2
1
1
1
1


        - -     .   -. .   .       .         - - - -     --
- -
.
-. .
.
.
- - - -
--
:
:
          .     ,
.
            ,
                                                              6
,
,
l'                        exception of the nitrogen backup supplies, the remaining two were
,
                          functional and could be operated during a steam generator tube rupture
6
                          event without complications resulting from a loss of offsite power or
,
                          instrument air. For a SG tube rupture event, the PORV on the affected
l
                          SG is assumed unavailable. With nitrogen backup supplies isolated on SG   <
exception of the nitrogen backup supplies, the remaining two were
                          PORVs 2SV-1 and 2SV-13, one SG PORV would have remained controllable
'
i
functional and could be operated during a steam generator tube rupture
                          from the main control room and SG PORVs 2SV-1 and 2SV-13 could be
event without complications resulting from a loss of offsite power or
;                         locally operated if needed per Emergency Operating Procedure
instrument air.
j                       EP/2/A/5000/ E-3. Steam Generator Tube Rupture.
For a SG tube rupture event, the PORV on the affected
                          Corrective Actions
SG is assumed unavailable.
With nitrogen backup supplies isolated on SG
<
PORVs 2SV-1 and 2SV-13, one SG PORV would have remained controllable
i
from the main control room and SG PORVs 2SV-1 and 2SV-13 could be
;
locally operated if needed per Emergency Operating Procedure
j
EP/2/A/5000/ E-3. Steam Generator Tube Rupture.
Corrective Actions
:
:
1~                       Upon discovery of the of the isolated nitrogen supplies on SG PORV 2SV-
1~
                          1. the licensee recognized the significance of the condition and
Upon discovery of the of the isolated nitrogen supplies on SG PORV 2SV-
1. the licensee recognized the significance of the condition and
promptly checked the remaining three Unit 2 SG PORVs and all four Unit 1
SG PORVS and identified that one additional SG PORV on Unit 2 (2SV-13)
'
'
                          promptly checked the remaining three Unit 2 SG PORVs and all four Unit 1
had its nitrogen supply isolated.
                          SG PORVS and identified that one additional SG PORV on Unit 2 (2SV-13)
The licensee 3romptly opened the valves and restored the nitrogen
                          had its nitrogen supply isolated.
1
1                        The licensee 3romptly opened the valves and restored the nitrogen
supplies for )oth SG PORVs.
                          supplies for )oth SG PORVs. In addition, after identification of the
In addition, after identification of the
,                        two mispositioning events the licensee displayed an appropriate
two mispositioning events the licensee displayed an appropriate
                          sensitivity to a possible tampering / sabotage event and performed
,
j                         additional verifications of equipment located in the same areas (i.e..
sensitivity to a possible tampering / sabotage event and performed
                          main steam safeties and turbine driven auxiliary feedwater steam supply
j
additional verifications of equipment located in the same areas (i.e..
main steam safeties and turbine driven auxiliary feedwater steam supply
valves).
The licensee also secured access to these rooms on both units
'
'
                          valves). The licensee also secured access to these rooms on both units
until investigation of the possible tampering concluded that the
                          until investigation of the possible tampering concluded that the           ;
                          mispositionings were not deliberate.
}
}
mispositionings were not deliberate.
In addition to the immediate corrective actions discussed above. the
licensee counseled the two individuals involved in performing the valve
'
manipulations and initiated revisions to the SG PORV surveillance
;
procedure to include separate steps and signoffs for each valve
;
-
-
manipulation.
Similar Engineering test procedures will be reviewed for
'
'
                          In addition to the immediate corrective actions discussed above. the      !
steps requiring multiple actions separated by time or distance and
                          licensee counseled the two individuals involved in performing the valve
changes will be made as necessary.
                          manipulations and initiated revisions to the SG PORV surveillance
The licensee submitted LER 50-
;                        procedure to include separate steps and signoffs for each valve
,
;
;
'
414/97-01 to address this issue on February 3, 1997.
              -  -
,
                          manipulation. Similar Engineering test procedures will be reviewed for
,
                          steps requiring multiple actions separated by time or distance and
The inspector concluded that the licensee's corrective actions were
,                        changes will be made as necessary. The licensee submitted LER 50-
4
;
.
  ,
appropriate and timely.
      ,
Failing to follow procedures which resulted in
                          414/97-01 to address this issue on February 3, 1997.
disabling the safety-related gas supplies for SG PORVs 2SV1 and 2SV13 is
4                        The inspector concluded that the licensee's corrective actions were
a violation of TS 6.8.1. Procedures and Programs. This violation meets
.                         appropriate and timely. Failing to follow procedures which resulted in
:
                          disabling the safety-related gas supplies for SG PORVs 2SV1 and 2SV13 is
the criteria of Section VII.B.1 of the Enforcement Policy for exercise
                          a violation of TS 6.8.1. Procedures and Programs. This violation meets
of discretion and will be considered a Non-Cited Violation (NCV 50-
:                       the criteria of Section VII.B.1 of the Enforcement Policy for exercise
j
                          of discretion and will be considered a Non-Cited Violation (NCV 50-
414/97-03-03. Mispositioned Nitrogen Backup Supply Valves Result in
j                         414/97-03-03. Mispositioned Nitrogen Backup Supply Valves Result in
r
r                         Degrading the Function of SG PORVs).
Degrading the Function of SG PORVs).
    -
-
                                                                                        Enclosure 2
Enclosure 2


                  - -                                     ..                       .
- -
                                                                                            i
..
    *
.
        t
i
      '
*
                                                                                            l
t
                                                                                            l
'
7
-
-
                                                    7
M8.2 (Closed) Licensee Event Reoort (LER) 50-414/94-002. Rev. 01: Reactor
                                                                                            1
Trip Breakers Opened Due to Component Failures
          M8.2 (Closed) Licensee Event Reoort (LER) 50-414/94-002. Rev. 01: Reactor         !
,
,
                Trip Breakers Opened Due to Component Failures
'
'
                The LER was revised by the licensee to correct inaccuracies identified
The LER was revised by the licensee to correct inaccuracies identified
                by the inspector during a previous inspection (refer to NRC Ins)ection     l
by the inspector during a previous inspection (refer to NRC Ins)ection
                                                                                            i
i
                Report 50-413.414/96-05).     The inspector reviewed the revised LER and
Report 50-413.414/96-05).
                verified the inaccuracies were corrected.     This item is closed.
The inspector reviewed the revised LER and
                                          III. Enaineerina
verified the inaccuracies were corrected.
          El   Conduct of Engineering
This item is closed.
          El.1 Review of Problem Identification Process
III. Enaineerina
            a. Insoection Scooe (40500)
El
                                                                                            :
Conduct of Engineering
                The inspectors reviewed a sample of the PIP reports identified by the
El.1 Review of Problem Identification Process
                licensee during 1996 and the first months of 1997. m order to assess
a.
                the licensee's corrective action process and the * ::pect of the Nuclear
Insoection Scooe (40500)
                Safety Review Board (NSRB) on the process,
The inspectors reviewed a sample of the PIP reports identified by the
            b. Observations and Findinas                                                   !
licensee during 1996 and the first months of 1997. m order to assess
                The inspectors reviewed the following PIP reports that were selected
the licensee's corrective action process and the * ::pect of the Nuclear
                from a list of PIPS written over the past year:
Safety Review Board (NSRB) on the process,
                -
b.
                      PIP No. 2-C96-1495. concerninq sheared or missing turbocharger
Observations and Findinas
                      bolts on Diesel Generator (D/G) 2B.
The inspectors reviewed the following PIP reports that were selected
                -
from a list of PIPS written over the past year:
                      PIP No. 2-C96-0475. concerning a leak coming from a cracked socket
-
                      weld on a vent line on D/G 2A.
PIP No. 2-C96-1495. concerninq sheared or missing turbocharger
                                                                                            I
bolts on Diesel Generator (D/G) 2B.
                (The remaining PIPS related to 10 CFR 50.59 safety evaluations.)
-
                                                                                            '
PIP No. 2-C96-0475. concerning a leak coming from a cracked socket
                -
weld on a vent line on D/G 2A.
                      PIP No. 0-C96-0812. involved conflicting information in the 50.59
(The remaining PIPS related to 10 CFR 50.59 safety evaluations.)
  ,
'
                      evaluation and a flow diagram.                                       ;
-
                -
PIP No. 0-C96-0812. involved conflicting information in the 50.59
                      PIP No. 0-C96-1024. did not contain a 50.59 evaluation or
evaluation and a flow diagram.
                      screening document because of personnel error.
;
                -
,
                      PIP No. 0-C96-2044 this was a question raised by the NSRB
-
                      screening concerning the adequacy of the documented discussion.
PIP No. 0-C96-1024. did not contain a 50.59 evaluation or
                -
screening document because of personnel error.
                      PIP No. 1-C96-2040, did not adequately discuss the decision that
-
                      the margin of safety discussed in the TS was not reduced (NSRB
PIP No. 0-C96-2044 this was a question raised by the NSRB
                      identi fied) .
screening concerning the adequacy of the documented discussion.
                                                                                            !
-
                -
PIP No. 1-C96-2040, did not adequately discuss the decision that
                      PIP No. 0-C96-2046 and PIP No. 1-C96-2049. questions concerning     i
the margin of safety discussed in the TS was not reduced (NSRB
                      adequacy of documented discussion raised by NSRB.
identi fied) .
                                                                                Enclosure 2
-
PIP No. 0-C96-2046 and PIP No. 1-C96-2049. questions concerning
i
adequacy of documented discussion raised by NSRB.
Enclosure 2


                                                                                        . _ .
. _ .
                                                                                              I
-
                                                                                              !
s
  -
.
      s
8
    .
-
                                                  8
PIP No. 1-C96-2049 and No. 2-C96-2051. questioned by the NSRB
              -
review.
                    PIP No. 1-C96-2049 and No. 2-C96-2051. questioned by the NSRB             l
Their review indicated that the 50.59 was directed at the
                    review. Their review indicated that the 50.59 was directed at the
modification implementation process when the safety analysis
                    modification implementation process when the safety analysis
should have been directed at the physical changes to the plant
                    should have been directed at the physical changes to the plant
that the modifications addressed.
                    that the modifications addressed.
None of the resolutions for the PIPS identified a failure to find a
              None of the resolutions for the PIPS identified a failure to find a
Unresolved Safety Question (US0).
              Unresolved Safety Question (US0).                                               j
j
        c.   Conclusions
c.
                                                                                              l
Conclusions
              The inspectors' review of selected PIPS and associated corrective               I
The inspectors' review of selected PIPS and associated corrective
              actions revealed that the licensee's threshold for problem                       I
actions revealed that the licensee's threshold for problem
              identification was at an appropriately low level and that the NSRB had a
identification was at an appropriately low level and that the NSRB had a
              positive impact on the licensee's corrective action process. For the
positive impact on the licensee's corrective action process.
              PIPS reviewed, the licensee had not failed to identify any US0.
For the
        E1.2 Review of Safety Evaluations
PIPS reviewed, the licensee had not failed to identify any US0.
        a.   Insoection Scooe (37550)
E1.2 Review of Safety Evaluations
              The inspectors reviewed a sample of the licensee's safety evaluations           !
a.
              per 10 CFR 50.59. The evaluations were reviewed with respect to the             ;
Insoection Scooe (37550)
              threshold for determining if an US0 existed because of an increase in           l
The inspectors reviewed a sample of the licensee's safety evaluations
              the probability of a design basis accident occurring, an increase in             '
per 10 CFR 50.59.
              equipment malfunction, a reduction in the margin of safety, or an               i
The evaluations were reviewed with respect to the
              increase in radiation dose consequences.                                         !
threshold for determining if an US0 existed because of an increase in
        b.   Observations and Findinas
the probability of a design basis accident occurring, an increase in
              The inspectors reviewed the following 10 CFR 50.59 safety evaluations
equipment malfunction, a reduction in the margin of safety, or an
              for modifications being performed to the Catawba Nuclear Station:               j
increase in radiation dose consequences.
              -
b.
                    50.59 evaluation for modification No. NSM CN-21341, which was used
Observations and Findinas
                    for the replacement of certain carbon steel sections of the               ,
The inspectors reviewed the following 10 CFR 50.59 safety evaluations
for modifications being performed to the Catawba Nuclear Station:
j
-
50.59 evaluation for modification No. NSM CN-21341, which was used
for the replacement of certain carbon steel sections of the
,
'
'
                    Nuclear Service Water System (RN) with stainless steel. Almost
Nuclear Service Water System (RN) with stainless steel. Almost
                    complete blockage due to corrosion products had been observed in.
complete blockage due to corrosion products had been observed in.
                    some of the two and four inch diameter lines.
some of the two and four inch diameter lines.
              -
-
                    50.59 evaluation for modification No. NSM CN-11355, which was used
50.59 evaluation for modification No. NSM CN-11355, which was used
                    for replacing Containment Penetration Valve Injection Water (NW)
for replacing Containment Penetration Valve Injection Water (NW)
                    globe valves with gate valves because of hydrogen embrittlement
globe valves with gate valves because of hydrogen embrittlement
                    problems with the stainless steel springs (type 17-7 PH). general
problems with the stainless steel springs (type 17-7 PH). general
                    operating difficulty, and problems with position indication.
operating difficulty, and problems with position indication.
              -
-
                    50.59 evaluation for modification No. NSM CN-21300, which was used
50.59 evaluation for modification No. NSM CN-21300, which was used
                    for refurbishment of the vertically mounted Containment Spray
for refurbishment of the vertically mounted Containment Spray
                    System (NS) Heat Exchangers 2A and 28. Baffle plates in the heat
System (NS) Heat Exchangers 2A and 28.
                    exchangers are supported by tie rods / spacers made from carbon
Baffle plates in the heat
                    steel and over a period of years corrosion had attacked these
exchangers are supported by tie rods / spacers made from carbon
                                                                            Enclosure 2
steel and over a period of years corrosion had attacked these
Enclosure 2


                                                                                        I
.
    .
.
  .
9
                                                9
components. The structural integrity was restored by inserting
                                                                                        :
rods both above and below the baffle plates and then welding the
                    components. The structural integrity was restored by inserting     l
rods to the shell.
                    rods both above and below the baffle plates and then welding the
-
                    rods to the shell.
50.59 evaluation for changing Test Procedure PT/2/A/4350/128 for
            -
Diesel Generator (D/G) 28.
                    50.59 evaluation for changing Test Procedure PT/2/A/4350/128 for
Additional loads were added to the
                    Diesel Generator (D/G) 28. Additional loads were added to the
test for this D/G and the test is used to demonstrate acceptable
                  test for this D/G and the test is used to demonstrate acceptable
response of the governor and voltage regulator to load changes
                    response of the governor and voltage regulator to load changes
after maintenance has been performed.
                    after maintenance has been performed.
c.
        c. Conclusions
Conclusions
            The inspectors concluded that the licensee had properly screened and       l
The inspectors concluded that the licensee had properly screened and
            performed the safety evaluations for the modifications and test             l
performed the safety evaluations for the modifications and test
            procedure change, and that no USQ existed.                                 i
procedure change, and that no USQ existed.
      El.3 Generic Letter 89-10 Program Imolementation                                 ;
i
                                                                                        l
El.3 Generic Letter 89-10 Program Imolementation
        a. Insoection Scooe (Temporary Instruction 2515/109)                           1
;
                                                                                        1
l
            This inspection provided an assessment of the licensee's implementation
a.
            of GL 89-10. " Safety-Related Motor-Operated Valve Testing and
Insoection Scooe (Temporary Instruction 2515/109)
            Surveillance". The licensee notified the NRC that they had completed
1
            implementation of GL 89-10 in a letter dated February 20, 1997.
This inspection provided an assessment of the licensee's implementation
            The assessment conducted during this inspection included evaluations of:
of GL 89-10. " Safety-Related Motor-Operated Valve Testing and
            the scope of MOVs included, the calculations of the design basis
Surveillance".
            differential pressure, the determinations of MOV settings and
The licensee notified the NRC that they had completed
            verifications of MOV capabilities. the periodic verification of MOV
implementation of GL 89-10 in a letter dated February 20, 1997.
            capabilities, and the MOV post maintenance and post modification
The assessment conducted during this inspection included evaluations of:
            testing. The inspectors conducted the assessment through a review of the
the scope of MOVs included, the calculations of the design basis
            licensee's GL 89-10 implementing documentation and through interviews
differential pressure, the determinations of MOV settings and
            with licensee personnel. The documents reviewed included: "NRC Generic
verifications of MOV capabilities. the periodic verification of MOV
            Letter 89-10 Program Plan," Rev. 4: " Guideline for Performing Motor
capabilities, and the MOV post maintenance and post modification
            0]erated
testing. The inspectors conducted the assessment through a review of the
            "
licensee's GL 89-10 implementing documentation and through interviews
                      Valve Reviews and Calculations" DPS-1205.19-00-0002. Rev. 0;
with licensee personnel.
The documents reviewed included: "NRC Generic
Letter 89-10 Program Plan," Rev. 4: " Guideline for Performing Motor
0]erated Valve Reviews and Calculations" DPS-1205.19-00-0002. Rev. 0;
" Evaluation of Rate-of-Loading Effects". DPC-1205.19-00-0002, Rev. 0;
'
'
              Evaluation of Rate-of-Loading Effects". DPC-1205.19-00-0002, Rev. 0;
DPC-1205.19-00-0001 Rev.1. " Evaluation of Stem Factor and Stem C.O.F.
            DPC-1205.19-00-0001 Rev.1. " Evaluation of Stem Factor and Stem C.O.F.
A:sumptions;" and the procedures, calculations, test records, etc. ,
            A:sumptions;" and the procedures, calculations, test records, etc. ,
referred to in the following paragraphs.
            referred to in the following paragraphs.     In addition, the inspectors
In addition, the inspectors
            reviewed summary tabulations of MOV information and calculation results
reviewed summary tabulations of MOV information and calculation results
            prepared by the licensee. Prominent among the tabulations was a list of
prepared by the licensee.
            "available valve factors" (AVFs) for the licensee's GL 89-10 gate and
Prominent among the tabulations was a list of
            globe valves. The licensee prepared this list at the inspectors'
"available valve factors" (AVFs) for the licensee's GL 89-10 gate and
            request to aid them in assessing the capabilities of the licensee's
globe valves.
            MOVs. The inspectors compared the AVFs of the licensee's valves to
The licensee prepared this list at the inspectors'
            valve factor requirements established through industry testing to
request to aid them in assessing the capabilities of the licensee's
            determine if the AVFs were conservatively higher. The AVFs were
MOVs. The inspectors compared the AVFs of the licensee's valves to
            calculated for each MOV using the formulas given below.
valve factor requirements established through industry testing to
                                                                            Enclosure 2
determine if the AVFs were conservatively higher. The AVFs were
calculated for each MOV using the formulas given below.
Enclosure 2


            .__._         _   _       _ _ _     . _ . _ _   _ _ _ _
.__._
                          -
_
        .
_
    .    .
_ _ _
      .
. _ . _ _
4
_ _ _ _
                                                            10
.
-
.
.
.
10
  4
  4
4
AVF (Close) = (Th * [1 - (LSB + U)]) - PL - SR/ (Disc Area * DBDP)
i
i
                  AVF (Close) = (Th * [1 - (LSB + U)]) - PL - SR/ (Disc Area * DBDP)
;
;                  AVF (0 pen) = (Th * [1 - (LSB + U)]) - PL + SR/ (Disc Area * DBDP)
AVF (0 pen) = (Th * [1 - (LSB + U)]) - PL + SR/ (Disc Area * DBDP)
:                  where.
where.
:
I
I
                          Th     - thrust available for limit switch control. thrust at
Th
                                  torque switch trip for torque switch control
- thrust available for limit switch control. thrust at
.                        LSB     = load sensitive behavior
torque switch trip for torque switch control
i                         U       - uncertainty (instrument and other uncertainties combined
LSB
                                  by square root sum of squares method)
= load sensitive behavior
                          PL     - packing load
.
}                         SR     = stem rejection load
i
l                         DBDP = design-basis differential pressure
U
- uncertainty (instrument and other uncertainties combined
by square root sum of squares method)
PL
- packing load
}
SR
= stem rejection load
l
DBDP = design-basis differential pressure
i
i
b.
Observations and Findinas
,
,
            b.    Observations and Findinas
Scone of MOVs Included in the Proaram
                  Scone of MOVs Included in the Proaram
i
i
                  The scope of valves in the licensee *s GL 89-10 program was reviewed
The scope of valves in the licensee *s GL 89-10 program was reviewed
previously by the NRC and was determined acceptable during Inspection
,
,
                  previously by the NRC and was determined acceptable during Inspection
i
i                  50-413.414/96-02. In the current inspection the NRC inspectors reviewed
50-413.414/96-02.
                  the list of MOVs contained in the licensee's program and verified that
In the current inspection the NRC inspectors reviewed
:                 the scope had not changed. The list was maintained as the Catawba
the list of MOVs contained in the licensee's program and verified that
:
the scope had not changed.
The list was maintained as the Catawba
Nuclear Station Units 1 and 2 Generic Letter 89-10 MOV List, CNS
-
-
                  Nuclear Station Units 1 and 2 Generic Letter 89-10 MOV List, CNS
1205.19-0081. Rev. D2.
                  1205.19-0081. Rev. D2. The scope included 252 gate valves. 154 globe
The scope included 252 gate valves. 154 globe
valves, and 66 butterfly valves for a total of 472 valves. This was one
'
'
                  valves, and 66 butterfly valves for a total of 472 valves. This was one
of the largest scopes of any plant.
                  of the largest scopes of any plant.
Determinations of Settinas and Verifications of Caoabilities for Gate
                  Determinations of Settinas and Verifications of Caoabilities for Gate
,
  ,
and Globe Valves
                  and Globe Valves
The inspectors selected and reviewed calculations, test data, and
                  The inspectors selected and reviewed calculations, test data, and
-
-
'                  evaluations for the following sample of valves in order to assess the
evaluations for the following sample of valves in order to assess the
                  licensee's validation of calculation assumptions and their
'
:                 determinations of MOV settings and capabilities:
licensee's validation of calculation assumptions and their
                  1-NC031B       Pressurizer power operated relief valve (PORV) block valve
:
                  :2-BB010B     Steam generator (S/G) D outside containment isolation valve
determinations of MOV settings and capabilities:
                                  (CIV)
1-NC031B
                  2-SV026B       Steam generator C PORV block valve
Pressurizer power operated relief valve (PORV) block valve
                  1-NV091B       Reactor coolant pump seal return CIV
:2-BB010B
                  1-NIO95A       Safety injection test header to sump CIV
Steam generator (S/G) D outside containment isolation valve
                  2-CA038A       Turbine driven auxiliary feedwater pump to S/G D isolation
(CIV)
                                  valve
2-SV026B
                                                                                  Enclosure 2
Steam generator C PORV block valve
1-NV091B
Reactor coolant pump seal return CIV
1-NIO95A
Safety injection test header to sump CIV
2-CA038A
Turbine driven auxiliary feedwater pump to S/G D isolation
valve
Enclosure 2


