IR 05000219/1993025

Insp Rept 50-219/93-25 on 931018-22.No Violations Noted. Major Areas Inspected:Design Mods & Engineering Support

ML20058B675
Person / Time
Site:	Oyster Creek
Issue date:	11/09/1993
From:	Eapan P, Gregg H NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I)
To:
Shared Package
ML20058B654	List: IR 05000219/1993025 ML20058B651
References
50-219-93-25, NUDOCS 9312020165
Download: ML20058B675 (8)

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U. S. NUCLEA'R REGULATORY COMMISSION

REGION I

REPORT / DOCKET NOS. 50-219/93-25 LICENSE NO.

DPR-16 L

r LICENSEE:

GPU Nuclear Corporation l

FACILITY NAME:

Oyster Creek Nuclear Generating Station l

INSPECTION AT:

Corporate Engineering Office, Parsippany, New Jersey

l INSPECTION DATES:

October 18 - 22, 1993 INSPECTOR:

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" Harold Gregg, Seitior Reac'or Engineer

Systems Section EB, DRS tt[f [f g APPROVED BY:

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Plackeel K. Eapen, Chief I Date Systems Section, EB, DRS-l l

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$DR ADOCK 05000219 PDR

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Areas inspected: Design modifications and engineering support for Oyster Creek activities.

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Inspection Results: Corporate engineering planning of design modifications have shown good results. The drywell corrosion /sandbed removal project was exceptionally well-planned and

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performed. Good progress continues in design bases document reconstitutions and in

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I performing design modifications in-house. Quality assurance assessments of engineering have been performance-based and meaningful.

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DETAILS j

i 1.0 DESIGN CIIANGES AND ENGINEERING SUPPORT (37700)

I The objectives of this inspection were to review the licensee's corporate engineering activities in support of design changes and modifications, and to assess the licensee's safety i

perspective related to these changes. Other new and ongoing corporate engineering programs were also assessed from a safety and performance perspective.

2.0 DESIGN MODIFICATIONS Several selected recently installed or planned modifications were reviewed by the inspector to

assess the adequacy of the implementation of the licensee's modification program. -In particular, the inspector reviewed design descriptions, drawings, engineering calculations and installation test packages to verify compliance with the applicable NRC requirements, as detailed below:

Drywell Corrosion Control Project (BA 402950). This was a major work effort

related to external drywell wall corrosion, wall thickness monitoring and sandbed removal that spanned the 1990 - 1993 time period. During the 14R outage, ten 20" diameter access manways were bored through the shield wall. Also, there was removal of the sandbed, removal of the corrosion from the drywell exterior and coating it with epoxy, and repair of the sandbed floor drainage system.

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This was a major engineering accomplishment that exhibited excellent engineering

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direction and management involvement. Visual inspection of the coating and ultrasonic measurements of the wall thickness will be conducted during the 15R-(

outage to verify that corrosion has been completely stopped. As a result of this

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project, the licensee's reanalyses established 44 psig at 292 F as the drywell post-accident design conditions. The licensee's safety evaluation and TS change request

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for these new post-accident conditions were comprehensive, and NRC approval was

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obtained for the requested change.

Deletion of Containment Spray Auto Start logic (BA 402894). This modification

deleted the automatic start logic of containment spray and emergency service water.

This resolved longstanding single failure concerns, eliminated possible inadvertent j

spraying of the drywell that could result in significant safety consequences, and j

improved operator capability to implement emergency operations procedures without lifting leads or installing jumpers.

Isolation Condenser Piping Outside Drywell (BA 402900). This modification utilized

the mechanical stress improvement process on all welds outside the drywell. The process plastically deforms welds and adjacent base metal and results in reversal of the residual welding stresses.

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4 Control Room Recorders Replacement (BA 402910A). Corrective actions to remedy

various human factor control room recorder deficiencies identified by the licensee's

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control room design review were completed. This modification replaced and l

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relocated control room recorders.

l Containment Isolation Valve (Appendix J) Replacement (BA 402946). This

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modification installed additional valves and spectacle fianges to enable testing of containment isolation valves in the same direction as required to perform their safety

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The inspector performed a selected review of design modifications planned for the 15R outage to assess the adequacy of the preparation and planning for modifications. The inspector reviewed the conceptual design packages, engineering calculations, and installation instructions to verify compliance with the applicable NRC requirements, as detailed below:

Emergency Diesel Generator Governor Upgrade (BA 402961). This modification is

to eliminate winter / summer rack settings, prevent operation in excess of rating and assure operation at rated load. The new governor controls are intended to resolve past difficulties in securing from fast starts.

Feedwater System Modifications, Phase II (BA 402901). This modification is to e

replace the existing GEMAC feedwater control system, which has replacement parts problems, does not have on-line calibration and maintenance capability, and has been the cause of trips at other plants. The new system by AECL, Canada is current state-of-the-art, has self diagnostic capabilities, and will enable better control at all operating conditions.

Recirculation Flow Scram Electronics Replacement (BA 402966). This modification e

is to replace sixteen existing analog modules with new digital electronic equipment that provides more stable and accurate performance.

