IR 05000244/1993013
| ML17263A427 | |
| Person / Time | |
|---|---|
| Site: | Ginna  |
| Issue date: | 09/23/1993 |
| From: | Eapen P, Gregg H NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML17263A426 | List: |
| References | |
| 50-244-93-13, NUDOCS 9310210130 | |
| Download: ML17263A427 (11) | |
Text
U.S. NUCLEAR REGULATORY COMMISSION
REGION I
REPORT NO:
DOCKET NO:
LICENSE NO:
LICENSEE'ACILITY NAME:
INSPECTION AT:
50-244/93-13 50-244 DPR-18 Rochester Gas and Electric Corporation 49 East Avenue Rochester, New York 14649 Rochester Gas and Electric Corporation (RG&E)
RG&E Nuclear Engineering Services Corporate Office and R. E. Ginna Nuclear Power Plant INSPECTION DATES:
June 14-18, and August 30 - September 3, 1993 INSPECTOR:
Harold I. Gregg, Sr. React r Engineer, Systems Section, EB, DRS 2-/ g3 Date APPROVEDBY'w,E Dr. P. K. Eapen, Chief, Systems Section, EB, DRS
~ra~/y>
9310210130 931006 PDR ADOCK 05000244
D fg MMfi
'
gf g
PP f
R. g. Gf activities.
DM gf
'gfil fg fd fg Mffi
'
g g
d results.
The main generator exiter voltage regulator replacement was exceptionally well performed, the steam generator replacement planning has been comprehensive, the new personnel fall-arrest cable installation was a good initiative, and the new vendor manuals were highly improved.
Several outputs from the process upgrade program are being implemented to further improve engineering performance and communications with the site.
Site engineering effectively responds to daily issues and there is good support of operations and maintenanc DETAILS 1.0 DESIGN CHANGES AND ENGINEERING SUPPORT (37700)
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 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 to be installed modifications were reviewed by the inspector as detailed below:
Pre-separator Drain Tank Replacements (EWR 3100 E).
The licensee's evaluation of the rupture that had occurred in the "A" tank wall, determined that the J-nozzle orientation in the tank created a flow impingement erosion/corrosion problem of the '/8" wall carbon steel tank.
This modification replaced the "A" and "B" drain tanks, utilized '8" thick wall 2~/~ chrome-1 moly steel, and redirected the J-nozzles to avoid wall impingement.
A comprehensive baseline ultrasonic examination of the tank was performed to enable future periodic inspection comparisons.
Containment Recirculating Fan Cooler Replacement (EWR 5275).
Increased frequency of cooling coil tube leaks, effective examination of removed tube samples that identified significant erosion/corrosion, and an indepth engineering evaluation that contained numerous recommended improvements led to the replacement of all the containment fan cooler coils during the 1993 outage.
This modification resulted in improvements in heat transfer capability, reduced velocity through the tubes, the use of austenitic stainless steel tubes and casings, a stainless steel waterbox with a removable cover design to provide inspection-cleaning-repair access, and installation of flow pressure and temperature instrumentation.
Good modification planning, in-house engineering, seismic reanalysis, and around-the-clock engineering support during installation and testing were evident in the performance of this modification.
~
Main Generator Exciter Voltage Regulator Replacement (EWR 5262).
This modification was developed as a team effort led by nuclear engineering services with extensive involvement of plant engineering, operations, maintenance and training departments:
The inspector assessed the planning, preparation, and control of this
modification to be exceptionally well performed.
The detailed step by step instructions for removal and reinstallation, constant presence during the modification, and the oversight of testing that was performed during operation demonstrated good engineering.
Containment Vessel Platform Upgrade and Personnel Fall-Arrest Cable Attachment System (EWR 5167B).
This modification provided improved access to the steam generator snubbers by installing a new industrial safety fall-arrest cable system that allows the worker to traverse the entire length of the cable without unhooking and reattaching at cable support locations.
The inspector observed the cable connection device capability to move past connection points without unhooking, and considered the licensee's new safety system installation a good initiative.
Resolution of Seismic Adequacy of Mechanical and Electrical Equipment-Unresolved Safety Issue A-46 Resolution (EWR 5984).
The inspector reviewed the licensee's progress for this long term project.
The inspector determined that walkdown verification was performed for the accessible equipment inside containment during the 1993 outage, and that walkdown of equipment outside containment was in process with plans to continue into 1994.
The review of equipment evaluated has not identified any concerns to date.
The licensee's progress in completing this project was found to be on schedule.
Steam Generator Replacement (EWR 10034).
Replacement of the two steam generators (SG) was the major project scheduled for the 1996 outage.
The licensee has formed a dedicated in-house project team to manage this project.
Cooperative efforts by the licensee, B&W-Canada, Bechtel Corporation, and Westinghouse (the NSSS original designer) was followed by extensive combined efforts of ten utilities to obtain SG replacement with improved materials and design features.
The SG replacements ordered from B&W-Canada specify the use of the latest materials and technology to minimize tube problems and improve maintenance.
The specified design features include: Inconel 690 tubes, forged shell components, cylindrical shell welds that are away from the transition discontinuities, stainless steel tube supports and safe ends, full tube depth hydraulic expansion of the tubes in the tube sheet, a lattice grid tube support, high circulation ratio, improved feedwater distribution, larger primary and secondary manways, additional hand holes, inspection ports, and a steam flow limiter. The SG installation through the top of containment at R.E. Ginna willbe the first of a kind.