    .   ,
.
      .
,
                                            11
.
          The inspectors' findings were as follows:
11
          MOV Sizino and Switch Settinas
The inspectors' findings were as follows:
          Catawba typically used standard industry equations to determine gate
MOV Sizino and Switch Settinas
          valve thrust requirements for setting and sizing their gate valves.
Catawba typically used standard industry equations to determine gate
          Valve factors for use in these equations were based on in-plant dynamic
valve thrust requirements for setting and sizing their gate valves.
          testing results or results from other industry sources. For some valves
Valve factors for use in these equations were based on in-plant dynamic
          on which in-plant testing was impractical, prototype testing was
testing results or results from other industry sources.
          performed.   For Westinghouse gate valves the licensee used the equation
For some valves
          and valve factor developed by Westinghouse to calculate minimum required
on which in-plant testing was impractical, prototype testing was
          thrust. In a few cases, the licensee used Electric Power Research
performed.
          Institute (EPRI) Performance Prediction Model (PPM) calculations to
For Westinghouse gate valves the licensee used the equation
          establish thrust requirements.
and valve factor developed by Westinghouse to calculate minimum required
          Most of the licensee's globe valves were manufactured by Kerotest. The
thrust.
          thrust requirements for these valves were either calculated using the
In a few cases, the licensee used Electric Power Research
          vendor's method, with an amount added to account for nonconservatism
Institute (EPRI) Performance Prediction Model (PPM) calculations to
          found by a licensee test program: or the standard industry equation was
establish thrust requirements.
          used. For the licensee's other globe valves thrust requirements were
Most of the licensee's globe valves were manufactured by Kerotest.
          calculated using the standard industry equation.
The
          Thrust Reauirements for Grouos
thrust requirements for these valves were either calculated using the
          The licensee grouped similar MOVs and established thrust setting
vendor's method, with an amount added to account for nonconservatism
          requirements for each group. From their reviews, the inspectors found
found by a licensee test program: or the standard industry equation was
          that the thrust setting requirements determined for each valve group and
used.
          the current setups of the MOVs were adequate for design-basis
For the licensee's other globe valves thrust requirements were
          capability. However, they noted weaknesses for several groups. These
calculated using the standard industry equation.
          weaknesses and the actions which the licensee initiated to address each
Thrust Reauirements for Grouos
          are described below:
The licensee grouped similar MOVs and established thrust setting
requirements for each group.
From their reviews, the inspectors found
that the thrust setting requirements determined for each valve group and
the current setups of the MOVs were adequate for design-basis
capability.
However, they noted weaknesses for several groups.
These
weaknesses and the actions which the licensee initiated to address each
are described below:
Group AD-02 consisted of six 6-inch 900# Anchor / Darling double
.
;
;
          .      Group AD-02 consisted of six 6-inch 900# Anchor / Darling double
disc gate valves. These MOVs had both a close and open safety
                disc gate valves. These MOVs had both a close and open safety
function.
                function. The thrust reauirements were deter'ained using EPRI PPM
The thrust reauirements were deter'ained using EPRI PPM
                                                                                    '
'
  '
'
                Anchor / Darling double disc hand calculations. The inspectors
Anchor / Darling double disc hand calculations. The inspectors
                found that the licensee's closing calculations were only for flow
found that the licensee's closing calculations were only for flow
                isolation and expressed concern that excessive leakage through the
isolation and expressed concern that excessive leakage through the
                valves might occur without full seating. To address this concern,
valves might occur without full seating. To address this concern,
                the licensee established an action item in PIP 0-C97-0421 to
the licensee established an action item in PIP 0-C97-0421 to
                respond to the conditions specified in the NRC Safety Evaluation
respond to the conditions specified in the NRC Safety Evaluation
                of the " Electric Power Research Institute Topical Report TR-
of the " Electric Power Research Institute Topical Report TR-
103237. EPRI Motor-Operated Valve Performance Prediction Program"
,
,
                103237. EPRI Motor-Operated Valve Performance Prediction Program"
(including consideration of leakage requirements).
                (including consideration of leakage requirements).
Group AD-04 consisted of six 3-inch 1500# Anchor / Darling double
          .      Group AD-04 consisted of six 3-inch 1500# Anchor / Darling double
.
                disc gate valves. Catawba evaluated November 1994 instrumented
disc gate valves. Catawba evaluated November 1994 instrumented
                " prototype" testing and EPRI PPM Anchor / Darling double disc gate
" prototype" testing and EPRI PPM Anchor / Darling double disc gate
                valve hand calculation results to establish the thrust
valve hand calculation results to establish the thrust
                requirements for these MOVs.   The NRC inspectors reviewed the
requirements for these MOVs.
                                                                        Enclosure 2
The NRC inspectors reviewed the
Enclosure 2


    ,
,
  .
.
                                        12
12
                                                                              i
i
          results and expressed concern that the licensee's evaluations
results and expressed concern that the licensee's evaluations
          showed that the capabilities of two valves in this group had only
showed that the capabilities of two valves in this group had only
          marginal capabilities (INC31 and 2NC33). The licensee established
marginal capabilities (INC31 and 2NC33).
          an action item in PIP 0-C97-0421 to provide future modifications
The licensee established
          to upgrade the margins for these valves.
an action item in PIP 0-C97-0421 to provide future modifications
                                                                              1
to upgrade the margins for these valves.
        .
1
          Group BW-01 consisted of eight 3-inch Borg Warner 150# gate
Group BW-01 consisted of eight 3-inch Borg Warner 150# gate
          valves. -From dynamic testing, the licensee determined a valve
.
          factor of 1.3 for this valve group. This valve factor was used to
valves. -From dynamic testing, the licensee determined a valve
          calculate thrust setting requirements for the group. The             i
factor of 1.3 for this valve group. This valve factor was used to
          inspectors questioned the reliability of this unexpectedly high       l
calculate thrust setting requirements for the group. The
          value, as it was supported only by a single test. The inspectors     '
i
          verified that the licensee had reviewed the MOV settings for the     ,
inspectors questioned the reliability of this unexpectedly high
          remainder of this group to ensure each could support a valve         l
value, as it was supported only by a single test.
          factor as high as 1.3. The inspectors found that the licensee
The inspectors
          already had plans to dynamic test three other valves from this
'
          group in the upcoming Spring 1997 outage to further assess the
verified that the licensee had reviewed the MOV settings for the
          valve factor. The licensee established an action item in PIP 0-
,
          C97-0421 specifying the additional dynamic testing of these three
remainder of this group to ensure each could support a valve
          valves.                                                               ,
factor as high as 1.3.
        . Group WL-01 consisted of two 6-inch Walworth 150# gate valves.
The inspectors found that the licensee
          The minimum thrust requirements for these MOVs was based on a       .
already had plans to dynamic test three other valves from this
          valve factor of 0.40 and they had open safety functions. The         !
group in the upcoming Spring 1997 outage to further assess the
          calculated open available valve factor for these MOVs was only a
valve factor.
                                                                                '
The licensee established an action item in PIP 0-
          little higher, at 0.42. The inspectors considered these MOVs to
C97-0421 specifying the additional dynamic testing of these three
          be marginal with respect to thrust capabilities. They reviewed
valves.
          the diagnostic traces for these MOVs to ensure they were lightly
,
          seated such that minimal unwedging force was required to open
Group WL-01 consisted of two 6-inch Walworth 150# gate valves.
          them.    Further, they verified that industry data showed a valve
.
          factor of 0.40 for these MOVs. The licensee established an action
The minimum thrust requirements for these MOVs was based on a
          item in PIP 0-C97-0421 specifying that these MOVs would be
.
      -
valve factor of 0.40 and they had open safety functions.
          modified to increase their thrust margins in the 1997 Spring
The
          outage.
calculated open available valve factor for these MOVs was only a
'
'
        . The thrust requirements for the following gate valve groups were
little higher, at 0.42. The inspectors considered these MOVs to
          determined using valve factors obtained from the results of a
be marginal with respect to thrust capabilities. They reviewed
          single dynamic test each: BW-11 BW-13 PC-01. WH-01, and WH-02.
the diagnostic traces for these MOVs to ensure they were lightly
          The inspectors found that such limited data provided weak support
seated such that minimal unwedging force was required to open
          for the requirements. The inspectors verified that the valves had
them.
          reasonably high available valve factors compared to general
Further, they verified that industry data showed a valve
          industry results and did not identify any current operability
factor of 0.40 for these MOVs.
          concerns.   The licensee established an action item in PIP 0-C97-
The licensee established an action
          0421 to put in place a plan to document this shortcoming and
item in PIP 0-C97-0421 specifying that these MOVs would be
          monitor and evaluate the future performance of these valves.
-
        * The thrust requirements determined for the following globe valve
modified to increase their thrust margins in the 1997 Spring
          groups were considered weak as they were supported by limited
outage.
          dynamic test data: BW-13. BW-14. and BW-15. Based on a review of
'
          the settings for these valves, the inspectors were satisfied that
The thrust requirements for the following gate valve groups were
                                                                  Enclosure 2
.
determined using valve factors obtained from the results of a
single dynamic test each: BW-11 BW-13 PC-01. WH-01, and WH-02.
The inspectors found that such limited data provided weak support
for the requirements. The inspectors verified that the valves had
reasonably high available valve factors compared to general
industry results and did not identify any current operability
concerns.
The licensee established an action item in PIP 0-C97-
0421 to put in place a plan to document this shortcoming and
monitor and evaluate the future performance of these valves.
The thrust requirements determined for the following globe valve
*
groups were considered weak as they were supported by limited
dynamic test data:
BW-13. BW-14. and BW-15.
Based on a review of
the settings for these valves, the inspectors were satisfied that
Enclosure 2


          . -             ._.   _       _                 .       .     -       .--   _
.
    .   s
-
      .
._.
                                                13
_
                    these groups had adequate thrust margins to assure operability.
_
                    The licensee established an action item in PIP 0-C97-0421 to
.
                    strengthen the validation data for these groups.
.
              The actions which the licensee initiated to address the above weaknesses
-
              were considered satisfactory.
.--
              Load Sensitive Behavior
_
                                                                                          l
.
              The licensee used measured load sensitive behavior values for valves
s
              that were dynamically tested and generally assumed a value of 30% for
.
              set-up of valves that were not dynamically tested. The licensee's
13
              evaluation of the load sensitive behavior data in their dynamic tests       I
these groups had adequate thrust margins to assure operability.
              was documented in calculation DPC-1205.19-00-0002. " Evaluation of Rate-
The licensee established an action item in PIP 0-C97-0421 to
              of-Loading Effects." The licensee was in the process of revising this
strengthen the validation data for these groups.
              evaluation and the inspectors reviewed both revisions. The inspectors
The actions which the licensee initiated to address the above weaknesses
              found that the 30% value which the licensee had used in setting up
were considered satisfactory.
              valves that were not dynamically tested exceeded the mean plus two
Load Sensitive Behavior
              standard deviations determined by both the original and new evaluations.
The licensee used measured load sensitive behavior values for valves
              The latest values were used to calculate the available valve factors       l
l
              that the inspectors had requested for use in evaluating Catawba's MOVs.     !
that were dynamically tested and generally assumed a value of 30% for
              The inspectors considered the licensee's assessment and application of     i
set-up of valves that were not dynamically tested. The licensee's
              load sensitive hehavior to be satisfactory.
evaluation of the load sensitive behavior data in their dynamic tests
                                                                                          l
was documented in calculation DPC-1205.19-00-0002. " Evaluation of Rate-
              Stem Friction Coefficient                                                   l
of-Loading Effects." The licensee was in the process of revising this
              Catawba's calculations assumed a stem friction coefficient value of 0.15
evaluation and the inspectors reviewed both revisions. The inspectors
              in determining actuator output capability. This value was obtained from
found that the 30% value which the licensee had used in setting up
              an evaluation of in-plant test data from several licensee facilities.
valves that were not dynamically tested exceeded the mean plus two
              However, based on a more recent evaluation of dynamic test data. Catawba
standard deviations determined by both the original and new evaluations.
              determined that a value of 0.20 should be used for opening dynamic
The latest values were used to calculate the available valve factors
              conditions. They continued to consider a 0.15 value acceptable for
that the inspectors had requested for use in evaluating Catawba's MOVs.
              closing. The licensee verified that closing static stem friction
The inspectors considered the licensee's assessment and application of
l            coefficients did not exceed 0.15 and relied on the assumed rate of
load sensitive hehavior to be satisfactory.
Stem Friction Coefficient
Catawba's calculations assumed a stem friction coefficient value of 0.15
in determining actuator output capability. This value was obtained from
an evaluation of in-plant test data from several licensee facilities.
However, based on a more recent evaluation of dynamic test data. Catawba
determined that a value of 0.20 should be used for opening dynamic
conditions.
They continued to consider a 0.15 value acceptable for
closing.
The licensee verified that closing static stem friction
coefficients did not exceed 0.15 and relied on the assumed rate of
l
loading to account for increased friction under dynamic conditions. The
,
,
              loading to account for increased friction under dynamic conditions. The
i
i
  '
licensee's PIP 0-C95-0879 provided an evaluation of the opening
              licensee's PIP 0-C95-0879 provided an evaluation of the opening             ,
'
              capabilities of the licensee's actuators using an opening stem friction
,
              coefficient of 0.20. The PIP documented that the current MOV
capabilities of the licensee's actuators using an opening stem friction
              capabilities were acceptable. The inspectors reviewed the licensee's
coefficient of 0.20.
              evaluation and concluded that the licensee had adequately determined and
The PIP documented that the current MOV
              accounted for stem coefficient in verifying the capabilities of their
capabilities were acceptable. The inspectors reviewed the licensee's
              MOVs.
evaluation and concluded that the licensee had adequately determined and
              Diaonostic Eauioment Uncertainties
accounted for stem coefficient in verifying the capabilities of their
              NRC Inspection 50-413.414/96-02 determined that the licensee was not
MOVs.
Diaonostic Eauioment Uncertainties
NRC Inspection 50-413.414/96-02 determined that the licensee was not
;
;
accounting for VOTES diagnostic equipment uncertainties in the open
'
'
              accounting for VOTES diagnostic equipment uncertainties in the open
direction when measurements were outside the sensor calibration range.
              direction when measurements were outside the sensor calibration range.
These errors can become very large if the measurements are significantly
              These errors can become very large if the measurements are significantly
;
;             outside the calibration range. This issue was addressed by the licensee
outside the calibration range.
                                                                            Enclosure 2
This issue was addressed by the licensee
Enclosure 2
:
:
l
l


                                                                                1
%
    %
1
  .
.
                                                                                1
14
                                        14
through PIPS 0-G95-0295 and 0-C95-0879.
      through PIPS 0-G95-0295 and 0-C95-0879.     The inspectors verified that
The inspectors verified that
      the PIPS assured that the uncertainties were appropriately accounted for
the PIPS assured that the uncertainties were appropriately accounted for
      through evaluations of the existing completed testing and that the
through evaluations of the existing completed testing and that the
      licensee's procedures were revised for future testing.
licensee's procedures were revised for future testing.
      Desian-Basis Capability
Desian-Basis Capability
      From reviews of examples of the dynamic test evaluations and associated   l
From reviews of examples of the dynamic test evaluations and associated
      test reports, the inspectors generally found that the licensee's testing   I
test reports, the inspectors generally found that the licensee's testing
      had been satisfactorily used in establishing the design-basis capability
had been satisfactorily used in establishing the design-basis capability
      of their MOVs. Catawba's dynamic tests were accurate and well             i
of their MOVs. Catawba's dynamic tests were accurate and well
      cocumented.   From the test results. the licensee calculated valve       !
i
      factors for each test. The valve factors for each group of valves were     i
cocumented.
      displayed graphically with separate lines plotted for flow isolation and   I
From the test results. the licensee calculated valve
      hard seat values. In general, the valve factor which the licensee
factors for each test. The valve factors for each group of valves were
      applied to a group of non-tested valves was selected by bounding the
displayed graphically with separate lines plotted for flow isolation and
      highest valve factor on the graph and then adding 0.01 to that value.
hard seat values.
      If a test group showed one test to have an abnormally high or low valve   l
In general, the valve factor which the licensee
      factor, an engineering evaluation was performed and that valve factor
applied to a group of non-tested valves was selected by bounding the
      was removed from the group if appropriate.
highest valve factor on the graph and then adding 0.01 to that value.
                                                                                l
If a test group showed one test to have an abnormally high or low valve
      The inspectors noted two weaknesses in methods which the licensee used     i
factor, an engineering evaluation was performed and that valve factor
      to determine the group valve factors:                                     !
was removed from the group if appropriate.
      .      The inspectors identified one instance in which the licensee used
The inspectors noted two weaknesses in methods which the licensee used
            multiple test data points from a single valve in graphically
i
            analyzing the valve factors for a group of valves. This could
to determine the group valve factors:
            have biased the selection of an appropriate group valve factor.
The inspectors identified one instance in which the licensee used
            For the instance in question (valve group BW-05), the inspectors
.
            independently analyzed the licensee's data and found that the
multiple test data points from a single valve in graphically
            valve factor which the licensee applied to the group was
analyzing the valve factors for a group of valves.
            satisfactory.
This could
      .      The inspectors noted that the licensee's selection of a grou)
have biased the selection of an appropriate group valve factor.
            valve factor by adding 0.01 to the highest valve factor on t1e
For the instance in question (valve group BW-05), the inspectors
independently analyzed the licensee's data and found that the
valve factor which the licensee applied to the group was
satisfactory.
The inspectors noted that the licensee's selection of a grou)
.
valve factor by adding 0.01 to the highest valve factor on t1e
'
'
            graph for a group might not adequately account for variations in
graph for a group might not adequately account for variations in
            valve factor performance if the valve factor data had a large
valve factor performance if the valve factor data had a large
            amount of scatter. The inspectors statistically assessed licensee
amount of scatter. The inspectors statistically assessed licensee
            data and identified an example (valve group BW-03) where the valve
data and identified an example (valve group BW-03) where the valve
            factor selected by the licensee was slightly lower than the mean
factor selected by the licensee was slightly lower than the mean
            plus two standard deviations. In this instance Catawba had
plus two standard deviations.
            selected an open and close valve factor of 0.60 for the MOVs.
In this instance Catawba had
            Using the mean plus 2 standard deviations of the data available
selected an open and close valve factor of 0.60 for the MOVs.
            for this group the inspectors calculated an caening valve factor
Using the mean plus 2 standard deviations of the data available
            of 0.65 and a closing valve factor of 0.64. iowever, the higher
for this group the inspectors calculated an caening valve factor
            values calculated by the inspectors were not an operability
of 0.65 and a closing valve factor of 0.64.
            problem, as the inspectors found that the minimum available valve
iowever, the higher
            factor for these MOVs was 0.69. The licensee stated that they
values calculated by the inspectors were not an operability
            would review those calculations where the valve factor data had a
problem, as the inspectors found that the minimum available valve
            large amount of scatter to ensure that an appropriate valve factor
factor for these MOVs was 0.69. The licensee stated that they
            had been selected for the group.
would review those calculations where the valve factor data had a
                                                                    Enclosure 2
large amount of scatter to ensure that an appropriate valve factor
                                                                                l
had been selected for the group.
Enclosure 2
l


                                                                                    I
      '
  -
        s
    .
                                            15
          Jeterminations of Settinas and Verifications of Caoabilities for
          3utterfly Valves
          The licensee documented their setting determinations and justifications
          for the capabilities of the Catawba butterfly valves in calculations.
          Additionally, they documented summary information on each butterfly
          valve in a spreadsheet which included information on the valves,
          0)erators. method of justifying capability (e. g., test program), and
          t1e calculated setting margin above that required. From a review of the
          spreadsheet, discussions with licensee personnel, and reviews of
          exam)les of the calculations, the inspectors found that the settings and
          capa)ilities of the licensee's butterfly valves were demonstrated to be
          satisfactory.
          Periodic Verification
          The licensee implemented MOV periodic verification from a valve list and
          test status tabulated in a database. The inspectors reviewed the
          tabulation and found that it recorded the date of the last test
          performed on each valve and specified the date of the next retest. The
          verifications were specified at intervals not exceeding 5 years or 3
          refueling outages for the licensee's more risk significant group 1
          valves.  Periods not exceeding 8 years or 6 refueling outages were
          specified for the less risk significant group 2 valves. The inspectors
          were informed that it was the responsibility of the system engineers to
                        -
          prepare work orders (W0s) to implement the testing. The inspectors
          selected three valves (2NC031B, 2RN846A, and 2NIO88B) and verified that
          W0s had been arepared requiring them to be static diagnostic tested in
          the upcoming Jnit 2 outage (March 1997).
          The licensee's periodic verification actions were considered adequate
          for closure of GL 89-10. The NRC may re-assess the licensee's long-term
          periodic verification program as part of its review of GL 96-05.
          " Periodic Verification of Design-Basis Capability of Safety-Related
          Motor-Operated Valves", dated September 18, 1996.
'
'
          Post Maintenance and Post Modification Testina
-
          The licensee's Post Maintenance Retest Manual (November 18. 1996
s
          revision), listed the )ost maintenance testing to be performed on
.
                                                                                    )
15
          licensee equipnent suc1 as MOVs. For maintenance activities potentially   -
Jeterminations of Settinas and Verifications of Caoabilities for
          affecting valve performance, such as packing adjustments, static
3utterfly Valves
          diagnostic tests were specified. However, the Manual permitted the
The licensee documented their setting determinations and justifications
          scope of such testing to be reduced where justified by engineering.
for the capabilities of the Catawba butterfly valves in calculations.
          Licensee personnel indicated that post modification test requirements
Additionally, they documented summary information on each butterfly
          were determined by engineers using the testing specified by the retest
valve in a spreadsheet which included information on the valves,
          manual as guidance.
0)erators. method of justifying capability (e. g., test program), and
          To assess the adequacy of the post modification testing implemented by   )
t1e calculated setting margin above that required.
          the licensee, the inspectors selected and reviewed the testing specified ;
From a review of the
                                                                                    I
spreadsheet, discussions with licensee personnel, and reviews of
                                                                        Enclosure 2
exam)les of the calculations, the inspectors found that the settings and
capa)ilities of the licensee's butterfly valves were demonstrated to be
satisfactory.
Periodic Verification
The licensee implemented MOV periodic verification from a valve list and
test status tabulated in a database.
The inspectors reviewed the
tabulation and found that it recorded the date of the last test
performed on each valve and specified the date of the next retest.
The
verifications were specified at intervals not exceeding 5 years or 3
refueling outages for the licensee's more risk significant group 1
valves.
Periods not exceeding 8 years or 6 refueling outages were
specified for the less risk significant group 2 valves. The inspectors
were informed that it was the responsibility of the system engineers to
-
prepare work orders (W0s) to implement the testing.
The inspectors
selected three valves (2NC031B, 2RN846A, and 2NIO88B) and verified that
W0s had been arepared requiring them to be static diagnostic tested in
the upcoming Jnit 2 outage (March 1997).
The licensee's periodic verification actions were considered adequate
for closure of GL 89-10. The NRC may re-assess the licensee's long-term
periodic verification program as part of its review of GL 96-05.
" Periodic Verification of Design-Basis Capability of Safety-Related
Motor-Operated Valves", dated September 18, 1996.
'
Post Maintenance and Post Modification Testina
The licensee's Post Maintenance Retest Manual (November 18. 1996
revision), listed the )ost maintenance testing to be performed on
)
licensee equipnent suc1 as MOVs.
For maintenance activities potentially
-
affecting valve performance, such as packing adjustments, static
diagnostic tests were specified. However, the Manual permitted the
scope of such testing to be reduced where justified by engineering.
Licensee personnel indicated that post modification test requirements
were determined by engineers using the testing specified by the retest
manual as guidance.
To assess the adequacy of the post modification testing implemented by
)
the licensee, the inspectors selected and reviewed the testing specified
Enclosure 2


  .   .
.
    .
.
                                              16
.
          on the controlling documents for the following maintenance and
16
          modification work: WO 95030544 (packing leak). WO 95057402 (packing
on the controlling documents for the following maintenance and
          leak). WO 96049626 (packing leak and actuator removal). WO 94055288
modification work: WO 95030544 (packing leak). WO 95057402 (packing
          (operator oil leak). Modification CN-11347 (replace main steam PORV
leak). WO 96049626 (packing leak and actuator removal). WO 94055288
          block valves). Minor Modification CNCE-7446 (gearbox and spring pack
(operator oil leak). Modification CN-11347 (replace main steam PORV
          changes), and Minor Modification CE-4715 (actuator replacement). The
block valves). Minor Modification CNCE-7446 (gearbox and spring pack
          inspectors found that the licensee had specified appropriate testing for
changes), and Minor Modification CE-4715 (actuator replacement).
          these maintenance and modification activities. For example, a full
The
          static diagnostic test was required following packing adjustments.
inspectors found that the licensee had specified appropriate testing for
          Aoolicability of McGuire Insoection Findinas to Catawba
these maintenance and modification activities.
          The inspectors questioned whether corporate program changes resulting
For example, a full
          from the NRC inspection of the licensee's McGuire facility would be
static diagnostic test was required following packing adjustments.
          reviewed for applicability to Catawba.   The licensee identified an
Aoolicability of McGuire Insoection Findinas to Catawba
          action item in PIP 0-C97-0421 to address the corporate program changes.
The inspectors questioned whether corporate program changes resulting
          Strenaths
from the NRC inspection of the licensee's McGuire facility would be
          The inspectors observed a number of strengths in the licensee's
reviewed for applicability to Catawba.
          implementation of GL 89-10. Particular examples included:
The licensee identified an
          .      Highly knowledgeable personnel who recognized and addressed the
action item in PIP 0-C97-0421 to address the corporate program changes.
                  problems identified by the Catawba testing and evaluations.
Strenaths
          .      Detailed thrust / torque requirement calculations that were
The inspectors observed a number of strengths in the licensee's
                  developed for each valve group.
implementation of GL 89-10.
          .      The strong plant and corporate support that was necessarily
Particular examples included:
                  provided to complete a program encompassing the number of MOVs
Highly knowledgeable personnel who recognized and addressed the
                  present at Catawba.
.
          .      The application of special test programs and state of the art
problems identified by the Catawba testing and evaluations.
                  technology.
Detailed thrust / torque requirement calculations that were
.
developed for each valve group.
The strong plant and corporate support that was necessarily
.
provided to complete a program encompassing the number of MOVs
present at Catawba.
The application of special test programs and state of the art
.
technology.
'
'
          .      Leadership in addressing industry problems such as increases in
Leadership in addressing industry problems such as increases in
                  actuator ratings.
.
        c. Conclusions
actuator ratings.
          The NRC inspectors concluded that the licensee had met the intent of GL
c.
          89-10 in verifying the design basis ca) abilities of their MOVs.
Conclusions
          However, the inspectors identified wea(nesses in certain hardware
The NRC inspectors concluded that the licensee had met the intent of GL
          capabilities and in some data used in the verifications. The licensee
89-10 in verifying the design basis ca) abilities of their MOVs.
          planned actions to resolve the more significant of these weaknesses
However, the inspectors identified wea(nesses in certain hardware
          which were documented for comaletion in PIP 0-C97-0421. The PIP
capabilities and in some data used in the verifications. The licensee
          specified that the NRC would ]e notified of the completion status of the
planned actions to resolve the more significant of these weaknesses
          planned actions by December 31. 1997. The inspectors identified the
which were documented for comaletion in PIP 0-C97-0421. The PIP
          completion of these actions as Inspector Followup Item 50-413.414/97-03-
specified that the NRC would ]e notified of the completion status of the
          04. Actions to Address Weaknesses in GL 89-10 Implementation. In
planned actions by December 31. 1997.
          addition, the inspectors also observed a number of licensee strengths.
The inspectors identified the
                                                                          Enclosure 2
completion of these actions as Inspector Followup Item 50-413.414/97-03-
04. Actions to Address Weaknesses in GL 89-10 Implementation.
In
addition, the inspectors also observed a number of licensee strengths.
Enclosure 2