"B" LP Turbine Pressure Plate Removal and Bucket Installation (BA 403010). This e

modification is to repair the cracking problem identified in outage 13R that required removal of low pressure blades that resulted in lost power. Longer blades of improved materials are to be installed.

Core Spray System Improvements (BA 403011). This modification is to install loop

seals in the core spray minimum recirculation lines to eliminate the potential of water

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hammer during a small break LOCA.

i Each of the planned 15R modifications were noted to result in safety benefits or plant improvements. The drywell sandbed removal was viewed as an outstanding and well-planned i

engineering accomplishment that also had strong management oversigh.

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l 3.0 DESIGN BASIS DOCUMENTS

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The licensee's design bases document (DBD) reconstitution program was very effective and continues to provide a positive safety influence. Currently, fourteen DBDs were completed, and two more arc. in the comment resolution phase. Core spray, main feed / condensate, containment program (Phase 1), and drywell cooling were completed in 1992. In 1993, i

radiation monitoring was completed, with containment program (Phase II), and control rod drive and hydraulics in the comment review phase.

DBDs have resulted in upgrades and some changes to operating procedures, surveillances, FSAR, drawings, and calculation reviews and upgrades. The containment spray DBD required removal of auto initiation logic and mode selector switch changes to bypass valve alignment so as not to inadvertently inject into the drywell. The standby gas / secondary containment DBD identified absent wall blowout panels and the core spray DBD required i

rework of piping stress calculations. A finding identified in the licensee's core spray SSFI resulted in a relief valve replacement and setpoint change.

4.0 CONFIGURATION CONTROL Improvements were made for the timely revision of Priority 2 drawings (connection diagrams and panel diagrams). These drawings are now required to be updated to incorporate individual revision within six months. Past practice to update drawings after six posted revisions was problem prone.

The drawing rollup practice was simplified. Construction drawings are required to be updated to reflect field changes and to eliminate multiple postings.

The engineering / component data base information has been expanded from 25,000 to 65,000 components and the original 33 information fields expanaed to several hundred. Information includes EQ, ISI, reference drawings, switches, relays, motors circuit breakers, preventive and corrective maintenance, instrument calibration, setpoints, NPRDS, ISI supports, and electrical load listings.

5.0 ENGINEERING ACTIVITIES IN SUPPORT OF SITE Corporate engineering continued to display effective leadership in performing almost all 14R modifications in-house. The use of contract personnel has been virtually eliminated and the expertise is maintained in-house. Support of modification activities during the 14R outage contributed to a notably, successful outag _

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l There are good communications between corporate and site engineering and cooperation was l

evident in the new systems performance team meetings and in the long-term planning of the j

site systems engineers.

6.0 ENGINEERING STAFFING The total technical functions staff has 465 positions, of which 101 have specific Oyster Creek assignments, 87 have TMI assignments, and 46 have multiple duties and are at the Reading laboratory. The nuclear engineering and design staff was recently increased by three engineers and currently totals ninety. Additionally, more emphasis has been directed to support valve activities and the erosion / corrosion program.

7.0 TECHNICAL FUNCTIONS ASSIGNED TASK ACTION ITEMS Engineering periormance in Task Action item scheduled completions continue to show improvement with only 4% of missed dates. The backlog of action items has been markedly reduced to 291 at present (from 360 on January 31,1993) and displays a concerted corrective action management effort.

8.0 QA AUDITS OF ENGINEERING Recent corporate QA audits of engineering reviewed by the inspector have been improved because they were more technically performance-based than compliance-based. Because of good technical findings identified in audits and team-building meetings between technical functions and quality assurance personnel, there has been an improved perception of the technical capability of QA. There was a high level of management interest in QA issues and two QA presentations are made to the board of directors per year and four presentations for each site are made to the General Office Review board each year.

Recent audit Endings were critical of the use of Technical Functions Assigned Action Items as a mechanism to resolve operability issues instead of the in-place NCR system, and lack of documentation on initial screening resolutions.

9.0 ENGINEERING TRAINING Two types of training are given to engineers. They are the engineering support personnel program that includes orientation, position specinc job task training, and continuing training for varied topics as needed. The other is the engineer development program for new engineers that include a year of technical course and rotational work assignments and a year at a site.

In addition, there are many opportunities for training in improving performance and supervisory techniques and general engineering topical training for all engineers. The licensee's personnel are involved with Boiling Water Reactor Owners Group and industry standards group,

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10.0 EXIT MEETING -

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The inspector met with the licensee's representatives at the conclusion of the inspection to summarize the findings of this inspection. Attendees at the exit meeting are listed in Attachment 1. The licensee acknowledged the inspector's findings.

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ATTACIIMENT 1 PERSONS CONTACTED GPU Nuclear A. Abramovici Mechanical Components Manager

• B. Elam Mechanical Engineering Director

• J. Flynn Project Manager

• J. Fornicola Licensing and Regulatory Affairs Director J. Knubel Director, Quality Assurance M. Laggert Manager, Corporate Licensing R. McGoey Electrical Engineering Director E. O'Connor Engineering Services Director

• S. Parsons Quality Assurance Audit Manager, Parsippany D. Slear Director, Engineering and Design C. Tracy Engineering Projects Director, Oyster Creek

• R. Zak Senior Licensing Engineer

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• Denotes those present at exit meeting.

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