                                  -.                     -                               -_
-.
                                                                                              l
-
    .   ,
-_
      '
.
,
l
'
i
7
Based on the NRC's review of th' Catawba GL 89-10 program and its
1
implementation, and the actiors established by the licensee in PIP 0-
i
C97-0421. the NRC is closing it!, review of the GL 89-10 3rogram at
i
Catawba.
The completion of tha actions identified in t7e PIP will be
assessed as part of the NRC staff's monitoring of the licensee's long-
term MOV program.
E2
Engineering Support of Facilities and Equipment
l
l
i                                                  7
E2.1 Procurement Enaineerina
                                                                                              1
a.
                Based on the NRC's review of th' Catawba GL 89-10 program and its            !
Insoection Scone (37550)
                implementation, and the actiors established by the licensee in PIP 0-        i
The inspector reviewed Procurement Engineering activity related to the
                C97-0421. the NRC is closing it!, review of the GL 89-10 3rogram at          i
purchase and receipt of safety-related replacement parts.
                Catawba.    The completion of tha actions identified in t7e PIP will be      l
The areas
                assessed as part of the NRC staff's monitoring of the licensee's long-
reviewed included commercial grade dedication (CGD). acceptable
                term MOV program.
substitutes. receipt inspection acceptance criteria and verification.
          E2    Engineering Support of Facilities and Equipment                              !
resolution of receipt inspection deficiencies, material Quality
                                                                                              l
Assurance (0A) quality level changes, and salvage / repair of equipment.
          E2.1 Procurement Enaineerina
T;n. impection included a sample review of licensee 3erformance in these
            a. Insoection Scone (37550)
areas to oetermine if activities were consistent wit 1 applicable
                The inspector reviewed Procurement Engineering activity related to the
,
                purchase and receipt of safety-related replacement parts. The areas
regulatory requirements and licensee procedures. Applicable regulatory
                reviewed included commercial grade dedication (CGD). acceptable
'
                substitutes. receipt inspection acceptance criteria and verification.
requirements included 10 CFR 50 Appendix B. FSAR, and the following:
                resolution of receipt inspection deficiencies, material Quality
ANSI N45.2.13-1976. 0A Requirements for Control of Items and
                Assurance (0A) quality level changes, and salvage / repair of equipment.
Services for Nuclear Power Plants
                T;n. impection included a sample review of licensee 3erformance in these
,
                areas to oetermine if activities were consistent wit 1 applicable             ,
RG 1.123. 0A Requirements for Control of Procurement of Items and
                regulatory requirements and licensee procedures. Applicable regulatory         '
Services for Nuclear Power Plant
                requirements included 10 CFR 50 Appendix B. FSAR, and the following:
GL 91-05. Licensee Conniiercial Grade Pro:urement and Dedications
                      ANSI N45.2.13-1976. 0A Requirements for Control of Items and
Programs
                      Services for Nuclear Power Plants
b.
                                                                                              ,
Observations and Findinas
                      RG 1.123. 0A Requirements for Control of Procurement of Items and
i
                      Services for Nuclear Power Plant
Technical evaluations for CGD and acceptable substitutes appropriately
                      GL 91-05. Licensee Conniiercial Grade Pro:urement and Dedications
'
                      Programs
identified and addressed replacement parts' critical characteristics.
            b. Observations and Findinas
Acceptance criteria for critical characteristics were adequately
                                                                                              i
addressed and verified at receipt inspection.
  '
Receipt inspectors
                Technical evaluations for CGD and acceptable substitutes appropriately
demonstrated a strict adherence to the established acceptance criteria
                identified and addressed replacement parts' critical characteristics.
,
                Acceptance criteria for critical characteristics were adequately               )
and deficiencies were appropriately documented and resolved.
                addressed and verified at receipt inspection. Receipt inspectors               ,
Required
                demonstrated a strict adherence to the established acceptance criteria         !
post-installation testing identified in acceptance criteria was
                and deficiencies were appropriately documented and resolved.     Required
appropriately designated on the item and tracked.
                post-installation testing identified in acceptance criteria was
Replacement parts * QA
                appropriately designated on the item and tracked. Replacement parts * QA       !
classification changes were adequately justified.
                classification changes were adequately justified. Procurement                 ,
Procurement
                Engineering evaluations were technically sound and well documented. The       l
,
                interface between the corporate and station procurement engineering             l
Engineering evaluations were technically sound and well documented.
                organizations was good                                                         I
The
                The inspector reviewed i.he storage and control of replacement aarts from
interface between the corporate and station procurement engineering
                the Spare Parts Diesel Generator (SPDG). This diesel was purclased as
organizations was good
                                                                              Enclosure 2
I
The inspector reviewed i.he storage and control of replacement aarts from
the Spare Parts Diesel Generator (SPDG). This diesel was purclased as
Enclosure 2


  .   . - . . -         . - . _ . _         - - -         . - - - _ .                     -. . - . - -             - ,
.
:                                                                                                                     4
. - . . -
. - . _ . _
- - -
. - - - _ .
-. . - . - -
-
,
:
4
j
*
*
                    .
.
                                                                                                                      j
;
          .
.
;                     ,
,
                -
;
-
j
18
i
,
:
nuclear safety-related equipment from the Carolina Power and Light
;
;
j                                                                    18
i
Company nuclear program in 1987
The nameplate and purchase
i
documentation indicated that this was the same make, model, and original
n
!
equipment manufacturer as the installed Catawba Emergency Diesel
,
,
:                                                                                                                    i
j
                              nuclear safety-related equipment from the Carolina Power and Light                      ;
Generators (EDGs). The item was designated for QA level.C storage. The
i                            Company nuclear program in 1987            The nameplate and purchase                  i
SPDG receiving document, dated August 28, 1987 for requisition 7330-
n                            documentation indicated that this was the same make, model, and original                ,
{
!                            equipment manufacturer as the installed Catawba Emergency Diesel                        !
873044, stated that all parts were to be placed on OA hold and that an
j                            Generators (EDGs). The item was designated for QA level.C storage. The                   l
i
                            SPDG receiving document, dated August 28, 1987 for requisition 7330-                     {
;-
                            873044, stated that all parts were to be placed on OA hold and that an                   i
acceptability evaluation or test would be made prior to use. The
;-                           acceptability evaluation or test would be made prior to use. The                         i
i
                            evaluation was to include a check to assure the physical. chemical and
evaluation was to include a check to assure the physical. chemical and
.
.
                            Non Destructive Examination (NDE) test requirements contained in the
Non Destructive Examination (NDE) test requirements contained in the
!                           Duke Power Electrical Diesel Generator Specification CNS 1301.00-00-
!
j                           0002. dated May 15, 1984, were met.                                                     i
Duke Power Electrical Diesel Generator Specification CNS 1301.00-00-
                                                                                                                      ,
j
0002. dated May 15, 1984, were met.
i
,
A walkdown of the SPDG storage building on February 4.1997, identified
4-
4-
i
i
                            A walkdown of the SPDG storage building on February 4.1997, identified
deficiencies related to the implemented storage requirements and
                            deficiencies related to the implemented storage requirements and
!
!                           conditions. The storage building was not a OA level C storage area and
conditions. The storage building was not a OA level C storage area and
!                           was not a designated hold area under QA organization control. The
!
i.                           building was controlled by the maintenance organization. The building                   i
was not a designated hold area under QA organization control. The
                                                                                                                      ,
i.
{                           was cluttered with other equipment and there was no apparent cleanliness
building was controlled by the maintenance organization. The building
i                           standards implemented. Parts were located on decking and railings.                       I
i
,
{
was cluttered with other equipment and there was no apparent cleanliness
i
standards implemented.
Parts were located on decking and railings.
4
4
                            There was no identification on the SPDG, parts, or vicinity that                         !
There was no identification on the SPDG, parts, or vicinity that
                            designated the equipment or parts as OA hold.                                           i
designated the equipment or parts as OA hold.
t                                                                                                                     i
i
t
i
!
!
A review of issued replacement parts identified deficiencies related to
'
'
                            A review of issued replacement parts identified deficiencies related to                  !
the control of material and parts from the SPDG.
                            the control of material and parts from the SPDG. The walkdown noted
The walkdown noted
i
i
                            that numerous parts were missing from the SPDG. These included the
that numerous parts were missing from the SPDG.
,
These included the
                            turbocharger, ten cylinder \ piston casing assemblies (power packs), shaft
,
!                           driven oil and cooling water pumps, and various piping and valves.                       ,
turbocharger, ten cylinder \\ piston casing assemblies (power packs), shaft
i                            There was no documentation available to demonstrate that the required                   i
!
j                           evaluations against the applicable Duke Power specification were
driven oil and cooling water pumps, and various piping and valves.
There was no documentation available to demonstrate that the required
i
,
i
j
evaluations against the applicable Duke Power specification were
i
performed and no documentation of final 0A disposition of these parts.
i
i
'
'
                            performed and no documentation of final 0A disposition of these parts.                  i
A receipt inspection report salvage evaluation dated February 21, 1996,
                            A receipt inspection report salvage evaluation dated February 21, 1996,
i
CN 38501. issued a fuel rack linkage spring from the SPDG as a
'
replacement part for an installed EDG. This was the only 0A final
i
disposition document located and it did not clearly specify the
l
acceptance criteria used nor reference the Duke Power EDG specification.
,
The inspector reviewed the licensee's procurement program and noted that
i
there were approved procedures for storage and control of OA condition
i
i
'                            CN 38501. issued a fuel rack linkage spring from the SPDG as a
equipment which spaaned the ten year period that the SPDG has been on
=
i
site. These included QAG-1, Receipt Inspection, and Control of OA
l
Condition Materials. Parts, and Components. Except Nuclear Fuel dated
:
June 5,1991: NPP-311. Receipt. Inspection, and Testing of 0A Condition
<
i
i
                            replacement part for an installed EDG. This was the only 0A final
Commodities, dated March 7. 1996: and NPP-315 Certification of Items
                            disposition document located and it did not clearly specify the
l
l    ,                      acceptance criteria used nor reference the Duke Power EDG specification.                  l
from Non-0A to 0A Condition and Re-certification of Salvageable Items.
                            The inspector reviewed the licensee's procurement program and noted that
dated July, 22, 1996.
i                          there were approved procedures for storage and control of OA condition
These procedures required that designated QA hold
i                          equipment which spaaned the ten year period that the SPDG has been on                      =
,
i                          site. These included QAG-1, Receipt Inspection, and Control of OA                          l
items were to be stored in a OA controlled hold area and a final 0A
l                          Condition Materials. Parts, and Components. Except Nuclear Fuel dated
:                          June 5,1991: NPP-311. Receipt. Inspection, and Testing of 0A Condition                    <
i                          Commodities, dated March 7. 1996: and NPP-315 Certification of Items
l                           from Non-0A to 0A Condition and Re-certification of Salvageable Items.
,                            dated July, 22, 1996. These procedures required that designated QA hold
-
-
                            items were to be stored in a OA controlled hold area and a final 0A
disposition performed prior to release.
                            disposition performed prior to release. The storage and material
The storage and material
i                           control deficiencies discussed in this section are identified as
i
j                           Violation 50-413.414/97-03-01. Failure to Follow Procedure for Receipt,
control deficiencies discussed in this section are identified as
                                                                                                        Enclosure 2
j
!                                                                                                                     1
Violation 50-413.414/97-03-01. Failure to Follow Procedure for Receipt,
Enclosure 2
!
1
1
1
i
i
.
.
                  .                                                     -     -_                           -
.
-
-_
-


        .
.
    .     .
.
      .
.
                                                    19
.
                  Inspection, and Control of 0A Condition Materials, Parts, and
19
                  Components.   During the inspection, the licensee documented this issue
Inspection, and Control of 0A Condition Materials, Parts, and
                  on PIP 0-C97-0322 and initiated actions to establish OA level C
Components.
                  cleanliness requirements for the SPDG storage building.
During the inspection, the licensee documented this issue
                  The inspector reviewed the EDG maintenance activities ard EDG
on PIP 0-C97-0322 and initiated actions to establish OA level C
                  maintenance history to determine if adequate barriers and performance
cleanliness requirements for the SPDG storage building.
                  information were.available to address potential EDG operability concerns.
The inspector reviewed the EDG maintenance activities ard EDG
                  related to this issue. The power packs had been refurbished and
maintenance history to determine if adequate barriers and performance
                  recycled in the installed EDGs over several years with no failures.
information were.available to address potential EDG operability concerns.
                  Periodic testing of the EDGs would have identified degraded performance
related to this issue. The power packs had been refurbished and
                  due to deficient components. Current maintenance procedures require
recycled in the installed EDGs over several years with no failures.
                  Quality Control (OC) verification of QA acceptance tags on all safety-
Periodic testing of the EDGs would have identified degraded performance
                  related replacement parts. Maintenance history did not indicate
due to deficient components.
                  equipment performance problems due to installation of degraded
Current maintenance procedures require
                  components of the type removed from the SPDG, Maintenance barriers and
Quality Control (OC) verification of QA acceptance tags on all safety-
                  performance history indicated that the EDG operability had not been
related replacement parts. Maintenance history did not indicate
                  degraded by the installation of SPDG replacement parts.
equipment performance problems due to installation of degraded
            c.   Conclusion
components of the type removed from the SPDG, Maintenance barriers and
                  Procurement Engineering performance related to identification, upgrade
performance history indicated that the EDG operability had not been
                  and validation of safety-related replacement parts was generally good.
degraded by the installation of SPDG replacement parts.
                  Engineering evaluations were technically sound and well documented.
c.
                  Violation 50-413,414/97-03-01 was identified for failure to follow
Conclusion
                  procedures for the storage and control of SPDG replacement parts.
Procurement Engineering performance related to identification, upgrade
                  Maintenance practices and EDG performance history indicated that the
and validation of safety-related replacement parts was generally good.
                  material control deficiencies did not degrade the operability of the
Engineering evaluations were technically sound and well documented.
                  installed EDGs.                                                             ;
Violation 50-413,414/97-03-01 was identified for failure to follow
            E2.2 Enaineerina Backloas
procedures for the storage and control of SPDG replacement parts.
Maintenance practices and EDG performance history indicated that the
material control deficiencies did not degrade the operability of the
installed EDGs.
E2.2 Enaineerina Backloas
-
-
            a.   Insoection Scooe (37550)                                                   I
a.
                  Engineering was actively pursuing backlogs in PIPS, Maintenance Work
Insoection Scooe (37550)
  '
Engineering was actively pursuing backlogs in PIPS, Maintenance Work
                  Orders Temporary Station Modifications, and Operator Work-Arounds.     The i
Orders Temporary Station Modifications, and Operator Work-Arounds.
                  inspector reviewed engineering's efforts in these areas.
The
            b.   Observations and Findinas
i
                                                                                              1
'
                  The engineering department was active in the identification and
inspector reviewed engineering's efforts in these areas.
                  reduction of backlogs in their own work areas, as well as those items
b.
                  affecting efficient operation of the facility. These items included
Observations and Findinas
                  operator work-arounds, captured in the Top Plant Work-Around Problem
The engineering department was active in the identification and
                  Resolution (WAPR), and Major Equipment Problem Resolution (MEPR) items.
reduction of backlogs in their own work areas, as well as those items
                  The inspectors reviewed the outsta.nding lists of these items.
affecting efficient operation of the facility. These items included
                  The inspectors reviewed the licensee's Top Equipment Problem Resolution
operator work-arounds, captured in the Top Plant Work-Around Problem
                  (TEPR) process.   This process provided for the identification and
Resolution (WAPR), and Major Equipment Problem Resolution (MEPR) items.
                  management focus on important and long-standing plant equipment
The inspectors reviewed the outsta.nding lists of these items.
                                                                                Enclosure 2
The inspectors reviewed the licensee's Top Equipment Problem Resolution
(TEPR) process.
This process provided for the identification and
management focus on important and long-standing plant equipment
Enclosure 2


                                                .  .    ..      . _ .              .
                                          ,
      4
    .
                                                  20
              problems.  The TEPR process includes MEPR and WAPR listings of
              long-standing repetitive or significant equipment problems and operator
;              work-arounds.  Discussions were held with members of the maintenance,
              modifications and operations staffs to determine the adequacy of
]              engineering support to those organizations.                                ,
                                                                                          !
.
.
            c. Conclusions
.
              The inspector concluded that the engineering department was providing     l
..
              aggressive and effective support to the operations, maintenance and       ;
. _ .
.
,
4
.
20
problems.
The TEPR process includes MEPR and WAPR listings of
long-standing repetitive or significant equipment problems and operator
;
work-arounds.
Discussions were held with members of the maintenance,
modifications and operations staffs to determine the adequacy of
]
engineering support to those organizations.
,
.
c.
Conclusions
The inspector concluded that the engineering department was providing
aggressive and effective support to the operations, maintenance and
J
J
              modification departments and were keeping the number of open items at an   I
modification departments and were keeping the number of open items at an
              acceptably low level. The TEPR process was identified as a strength by     '
acceptably low level.
              the inspector.                                                             ;
The TEPR process was identified as a strength by
,
'
'                                                                                        !
the inspector.
        E7    Quality Assurance in Engineering Activities
                    .
                                                                                          l
,
,
        E7.1 Procurement Enaineerina                                                     '
'
            a. Insoection Stone (37550. 40500)
E7
.             The inspector reviewed the licensee's self-assessment activities           j
Quality Assurance in Engineering Activities
'
l
              associated with procurement engineering processes. Applicable
.
E7.1 Procurement Enaineerina
'
,
a.
Insoection Stone (37550. 40500)
.
The inspector reviewed the licensee's self-assessment activities
j
associated with procurement engineering processes. Applicable
'
regulatory guidance was provided by 10 CFR 50. Appendix B.
The
4
4
              regulatory guidance was provided by 10 CFR 50. Appendix B. The
;
;              following Procurement Engineering self-assessments were reviewed:
following Procurement Engineering self-assessments were reviewed:
              -
-
                      CTS 08-96. Catawba OA Receiving Assessment                         4
CTS 08-96. Catawba OA Receiving Assessment
*              -
4
                      CTS 07-96. NPP-212-Acceptable Substitutes Procedure
CTS 07-96. NPP-212-Acceptable Substitutes Procedure
*
-
j
j
              -
-
                      CTS 06-96 Catawba OA Services Assessment
CTS 06-96 Catawba OA Services Assessment
i             -
i
                      SA 96-06. Catawba Commodities and Facilities Work Control
-
j             -     SA 96-02(GO), Consolidated Performance Audit
SA 96-06. Catawba Commodities and Facilities Work Control
  ,
j
            b. Observations. Findinas. and Conclusion
-
              The scope of the self-assessments was adequate to evaluate performance
SA 96-02(GO), Consolidated Performance Audit
              of the procurement activity under review. Findings were appropriately
,
              documented and tracked for resolution.
b.
.        E7.2 Quality Assurance and Self-Assessments
Observations. Findinas. and Conclusion
            a. Inspection Scooe (37550. 40500)
The scope of the self-assessments was adequate to evaluate performance
              The inspectors reviewed completed self-assessments in the engineering
of the procurement activity under review.
              department and corrective actions asr ' ted with those assessments.
Findings were appropriately
                                                                            Enclosure 2
documented and tracked for resolution.
E7.2 Quality Assurance and Self-Assessments
.
a.
Inspection Scooe (37550. 40500)
The inspectors reviewed completed self-assessments in the engineering
department and corrective actions asr ' ted with those assessments.
Enclosure 2


  .     --   --                 - -     _ _ _ - . - - . - . - - . - . - - - - . _ - .               _ - - . .
.
                                                                                                                )
--
      *   *
--
- -
_ _ _ - . - - . - . - - . - . - - - - . _ - .
_
- - . .
)
*
*
,
1
21
'
}
b.
Observations and Findinas
i
l
The inspectors reviewed selected engineering department self-assessments
and corrective actions. These included:
,
,
                                                                                                                l
-
1                                                                                                              l
MOD-01-96, Quality of limited drawings to assure accuracy and
                                                                                                                '
quality
                                                                                        21
}                b.    Observations and Findinas                                                                i
l                      The inspectors reviewed selected engineering department self-assessments
                      and corrective actions. These included:                                                  ,
                      -
                              MOD-01-96, Quality of limited drawings to assure accuracy and
                              quality
.
.
                      -
-
                              MOD-02-96, Corrective Minor Modification Process
MOD-02-96, Corrective Minor Modification Process
:
:
                                                                                                                l
M00-10-96, Flow Diagram Assessment
                      -
-
                              M00-10-96, Flow Diagram Assessment                                               I
;
;                     -
-
                              MOD-04-96, Assess all aspects of at least two modifications
MOD-04-96, Assess all aspects of at least two modifications
I
i
i
-
MOD-08-96, Review modifications in progress and interim as-built
'
'
                      -
drawings
                              MOD-08-96, Review modifications in progress and interim as-built                  I
-
                              drawings
CER-03-96. Review three calculations for lead shielding
                      -
".
                              CER-03-96. Review three calculations for lead shielding
-
                      -
CER-07-96 I&C staff understanding of ICS-A-20. Instrumentation
                              CER-07-96 I&C staff understanding of ICS-A-20. Instrumentation
Installation Standards
".                            Installation Standards
,
,
l
l
                      -
CER-08-96. Quality of engineering calculations
                              CER-08-96. Quality of engineering calculations
-
i
i
3
3
                      -
-
                              CER-12-96, Assessment of snubber program
CER-12-96, Assessment of snubber program
1
1
                      -
-
                              CER-14-96, Vital battery modification assessment
CER-14-96, Vital battery modification assessment
                      -
-
                              MSE-03-96, Self-assessment of IST program
MSE-03-96, Self-assessment of IST program
i                     -
i
                              MSE-04-96, Self-assessment of safety-related heat exchangers
-
                      -
MSE-04-96, Self-assessment of safety-related heat exchangers
                              MSE-05-96. Technical support program execution
-
l               c.   Conclusions
MSE-05-96. Technical support program execution
    '
l
                      The inspectors concluded that the engineering department was performing
c.
                      effective self-assessments. The assessments were performed by
Conclusions
;                      knowledgeable individuals and were, for the most part.of the proper
'
!                     depth. Corrective actions planned for assessment findings were
The inspectors concluded that the engineering department was performing
l                     comprehensive and of adequate scope.
effective self-assessments.
The assessments were performed by
knowledgeable individuals and were, for the most part.of the proper
;
!
depth. Corrective actions planned for assessment findings were
l
comprehensive and of adequate scope.
;
;
4
4
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;
;
l                                                                                         Enclosure 2
l
                                                                                                                ,
Enclosure 2
                                                                                                                ,
,
,
9
9
4
4
                    e-   -w. -
e-
-w.
-


      -   -. - _-                 .     -       -   --. .- .           - - _ - - . - .     .   - - - - -
-
                                                                                                            i
-. - _-
              .                                                                                             \
.
      .           .
-
\
-
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--. .- .
                                                                    22                                       ,
- - _ - - . - .
l                                                                                                           l
.
                    E8     Miscellaneous Engineering Issues (92903)
- - - - -
                    E8.1 Review of Licensee Actions to Imorove Service Water Quality
i
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22
,
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E8
Miscellaneous Engineering Issues (92903)
E8.1 Review of Licensee Actions to Imorove Service Water Quality
l
l
a.
Inspection Scone
The cover letter for Inspection Report 94-17 required the licensee to
- describe actions planned or taken to address poor service water quality
l
and the clam population.
While this issue did not require inspector
l
l
l                      a.  Inspection Scone
followup, the inspector did review the licensees actions to date to
                            The cover letter for Inspection Report 94-17 required the licensee to
improve service water quality.
                          - describe actions planned or taken to address poor service water quality
b.
l                          and the clam population. While this issue did not require inspector
Observations and Findinas
l                          followup, the inspector did review the licensees actions to date to
                            improve service water quality.
,
,
                      b.  Observations and Findinas
1
1
!                           The licensee had established a testing 3rogram to' determine the most
!
l                           effective means of addressing these pro)lems. Based on this testing,
The licensee had established a testing 3rogram to' determine the most
                            the licensee had determined that dispersant addition into the service
l
                            water pump suction pit would reduce service water piping corrosion due
effective means of addressing these pro)lems.
Based on this testing,
the licensee had determined that dispersant addition into the service
water pump suction pit would reduce service water piping corrosion due
to silt deposition.
The licensee )lanned to implement a full-scale test
,
,
                            to silt deposition. The licensee )lanned to implement a full-scale test
ir the near future.
The licensee lad also determined that a flocculent-
'
'
                            ir the near future. The licensee lad also determined that a flocculent-
addition was more effective at reducing silt deposition than the
                            addition was more effective at reducing silt deposition than the
dispersant.
                            dispersant. The licensee was in the process of getting state
The licensee was in the process of getting state
l                          environmental approval to use the flocculent. The licensee planned to
                            use the flocculent once state approval was obtained.
I                          In July 1996, the licensee informed the NRC that injection of a biocide
!                          resulted in unacceptable corrosion rates for service water piping. The
l                          licensee had concluded that an active biocide program would not provide
l
l
                            an additional benefit than already provided by the flushing program:
environmental approval to use the flocculent. The licensee planned to
                            therefore, biocide injection would not be pursued. The licensee was
use the flocculent once state approval was obtained.
                            continuing a program of monthly flushes on portions of the service water
I
In July 1996, the licensee informed the NRC that injection of a biocide
!
resulted in unacceptable corrosion rates for service water piping. The
l
licensee had concluded that an active biocide program would not provide
l
an additional benefit than already provided by the flushing program:
therefore, biocide injection would not be pursued. The licensee was
continuing a program of monthly flushes on portions of the service water
f
f
system susceptible to clam infestation.
The service water (RN) to
'
'
                            system susceptible to clam infestation. The service water (RN) to
component cooling and the service water to auxiliary feedwater (CA)
  -
-
                            component cooling and the service water to auxiliary feedwater (CA)
piping flush procedures directed that a representative sample be
                            piping flush procedures directed that a representative sample be
collected during these routine flushes to determine the clam population
                            collected during these routine flushes to determine the clam population
in the service water system. Additionally. Procedure PT/1(2)/A/4200/59.
    '
                            in the service water system. Additionally. Procedure PT/1(2)/A/4200/59.
                            RN to CA Piping Flush, retype 13. directed additional flushing
                            depending on the number of clams found in the sample. The inspector
                            reviewed the data taken for both component cooling and auxiliary
                            feedwater flushings from December 1992 to December 1996. Except for the
;                          summer months (June through September), the clam count in the sample was        t
                            consistently five or less.
'
'
                                                                During June through September, the maximum
RN to CA Piping Flush, retype 13. directed additional flushing
                            clam count was 28.   The inspector noted these values were consistent on       i
depending on the number of clams found in the sample. The inspector
                            an annual basis.
reviewed the data taken for both component cooling and auxiliary
                      c.   Conclusions
feedwater flushings from December 1992 to December 1996.
                            The inspector concluded that the monthly flushing program was effective
Except for the
:                          in controlling clam population in service water piping. The
;
summer months (June through September), the clam count in the sample was
t
'
consistently five or less.
During June through September, the maximum
clam count was 28.
The inspector noted these values were consistent on
i
an annual basis.
c.
Conclusions
The inspector concluded that the monthly flushing program was effective
in controlling clam population in service water piping. The
:
I
I
                            effectiveness of the dispersant could not be assessed.
effectiveness of the dispersant could not be assessed.
l
l
                                                                                                Enclosure 2
Enclosure 2
J
J
!
!
!
!


                                  -           - - . -       _ - . - .       .           -    - -.
- - -
        - - -                                                          _ _ _      -
-
            .
- - . -
    .         .
_ - . -
      .
.
                                                        23
_ _ _
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-
-
- -.
.
.
.
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23
3
3
                E8.2 (Closed) Insoector Followuo item (IFI) 50-413.414/94-17-01: Analysis of
E8.2 (Closed) Insoector Followuo item (IFI) 50-413.414/94-17-01: Analysis of
                      Skewed SNSWP Discharge Flow
Skewed SNSWP Discharge Flow
                      Paragraph 4 a. of NRC Inspection Report 50-413.414/94-17 stated that
Paragraph 4 a. of NRC Inspection Report 50-413.414/94-17 stated that
                      certain plant configurations could allow the heated service water
certain plant configurations could allow the heated service water
discharge to the Standby Nuclear Service Water Pond (SNSWP) to reenter
4
4
                      discharge to the Standby Nuclear Service Water Pond (SNSWP) to reenter
the service water intake before any significant cooling had occurred.
                      the service water intake before any significant cooling had occurred.
This "short cycling" would reduce the heat removal capability of the
.
.
                      This "short cycling" would reduce the heat removal capability of the
i
i                      service water system. The licensee submitted a new analysis of the
service water system.
                      SNSWP which addressed the skewed discharge flow. The NRC accepted the
The licensee submitted a new analysis of the
                      licensee's new analysis and issued an SER on November 19, 1996.
SNSWP which addressed the skewed discharge flow. The NRC accepted the
                      Accordingly, this IFI is closed.
licensee's new analysis and issued an SER on November 19, 1996.
                E8.3 (Closed) Violation (VIO) 50-413.414/94-17-02: Failure to Properly
Accordingly, this IFI is closed.
                      Translate Regulatory Requirements into Specifications, Drawings, and
E8.3 (Closed) Violation (VIO) 50-413.414/94-17-02: Failure to Properly
;                     Procedures
Translate Regulatory Requirements into Specifications, Drawings, and
                      Example one of this violation detailed findings that the instrument
;
,                      inaccuracies for SNSWP temperature and level were not included,
Procedures
Example one of this violation detailed findings that the instrument
inaccuracies for SNSWP temperature and level were not included,
,
resulting in the SNSWP exceeding the maximum allowable temperature of
'
'
                      resulting in the SNSWP exceeding the maximum allowable temperature of
100 F.
                      100 F. The licensee had replaced the temperature sensor and performed
The licensee had replaced the temperature sensor and performed
                      loop accuracy Calculation CNC-1210.04-00-0067. Loop Accuracy Calculation
loop accuracy Calculation CNC-1210.04-00-0067. Loop Accuracy Calculation
.                     for the Standby RN Pond Temperature. Based on that calculation, the
.
                      licensee determined that loop uncertainty was 1.03 F for the control
for the Standby RN Pond Temperature.
i'
Based on that calculation, the
                      room indicator and was 1.04 F for the Operator Aid Com] uter (OAC).
licensee determined that loop uncertainty was 1.03 F for the control
                      These values represented a substantial reduction from tie previous             1
i
                      uncertainties of 3.4 F and 2.13 F, respectively stated in Inspection
room indicator and was 1.04 F for the Operator Aid Com] uter (OAC).
'
These values represented a substantial reduction from tie previous
1
uncertainties of 3.4 F and 2.13 F, respectively stated in Inspection
-
-
                      Report 94-17.
Report 94-17.
The licensee also performed Calculation CNC-1210.04-00-0069 Loop
i
i
                      The licensee also performed Calculation CNC-1210.04-00-0069 Loop
Accuracy Calculation for Standby Nuclear Service Water Pond Level - Loop
                      Accuracy Calculation for Standby Nuclear Service Water Pond Level - Loop
RN7350.
                      RN7350. The loop uncertainty for SNSWP level was determined to be 0.43
The loop uncertainty for SNSWP level was determined to be 0.43
3                      ft for the control room indicator and 0.34 ft for both the alarm and
ft for the control room indicator and 0.34 ft for both the alarm and
;                     the OAC.   These values represented an increased uncertainty from the
3
l                     previous values of 0.202 ft and 0.157 ft, respectively. The licensee
;
the OAC.
These values represented an increased uncertainty from the
l
previous values of 0.202 ft and 0.157 ft, respectively. The licensee
2
2
'  '
attributed this increased uncertainty to rescaling of the level sensor
                      attributed this increased uncertainty to rescaling of the level sensor
'
                      when SNSWP level was raised by an additional three feet. Although the
'
f                     SNSWP level uncertainties increased, the inspector concluded that the
when SNSWP level was raised by an additional three feet. Although the
                      additional three feet compensated for this increase.
f
SNSWP level uncertainties increased, the inspector concluded that the
additional three feet compensated for this increase.
.
.
l                     Based on the uncertainty reduction for the SNSWP tem)erature instrument
l
Based on the uncertainty reduction for the SNSWP tem)erature instrument
loop and the additional three feet of SNSWP level, t1e inspector
concluded that the inclusion of instrument uncertainties would not
'
'
                      loop and the additional three feet of SNSWP level, t1e inspector
,
                      concluded that the inclusion of instrument uncertainties would not              ,
result in exceeding the SNSWP maximum temperature limit.
                      result in exceeding the SNSWP maximum temperature limit.                       j
j
                      The inspector reviewed both calculations and found that the licensee had
The inspector reviewed both calculations and found that the licensee had
                      used vendor-supplied data where provided. Since sensor drift data was
used vendor-supplied data where provided.
Since sensor drift data was
'
'
;                     not provided for the temperature or level sensors, the licensee had
;
;                     assumed that sensor drift was equal to sensor calibration accuracy
not provided for the temperature or level sensors, the licensee had
                      according to EDM-102. Instrument Setpoint/ Uncertainty Calculations.
;
                                                                                      Enclosure 2
assumed that sensor drift was equal to sensor calibration accuracy
according to EDM-102. Instrument Setpoint/ Uncertainty Calculations.
Enclosure 2
I
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      _-. -           - _       - ..   . = . - .     -   _--.     .     . _ _ _
_-. -
      O
- _
    6
-
                                                    24
..
                  revision 1. However EDM-102 stated that this assumption was valid only
. = . -
                  for electronic modules and indicators. EDM-102 stated that sensor drift
.
                  for )rocess sensors should not be assumed to be ecual to the sensor
-
                  cali) ration accuracy unless supported by publishec or actual data. The
_--.
                  licensee reviewed data published in NUREG/CR-5560, Aging of Nuclear
.
                  Plant Resistance Temperature Detectors, and found that sensor drift for
. _ _
                  the type of temperature sensor used was greater than that assumed. The
_
                  total loop uncertainty calculated using the revised value for sensor
O
                  drift was 1.06 F for the control room indicator and the OAC. Since the
6
                  licensee was using a conservative value of 1.1 F. the higher
24
                  temperature sensor drift value had a small effect. The inspector also
revision 1.
                  found the same assumption was used for Calculation CNC-1210.04-00-0069.
However EDM-102 stated that this assumption was valid only
                  The licensee provided field calibration results for the SNSWP level
for electronic modules and indicators.
                  transmitter from May 1988 to January 1996. Using the field calibration
EDM-102 stated that sensor drift
                  data, the inspector calculated that sensor drift was about 2.0% of
for )rocess sensors should not be assumed to be ecual to the sensor
                  calibrated span. Calculation CNC-1210.04-00-0069 assumed that sensor
cali) ration accuracy unless supported by publishec or actual data. The
                  drift was 0.51% of calibrated saan. The inspector recalculated the
licensee reviewed data published in NUREG/CR-5560, Aging of Nuclear
                  total loop uncertainties using tie 2.0% of calibrated span value and
Plant Resistance Temperature Detectors, and found that sensor drift for
                  found that the overall effect was small. The inspector also noted that
the type of temperature sensor used was greater than that assumed. The
                  the level transmitter had been replaced in January 1996. Since the
total loop uncertainty calculated using the revised value for sensor
                  SNSWP level loop calibration frequency was 18 months, no recent data was
drift was 1.06 F for the control room indicator and the OAC.
                  available to determine the sensor drift for the new transmitter.
Since the
                  Discussions with the licensee's engineers indicated some confusion about
licensee was using a conservative value of 1.1 F. the higher
                  the intent of the allowance of using sensor calibration accuracy as
temperature sensor drift value had a small effect. The inspector also
                  sensor drift. EDM-102 stated that sensor drift should not be assumed
found the same assumption was used for Calculation CNC-1210.04-00-0069.
                  equal to device reference accuracy unless supported by published or
The licensee provided field calibration results for the SNSWP level
                  historical data. While this statement appeared to discourage equating
transmitter from May 1988 to January 1996.
                  sensor drift to device reference accuracy, it does not expressly forbid
Using the field calibration
                  making such an assumption.   Also. EDM-102 defined five instrumentation
data, the inspector calculated that sensor drift was about 2.0% of
                  categories to aid in the determination of the type of uncertainty
calibrated span.
                  analysis required. Since the licensee had recently initiated efforts to
Calculation CNC-1210.04-00-0069 assumed that sensor
                  apply the EDM-102 instrumentation categories plant-wide, the licensee
drift was 0.51% of calibrated saan. The inspector recalculated the
                  had not determined which instrumentation category the SNSWP temperature
total loop uncertainties using tie 2.0% of calibrated span value and
                  and level instrument loops would fall into. The inspector considered
found that the overall effect was small.
  '
The inspector also noted that
                  this determination important due to the potential impact on instrument
the level transmitter had been replaced in January 1996.
                  loop calibration 3rocedures and SNSWP operability determinations.
Since the
                  Failure to use pu)lished or actual data to determine sensor drift as
SNSWP level loop calibration frequency was 18 months, no recent data was
                  indicated by EDM-102 could result in nonconservative calibration
available to determine the sensor drift for the new transmitter.
                  acceptance criteria. As stated previously, the licensee had initiated a
Discussions with the licensee's engineers indicated some confusion about
                  programmatic review to apply the EDM-102 instrument categories to all
the intent of the allowance of using sensor calibration accuracy as
                  plant instrumentation.
sensor drift.
            E8.4 (Closed) InsDector Followuo Item 50-413.414/94-17-03: Short Discharge
EDM-102 stated that sensor drift should not be assumed
                  Leg Flow Verification
equal to device reference accuracy unless supported by published or
                  Paragraph 4 c. of Inspection Report 94-17 stated that silt accumulation
historical data.
,                  near the long service water discharge aath indicated that the service
While this statement appeared to discourage equating
sensor drift to device reference accuracy, it does not expressly forbid
making such an assumption.
Also. EDM-102 defined five instrumentation
categories to aid in the determination of the type of uncertainty
analysis required.
Since the licensee had recently initiated efforts to
apply the EDM-102 instrumentation categories plant-wide, the licensee
had not determined which instrumentation category the SNSWP temperature
and level instrument loops would fall into.
The inspector considered
'
this determination important due to the potential impact on instrument
loop calibration 3rocedures and SNSWP operability determinations.
Failure to use pu)lished or actual data to determine sensor drift as
indicated by EDM-102 could result in nonconservative calibration
acceptance criteria. As stated previously, the licensee had initiated a
programmatic review to apply the EDM-102 instrument categories to all
plant instrumentation.
E8.4 (Closed) InsDector Followuo Item 50-413.414/94-17-03: Short Discharge
Leg Flow Verification
Paragraph 4 c. of Inspection Report 94-17 stated that silt accumulation
near the long service water discharge aath indicated that the service
,
water discharge flow to the long and s1 ort service water discharge paths
:
:
                  water discharge flow to the long and s1 ort service water discharge paths
was not evenly split contrary to the engineering analysis.
                  was not evenly split contrary to the engineering analysis. The licensee
The licensee
                                                                                  Enclosure 2
Enclosure 2
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l


              _ _.     -                  .      _ - - - - _ _    _ - . - . _ -  ..  -.  .  --  -.
_ _.
                                                                                                      l
        .
            .
          .                                                                                            !
-
-
                                                                                                      \
.
                                                                                                      '
_ - - - - _ _
                                                                25
_ - . - . _ -
                        conducted short discharge leg flow verification as part of the SNSWP           '
..
    .                    reanalysis. The NRC accepted the licensee's reanalysis and issued a SER
-.
                        on November 19. 1996.                                                         I
.
                  E8.5 (Closed) Insoector Followuo Item 50-413.414/94-17-10: Flush Program           !
--
-.
.
.
.
\\
-
25
'
conducted short discharge leg flow verification as part of the SNSWP
'
reanalysis. The NRC accepted the licensee's reanalysis and issued a SER
.
on November 19. 1996.
E8.5 (Closed) Insoector Followuo Item 50-413.414/94-17-10: Flush Program
Improvements
,
As documented in Inspection Report 96-10 and 96-16. the licensee had
radiographed both trains of service water supply to auxiliary feedwater
,
,
                          Improvements
piping foe Units 1 and 2.
                        As documented in Inspection Report 96-10 and 96-16. the licensee had
However, the licensee did not document the
,                        radiographed both trains of service water supply to auxiliary feedwater
as-found condition for the 'A' train lines and could not produce the
                        piping foe Units 1 and 2. However, the licensee did not document the
i
i
                        as-found condition for the 'A' train lines and could not produce the
radiographs.
                        radiographs. The licensee took additional radiographs of this piping
The licensee took additional radiographs of this piping
l                       near valve RN-250A for both Units 1 and 2 on December 30. 1996, and
l
near valve RN-250A for both Units 1 and 2 on December 30. 1996, and
;
;
                        October 28. 1996. respectively. The inspector reviewed the radiographs
October 28. 1996. respectively.
j                       and concluded the piping was not fouled.
The inspector reviewed the radiographs
                  E8.6 (Closed) Insoector Followuo Item 50-413.414/94-17-14: Quantifying Flow
j
l                       Measurement Error
and concluded the piping was not fouled.
E8.6 (Closed) Insoector Followuo Item 50-413.414/94-17-14: Quantifying Flow
l
Measurement Error
.
.
J                       Paragraph 7.e.(3) of Inspection Report 94-17 stated that service water
J
i                       flow measurements were potentially affected due to fouling and
Paragraph 7.e.(3) of Inspection Report 94-17 stated that service water
!                       corrosion. The inspector reviewed data obtained during heat exchancer
i
                        performance testing and service water pump in-service testing for
flow measurements were potentially affected due to fouling and
!
corrosion.
The inspector reviewed data obtained during heat exchancer
performance testing and service water pump in-service testing for
indications of flow measurement inaccuracies.
The containment spray
1
1
                        indications of flow measurement inaccuracies. The containment spray
heat exchangers had an orifice type flow element that provided both
,'
control room and local flow indication. The inspector reviewed
Jerformance data from March 1993 to present for the 1B containment spray
:
leat exchanger. Analysis of the data found that nearly identical
j
temperature differences could be correlated to about the same flowrate
'
'
  ,                      heat exchangers had an orifice type flow element that provided both
over the entire 3eriod. This indicated there had been no substantial
                        control room and local flow indication. The inspector reviewed
j
                          Jerformance data from March 1993 to present for the 1B containment spray
degradation in t1e flow sensing element over the period reviewed.
:                        leat exchanger. Analysis of the data found that nearly identical
Annubars were used to measure service water pump flow during in-service
j                        temperature differences could be correlated to about the same flowrate
:
                        over the entire 3eriod. This indicated there had been no substantial
testing.
'
The inspector reviewed the service water pump in-service test
j                        degradation in t1e flow sensing element over the period reviewed.
data from April 1995 through December 1996.
:                        Annubars were used to measure service water pump flow during in-service
The licensee also provided
                        testing. The inspector reviewed the service water pump in-service test
                        data from April 1995 through December 1996. The licensee also provided
i
i
      '                  a trend of in-service test flow data for service water pumps 1B and 2A
a trend of in-service test flow data for service water pumps 1B and 2A
,
'
                        obtained from September 1994 through November 1996. The trend data was
obtained from September 1994 through November 1996. The trend data was
i                       consistent with a slight flow increase noted after all four annubars
,
j                       were cleaned in late 1996. This indicated that the flow measured by the
i
consistent with a slight flow increase noted after all four annubars
j
were cleaned in late 1996. This indicated that the flow measured by the
annubars was insignificant 1y affected by fouling.
The inspector also
:
:
                        annubars was insignificant 1y affected by fouling. The inspector also
reviewed the in-service data and found that the measured flow only
,
,
                        reviewed the in-service data and found that the measured flow only           1
1
!                       differed about 0.5% between in-service test periods. Based on che
!
!                       inspectors review of this data, the inspector concluded that any annubar
differed about 0.5% between in-service test periods.
                        fouling was not adversely effecting flowrate measurement.
Based on che
                        Ultrasonic flow measurement was used to verify room cooler flowrates,
!
                        but was not relied on for operability determinations or cooler
inspectors review of this data, the inspector concluded that any annubar
fouling was not adversely effecting flowrate measurement.
Ultrasonic flow measurement was used to verify room cooler flowrates,
but was not relied on for operability determinations or cooler
performance calculations. The licensee stated that ultrasonic flow
-
-
                        performance calculations. The licensee stated that ultrasonic flow
measurement was no longer used due to difficulties installing the
                        measurement was no longer used due to difficulties installing the
equipment although procedures permitted its use as an option.
  ;
;
                        equipment although procedures permitted its use as an option.
Enclosure 2
                                                                                        Enclosure 2
i
  i
;
  ;
Y
Y


          _           _ - _ _ . _     _       . _ .       __   _ . - _     ._ ._ _ _           . _ _ _ .
_
      .
_ - _ _ . _
_
. _ .
__
_ . - _
._ ._ _ _
. _ _ _ .
.
-
-
    .   .
.
                                                      26
.
26
Based on the information provided to the inspector, the inspector
,
,
                Based on the information provided to the inspector, the inspector
concluded that flow sensor fouling was not contributing significant
                concluded that flow sensor fouling was not contributing significant
errors to service water flow measurement.
                errors to service water flow measurement.
E8.7 (Closed) Unresolved Item 50-413.414/94-17-16: Split Flow Orifice Flow
,
,
          E8.7 (Closed) Unresolved Item 50-413.414/94-17-16: Split Flow Orifice Flow
Resistance Factor
                Resistance Factor
1
1
                This Unresolved Item was Example 2 of Violation 94-17-02. SNSWP split
This Unresolved Item was Example 2 of Violation 94-17-02.
                flow was addressed as part of the licensee's SNSWP reanalysis. The NRC
SNSWP split
                had issued a SER on November 19. 1996, accepting the licensee's
flow was addressed as part of the licensee's SNSWP reanalysis. The NRC
had issued a SER on November 19. 1996, accepting the licensee's
reanalysis.
,
E8.8 NRC Information Notice 92-18:
Potential For Loss Of Remote Shutdown
Capability During A Control Room Fire
a
1'
Information Notice (IN) 92-18 alerted licensees of the potential for
loss of safe shutdown capability during a fire in the control room.
The
IN reported that hot shorts occurring during the fire could potentially
cause the MOVs needed for safe shutdown to go to a stall condition.
This stall could result in valve and/or actuator damage that would
preclude use of the MOVs for shutdown.
The inspectors reviewed the licensee's April 8.1992, internal response
for IN 92-18 which concluded that a control room fire would not affect
Catawba's ability to open feedwater valves to provide safe shutdown.
The response indicated that the motors for the needed valves were wired
downstream of the control room, such that their operation from the safe
gutdownfacilitywouldnotbeadverselyaffectedbyacontrolroom
tire.
During the current inspectiori, the licensee stated that their original
determir.3 tion regarding the affects of a control room fire had been
reviewd and was still considered valid.
However, they decided to
reexamine the issue relative to the impact of a fire in other areas.
such as the cable spreading room.
The reexamination was initiated
through PIP 0-G97-0059.
,
E8.9 (Closed) IFI 50-413.414/96-02-01:
Reliance on Testing of a Single Valve
to Support the Capabilities of a Group
This issue identified a concern that the licensee relied on the results
of a single test in establishing the thrust requirements for some groups
of GL 89-10 valves and that, in one instance, the adecuacy of even the
one test was uncertain.
In a GL 89-10 assessment concucted during the
current inspection and documented in El.1 (Thrust Requirements for
Groups) above. the ins)ectors catermined that this issue was being
adequately addressed t1 rough al action item in PIP 0-C97-0421.
IFI 50-413.414/97-03-04 Actions to Address Weaknesses in GL 89-10
Implementation, was opened in Section E1.3 to track the licensee's
completion of this and other PIP actions.
Enclosure 2
 
. .
.
-
-
.
.
__
,
,
                reanalysis.
.. .
          E8.8 NRC Information Notice 92-18: Potential For Loss Of Remote Shutdown
.
a               Capability During A Control Room Fire
'
i
*
,
-
,
'
27
E8.10 (Closed) 50-413.41.4/96-02-02:
Stem Coefficient of Friction for MOV
Opening Setting Calculations
i
The issue identified by this item was evaluated during the current
inspection, as described in Section E1.3 (Stem Friction Coefficient).
The issue was considered resolved through the licensee's increase of the
1
MOV opening stem friction coefficient value to 0.20 and the licensee's
evaluation provided by PIP 0-C95-0879.
E8.11 (Closed) 50-413.414/96-02-03:
MOV Opening Thrust Requirement
Uncertainties
The issue identified by this item was evaluated during the current
inspection. as described in Section E1.3 (Diagnostic Equipment
Uncertainties). The issue was considered resolved by the inspectors
through actions documented in PIPS 0-C95-0295 and -0879.
E8.12 (Closed) 50-413.414/96-02-04:
Unpredictable Behavior Experienced in
Pressurizer PORV Block Valve MOV Testing
The issue identified by this item was that the prototype PORV block
valve tested by the licensee exhibited unpredictable behavior prior to
flow isolation during a blowdown closing test. This test was conducted
j
as part of the licensee's GL 89-10 program.
In the current inspection,
l
the inspectors reviewed a licensee engineering evaluation of this test,
i
which was described in their "3-Inch Anchor Darling Double-Disk Gate
Valve Summary Test Report." The inspectors found that the report
1
1
'
provided satisfactory evidence that the unpredictable behavior exhibited
                Information Notice (IN) 92-18 alerted licensees of the potential for
in the one test was due to a unique, unsatisfactory packing
                loss of safe shutdown capability during a fire in the control room. The
configuration (not applicable to the licensee's installed valves). The
                IN reported that hot shorts occurring during the fire could potentially
inspectors considered the issue resolved.
                cause the MOVs needed for safe shutdown to go to a stall condition.
IV. Plant Support
                This stall could result in valve and/or actuator damage that would
R2
                preclude use of the MOVs for shutdown.
Status of Radiological Protection and Control (RP&C) Facilities and
                The inspectors reviewed the licensee's April 8.1992, internal response
,
                for IN 92-18 which concluded that a control room fire would not affect
Equipment
                Catawba's ability to open feedwater valves to provide safe shutdown.
R2.1 Comoliance with 10 CFR 70.24 Criticality Accident Reauirements
                The response indicated that the motors for the needed valves were wired
a.
                downstream of the control room, such that their operation from the safe
Insoection Scone (71750)
                gutdownfacilitywouldnotbeadverselyaffectedbyacontrolroom
                tire.
                During the current inspectiori, the licensee stated that their original
                determir.3 tion regarding the affects of a control room fire had been
                reviewd and was still considered valid. However, they decided to
                reexamine the issue relative to the impact of a fire in other areas.
                such as the cable spreading room.        The reexamination was initiated
  ,
                through PIP 0-G97-0059.
          E8.9 (Closed) IFI 50-413.414/96-02-01: Reliance on Testing of a Single Valve
                to Support the Capabilities of a Group
                This issue identified a concern that the licensee relied on the results
                of a single test in establishing the thrust requirements for some groups
                of GL 89-10 valves and that, in one instance, the adecuacy of even the
                one test was uncertain. In a GL 89-10 assessment concucted during the
                current inspection and documented in El.1 (Thrust Requirements for
                Groups) above. the ins)ectors catermined that this issue was being
                adequately addressed t1 rough al action item in PIP 0-C97-0421.
                IFI 50-413.414/97-03-04 Actions to Address Weaknesses in GL 89-10
                Implementation, was opened in Section E1.3 to track the licensee's
                completion of this and other PIP actions.
                                                                                      Enclosure 2
 
        . .      .    -            -                  .        .                        __    ,    .. .
                                                                                                            1
            .
    '
              *
          ,                                                                                                i
      -
                                                                                                            ,
                                                                                                            '
                                                            27
                E8.10 (Closed) 50-413.41.4/96-02-02:        Stem Coefficient of Friction for MOV            !
                        Opening Setting Calculations                                                      i
                        The issue identified by this item was evaluated during the current                l
                        inspection, as described in Section E1.3 (Stem Friction Coefficient).              !
                        The issue was considered resolved through the licensee's increase of the          1
                        MOV opening stem friction coefficient value to 0.20 and the licensee's            i
                        evaluation provided by PIP 0-C95-0879.
                E8.11 (Closed) 50-413.414/96-02-03:        MOV Opening Thrust Requirement
                        Uncertainties
                        The issue identified by this item was evaluated during the current
                        inspection. as described in Section E1.3 (Diagnostic Equipment
                        Uncertainties). The issue was considered resolved by the inspectors
                        through actions documented in PIPS 0-C95-0295 and -0879.
                E8.12 (Closed) 50-413.414/96-02-04: Unpredictable Behavior Experienced in
                        Pressurizer PORV Block Valve MOV Testing
                        The issue identified by this item was that the prototype PORV block
                        valve tested by the licensee exhibited unpredictable behavior prior to            i
                        flow isolation during a blowdown closing test. This test was conducted            j
                        as part of the licensee's GL 89-10 program. In the current inspection,            l
                        the inspectors reviewed a licensee engineering evaluation of this test,            i
                        which was described in their "3-Inch Anchor Darling Double-Disk Gate
                        Valve Summary Test Report." The inspectors found that the report                  1
                        provided satisfactory evidence that the unpredictable behavior exhibited
                        in the one test was due to a unique, unsatisfactory packing
                        configuration (not applicable to the licensee's installed valves). The             i
                        inspectors considered the issue resolved.
                                                    IV. Plant Support
                R2       Status of Radiological Protection and Control (RP&C) Facilities and
  ,
                        Equipment
                R2.1 Comoliance with 10 CFR 70.24 Criticality Accident Reauirements
                    a.   Insoection Scone (71750)
.
.
                        The inspector reviewed the licensee's compliance with 10 CFR 70.24
The inspector reviewed the licensee's compliance with 10 CFR 70.24
!
!
                        criticality accident requirements and associated PIP documentation in
criticality accident requirements and associated PIP documentation in
i
i
response to the NRC staff's recent identification that several licensees
'
'
                        response to the NRC staff's recent identification that several licensees
in the industry were not in conformance with the requirements of 10 CFR
                        in the industry were not in conformance with the requirements of 10 CFR
70.24. nor had they been granted exemptions to this regulation.
                        70.24. nor had they been granted exemptions to this regulation.
Enclosure 2
                                                                                          Enclosure 2
-
                    -   .
.


                                      .. --         .__-       .. -- . _ - -               --
..
          .
--
J    -
.__-
            .
.. --
        ,
. _ - -
      .
--
                                                          28
J
                  b. Observations and Findinas
-
                      Both Units at Catawba have radiation monitoring systems installed in the
.
                      new fuel unloading and storage areas. The inspector verified by
.
'
,
                      reviewing PIP documentation that the monitoring instrumentation meets 10
.
                      CFR 70.24(a) requirements (PIP 0-C97-0192). In addition to criticality
28
                      accident monitoring instrumentation and alarm capability requirements
b. Observations and Findinas
                      the licensee is required by 10 CFR 70.24(a)(3) to have emergency           <
Both Units at Catawba have radiation monitoring systems installed in the
                      procedures in place for evacuating personal when a criticality alarm       J
new fuel unloading and storage areas.
                    sounds and to conduct evacuation drills. The licensee has not developed
The inspector verified by
:                     procedures or conducted drills to meet the provisions of 10 CFR
reviewing PIP documentation that the monitoring instrumentation meets 10
                      70.24(a)(3). The licensee has initiated a corrective action as part of
CFR 70.24(a) requirements (PIP 0-C97-0192).
                    the PIP referenced above to evaluate compliance with emergency procedure
In addition to criticality
                      requirements.
'
accident monitoring instrumentation and alarm capability requirements
the licensee is required by 10 CFR 70.24(a)(3) to have emergency
<
procedures in place for evacuating personal when a criticality alarm
J
sounds and to conduct evacuation drills. The licensee has not developed
:
procedures or conducted drills to meet the provisions of 10 CFR
70.24(a)(3).
The licensee has initiated a corrective action as part of
the PIP referenced above to evaluate compliance with emergency procedure
requirements.
5
5
                      Both units at Catawba were previously granted exemptions from 10 CFR
Both units at Catawba were previously granted exemptions from 10 CFR
                      70.24 requirements by the NRC staff as part of their special nuclear
70.24 requirements by the NRC staff as part of their special nuclear
                    material license during construction. The licensee did not submit a         :
material license during construction.
                      request to continue the exemption when the special nuclear material
The licensee did not submit a
                      licenses expired upon issuance of operating licenses on January 17
request to continue the exemption when the special nuclear material
                      1985, and May 15, 1986, for Unit 1 and Unit 2, respectively. The
licenses expired upon issuance of operating licenses on January 17
                      licensee has not complied with the (a)(3) Sortion of the regulation
1985, and May 15, 1986, for Unit 1 and Unit 2, respectively.
The
licensee has not complied with the (a)(3) Sortion of the regulation
since these dates. On February 4, 1997, tie licensee submitted a
,
,
                    since these dates. On February 4, 1997, tie licensee submitted a
request for an exemption to the requirements of 10 CFR 70.24.
                      request for an exemption to the requirements of 10 CFR 70.24.
c. Conclusions
.                c. Conclusions
.
The licensee has existing radiation monitoring systems installed in the
4
4
Unit 1 and Unit 2 new fuel unloading and storage areas which are capable
*
*
                    The licensee has existing radiation monitoring systems installed in the
of alarming should an accidental criticality occur. The licensee has
                    Unit 1 and Unit 2 new fuel unloading and storage areas which are capable    1
i
                    of alarming should an accidental criticality occur. The licensee has       i
not developed emergency procedures or conducted drills to ensure
                    not developed emergency procedures or conducted drills to ensure           !
personnel are withdrawn to an area of safety when an alarm sounds.
The
<
<
'
5
5
                    personnel are withdrawn to an area of safety when an alarm sounds. The      '
failure to implement criticality accident emergency procedures and to
                      failure to implement criticality accident emergency procedures and to
:
:                   conduct evacuation drills is characterized as Violation 50-413.414/97-
conduct evacuation drills is characterized as Violation 50-413.414/97-
                    03-02, Noncompliance with 10 CFR 70.24(a)(3) Criticality Accident
03-02, Noncompliance with 10 CFR 70.24(a)(3) Criticality Accident
  '
'
                    Requirements Regarding Evacuation Procedures and Drills. The licensee
Requirements Regarding Evacuation Procedures and Drills.
The licensee
has submitted a request to the NRC staff for an exemption to the
<
<
                    has submitted a request to the NRC staff for an exemption to the
requirements of 70.24.
                    requirements of 70.24.
:
:
V. Manaaement Meetinas
4
4
                                              V. Manaaement Meetinas
X1
              X1    Exit Meetina Summarv
Exit Meetina Summarv
;
;
                    The inspectors ] resented the inspection results to members of licensee     l
The inspectors ] resented the inspection results to members of licensee
                    management at t1e conclusion of the inspection on February 20, 1997.
l
                    The licensee acknowledged the findings presented. No proprietary           .
management at t1e conclusion of the inspection on February 20, 1997.
                      information was identified.                                               !
The licensee acknowledged the findings presented.
.
No proprietary
                                                                                  Enclosure 2
.
                                                                                                l
information was identified.
[
.
Enclosure 2
[


          _- -         -._       -     . -.   .-               - . - - -         .=       .
_- -
:             .
-._
    .
-
                .
. -.
        ,
.-
- . - -
-
.=
.
:
.
.
.
,
<
<
      .
.
                                                            29
29
                                            PARTIAL LIST OF PERSONS CONTACTED
PARTIAL LIST OF PERSONS CONTACTED
j                 Licensee
j
:i                 Bhatnagar, A. , Operations Superintendent
Licensee
:                 Cline. T.,   Senior Technical Specialist, General Office Support
:i
                  Coy, S., Radiation Protection Manager
Bhatnagar, A. , Operations Superintendent
                  Edwards, T., Valve Group Supervisor
:
                  Forbes, J., Engineering Manager
Cline. T., Senior Technical Specialist, General Office Support
Coy, S., Radiation Protection Manager
Edwards,
T., Valve Group Supervisor
Forbes, J.,
Engineering Manager
Harrall
T. , IAE Maintenance Suparintendent
,
,
'
'
                  Harrall T. , IAE Maintenance Suparintendent
Helmers. C. . Engineer, Valve Group
                  Helmers. C. . Engineer, Valve Group
Henkel
                  Henkel H. , Engineer Valve Group
H. , Engineer Valve Group
                  Kelly, C.,   Maintenance Manager
Kelly, C., Maintenance Manager
'
Kimball, D., Safety Review Group Manager
                  Kimball, D., Safety Review Group Manager
'
1                  Kitlan, M.. Regulatory Compliance Manager
Kitlan, M.. Regulatory Compliance Manager
1
1
                  McCollum, W., Catawba Site Vice-President
McCollum, W., Catawba Site Vice-President
1
Nicholson, K., Compliance Specialist
'
'
                  Nicholson, K., Compliance Specialist
Peterson, G., Station Manager
                  Peterson, G., Station Manager
Propst. R.. Chemistry Manager
'
'
                  Propst. R.. Chemistry Manager
Rogers, D.. Mechanical Maintenance Manager
'
'
                  Rogers, D.. Mechanical Maintenance Manager
Simril, J. , Engineer. Valve Group
                  Simril, J. , Engineer. Valve Group
:
:                 Smith. C., MOV Program Lead, General Offico Support
Smith. C., MOV Program Lead, General Offico Support
Tower, D., Compliance Engineer
,
,
                  Tower, D., Compliance Engineer
.
.
}
}
Line 1,915: Line 2,582:
,
,
I
I
.
.
k
k
,
Enclosure 2
  ,
,
                                                                                      Enclosure 2
,


                                                                  . . _ _ _ . . ._.
. . _ _ _ .
,
. ._.
4       .
,
I     h
4
      9
.
                                                      30
I
                                        INSPECTION PROCEDdRES USED
h
9
30
INSPECTION PROCEDdRES USED
;
;
            IP 37550:     Engineering
IP 37550:
Engineering
IP 37551:
Onsite Engineering
-
-
            IP 37551:     Onsite Engineering
IP 40500:
            IP 40500:    Self Assessment
Self Assessment
l         IP 61726:     Surveillance Observation
l
            IP 62707:     Maintenance Observation
IP 61726:
Surveillance Observation
IP 62707:
Maintenance Observation
IP 71707:
Plant Opera ~ ions
IP 71750:
Plant Suppor *. Activities
'
'
            IP 71707:     Plant Opera ~ ions
IP 92902:
            IP 71750:    Plant Suppor *. Activities
Followup - Mcintenance
            IP 92902:    Followup - Mcintenance
;
;           IP 92903:     Followup - En 'ineering
IP 92903:
.          TI 2515/169: GL 89-10 MOV frogram Review
Followup - En 'ineering
  .
TI 2515/169: GL 89-10 MOV frogram Review
                                  ITEMS OPENED. CLOSED. AND DISCUSSED
.
',         Doened
.
i           50-413.414/97-03-01       VIO         Failure to Follow Procedure for Receipt.
ITEMS OPENED. CLOSED. AND DISCUSSED
;                                                   Inspection, and Control of 0A Condition
',
Doened
i
50-413.414/97-03-01
VIO
Failure to Follow Procedure for Receipt.
;
Inspection, and Control of 0A Condition
:
:
                                                  Materials., Parts, and Components (Section
Materials., Parts, and Components (Section
                                                  E2.1)
E2.1)
            50-413.414/97-03-02       VIO         Noncompliance with 10 CFR 70.24(a)(3)
50-413.414/97-03-02
                                                  Criticality Accident Requirements
VIO
.                                                 Regarding Evacuation Procedures and Drills
Noncompliance with 10 CFR 70.24(a)(3)
.                                                  (Section R2.1)
Criticality Accident Requirements
!           50-414/97-03-03           NCV         Mispositioned Nitrogen Backu) Supply
.
                                                  Valves Result in Degrading T1e Function of
Regarding Evacuation Procedures and Drills
!                                                 SG PORVs (Section M8.1)
l
(Section R2.1)
.
!
50-414/97-03-03
NCV
Mispositioned Nitrogen Backu) Supply
Valves Result in Degrading T1e Function of
!
SG PORVs (Section M8.1)
:
:
;           50-413.414/97-03-04       IFI         Actions to Address Weaknesses in GL 89-10
;
;                                                   Implementation (Section El.3)
50-413.414/97-03-04
            Closed
IFI
Actions to Address Weaknesses in GL 89-10
;
Implementation (Section El.3)
Closed
!
!
    '
'
            50-413.414/94-17-01       IFI         Analysis of Skewed SNSWP Discharge Flow
50-413.414/94-17-01
.                                                  (Section E8.2)
IFI
Analysis of Skewed SNSWP Discharge Flow
(Section E8.2)
.
4
4
'
'
            50-413.414/94-17-02       VIO         Failure to Properly Translate Regulatory
50-413.414/94-17-02
i                                                 Requirements into Specifications.
VIO
Failure to Properly Translate Regulatory
i
Requirements into Specifications.
Drawings, and Procedures (Section E8.3)
,
,
                                                  Drawings, and Procedures (Section E8.3)
'
'
            50-413.414/94-17-03       IFI         Short Discharge Leg Flow Verification
50-413.414/94-17-03
                                                  (Section E8.4)
IFI
:           50-413.414/94-17-10       IFI         Flush Program Improvements (Section E8.5)
Short Discharge Leg Flow Verification
            50-413.414/94-17-14       IFI         Quantif.fing Flow Measurement Error
(Section E8.4)
                                                  (Section E8.6)
:
50-413.414/94-17-10
IFI
Flush Program Improvements (Section E8.5)
50-413.414/94-17-14
IFI
Quantif.fing Flow Measurement Error
(Section E8.6)
'
'
                                                                                    Enclosure 2
Enclosure 2
,
,
I
I
.


          *
*
        ,
,
      .
.
                                      31
31
            50-413.414/94-17-16 URI Split Flow Orifice Flow Resistance Factor
50-413.414/94-17-16
                                    (Section E8.7)
URI
            50-414/96-20-01     URI Mispositioned Nitrogen Backup Supply
Split Flow Orifice Flow Resistance Factor
                                    Valves Result in Degrading The Function of
(Section E8.7)
                                    Steam Generator Power Operated Relief
50-414/96-20-01
                                    Valves (Section M8.1)
URI
            50-414/94-02, Rev 1 LER Reactor Trip Breakers Opened Due to
Mispositioned Nitrogen Backup Supply
                                    Component Failures (Section M8.2)
Valves Result in Degrading The Function of
            50-413.414/96-02-01 IFI Reliance on Testing of a Single Valve to   ;
Steam Generator Power Operated Relief
                                    Support the Capabilities of a Group
Valves (Section M8.1)
                                    (Section E8.9)
50-414/94-02, Rev 1
            50-413,414/96-02-02 IFI Stem Coefficient of Friction for MOV
LER
                                    Opening Setting Calculations (Section
Reactor Trip Breakers Opened Due to
                                    E8.10)
Component Failures (Section M8.2)
            50-413,414/96-02-03 IFI MOV Opening Thrust Requirement
50-413.414/96-02-01
IFI
Reliance on Testing of a Single Valve to
Support the Capabilities of a Group
(Section E8.9)
50-413,414/96-02-02
IFI
Stem Coefficient of Friction for MOV
Opening Setting Calculations (Section
E8.10)
50-413,414/96-02-03
IFI
MOV Opening Thrust Requirement
4
4
                                    Uncertainties (Section E8.11)
Uncertainties (Section E8.11)
            50-413,414/96-02-04 IFI Unpredictable Behavior Experienced in     l
50-413,414/96-02-04
                                    Pressurizer PORV Block Valve MOV Testing
IFI
                                    (Section E8.12)
Unpredictable Behavior Experienced in
                                                                              l
Pressurizer PORV Block Valve MOV Testing
                                                                              l
(Section E8.12)
  .
l
                                                                              !
.
    .
.
                                                                              I
I
                                                                  Enclosure 2
Enclosure 2
                                                                              j
j


                            ._ .     .               .-   __. _ .     _       .
._
          .
.
        *
.
      o
.-
__. _ .
_
.
.
*
o
-
-
                                                  32
32
                                      LIST OF ACRONYMS USED
LIST OF ACRONYMS USED
'
'
            ANSI   -
ANSI
                    American National Standards Institute
-
!         CGD   -
American National Standards Institute
                    Commercial Grade Dedication
!
            CFR   -
CGD
                    Code of Federal Regulations
-
            CNS   -
Commercial Grade Dedication
                    Catawba Nuclear Station
CFR
            DPC   -
-
                    Duke Power Company
Code of Federal Regulations
            ECCS -   Emergency Core Cooling System
CNS
            EDG   -
-
                    Emergency Diesel Generator
Catawba Nuclear Station
;           EDM   -
DPC
                    Engineering Directives Manual
-
            FSAR -   Final Safety Analysis Report
Duke Power Company
            GL   -
ECCS -
                    Generic Letter
Emergency Core Cooling System
            IAE   -
EDG
                    Instrument and Electrical
-
:           IFI   -
Emergency Diesel Generator
                    Inspector Fullowup Item
;
            IR     -
EDM
                    Inspection Report
-
            IST   -
Engineering Directives Manual
                    In-Service Test
FSAR -
            LER   -
Final Safety Analysis Report
                    Licensee Event Report
GL
            MEPR -   Major Equipment Problem Resolution
-
:.          MOV   -
Generic Letter
                    Motor Operated Valve
IAE
            NCV   -
-
                    Non-Cited Violation
Instrument and Electrical
            NDE   -
:
                    Non-Destructive Examination
IFI
-
Inspector Fullowup Item
IR
-
Inspection Report
IST
-
In-Service Test
LER
-
Licensee Event Report
:.
MEPR -
Major Equipment Problem Resolution
MOV
-
Motor Operated Valve
NCV
-
Non-Cited Violation
NDE
-
Non-Destructive Examination
:
NS
-
Containment Spray System
'
'
:          NS    -
NSRB -
                    Containment Spray System
Nuclear Safety Review Board
            NSRB -  Nuclear Safety Review Board
NSM
            NSM   -
-
                    Nuclear Station Modification
Nuclear Station Modification
0AC
-
Operator Aide Computer
.
.
            0AC  -
;
                    Operator Aide Computer
QA
;          QA    -
-
                    Quality Assurance
Quality Assurance
.          OC   -
OC
                    Quality Control
-
Quality Control
.
PIP
-
Problem Investigation Process
,
,
            PIP  -
PORV -
                    Problem Investigation Process
Power Operated Relief Valve
            PORV -  Power Operated Relief Valve
-
RCS
-
-
Reactor Coolant System
4
4
            RCS  -
RG
                    Reactor Coolant System
-
Regulatory Guide
>
>
            RG    -
RHR
                    Regulatory Guide
-
            RHR  -
Resididual Heat Removal
                    Resididual Heat Removal
,-
,-         RP&C -   Radiological Protection & Control
RP&C -
            RTB   -
Radiological Protection & Control
                    Reactor Trip Breaker
RTB
            SER   -
-
                    Safety Evaluation Report
Reactor Trip Breaker
    ~
SER
            SG    -
-
                    Steam Generator
Safety Evaluation Report
            SNM   -
SG
                    Special Nuclear Material
-
;           SNSWP - Standby Nuclear Service Water Pond
Steam Generator
:           SPDG -   Spare Parts Diesel Generator
~
            SSF   -
SNM
                    Safe Shutdown Facility
-
            SSPS -   Solid S. ate Protection System
Special Nuclear Material
            TDAFW - Turbine Driven Aux. Feedwater Pump
;
            TEPR -   Top Equioment Problem Resolution
SNSWP -
            TI   -
Standby Nuclear Service Water Pond
                    Tem 3orary Instruction
:
l           TS   -
SPDG -
                    Tec1nical Specifications
Spare Parts Diesel Generator
.          UFSAR - Updated Final Safety Analysis Report
SSF
i           URI   -
-
                    Unresolved item
Safe Shutdown Facility
            US0   -
SSPS -
                    Unreviewed Safety Question
Solid S. ate Protection System
            VIO   -
TDAFW -
                    Violation
Turbine Driven Aux. Feedwater Pump
            WAPR -   Top Plant Work-Around Problem Resolution
TEPR -
            WO   -
Top Equioment Problem Resolution
                    Work Order
TI
  i
-
                                                                    Enclosure 2
Tem3orary Instruction
l
TS
-
Tec1nical Specifications
UFSAR -
Updated Final Safety Analysis Report
.
i
URI
-
Unresolved item
US0
-
Unreviewed Safety Question
VIO
-
Violation
WAPR -
Top Plant Work-Around Problem Resolution
WO
-
Work Order
i
Enclosure 2
}}
}}

Latest revision as of 17:18, 11 December 2024

Insp Repts 50-413/97-03 & 50-414/97-03 on 970112-0215. Violations Noted.Major Areas Inspected:Licensee Operation, Maint,Engineering & Plant Support
ML20140B763
Person / Time
Site: Catawba  Duke Energy icon.png
Issue date: 03/17/1997
From:
NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
To:
Shared Package
ML20140B755 List:
References
50-413-97-03, 50-413-97-3, 50-414-97-03, 50-414-97-3, NUDOCS 9704010094
Download: ML20140B763 (35)


See also: IR 05000413/1997003

Text

__

__

._

_ __ __

_

.

.

.

4

U.S. NUCLEAR REGULATORY COMMISSION

REGION II

Docket Nos:

50-413. 50-414

License Nos:

NPF-35 NPF-52

Report Nos.:

50-413/97-03, 50-414/97-03

Licensee:

Duke Power Company

Facility:

Catawba Nuclear Station Units 1 and 2

Location:

422 South Church Street

Charlotte, NC 28242

Dates:

January 12 - February 15, 1997

Inspectors:

R. J. Freudenberger. Senior Resident Inspector

P. A. Balmain. Resident Inspector

R. L. Franovich, Resident Inspector

l

E. H. Girard, Reactor Inspector (Sections E1.3 & E8.8-12)

P. J. Kellogg. Reactor Inspector (Sections E2.2 & E7.2)

R. L. Moore. Reactor Inspector (Sections E2.1 & E7.1)

C. W. Rap). Senior Reactor Inspector (Sections E8.1-7)

J. W. Yorc, Reactor Inspector (Sections E1.1-2)

Approved by:

C. A. Casto Chief

Reactor Projects Branch 1

Division of Reactor Projects

,

i

f

Enclosure 2

1

9704010094 970317

PDR

ADOCK 05000413

G

PDR

.

-

.

.

EXECUTIVE SUMMARY

Catawba Nuclear Station. Units 1 & 2

NRC Inspection Report 50-413/97-03. 50-414/97-03

This integrated inspection included aspects of licensee operations,

maintenance, engineering and plant support.

The report covers a 6-week

period of resident ins)ection: in addition, it includes the results of

announced inspections ay regional reactor safety inspectors.

Doerations

i

Emergency Core Cooling System valve stem leakage flow alarm panels

.

i

provided in the auxiliary building, although not required by the Final

Safety Analysis Report, were not being maintained as a reliable means of

i

locating potential reactor coolant system leakage sources (Section

01.1).

Maintenance

The time allowed by Technical Specifications for reactor trip breaker

.

testing was exceeded because procedural changes to incorporate

additional tasks were not evaluated to verify that those changes would

not extend the time to perform the test beyond the time allowed (Section

M1.1).

The inspector identified that material condition and housekeeping in the

Unit 2 Residual Heat Removal / Containment Spray Heat Exchanger Rooms was

poor (Section M2.1).

A non-cited violation was identified for failure to follow procedures

.

that resulted in mispositioned nitrogen backup supply valves that

i

degraded the function of two steam generator power operated relief

valves (Section M8.1).

Enaineerina

~

A review of station Problem Identification Process (PIP) reports and

.

associated corrective actions revealed that the licensee's threshold for

problem identification was at an appropriately low level and that the

Nuclear Safety Review Board had a positive impact on the licensee's

corrective action process.

For the PIPS reviewed the licensee had not

failed to identify any unreviewed safety questions (Section E1.1).

A review of modification packages revealed that the licensee properly

.

screened and performed the safety evaluations for modifications and test

procedure changes and that no unreviewed safety questions existed

(Section E1.2).

The licensee met the intent of Generic Letter (GL) 89-10 in verifying

.

the design-basis capabilities of their motor-operated valves (MOVs).

Several weaknesses were identified. Of these, the more important were

the limited data that was used to establish the capabilities of several

groups of MOVs.and the marginal capabilities of several groups of MOVs.

Enclosure 2

.

.

.

4

2

l

An Inspector Followup Item was identified to track the completion of

licensee initiated corrective actions.

Strengths were identified which

included: knowledgeable personnel who recognized and addressed the

problems identified, strong

state of the art technology. plant and corporate support, application of

l

leadership in addressing industry problems,

and the detailed thrust / torque requirement calculations that were

developed for each valve group.

Based on the NP,C staff's review of the

Catawba GL 89-10 program and its implementation, and the corrective

actions initiated by the licensee, the NRC is closing its review of the

GL 89-10 program at Catawba.

The completion of these licensee actions

will be assessed as part of the NRC staff's monitoring of the licensee's

long-term MOV program (Section E1.3).

j

Procurement Engineering performance related to identification, upgrade

.

and validation of safety-related replacement parts was generally good.

A violation was identified for failure to follow procedures for the

storage and control of the spare parts diesel generator (Section E2.1).

The engineering department was providing aggressive and effective

.

support to the operations, maintenance, and modification departments:

the number of open items was at an acceptably low level; and the Top

Equipment Problem Resolution Process was a strength (Section E2.2).

The scope of the procurement self-assessments was adequate to evaluate

.

performance of the activity under review.

Findings were appropriately

documented and tracked for resolution (Section E7.1).

Engineering was aggressively pursuing identified equipment problems and

.

self-assessments were effective in identifying areas for improvement in

the engineering department (Section E7.2).

The monthly flushing program was effective in controlling clam

.

population in service water piping (Section E8.1).

Plant Stocort

'

The licensee had existing radiation monitoring systems in the new fuel

.

unloading and storage areas that were capable of alarming should an

accidental criticality occur. A violation for failure to implement

criticality accident emergency procedures and failure to conduct

evacuation drills was identified (Section R2.1).

1

Enclosure 2

__

.

.__

_ _ _ _ _ _ _ _ _ _ _ . _ _ _ .

__

_ _ .

._

._

. _ _

.

.

.

.

!

Report Details

Summary of Plant Status

Unit 1 began the period operating at 100% power and operated at that power

level until February 14, when power was decreased to 59% so that a failed

speed sensor (one of two) associated with the IB main feedwater pump turbine

could be replaced. The specd sensor was replaced, and the unit returned to

full power on February 15.

Unit 2 began the Jeriod operating at 100% power and operated at essentially

'

full power througlout the inspection period.

!

Review of Vodated Final Safety Analysis Reoort (UFSAR) Commitment.s

l

While performing inspections discussed in this report, the inspectors reviewed

the applicable portions of the UFSAR that were related to the areas inspected.

The inspectors verified that the UFSAR wording was consistent with the

observed plant practices, procedures, and/or parameters.

I. Doerations

,

l

01

Conduct of Operations

01.1 Valve Stem Leakoff Flow Monitorina Indication

l

l

a.

Insoection Scone (71707, 40500)

l

l

The resident inspector noted that annunciator panels located in the

l

auxiliary building, designed to provide flow indication from valve stem

l

leakoff lines, had numerous indications of valve stem leakoff. The

inspector questioned the alarm status of these leakoff lines and

referred to pertinent design basis documents to determine the function

of the annunciator panels.

l

b.

Observations and Findinas

i

During a routine tour of the auxiliary building on January 29. the

'

resident inspector identified a number of flow alarms associated with

i

Emergency Core Cooling System (ECCS) valve stem leakoff flow monitoring.

The inspector questioned operations personnel about the alarms and

determined that the annunciator panel indications were not considered

reliable and, therefore. the alarms were not attended to.

The inspector

also noted that annunciator response procedures were not available to

j

provide guidance in response to the alarms.

The licensee generated station Problem Investigation Process (PIP)

'

report 0-C97-0265 to document the alarm status on these annunciator

panels.

According to the PIP. the reliability 3roblems associated with

the flow alarms has been an ongoing 3roblem.

T1e 3rocedure for

'

identifying Reactor Coolant System (RCS) leakage.

)T/1&2/B/4150/01E.

Identifying Reactor Coolant System Leakage, provides guidance for using

Enclosure 2

.

.

.

.

.

_-

-.

.

.

.

r

2

l

I

these annunciator panels to identify sources of RCS leakage.

The

inspector obtained a copy of the procedure, approved July 16,1996, and

reviewed Enclosure 13.3 Valve Stem Leakoffs to the Recycle Holdup Tank.

Although the enclosure lists the ECCS valves that are represented on the

annunciator panels, using this method to identify RCS leakage is not

required and is implemented at the discretion of the Operations Shift

. Supervisor.

The inspector consulted the FSAR in an effort to determine the design

basis of the valve stem leakoff flow indications. Although ECCS valve

stem leakoff collection was briefly discussed, a discussion of flow

i

monitoring of the leakoff was not provided in the context of reactor

coolant system leakage detection or auxiliary building radiological

activity limits.

c.

Conclusions

'

The inspector concluded that the ECCS valve stem leakage flow alarms

that were not being maintained as a means of locating potential reactor

coolant system leakage sources. Although no safety basis for the flow

i

indication could be identified in the FSAR, an evaluation is appropriate

i

to determine whether the equipment should be available and maintained in

J

good working condition or should be abandoned.

l

II. Maintenance

M1

Conduct of Maintenance

'

M1.1 Reactor Trio Breaker Surveillance Testina

a.

Jnsoection Scooe (61726)

On February 6. the licensee determined that the time allowed for Unit 2

reactor trip breaker (RTB) testing was exceeded, and RTB inoperability

had exceeded the 2-hour limit specified in Technical Specification (TS) 3.3.1. Item 18. Action 9.

The inspector reviewed station PIP 2-C97-

'

0341, reviewed associated testing procedures, and discussed the issue

with licensee personnel.

b.

Observations and Findinas

The licensee conducted RTB testing concurrent with Solid State

Protection System testing on February 6.

According to TS 3.3.1. Item

18. Action 9. one RTB channel may be bypassed (inoperable) for up to two

hours for surveillance testing per TS Surveillance Requirement 4.3.1.1.

provided that the other RTB channel is operable. The work associated

with the surveillance testing was completed within the allowed 2-hour

time )eriod; however, paper work to clear the work order and declare the

RTB clannel operable was not completed until after the allowed time

period had elapsed by 20 minutes. As a result. RTB testing required

Enclosure 2

.

--

_

-_

.

-

-

.

..-.

i

.

s

.

l

3

entry into the 6 hour6.944444e-5 days <br />0.00167 hours <br />9.920635e-6 weeks <br />2.283e-6 months <br /> shutdown action of TS 3.3.1. Item 18. Action 9.

I

The licensee initiated P75 2-C97-0341 to document the issue. The

'

inspector reviewed the 'T and discussed the occurrence with licensee

i

personnel.

The cause of the time delay was attributed to multiple

changes to the test ?rocedure that required the performance of

additional tasks. T1e licensee did not attemat a walkthrough

,

verification to ensure that these procedure c1anges did not

significantly impact the time necessary to cc.oplete testing. Corrective

actions proposed in the PIP include procedural changes to enhance the

efficient use of time in conducting the test.

I

l

c.

_ Conclusions

The inspector concluded that exceeding the time allowed by TS for RTB

'

testing because of outstanding papenvork did not adversely impact plant

1

safety. However, the procedural changes to incorporate additional tasks

-

were not evaluated to verify that those changes would not extend the

time to perform th.e test beyond the time allowed by TS, without entering

4

a shutdown TS action.

1

M2 Maintenance and Material Condition of Facilities and Equipment

M2.1 Unit 2 Containment Soray and RHR Heat Exchanger Room Observations

a.

Insoection Scooe (62707, 61726, 40500)

i

The inspector observed portions of the following surveillance activities

l

performed on the 2B containment spray pump:

-

PT/2/A/4200/09A, Auxiliary Safeguards Test Cabinet Periodic Test

-

-PT/2/A/4200/04C, Containment Spray Pump 2B Performance Test

-

PT/2/A/4203/03. Leak Rate Determination for NS System Outside of

,

Containment

During the performance of these tests, the inspector observed poor

housekeepino and material conditions in the Unit 2 Residual Heat Removal

(RHR)/ Containment Spray heat exchanger rooms.

.

b.

Observations and Findinas

4

Surveillance Test PT/2/A/4203/03, Leak Rate Determination for NS System

Outside of Containment, is performed within six months of each refueling

outage and consists of a walkdown of containment spray system piping and

i

components located outside of the reactor containment while the system

is pressurized.

Components with evidence of leakage are identified for

,

j

repair.

During the portion of the walkdown performed in the 2B

1

RHR/Contaiu,,ent Spray heat exchanger room the inspector and the licensee

Enclosure 2

-_

.

- -

._

--- - _ .-- -

-- __.

-

-.

.

.

.

.

4

technician observed an uncontained leak spraying from a containment

saray system vent located above the containment spray heat exchanger.

T1e inspector investigated areas in the lower part of the room and

identified that a significant amount of boric acid had accumulated on

safety-related components in this area, including the heat exchanger

hold down bolts and supporting structure. The accumulation of boric

acid indicated that this leakage source had existed previously and would

occur when the system was in operation and pressurized.

The inspector

found similar boric acid accumulation in the A train heat exchanger

room.

In contrast to the conditions in the 2B heat exchanger room, a previous

atte.nn D contain leakage was obvious in the A train heat exchanger

room as evidenced by a drip bag installed on the heat exchanger vent

piping.

The inspector discussed the licensee's leak containment

practices for these rooms with radiation protection management.

The

,

inspector found that the heat exchanger rooms were classified as

nonrecoverable from a radiological contamination standpoint because of

the chronic leakage sources which make the rooms difficult to maintain

,

decontaminated.

From the dicussions, the inspector discerned that the

'

licensee did not routinely install drip bags or leak containments in

areas which are considered " nonrecoverable."

The inspector performed additional inspections in these rooms and

identified a substantial amount of debris left in the heat exchanger

rooms, including discarded scaffold tie down wires, several ropes tied

,

to instrument air lines and safety-related valves, sections of unsecured

'

1

insulation left on valve actuators, damaged flexible electrical conduit,

trash, and discarded rubber gloves.

Following identification of these issues the licensee developed a plan

to repair the leaks and correct housekeeping issues.

The licensee

,

tightened the 2B heat exchanger pipe cap and the associated vent valves

l

which stopped the leak,

Vent valves associated with the 2A heat

exchanger were also tightened and no leakage was observed when the pump

'

was subsequently operated (PIP 2-C97-0349). Station management

.

requested a root cause evaluation be performed by the safety review

'

group to determine how conditions were allowed to degrade in the heat

exchanger rooms and to assess how ioentified leaks are addressed on all

ECCS components.

The licensee oIso performed walkdowns of other

infrequently entered areas and found additional instances of where

material condition or housekeeping were substandard, but not as poor as

l

conditions in the Unit 2 RHR/ containment spray heat exchanger rooms.

!

l

c.

Conclusions

The ins'ector identified that material condition and housekeeping in the

>

Unit 2 Residual Heat Removal / Containment Spray Heat Exchanger Rooms was

poor.

Poor conditions resulted in part because of uncaptured

containment spray system leakage that resulted in accumulation of boric

Enclosure 2

,

__

_

_ ._ .

__

__ _

_ _ _ _ _ _ . _ . _ _ _ _

_ _ _

1

.

j

s

.,

4

i

technician observed an uncontained leak spraying from a containment

'

s) ray system vent located above the containment spray heat exchanger.

Tie inspector investigated areas in the lower part of the room and

4

identified that a significant amount of boric acid had accumulated on

safety-related components in this area, including the heat exchanger

hold down bolts and supporting structure.

The accumulation of boric

,

acid indicated that this leakage source had existed previously and would

,

occur when the system was in operation and pressurized. The inspector

found similar boric acid accumulation in the A train heat exchanger

.

room.

,

I

In contrast to the conditions in the 2B heat exchanger room, a previous

attempt to contain leakage was obvious in the A train heat exchanger

room as evidenced by a drip bag installed on the heat exchanger vent

<

piping. The inspector discussed the licensee's leak containment

practices for these rooms with radiation protection management.

The

,

inspector found that the heat exchanger rooms were classified as

nonrecoverable from a radiological contamination standpoint because of

the chronic leakage sources which make the rooms difficult to maintain

,

i

decontaminated.

From the dicussions, the inspector discerned that the

licensee did not routinely install drip bags or leak containments in

'

areas which are considered " nonrecoverable."

The inspector performed additional inspections in these rooms and

identified a substantial amount of debris left in the heat exchanger

rocms, including discarded scaffold tie down wires, several ropes tied

to instrument air lines and safety-related valves, sections of unsecured

'

insulation left on valve actuators, damaged flexible electrical conduit.

'

trash, and discarded rubber gloves.

i

Following identification of these issues the licensee developed a plan

to repair the leaks and correct housekeeping issues.

The licensee

tightened the 2B heat exchanger pipe cap and the associated vent valves

which stopped the leak.

Vent valves associated with the 2A heat

exchanger were also tightened and no leakage was observed when the pump

i

was subsequently operated (PIP 2-C97-0349). Station management

'

requested a root cause evaluation be performed by the safety review

group to determine how conditions were allowed to degrade in the heat

exchanger rooms and to assess how identified leaks are addressed on all

ECCS components. The licensee also performed walkdowns of other

infrequently entered areas and found additional instances of where

material condition or housekeeping were substandard, but not as poor as

conditions in the Unit 2 RHR/ containment spray heat exchanger rooms.

c.

Conclusions

The inspector identified that material condition and housekeeping in the

Unit 2 Residual Heat Removal / Containment Spray Heat Exchanger Rooms was

poor.

Poor conditions resulted in part because of uncaptured

containment spray system leakage that resulted in accumulation of boric

Enclosure 2

J

.

.

5

acid on safety-related components in these rooms.

The inspector also

identified material condition discrepancies.

The licensee's subsequent

inspection of other infrequently accessed areas identified similar

conditions.

These observations indicated that areas which are

considered " nonrecoverable" from a radiological contamination

perspective had not received a commensurate level of care as frequently

traveled areas in the plant.

M8

Miscellaneous Maintenance Issues (92902)

M8.1 LClosed) Unresolved item (URI) 50-414/96-20-01: Mispositioned Nitrogen

Backup Supply Valves Result in Degrading the Function of Steam Generator

(SG) Power Operated Relief Valves (PORVs)

During this inspection period the licensee completed investigation of

this valve mispositioning event.

The licensee identified that the

nitrogen supply isolation valves were in the closed position for SG PORV

2SV-1 in response to a low nitrogen pressure alarm received in the main

'

control room when a maintenance technician found the valves closed in

the process of changing nitrogen bottles.

Additional licensee

inspections identified that nitrogen supply isolation valves for SG PORV

2SV-13 were also closed. This was the first opportunity to iuentify the

mispositioned valves.

The licensee determined that four nitrogen supply isolation valves were

left closed for a period of approximately 13 days following surveillance

testing performed on SG PORVs 2"V-1 and 2SV-13 on December 22. 1996.

Two individuals performing the t?st failed to follow a portion of

restoration steps in Surveillance Procedure PT/2/A/4200/31A. SG PORV and

Block valve D/P Stroke Test.

Specifically, two restoration steps were

not completed to open the nitrogen supply isolation valves (Steps

12.1.21.5 of Enclosures 13.1 and 13.3 for SG PORVs 2SV-1 and 2SV-13.

respectively).

The licensee determined that a contributing cause was

providing one procedure step to perform multiple actions that were in

separate areas of the valve room areas.

'

'

Failing to follow Procedure PT/2/A/4200/31A restoration steps resulted

in disabling the safety-related gas su) plies for SG PORVs 2SV-1 and 2SV-

13 for a period of time in excess of t1e time allowed by TS 3.7.1.6.

Steam Generator Power Operated Relief Valves.

With one less than three

required operable SG PORVS the licensee is required to restore the

i

inoperable SG PORV to operable status within 7 days or take additional

I

actions to shutdown and place RHR inservice.

This TS allows one SG PORV

l

to remain inoperable indefinitely.

The purpose of the safety-related backup supply as stated in the TS

!

Bases is to mitigate the consequences of a steam generator tube rupture

I

accident concurrent with a loss of offsite power (i.e.

loss of

instrument air which normally controls the SG PORVS).

During this

.

period, two of the four Unit 2 SG PORVs were fully operable. With the

4

Enclosure 2

1

1

- -

.

-. .

.

.

- - - -

--

.

,

,

6

,

l

exception of the nitrogen backup supplies, the remaining two were

'

functional and could be operated during a steam generator tube rupture

event without complications resulting from a loss of offsite power or

instrument air.

For a SG tube rupture event, the PORV on the affected

SG is assumed unavailable.

With nitrogen backup supplies isolated on SG

<

PORVs 2SV-1 and 2SV-13, one SG PORV would have remained controllable

i

from the main control room and SG PORVs 2SV-1 and 2SV-13 could be

locally operated if needed per Emergency Operating Procedure

j

EP/2/A/5000/ E-3. Steam Generator Tube Rupture.

Corrective Actions

1~

Upon discovery of the of the isolated nitrogen supplies on SG PORV 2SV-

1. the licensee recognized the significance of the condition and

promptly checked the remaining three Unit 2 SG PORVs and all four Unit 1

SG PORVS and identified that one additional SG PORV on Unit 2 (2SV-13)

'

had its nitrogen supply isolated.

The licensee 3romptly opened the valves and restored the nitrogen

1

supplies for )oth SG PORVs.

In addition, after identification of the

two mispositioning events the licensee displayed an appropriate

,

sensitivity to a possible tampering / sabotage event and performed

j

additional verifications of equipment located in the same areas (i.e..

main steam safeties and turbine driven auxiliary feedwater steam supply

valves).

The licensee also secured access to these rooms on both units

'

until investigation of the possible tampering concluded that the

}

mispositionings were not deliberate.

In addition to the immediate corrective actions discussed above. the

licensee counseled the two individuals involved in performing the valve

'

manipulations and initiated revisions to the SG PORV surveillance

procedure to include separate steps and signoffs for each valve

-

-

manipulation.

Similar Engineering test procedures will be reviewed for

'

steps requiring multiple actions separated by time or distance and

changes will be made as necessary.

The licensee submitted LER 50-

,

414/97-01 to address this issue on February 3, 1997.

,

,

The inspector concluded that the licensee's corrective actions were

4

.

appropriate and timely.

Failing to follow procedures which resulted in

disabling the safety-related gas supplies for SG PORVs 2SV1 and 2SV13 is

a violation of TS 6.8.1. Procedures and Programs. This violation meets

the criteria of Section VII.B.1 of the Enforcement Policy for exercise

of discretion and will be considered a Non-Cited Violation (NCV 50-

j

414/97-03-03. Mispositioned Nitrogen Backup Supply Valves Result in

r

Degrading the Function of SG PORVs).

-

Enclosure 2

- -

..

.

i

t

'

7

-

M8.2 (Closed) Licensee Event Reoort (LER) 50-414/94-002. Rev. 01: Reactor

Trip Breakers Opened Due to Component Failures

,

'

The LER was revised by the licensee to correct inaccuracies identified

by the inspector during a previous inspection (refer to NRC Ins)ection

i

Report 50-413.414/96-05).

The inspector reviewed the revised LER and

verified the inaccuracies were corrected.

This item is closed.

III. Enaineerina

El

Conduct of Engineering

El.1 Review of Problem Identification Process

a.

Insoection Scooe (40500)

The inspectors reviewed a sample of the PIP reports identified by the

licensee during 1996 and the first months of 1997. m order to assess

the licensee's corrective action process and the * ::pect of the Nuclear

Safety Review Board (NSRB) on the process,

b.

Observations and Findinas

The inspectors reviewed the following PIP reports that were selected

from a list of PIPS written over the past year:

-

PIP No. 2-C96-1495. concerninq sheared or missing turbocharger

bolts on Diesel Generator (D/G) 2B.

-

PIP No. 2-C96-0475. concerning a leak coming from a cracked socket

weld on a vent line on D/G 2A.

(The remaining PIPS related to 10 CFR 50.59 safety evaluations.)

'

-

PIP No. 0-C96-0812. involved conflicting information in the 50.59

evaluation and a flow diagram.

,

-

PIP No. 0-C96-1024. did not contain a 50.59 evaluation or

screening document because of personnel error.

-

PIP No. 0-C96-2044 this was a question raised by the NSRB

screening concerning the adequacy of the documented discussion.

-

PIP No. 1-C96-2040, did not adequately discuss the decision that

the margin of safety discussed in the TS was not reduced (NSRB

identi fied) .

-

PIP No. 0-C96-2046 and PIP No. 1-C96-2049. questions concerning

i

adequacy of documented discussion raised by NSRB.

Enclosure 2

. _ .

-

s

.

8

-

PIP No. 1-C96-2049 and No. 2-C96-2051. questioned by the NSRB

review.

Their review indicated that the 50.59 was directed at the

modification implementation process when the safety analysis

should have been directed at the physical changes to the plant

that the modifications addressed.

None of the resolutions for the PIPS identified a failure to find a

Unresolved Safety Question (US0).

j

c.

Conclusions

The inspectors' review of selected PIPS and associated corrective

actions revealed that the licensee's threshold for problem

identification was at an appropriately low level and that the NSRB had a

positive impact on the licensee's corrective action process.

For the

PIPS reviewed, the licensee had not failed to identify any US0.

E1.2 Review of Safety Evaluations

a.

Insoection Scooe (37550)

The inspectors reviewed a sample of the licensee's safety evaluations

per 10 CFR 50.59.

The evaluations were reviewed with respect to the

threshold for determining if an US0 existed because of an increase in

the probability of a design basis accident occurring, an increase in

equipment malfunction, a reduction in the margin of safety, or an

increase in radiation dose consequences.

b.

Observations and Findinas

The inspectors reviewed the following 10 CFR 50.59 safety evaluations

for modifications being performed to the Catawba Nuclear Station:

j

-

50.59 evaluation for modification No. NSM CN-21341, which was used

for the replacement of certain carbon steel sections of the

,

'

Nuclear Service Water System (RN) with stainless steel. Almost

complete blockage due to corrosion products had been observed in.

some of the two and four inch diameter lines.

-

50.59 evaluation for modification No. NSM CN-11355, which was used

for replacing Containment Penetration Valve Injection Water (NW)

globe valves with gate valves because of hydrogen embrittlement

problems with the stainless steel springs (type 17-7 PH). general

operating difficulty, and problems with position indication.

-

50.59 evaluation for modification No. NSM CN-21300, which was used

for refurbishment of the vertically mounted Containment Spray

System (NS) Heat Exchangers 2A and 28.

Baffle plates in the heat

exchangers are supported by tie rods / spacers made from carbon

steel and over a period of years corrosion had attacked these

Enclosure 2

.

.

9

components. The structural integrity was restored by inserting

rods both above and below the baffle plates and then welding the

rods to the shell.

-

50.59 evaluation for changing Test Procedure PT/2/A/4350/128 for

Diesel Generator (D/G) 28.

Additional loads were added to the

test for this D/G and the test is used to demonstrate acceptable

response of the governor and voltage regulator to load changes

after maintenance has been performed.

c.

Conclusions

The inspectors concluded that the licensee had properly screened and

performed the safety evaluations for the modifications and test

procedure change, and that no USQ existed.

i

El.3 Generic Letter 89-10 Program Imolementation

l

a.

Insoection Scooe (Temporary Instruction 2515/109)

1

This inspection provided an assessment of the licensee's implementation

of GL 89-10. " Safety-Related Motor-Operated Valve Testing and

Surveillance".

The licensee notified the NRC that they had completed

implementation of GL 89-10 in a letter dated February 20, 1997.

The assessment conducted during this inspection included evaluations of:

the scope of MOVs included, the calculations of the design basis

differential pressure, the determinations of MOV settings and

verifications of MOV capabilities. the periodic verification of MOV

capabilities, and the MOV post maintenance and post modification

testing. The inspectors conducted the assessment through a review of the

licensee's GL 89-10 implementing documentation and through interviews

with licensee personnel.

The documents reviewed included: "NRC Generic Letter 89-10 Program Plan," Rev. 4: " Guideline for Performing Motor

0]erated Valve Reviews and Calculations" DPS-1205.19-00-0002. Rev. 0;

" Evaluation of Rate-of-Loading Effects". DPC-1205.19-00-0002, Rev. 0;

'

DPC-1205.19-00-0001 Rev.1. " Evaluation of Stem Factor and Stem C.O.F.

A:sumptions;" and the procedures, calculations, test records, etc. ,

referred to in the following paragraphs.

In addition, the inspectors

reviewed summary tabulations of MOV information and calculation results

prepared by the licensee.

Prominent among the tabulations was a list of

"available valve factors" (AVFs) for the licensee's GL 89-10 gate and

globe valves.

The licensee prepared this list at the inspectors'

request to aid them in assessing the capabilities of the licensee's

MOVs. The inspectors compared the AVFs of the licensee's valves to

valve factor requirements established through industry testing to

determine if the AVFs were conservatively higher. The AVFs were

calculated for each MOV using the formulas given below.

Enclosure 2

.__._

_

_

_ _ _

. _ . _ _

_ _ _ _

.

-

.

.

.

10

4

4

AVF (Close) = (Th * [1 - (LSB + U)]) - PL - SR/ (Disc Area * DBDP)

i

AVF (0 pen) = (Th * [1 - (LSB + U)]) - PL + SR/ (Disc Area * DBDP)

where.

I

Th

- thrust available for limit switch control. thrust at

torque switch trip for torque switch control

LSB

= load sensitive behavior

.

i

U

- uncertainty (instrument and other uncertainties combined

by square root sum of squares method)

PL

- packing load

}

SR

= stem rejection load

l

DBDP = design-basis differential pressure

i

b.

Observations and Findinas

,

Scone of MOVs Included in the Proaram

i

The scope of valves in the licensee *s GL 89-10 program was reviewed

previously by the NRC and was determined acceptable during Inspection

,

i

50-413.414/96-02.

In the current inspection the NRC inspectors reviewed

the list of MOVs contained in the licensee's program and verified that

the scope had not changed.

The list was maintained as the Catawba

Nuclear Station Units 1 and 2 Generic Letter 89-10 MOV List, CNS

-

1205.19-0081. Rev. D2.

The scope included 252 gate valves. 154 globe

valves, and 66 butterfly valves for a total of 472 valves. This was one

'

of the largest scopes of any plant.

Determinations of Settinas and Verifications of Caoabilities for Gate

,

and Globe Valves

The inspectors selected and reviewed calculations, test data, and

-

evaluations for the following sample of valves in order to assess the

'

licensee's validation of calculation assumptions and their

determinations of MOV settings and capabilities:

1-NC031B

Pressurizer power operated relief valve (PORV) block valve

2-BB010B

Steam generator (S/G) D outside containment isolation valve

(CIV)

2-SV026B

Steam generator C PORV block valve

1-NV091B

Reactor coolant pump seal return CIV

1-NIO95A

Safety injection test header to sump CIV

2-CA038A

Turbine driven auxiliary feedwater pump to S/G D isolation

valve

Enclosure 2

.

,

.

11

The inspectors' findings were as follows:

MOV Sizino and Switch Settinas

Catawba typically used standard industry equations to determine gate

valve thrust requirements for setting and sizing their gate valves.

Valve factors for use in these equations were based on in-plant dynamic

testing results or results from other industry sources.

For some valves

on which in-plant testing was impractical, prototype testing was

performed.

For Westinghouse gate valves the licensee used the equation

and valve factor developed by Westinghouse to calculate minimum required

thrust.

In a few cases, the licensee used Electric Power Research

Institute (EPRI) Performance Prediction Model (PPM) calculations to

establish thrust requirements.

Most of the licensee's globe valves were manufactured by Kerotest.

The

thrust requirements for these valves were either calculated using the

vendor's method, with an amount added to account for nonconservatism

found by a licensee test program: or the standard industry equation was

used.

For the licensee's other globe valves thrust requirements were

calculated using the standard industry equation.

Thrust Reauirements for Grouos

The licensee grouped similar MOVs and established thrust setting

requirements for each group.

From their reviews, the inspectors found

that the thrust setting requirements determined for each valve group and

the current setups of the MOVs were adequate for design-basis

capability.

However, they noted weaknesses for several groups.

These

weaknesses and the actions which the licensee initiated to address each

are described below:

Group AD-02 consisted of six 6-inch 900# Anchor / Darling double

.

disc gate valves. These MOVs had both a close and open safety

function.

The thrust reauirements were deter'ained using EPRI PPM

'

'

Anchor / Darling double disc hand calculations. The inspectors

found that the licensee's closing calculations were only for flow

isolation and expressed concern that excessive leakage through the

valves might occur without full seating. To address this concern,

the licensee established an action item in PIP 0-C97-0421 to

respond to the conditions specified in the NRC Safety Evaluation

of the " Electric Power Research Institute Topical Report TR-

103237. EPRI Motor-Operated Valve Performance Prediction Program"

,

(including consideration of leakage requirements).

Group AD-04 consisted of six 3-inch 1500# Anchor / Darling double

.

disc gate valves. Catawba evaluated November 1994 instrumented

" prototype" testing and EPRI PPM Anchor / Darling double disc gate

valve hand calculation results to establish the thrust

requirements for these MOVs.

The NRC inspectors reviewed the

Enclosure 2

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.

12

i

results and expressed concern that the licensee's evaluations

showed that the capabilities of two valves in this group had only

marginal capabilities (INC31 and 2NC33).

The licensee established

an action item in PIP 0-C97-0421 to provide future modifications

to upgrade the margins for these valves.

1

Group BW-01 consisted of eight 3-inch Borg Warner 150# gate

.

valves. -From dynamic testing, the licensee determined a valve

factor of 1.3 for this valve group. This valve factor was used to

calculate thrust setting requirements for the group. The

i

inspectors questioned the reliability of this unexpectedly high

value, as it was supported only by a single test.

The inspectors

'

verified that the licensee had reviewed the MOV settings for the

,

remainder of this group to ensure each could support a valve

factor as high as 1.3.

The inspectors found that the licensee

already had plans to dynamic test three other valves from this

group in the upcoming Spring 1997 outage to further assess the

valve factor.

The licensee established an action item in PIP 0-

C97-0421 specifying the additional dynamic testing of these three

valves.

,

Group WL-01 consisted of two 6-inch Walworth 150# gate valves.

.

The minimum thrust requirements for these MOVs was based on a

.

valve factor of 0.40 and they had open safety functions.

The

calculated open available valve factor for these MOVs was only a

'

little higher, at 0.42. The inspectors considered these MOVs to

be marginal with respect to thrust capabilities. They reviewed

the diagnostic traces for these MOVs to ensure they were lightly

seated such that minimal unwedging force was required to open

them.

Further, they verified that industry data showed a valve

factor of 0.40 for these MOVs.

The licensee established an action

item in PIP 0-C97-0421 specifying that these MOVs would be

-

modified to increase their thrust margins in the 1997 Spring

outage.

'

The thrust requirements for the following gate valve groups were

.

determined using valve factors obtained from the results of a

single dynamic test each: BW-11 BW-13 PC-01. WH-01, and WH-02.

The inspectors found that such limited data provided weak support

for the requirements. The inspectors verified that the valves had

reasonably high available valve factors compared to general

industry results and did not identify any current operability

concerns.

The licensee established an action item in PIP 0-C97-

0421 to put in place a plan to document this shortcoming and

monitor and evaluate the future performance of these valves.

The thrust requirements determined for the following globe valve

groups were considered weak as they were supported by limited

dynamic test data:

BW-13. BW-14. and BW-15.

Based on a review of

the settings for these valves, the inspectors were satisfied that

Enclosure 2

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s

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13

these groups had adequate thrust margins to assure operability.

The licensee established an action item in PIP 0-C97-0421 to

strengthen the validation data for these groups.

The actions which the licensee initiated to address the above weaknesses

were considered satisfactory.

Load Sensitive Behavior

The licensee used measured load sensitive behavior values for valves

l

that were dynamically tested and generally assumed a value of 30% for

set-up of valves that were not dynamically tested. The licensee's

evaluation of the load sensitive behavior data in their dynamic tests

was documented in calculation DPC-1205.19-00-0002. " Evaluation of Rate-

of-Loading Effects." The licensee was in the process of revising this

evaluation and the inspectors reviewed both revisions. The inspectors

found that the 30% value which the licensee had used in setting up

valves that were not dynamically tested exceeded the mean plus two

standard deviations determined by both the original and new evaluations.

The latest values were used to calculate the available valve factors

that the inspectors had requested for use in evaluating Catawba's MOVs.

The inspectors considered the licensee's assessment and application of

load sensitive hehavior to be satisfactory.

Stem Friction Coefficient

Catawba's calculations assumed a stem friction coefficient value of 0.15

in determining actuator output capability. This value was obtained from

an evaluation of in-plant test data from several licensee facilities.

However, based on a more recent evaluation of dynamic test data. Catawba

determined that a value of 0.20 should be used for opening dynamic

conditions.

They continued to consider a 0.15 value acceptable for

closing.

The licensee verified that closing static stem friction

coefficients did not exceed 0.15 and relied on the assumed rate of

l

loading to account for increased friction under dynamic conditions. The

,

i

licensee's PIP 0-C95-0879 provided an evaluation of the opening

'

,

capabilities of the licensee's actuators using an opening stem friction

coefficient of 0.20.

The PIP documented that the current MOV

capabilities were acceptable. The inspectors reviewed the licensee's

evaluation and concluded that the licensee had adequately determined and

accounted for stem coefficient in verifying the capabilities of their

MOVs.

Diaonostic Eauioment Uncertainties

NRC Inspection 50-413.414/96-02 determined that the licensee was not

accounting for VOTES diagnostic equipment uncertainties in the open

'

direction when measurements were outside the sensor calibration range.

These errors can become very large if the measurements are significantly

outside the calibration range.

This issue was addressed by the licensee

Enclosure 2

l

%

1

.

14

through PIPS 0-G95-0295 and 0-C95-0879.

The inspectors verified that

the PIPS assured that the uncertainties were appropriately accounted for

through evaluations of the existing completed testing and that the

licensee's procedures were revised for future testing.

Desian-Basis Capability

From reviews of examples of the dynamic test evaluations and associated

test reports, the inspectors generally found that the licensee's testing

had been satisfactorily used in establishing the design-basis capability

of their MOVs. Catawba's dynamic tests were accurate and well

i

cocumented.

From the test results. the licensee calculated valve

factors for each test. The valve factors for each group of valves were

displayed graphically with separate lines plotted for flow isolation and

hard seat values.

In general, the valve factor which the licensee

applied to a group of non-tested valves was selected by bounding the

highest valve factor on the graph and then adding 0.01 to that value.

If a test group showed one test to have an abnormally high or low valve

factor, an engineering evaluation was performed and that valve factor

was removed from the group if appropriate.

The inspectors noted two weaknesses in methods which the licensee used

i

to determine the group valve factors:

The inspectors identified one instance in which the licensee used

.

multiple test data points from a single valve in graphically

analyzing the valve factors for a group of valves.

This could

have biased the selection of an appropriate group valve factor.

For the instance in question (valve group BW-05), the inspectors

independently analyzed the licensee's data and found that the

valve factor which the licensee applied to the group was

satisfactory.

The inspectors noted that the licensee's selection of a grou)

.

valve factor by adding 0.01 to the highest valve factor on t1e

'

graph for a group might not adequately account for variations in

valve factor performance if the valve factor data had a large

amount of scatter. The inspectors statistically assessed licensee

data and identified an example (valve group BW-03) where the valve

factor selected by the licensee was slightly lower than the mean

plus two standard deviations.

In this instance Catawba had

selected an open and close valve factor of 0.60 for the MOVs.

Using the mean plus 2 standard deviations of the data available

for this group the inspectors calculated an caening valve factor

of 0.65 and a closing valve factor of 0.64.

iowever, the higher

values calculated by the inspectors were not an operability

problem, as the inspectors found that the minimum available valve

factor for these MOVs was 0.69. The licensee stated that they

would review those calculations where the valve factor data had a

large amount of scatter to ensure that an appropriate valve factor

had been selected for the group.

Enclosure 2

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15

Jeterminations of Settinas and Verifications of Caoabilities for

3utterfly Valves

The licensee documented their setting determinations and justifications

for the capabilities of the Catawba butterfly valves in calculations.

Additionally, they documented summary information on each butterfly

valve in a spreadsheet which included information on the valves,

0)erators. method of justifying capability (e. g., test program), and

t1e calculated setting margin above that required.

From a review of the

spreadsheet, discussions with licensee personnel, and reviews of

exam)les of the calculations, the inspectors found that the settings and

capa)ilities of the licensee's butterfly valves were demonstrated to be

satisfactory.

Periodic Verification

The licensee implemented MOV periodic verification from a valve list and

test status tabulated in a database.

The inspectors reviewed the

tabulation and found that it recorded the date of the last test

performed on each valve and specified the date of the next retest.

The

verifications were specified at intervals not exceeding 5 years or 3

refueling outages for the licensee's more risk significant group 1

valves.

Periods not exceeding 8 years or 6 refueling outages were

specified for the less risk significant group 2 valves. The inspectors

were informed that it was the responsibility of the system engineers to

-

prepare work orders (W0s) to implement the testing.

The inspectors

selected three valves (2NC031B, 2RN846A, and 2NIO88B) and verified that

W0s had been arepared requiring them to be static diagnostic tested in

the upcoming Jnit 2 outage (March 1997).

The licensee's periodic verification actions were considered adequate

for closure of GL 89-10. The NRC may re-assess the licensee's long-term

periodic verification program as part of its review of GL 96-05.

" Periodic Verification of Design-Basis Capability of Safety-Related

Motor-Operated Valves", dated September 18, 1996.

'

Post Maintenance and Post Modification Testina

The licensee's Post Maintenance Retest Manual (November 18. 1996

revision), listed the )ost maintenance testing to be performed on

)

licensee equipnent suc1 as MOVs.

For maintenance activities potentially

-

affecting valve performance, such as packing adjustments, static

diagnostic tests were specified. However, the Manual permitted the

scope of such testing to be reduced where justified by engineering.

Licensee personnel indicated that post modification test requirements

were determined by engineers using the testing specified by the retest

manual as guidance.

To assess the adequacy of the post modification testing implemented by

)

the licensee, the inspectors selected and reviewed the testing specified

Enclosure 2

.

.

.

16

on the controlling documents for the following maintenance and

modification work: WO 95030544 (packing leak). WO 95057402 (packing

leak). WO 96049626 (packing leak and actuator removal). WO 94055288

(operator oil leak). Modification CN-11347 (replace main steam PORV

block valves). Minor Modification CNCE-7446 (gearbox and spring pack

changes), and Minor Modification CE-4715 (actuator replacement).

The

inspectors found that the licensee had specified appropriate testing for

these maintenance and modification activities.

For example, a full

static diagnostic test was required following packing adjustments.

Aoolicability of McGuire Insoection Findinas to Catawba

The inspectors questioned whether corporate program changes resulting

from the NRC inspection of the licensee's McGuire facility would be

reviewed for applicability to Catawba.

The licensee identified an

action item in PIP 0-C97-0421 to address the corporate program changes.

Strenaths

The inspectors observed a number of strengths in the licensee's

implementation of GL 89-10.

Particular examples included:

Highly knowledgeable personnel who recognized and addressed the

.

problems identified by the Catawba testing and evaluations.

Detailed thrust / torque requirement calculations that were

.

developed for each valve group.

The strong plant and corporate support that was necessarily

.

provided to complete a program encompassing the number of MOVs

present at Catawba.

The application of special test programs and state of the art

.

technology.

'

Leadership in addressing industry problems such as increases in

.

actuator ratings.

c.

Conclusions

The NRC inspectors concluded that the licensee had met the intent of GL 89-10 in verifying the design basis ca) abilities of their MOVs.

However, the inspectors identified wea(nesses in certain hardware

capabilities and in some data used in the verifications. The licensee

planned actions to resolve the more significant of these weaknesses

which were documented for comaletion in PIP 0-C97-0421. The PIP

specified that the NRC would ]e notified of the completion status of the

planned actions by December 31. 1997.

The inspectors identified the

completion of these actions as Inspector Followup Item 50-413.414/97-03-

04. Actions to Address Weaknesses in GL 89-10 Implementation.

In

addition, the inspectors also observed a number of licensee strengths.

Enclosure 2

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l

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i

7

Based on the NRC's review of th' Catawba GL 89-10 program and its

1

implementation, and the actiors established by the licensee in PIP 0-

i

C97-0421. the NRC is closing it!, review of the GL 89-10 3rogram at

i

Catawba.

The completion of tha actions identified in t7e PIP will be

assessed as part of the NRC staff's monitoring of the licensee's long-

term MOV program.

E2

Engineering Support of Facilities and Equipment

l

E2.1 Procurement Enaineerina

a.

Insoection Scone (37550)

The inspector reviewed Procurement Engineering activity related to the

purchase and receipt of safety-related replacement parts.

The areas

reviewed included commercial grade dedication (CGD). acceptable

substitutes. receipt inspection acceptance criteria and verification.

resolution of receipt inspection deficiencies, material Quality

Assurance (0A) quality level changes, and salvage / repair of equipment.

T;n. impection included a sample review of licensee 3erformance in these

areas to oetermine if activities were consistent wit 1 applicable

,

regulatory requirements and licensee procedures. Applicable regulatory

'

requirements included 10 CFR 50 Appendix B. FSAR, and the following:

ANSI N45.2.13-1976. 0A Requirements for Control of Items and

Services for Nuclear Power Plants

,

RG 1.123. 0A Requirements for Control of Procurement of Items and

Services for Nuclear Power Plant

GL 91-05. Licensee Conniiercial Grade Pro:urement and Dedications

Programs

b.

Observations and Findinas

i

Technical evaluations for CGD and acceptable substitutes appropriately

'

identified and addressed replacement parts' critical characteristics.

Acceptance criteria for critical characteristics were adequately

addressed and verified at receipt inspection.

Receipt inspectors

demonstrated a strict adherence to the established acceptance criteria

,

and deficiencies were appropriately documented and resolved.

Required

post-installation testing identified in acceptance criteria was

appropriately designated on the item and tracked.

Replacement parts * QA

classification changes were adequately justified.

Procurement

,

Engineering evaluations were technically sound and well documented.

The

interface between the corporate and station procurement engineering

organizations was good

I

The inspector reviewed i.he storage and control of replacement aarts from

the Spare Parts Diesel Generator (SPDG). This diesel was purclased as

Enclosure 2

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. - . . -

. - . _ . _

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. - - - _ .

-. . - . - -

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18

i

,

nuclear safety-related equipment from the Carolina Power and Light

i

Company nuclear program in 1987

The nameplate and purchase

i

documentation indicated that this was the same make, model, and original

n

!

equipment manufacturer as the installed Catawba Emergency Diesel

,

j

Generators (EDGs). The item was designated for QA level.C storage. The

SPDG receiving document, dated August 28, 1987 for requisition 7330-

{

873044, stated that all parts were to be placed on OA hold and that an

i

-

acceptability evaluation or test would be made prior to use. The

i

evaluation was to include a check to assure the physical. chemical and

.

Non Destructive Examination (NDE) test requirements contained in the

!

Duke Power Electrical Diesel Generator Specification CNS 1301.00-00-

j

0002. dated May 15, 1984, were met.

i

,

A walkdown of the SPDG storage building on February 4.1997, identified

4-

i

deficiencies related to the implemented storage requirements and

!

conditions. The storage building was not a OA level C storage area and

!

was not a designated hold area under QA organization control. The

i.

building was controlled by the maintenance organization. The building

i

,

{

was cluttered with other equipment and there was no apparent cleanliness

i

standards implemented.

Parts were located on decking and railings.

4

There was no identification on the SPDG, parts, or vicinity that

designated the equipment or parts as OA hold.

i

t

i

!

A review of issued replacement parts identified deficiencies related to

'

the control of material and parts from the SPDG.

The walkdown noted

i

that numerous parts were missing from the SPDG.

These included the

,

turbocharger, ten cylinder \\ piston casing assemblies (power packs), shaft

!

driven oil and cooling water pumps, and various piping and valves.

There was no documentation available to demonstrate that the required

i

,

i

j

evaluations against the applicable Duke Power specification were

i

performed and no documentation of final 0A disposition of these parts.

i

'

A receipt inspection report salvage evaluation dated February 21, 1996,

i

CN 38501. issued a fuel rack linkage spring from the SPDG as a

'

replacement part for an installed EDG. This was the only 0A final

i

disposition document located and it did not clearly specify the

l

acceptance criteria used nor reference the Duke Power EDG specification.

,

The inspector reviewed the licensee's procurement program and noted that

i

there were approved procedures for storage and control of OA condition

i

equipment which spaaned the ten year period that the SPDG has been on

=

i

site. These included QAG-1, Receipt Inspection, and Control of OA

l

Condition Materials. Parts, and Components. Except Nuclear Fuel dated

June 5,1991: NPP-311. Receipt. Inspection, and Testing of 0A Condition

<

i

Commodities, dated March 7. 1996: and NPP-315 Certification of Items

l

from Non-0A to 0A Condition and Re-certification of Salvageable Items.

dated July, 22, 1996.

These procedures required that designated QA hold

,

items were to be stored in a OA controlled hold area and a final 0A

-

disposition performed prior to release.

The storage and material

i

control deficiencies discussed in this section are identified as

j

Violation 50-413.414/97-03-01. Failure to Follow Procedure for Receipt,

Enclosure 2

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19

Inspection, and Control of 0A Condition Materials, Parts, and

Components.

During the inspection, the licensee documented this issue

on PIP 0-C97-0322 and initiated actions to establish OA level C

cleanliness requirements for the SPDG storage building.

The inspector reviewed the EDG maintenance activities ard EDG

maintenance history to determine if adequate barriers and performance

information were.available to address potential EDG operability concerns.

related to this issue. The power packs had been refurbished and

recycled in the installed EDGs over several years with no failures.

Periodic testing of the EDGs would have identified degraded performance

due to deficient components.

Current maintenance procedures require

Quality Control (OC) verification of QA acceptance tags on all safety-

related replacement parts. Maintenance history did not indicate

equipment performance problems due to installation of degraded

components of the type removed from the SPDG, Maintenance barriers and

performance history indicated that the EDG operability had not been

degraded by the installation of SPDG replacement parts.

c.

Conclusion

Procurement Engineering performance related to identification, upgrade

and validation of safety-related replacement parts was generally good.

Engineering evaluations were technically sound and well documented.

Violation 50-413,414/97-03-01 was identified for failure to follow

procedures for the storage and control of SPDG replacement parts.

Maintenance practices and EDG performance history indicated that the

material control deficiencies did not degrade the operability of the

installed EDGs.

E2.2 Enaineerina Backloas

-

a.

Insoection Scooe (37550)

Engineering was actively pursuing backlogs in PIPS, Maintenance Work

Orders Temporary Station Modifications, and Operator Work-Arounds.

The

i

'

inspector reviewed engineering's efforts in these areas.

b.

Observations and Findinas

The engineering department was active in the identification and

reduction of backlogs in their own work areas, as well as those items

affecting efficient operation of the facility. These items included

operator work-arounds, captured in the Top Plant Work-Around Problem

Resolution (WAPR), and Major Equipment Problem Resolution (MEPR) items.

The inspectors reviewed the outsta.nding lists of these items.

The inspectors reviewed the licensee's Top Equipment Problem Resolution

(TEPR) process.

This process provided for the identification and

management focus on important and long-standing plant equipment

Enclosure 2

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20

problems.

The TEPR process includes MEPR and WAPR listings of

long-standing repetitive or significant equipment problems and operator

work-arounds.

Discussions were held with members of the maintenance,

modifications and operations staffs to determine the adequacy of

]

engineering support to those organizations.

,

.

c.

Conclusions

The inspector concluded that the engineering department was providing

aggressive and effective support to the operations, maintenance and

J

modification departments and were keeping the number of open items at an

acceptably low level.

The TEPR process was identified as a strength by

'

the inspector.

,

'

E7

Quality Assurance in Engineering Activities

l

.

E7.1 Procurement Enaineerina

'

,

a.

Insoection Stone (37550. 40500)

.

The inspector reviewed the licensee's self-assessment activities

j

associated with procurement engineering processes. Applicable

'

regulatory guidance was provided by 10 CFR 50. Appendix B.

The

4

following Procurement Engineering self-assessments were reviewed:

-

CTS 08-96. Catawba OA Receiving Assessment

4

CTS 07-96. NPP-212-Acceptable Substitutes Procedure

-

j

-

CTS 06-96 Catawba OA Services Assessment

i

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SA 96-06. Catawba Commodities and Facilities Work Control

j

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SA 96-02(GO), Consolidated Performance Audit

,

b.

Observations. Findinas. and Conclusion

The scope of the self-assessments was adequate to evaluate performance

of the procurement activity under review.

Findings were appropriately

documented and tracked for resolution.

E7.2 Quality Assurance and Self-Assessments

.

a.

Inspection Scooe (37550. 40500)

The inspectors reviewed completed self-assessments in the engineering

department and corrective actions asr ' ted with those assessments.

Enclosure 2

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_ _ _ - . - - . - . - - . - . - - - - . _ - .

_

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b.

Observations and Findinas

i

l

The inspectors reviewed selected engineering department self-assessments

and corrective actions. These included:

,

-

MOD-01-96, Quality of limited drawings to assure accuracy and

quality

.

-

MOD-02-96, Corrective Minor Modification Process

M00-10-96, Flow Diagram Assessment

-

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MOD-04-96, Assess all aspects of at least two modifications

I

i

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MOD-08-96, Review modifications in progress and interim as-built

'

drawings

-

CER-03-96. Review three calculations for lead shielding

".

-

CER-07-96 I&C staff understanding of ICS-A-20. Instrumentation

Installation Standards

,

l

CER-08-96. Quality of engineering calculations

-

i

3

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CER-12-96, Assessment of snubber program

1

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CER-14-96, Vital battery modification assessment

-

MSE-03-96, Self-assessment of IST program

i

-

MSE-04-96, Self-assessment of safety-related heat exchangers

-

MSE-05-96. Technical support program execution

l

c.

Conclusions

'

The inspectors concluded that the engineering department was performing

effective self-assessments.

The assessments were performed by

knowledgeable individuals and were, for the most part.of the proper

!

depth. Corrective actions planned for assessment findings were

l

comprehensive and of adequate scope.

4

i

l

Enclosure 2

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E8

Miscellaneous Engineering Issues (92903)

E8.1 Review of Licensee Actions to Imorove Service Water Quality

l

l

a.

Inspection Scone

The cover letter for Inspection Report 94-17 required the licensee to

- describe actions planned or taken to address poor service water quality

l

and the clam population.

While this issue did not require inspector

l

followup, the inspector did review the licensees actions to date to

improve service water quality.

b.

Observations and Findinas

,

1

!

The licensee had established a testing 3rogram to' determine the most

l

effective means of addressing these pro)lems.

Based on this testing,

the licensee had determined that dispersant addition into the service

water pump suction pit would reduce service water piping corrosion due

to silt deposition.

The licensee )lanned to implement a full-scale test

,

ir the near future.

The licensee lad also determined that a flocculent-

'

addition was more effective at reducing silt deposition than the

dispersant.

The licensee was in the process of getting state

l

environmental approval to use the flocculent. The licensee planned to

use the flocculent once state approval was obtained.

I

In July 1996, the licensee informed the NRC that injection of a biocide

!

resulted in unacceptable corrosion rates for service water piping. The

l

licensee had concluded that an active biocide program would not provide

l

an additional benefit than already provided by the flushing program:

therefore, biocide injection would not be pursued. The licensee was

continuing a program of monthly flushes on portions of the service water

f

system susceptible to clam infestation.

The service water (RN) to

'

component cooling and the service water to auxiliary feedwater (CA)

-

piping flush procedures directed that a representative sample be

collected during these routine flushes to determine the clam population

in the service water system. Additionally. Procedure PT/1(2)/A/4200/59.

'

RN to CA Piping Flush, retype 13. directed additional flushing

depending on the number of clams found in the sample. The inspector

reviewed the data taken for both component cooling and auxiliary

feedwater flushings from December 1992 to December 1996.

Except for the

summer months (June through September), the clam count in the sample was

t

'

consistently five or less.

During June through September, the maximum

clam count was 28.

The inspector noted these values were consistent on

i

an annual basis.

c.

Conclusions

The inspector concluded that the monthly flushing program was effective

in controlling clam population in service water piping. The

I

effectiveness of the dispersant could not be assessed.

l

Enclosure 2

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23

3

E8.2 (Closed) Insoector Followuo item (IFI) 50-413.414/94-17-01: Analysis of

Skewed SNSWP Discharge Flow

Paragraph 4 a. of NRC Inspection Report 50-413.414/94-17 stated that

certain plant configurations could allow the heated service water

discharge to the Standby Nuclear Service Water Pond (SNSWP) to reenter

4

the service water intake before any significant cooling had occurred.

This "short cycling" would reduce the heat removal capability of the

.

i

service water system.

The licensee submitted a new analysis of the

SNSWP which addressed the skewed discharge flow. The NRC accepted the

licensee's new analysis and issued an SER on November 19, 1996.

Accordingly, this IFI is closed.

E8.3 (Closed) Violation (VIO) 50-413.414/94-17-02: Failure to Properly

Translate Regulatory Requirements into Specifications, Drawings, and

Procedures

Example one of this violation detailed findings that the instrument

inaccuracies for SNSWP temperature and level were not included,

,

resulting in the SNSWP exceeding the maximum allowable temperature of

'

100 F.

The licensee had replaced the temperature sensor and performed

loop accuracy Calculation CNC-1210.04-00-0067. Loop Accuracy Calculation

.

for the Standby RN Pond Temperature.

Based on that calculation, the

licensee determined that loop uncertainty was 1.03 F for the control

i

room indicator and was 1.04 F for the Operator Aid Com] uter (OAC).

'

These values represented a substantial reduction from tie previous

1

uncertainties of 3.4 F and 2.13 F, respectively stated in Inspection

-

Report 94-17.

The licensee also performed Calculation CNC-1210.04-00-0069 Loop

i

Accuracy Calculation for Standby Nuclear Service Water Pond Level - Loop

RN7350.

The loop uncertainty for SNSWP level was determined to be 0.43

ft for the control room indicator and 0.34 ft for both the alarm and

3

the OAC.

These values represented an increased uncertainty from the

l

previous values of 0.202 ft and 0.157 ft, respectively. The licensee

2

attributed this increased uncertainty to rescaling of the level sensor

'

'

when SNSWP level was raised by an additional three feet. Although the

f

SNSWP level uncertainties increased, the inspector concluded that the

additional three feet compensated for this increase.

.

l

Based on the uncertainty reduction for the SNSWP tem)erature instrument

loop and the additional three feet of SNSWP level, t1e inspector

concluded that the inclusion of instrument uncertainties would not

'

,

result in exceeding the SNSWP maximum temperature limit.

j

The inspector reviewed both calculations and found that the licensee had

used vendor-supplied data where provided.

Since sensor drift data was

'

not provided for the temperature or level sensors, the licensee had

assumed that sensor drift was equal to sensor calibration accuracy

according to EDM-102. Instrument Setpoint/ Uncertainty Calculations.

Enclosure 2

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24

revision 1.

However EDM-102 stated that this assumption was valid only

for electronic modules and indicators.

EDM-102 stated that sensor drift

for )rocess sensors should not be assumed to be ecual to the sensor

cali) ration accuracy unless supported by publishec or actual data. The

licensee reviewed data published in NUREG/CR-5560, Aging of Nuclear

Plant Resistance Temperature Detectors, and found that sensor drift for

the type of temperature sensor used was greater than that assumed. The

total loop uncertainty calculated using the revised value for sensor

drift was 1.06 F for the control room indicator and the OAC.

Since the

licensee was using a conservative value of 1.1 F. the higher

temperature sensor drift value had a small effect. The inspector also

found the same assumption was used for Calculation CNC-1210.04-00-0069.

The licensee provided field calibration results for the SNSWP level

transmitter from May 1988 to January 1996.

Using the field calibration

data, the inspector calculated that sensor drift was about 2.0% of

calibrated span.

Calculation CNC-1210.04-00-0069 assumed that sensor

drift was 0.51% of calibrated saan. The inspector recalculated the

total loop uncertainties using tie 2.0% of calibrated span value and

found that the overall effect was small.

The inspector also noted that

the level transmitter had been replaced in January 1996.

Since the

SNSWP level loop calibration frequency was 18 months, no recent data was

available to determine the sensor drift for the new transmitter.

Discussions with the licensee's engineers indicated some confusion about

the intent of the allowance of using sensor calibration accuracy as

sensor drift.

EDM-102 stated that sensor drift should not be assumed

equal to device reference accuracy unless supported by published or

historical data.

While this statement appeared to discourage equating

sensor drift to device reference accuracy, it does not expressly forbid

making such an assumption.

Also. EDM-102 defined five instrumentation

categories to aid in the determination of the type of uncertainty

analysis required.

Since the licensee had recently initiated efforts to

apply the EDM-102 instrumentation categories plant-wide, the licensee

had not determined which instrumentation category the SNSWP temperature

and level instrument loops would fall into.

The inspector considered

'

this determination important due to the potential impact on instrument

loop calibration 3rocedures and SNSWP operability determinations.

Failure to use pu)lished or actual data to determine sensor drift as

indicated by EDM-102 could result in nonconservative calibration

acceptance criteria. As stated previously, the licensee had initiated a

programmatic review to apply the EDM-102 instrument categories to all

plant instrumentation.

E8.4 (Closed) InsDector Followuo Item 50-413.414/94-17-03: Short Discharge

Leg Flow Verification

Paragraph 4 c. of Inspection Report 94-17 stated that silt accumulation

near the long service water discharge aath indicated that the service

,

water discharge flow to the long and s1 ort service water discharge paths

was not evenly split contrary to the engineering analysis.

The licensee

Enclosure 2

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_ - . - . _ -

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25

'

conducted short discharge leg flow verification as part of the SNSWP

'

reanalysis. The NRC accepted the licensee's reanalysis and issued a SER

.

on November 19. 1996.

E8.5 (Closed) Insoector Followuo Item 50-413.414/94-17-10: Flush Program

Improvements

,

As documented in Inspection Report 96-10 and 96-16. the licensee had

radiographed both trains of service water supply to auxiliary feedwater

,

piping foe Units 1 and 2.

However, the licensee did not document the

as-found condition for the 'A' train lines and could not produce the

i

radiographs.

The licensee took additional radiographs of this piping

l

near valve RN-250A for both Units 1 and 2 on December 30. 1996, and

October 28. 1996. respectively.

The inspector reviewed the radiographs

j

and concluded the piping was not fouled.

E8.6 (Closed) Insoector Followuo Item 50-413.414/94-17-14: Quantifying Flow

l

Measurement Error

.

J

Paragraph 7.e.(3) of Inspection Report 94-17 stated that service water

i

flow measurements were potentially affected due to fouling and

!

corrosion.

The inspector reviewed data obtained during heat exchancer

performance testing and service water pump in-service testing for

indications of flow measurement inaccuracies.

The containment spray

1

heat exchangers had an orifice type flow element that provided both

,'

control room and local flow indication. The inspector reviewed

Jerformance data from March 1993 to present for the 1B containment spray

leat exchanger. Analysis of the data found that nearly identical

j

temperature differences could be correlated to about the same flowrate

'

over the entire 3eriod. This indicated there had been no substantial

j

degradation in t1e flow sensing element over the period reviewed.

Annubars were used to measure service water pump flow during in-service

testing.

The inspector reviewed the service water pump in-service test

data from April 1995 through December 1996.

The licensee also provided

i

a trend of in-service test flow data for service water pumps 1B and 2A

'

obtained from September 1994 through November 1996. The trend data was

,

i

consistent with a slight flow increase noted after all four annubars

j

were cleaned in late 1996. This indicated that the flow measured by the

annubars was insignificant 1y affected by fouling.

The inspector also

reviewed the in-service data and found that the measured flow only

,

1

!

differed about 0.5% between in-service test periods.

Based on che

!

inspectors review of this data, the inspector concluded that any annubar

fouling was not adversely effecting flowrate measurement.

Ultrasonic flow measurement was used to verify room cooler flowrates,

but was not relied on for operability determinations or cooler

performance calculations. The licensee stated that ultrasonic flow

-

measurement was no longer used due to difficulties installing the

equipment although procedures permitted its use as an option.

Enclosure 2

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26

Based on the information provided to the inspector, the inspector

,

concluded that flow sensor fouling was not contributing significant

errors to service water flow measurement.

E8.7 (Closed) Unresolved Item 50-413.414/94-17-16: Split Flow Orifice Flow

,

Resistance Factor

1

This Unresolved Item was Example 2 of Violation 94-17-02.

SNSWP split

flow was addressed as part of the licensee's SNSWP reanalysis. The NRC

had issued a SER on November 19. 1996, accepting the licensee's

reanalysis.

,

E8.8 NRC Information Notice 92-18:

Potential For Loss Of Remote Shutdown

Capability During A Control Room Fire

a

1'

Information Notice (IN) 92-18 alerted licensees of the potential for

loss of safe shutdown capability during a fire in the control room.

The

IN reported that hot shorts occurring during the fire could potentially

cause the MOVs needed for safe shutdown to go to a stall condition.

This stall could result in valve and/or actuator damage that would

preclude use of the MOVs for shutdown.

The inspectors reviewed the licensee's April 8.1992, internal response

for IN 92-18 which concluded that a control room fire would not affect

Catawba's ability to open feedwater valves to provide safe shutdown.

The response indicated that the motors for the needed valves were wired

downstream of the control room, such that their operation from the safe

gutdownfacilitywouldnotbeadverselyaffectedbyacontrolroom

tire.

During the current inspectiori, the licensee stated that their original

determir.3 tion regarding the affects of a control room fire had been

reviewd and was still considered valid.

However, they decided to

reexamine the issue relative to the impact of a fire in other areas.

such as the cable spreading room.

The reexamination was initiated

through PIP 0-G97-0059.

,

E8.9 (Closed) IFI 50-413.414/96-02-01:

Reliance on Testing of a Single Valve

to Support the Capabilities of a Group

This issue identified a concern that the licensee relied on the results

of a single test in establishing the thrust requirements for some groups

of GL 89-10 valves and that, in one instance, the adecuacy of even the

one test was uncertain.

In a GL 89-10 assessment concucted during the

current inspection and documented in El.1 (Thrust Requirements for

Groups) above. the ins)ectors catermined that this issue was being

adequately addressed t1 rough al action item in PIP 0-C97-0421.

IFI 50-413.414/97-03-04 Actions to Address Weaknesses in GL 89-10

Implementation, was opened in Section E1.3 to track the licensee's

completion of this and other PIP actions.

Enclosure 2

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27

E8.10 (Closed) 50-413.41.4/96-02-02:

Stem Coefficient of Friction for MOV

Opening Setting Calculations

i

The issue identified by this item was evaluated during the current

inspection, as described in Section E1.3 (Stem Friction Coefficient).

The issue was considered resolved through the licensee's increase of the

1

MOV opening stem friction coefficient value to 0.20 and the licensee's

evaluation provided by PIP 0-C95-0879.

E8.11 (Closed) 50-413.414/96-02-03:

MOV Opening Thrust Requirement

Uncertainties

The issue identified by this item was evaluated during the current

inspection. as described in Section E1.3 (Diagnostic Equipment

Uncertainties). The issue was considered resolved by the inspectors

through actions documented in PIPS 0-C95-0295 and -0879.

E8.12 (Closed) 50-413.414/96-02-04:

Unpredictable Behavior Experienced in

Pressurizer PORV Block Valve MOV Testing

The issue identified by this item was that the prototype PORV block

valve tested by the licensee exhibited unpredictable behavior prior to

flow isolation during a blowdown closing test. This test was conducted

j

as part of the licensee's GL 89-10 program.

In the current inspection,

l

the inspectors reviewed a licensee engineering evaluation of this test,

i

which was described in their "3-Inch Anchor Darling Double-Disk Gate

Valve Summary Test Report." The inspectors found that the report

1

provided satisfactory evidence that the unpredictable behavior exhibited

in the one test was due to a unique, unsatisfactory packing

configuration (not applicable to the licensee's installed valves). The

inspectors considered the issue resolved.

IV. Plant Support

R2

Status of Radiological Protection and Control (RP&C) Facilities and

,

Equipment

R2.1 Comoliance with 10 CFR 70.24 Criticality Accident Reauirements

a.

Insoection Scone (71750)

.

The inspector reviewed the licensee's compliance with 10 CFR 70.24

!

criticality accident requirements and associated PIP documentation in

i

response to the NRC staff's recent identification that several licensees

'

in the industry were not in conformance with the requirements of 10 CFR 70.24. nor had they been granted exemptions to this regulation.

Enclosure 2

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b. Observations and Findinas

Both Units at Catawba have radiation monitoring systems installed in the

new fuel unloading and storage areas.

The inspector verified by

reviewing PIP documentation that the monitoring instrumentation meets 10 CFR 70.24(a) requirements (PIP 0-C97-0192).

In addition to criticality

'

accident monitoring instrumentation and alarm capability requirements

the licensee is required by 10 CFR 70.24(a)(3) to have emergency

<

procedures in place for evacuating personal when a criticality alarm

J

sounds and to conduct evacuation drills. The licensee has not developed

procedures or conducted drills to meet the provisions of 10 CFR 70.24(a)(3).

The licensee has initiated a corrective action as part of

the PIP referenced above to evaluate compliance with emergency procedure

requirements.

5

Both units at Catawba were previously granted exemptions from 10 CFR 70.24 requirements by the NRC staff as part of their special nuclear

material license during construction.

The licensee did not submit a

request to continue the exemption when the special nuclear material

licenses expired upon issuance of operating licenses on January 17

1985, and May 15, 1986, for Unit 1 and Unit 2, respectively.

The

licensee has not complied with the (a)(3) Sortion of the regulation

since these dates. On February 4, 1997, tie licensee submitted a

,

request for an exemption to the requirements of 10 CFR 70.24.

c. Conclusions

.

The licensee has existing radiation monitoring systems installed in the

4

Unit 1 and Unit 2 new fuel unloading and storage areas which are capable

of alarming should an accidental criticality occur. The licensee has

i

not developed emergency procedures or conducted drills to ensure

personnel are withdrawn to an area of safety when an alarm sounds.

The

<

'

5

failure to implement criticality accident emergency procedures and to

conduct evacuation drills is characterized as Violation 50-413.414/97-

03-02, Noncompliance with 10 CFR 70.24(a)(3) Criticality Accident

'

Requirements Regarding Evacuation Procedures and Drills.

The licensee

has submitted a request to the NRC staff for an exemption to the

<

requirements of 70.24.

V. Manaaement Meetinas

4

X1

Exit Meetina Summarv

The inspectors ] resented the inspection results to members of licensee

l

management at t1e conclusion of the inspection on February 20, 1997.

The licensee acknowledged the findings presented.

No proprietary

.

information was identified.

.

Enclosure 2

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29

PARTIAL LIST OF PERSONS CONTACTED

j

Licensee

i

Bhatnagar, A. , Operations Superintendent

Cline. T., Senior Technical Specialist, General Office Support

Coy, S., Radiation Protection Manager

Edwards,

T., Valve Group Supervisor

Forbes, J.,

Engineering Manager

Harrall

T. , IAE Maintenance Suparintendent

,

'

Helmers. C. . Engineer, Valve Group

Henkel

H. , Engineer Valve Group

Kelly, C., Maintenance Manager

Kimball, D., Safety Review Group Manager

'

Kitlan, M.. Regulatory Compliance Manager

1

McCollum, W., Catawba Site Vice-President

1

Nicholson, K., Compliance Specialist

'

Peterson, G., Station Manager

Propst. R.. Chemistry Manager

'

Rogers, D.. Mechanical Maintenance Manager

'

Simril, J. , Engineer. Valve Group

Smith. C., MOV Program Lead, General Offico Support

Tower, D., Compliance Engineer

,

.

}

}

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k

Enclosure 2

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h

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30

INSPECTION PROCEDdRES USED

IP 37550:

Engineering

IP 37551:

Onsite Engineering

-

IP 40500:

Self Assessment

l

IP 61726:

Surveillance Observation

IP 62707:

Maintenance Observation

IP 71707:

Plant Opera ~ ions

IP 71750:

Plant Suppor *. Activities

'

IP 92902:

Followup - Mcintenance

IP 92903:

Followup - En 'ineering

TI 2515/169: GL 89-10 MOV frogram Review

.

.

ITEMS OPENED. CLOSED. AND DISCUSSED

',

Doened

i

50-413.414/97-03-01

VIO

Failure to Follow Procedure for Receipt.

Inspection, and Control of 0A Condition

Materials., Parts, and Components (Section

E2.1)

50-413.414/97-03-02

VIO

Noncompliance with 10 CFR 70.24(a)(3)

Criticality Accident Requirements

.

Regarding Evacuation Procedures and Drills

l

(Section R2.1)

.

!

50-414/97-03-03

NCV

Mispositioned Nitrogen Backu) Supply

Valves Result in Degrading T1e Function of

!

SG PORVs (Section M8.1)

50-413.414/97-03-04

IFI

Actions to Address Weaknesses in GL 89-10

Implementation (Section El.3)

Closed

!

'

50-413.414/94-17-01

IFI

Analysis of Skewed SNSWP Discharge Flow

(Section E8.2)

.

4

'

50-413.414/94-17-02

VIO

Failure to Properly Translate Regulatory

i

Requirements into Specifications.

Drawings, and Procedures (Section E8.3)

,

'

50-413.414/94-17-03

IFI

Short Discharge Leg Flow Verification

(Section E8.4)

50-413.414/94-17-10

IFI

Flush Program Improvements (Section E8.5)

50-413.414/94-17-14

IFI

Quantif.fing Flow Measurement Error

(Section E8.6)

'

Enclosure 2

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50-413.414/94-17-16

URI

Split Flow Orifice Flow Resistance Factor

(Section E8.7)

50-414/96-20-01

URI

Mispositioned Nitrogen Backup Supply

Valves Result in Degrading The Function of

Steam Generator Power Operated Relief

Valves (Section M8.1)

50-414/94-02, Rev 1

LER

Reactor Trip Breakers Opened Due to

Component Failures (Section M8.2)

50-413.414/96-02-01

IFI

Reliance on Testing of a Single Valve to

Support the Capabilities of a Group

(Section E8.9)

50-413,414/96-02-02

IFI

Stem Coefficient of Friction for MOV

Opening Setting Calculations (Section

E8.10)

50-413,414/96-02-03

IFI

MOV Opening Thrust Requirement

4

Uncertainties (Section E8.11)

50-413,414/96-02-04

IFI

Unpredictable Behavior Experienced in

Pressurizer PORV Block Valve MOV Testing

(Section E8.12)

l

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Enclosure 2

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LIST OF ACRONYMS USED

'

ANSI

-

American National Standards Institute

!

CGD

-

Commercial Grade Dedication

CFR

-

Code of Federal Regulations

CNS

-

Catawba Nuclear Station

DPC

-

Duke Power Company

ECCS -

Emergency Core Cooling System

EDG

-

Emergency Diesel Generator

EDM

-

Engineering Directives Manual

FSAR -

Final Safety Analysis Report

GL

-

Generic Letter

IAE

-

Instrument and Electrical

IFI

-

Inspector Fullowup Item

IR

-

Inspection Report

IST

-

In-Service Test

LER

-

Licensee Event Report

.

MEPR -

Major Equipment Problem Resolution

MOV

-

Motor Operated Valve

NCV

-

Non-Cited Violation

NDE

-

Non-Destructive Examination

NS

-

Containment Spray System

'

NSRB -

Nuclear Safety Review Board

NSM

-

Nuclear Station Modification

0AC

-

Operator Aide Computer

.

QA

-

Quality Assurance

OC

-

Quality Control

.

PIP

-

Problem Investigation Process

,

PORV -

Power Operated Relief Valve

-

RCS

-

Reactor Coolant System

4

RG

-

Regulatory Guide

>

RHR

-

Resididual Heat Removal

,-

RP&C -

Radiological Protection & Control

RTB

-

Reactor Trip Breaker

SER

-

Safety Evaluation Report

SG

-

Steam Generator

~

SNM

-

Special Nuclear Material

SNSWP -

Standby Nuclear Service Water Pond

SPDG -

Spare Parts Diesel Generator

SSF

-

Safe Shutdown Facility

SSPS -

Solid S. ate Protection System

TDAFW -

Turbine Driven Aux. Feedwater Pump

TEPR -

Top Equioment Problem Resolution

TI

-

Tem3orary Instruction

l

TS

-

Tec1nical Specifications

UFSAR -

Updated Final Safety Analysis Report

.

i

URI

-

Unresolved item

US0

-

Unreviewed Safety Question

VIO

-

Violation

WAPR -

Top Plant Work-Around Problem Resolution

WO

-

Work Order

i

Enclosure 2