The licensee's engineering planning, management performance and initiatives for this project were noteworth J
ENGINEERING PROGRAM ACTIVITIES Cobalt Reduction Program.
Nuclear Engineering Services is actively involved in a program to reduce the use of cobalt, a significant source of radiation exposure when performing maintenance.
A design guide has been issued that focuses on evaluating valve hardfacings, and a corporate plan is under development to promote cobalt reduction within the plant functional groups.
Engineering initiatives were evident in the participation in industry group activities and studies for a cobalt replacement to reduce a significant source of radiation exposure.
Process Upgrade Program.
Several engineering programmatic improvements resulting from the process upgrade program have been the short form EWR process, the engineering work tracking system, and the integrated design process.
The short form EWR provides a formal method for plant requests and documentation of short duration engineering work other than modifications.
This short form process has been successful as evident from the 130 requests since its July 1992 inception, and has resulted in improved communications between the plant and corporate engineering.
The integrated design process being implemented by nuclear engineering services establishes team concepts and requirements for early communications of project issues and defines individual responsibility assignments.
A computerized engineering work tracking system was developed to optimize management's use of engineers and to effectively monitor their performance.
The system provides a listing of assigned tasks and resources needed for task completions for each engineer.
The system is currently being implemented in the electrical engineering disciplines.
4.0 CONFlGURATIONMANAGEMPIT The inspector's review of several ongoing and recently completed configuration management projects are discussed below.
~
Configuration Management Information System (CMIS).
Significant progress has been made in the assimilation of over 50 existing data bases into a central data base information system that has widespread user access.
During the past year, plant activities relating to equipment such as work orders, change
requests, and vendor information were placed in the system.
The inspector determined that preliminary training has been performed and interim system use of CMIS is scheduled for October 1993.
Management involvement in the development of an effective information system was evident in personnel assignments and resource commitments made to this program.
Electrical Control Configuration Drawing Upgrade.
The release of some 3600 new and revised electrical control configuration drawings during the past year was a major undertaking and a significant accomplishment.
Extensive walkdowns verified or corrected equipment identification, component type, and safety class.
Sample drawing format presentations were made to ensure information was appropriate to the users.
Computer aided drafting was utilized to improve the quality of the final drawings.
New drawings viewed by the inspector were of good quality.
Released drawings included elementaries, control schematics, instrument loop wiring diagrams, and motor-operated valve connection diagrams.
Vendor Technical Manual Upgrade.
Walkdown verification was performed for manufacturer, make, and model of safety-related, safety significant, and reliability centered components.
Subsequent vendor contacts produced approximately 3,000 information and document receipts.
The old vendor manual system comprised of over 10,000 manuals was replaced with 240 updated and highly improved individual manuals that contain data on each component supplied by that vendor.
Six satellite locations where approved manuals are kept were established in high use areas such as maintenance, work planning, and corporate engineering.
The new vendor manuals were of excellent quality and format and this upgrade was a noteworthy accomplishment, P&ID Drawing Upgrade.
This project completed in April 1993 addressed drawing change requests and technical problem reports, information feedback of walkdown findings and a contracted assessment of the original P&ID release.
Current upgrades included movement of safety class boundary flags, and reconciliation and incorporation of HVAC and fire protection equipment identification numbers.
Approximately 189 drawings were affected in completing this project.
Design Bases Document Reconstitutions.
Three Design Bases Documents (DBD), as a combined effort of two loop owners, were completed by Westinghouse.
The three DBDs completed for reactor coolant system, reactor protection system, and chemical and volume control system, contain design bases up to commercial operation.
Because some NSSS vendor proprietary
material was nonreleasable and the turnkey concept of early plants, such as R. E.
Ginna, the licensee will have abstracts prepared that provide general information an'd specific references that target the proprietary information.
Management has also approved the upgrading of the three completed DBDs to current status.
The licensee is contemplating a joint effort with Point Beach for DBDs of the residual heat removal, safety injection, component cooling water, and engineered safeguards system features actuation.
The licensee is particularly attentive to ensuring the DBDs meet users needs and an effective methodology to maintain the DBDs.
5.0 ENGINEERING ORGANIZATIONAND EFFECTIVENESS The nuclear engineering services (corporate engineering) organization has remained relatively unchanged.
The organization is structured by engineering discipline except for several groups such as configuration management.
Current staffing is 112 positions and all vacancies have been filled. Engineering management focused attention on team work, being specific on how better engineering performance can be obtained, and improving communications.
The licensee has given team building training to the engineering managers and staff to better accomplish these objectives.
The steam generator replacement project, a major facility improvement scheduled for the 1996 outage, is a separate organization reporting to the vice president of nuclear production.
The inspector reviewed the licensee's performance in reducing the backlog of engineering work requests.
The goal established to close 100 engineering work requests in a one-year period is being met and is adequate to address new requests.
The licensee has made good progress in reducing the backlog.
Communications with the site, a past strength, has shown further improvement.
The nuclear engineering services personnel were encouraged to work onsite with their counterparts and the number of engineer days onsite is tracked.
The proximity of corporate engineering to the site facilitated effective attendance of corporate engineers and management at each of the site meetings as observed by the inspector.
Effective engineering was evident in the quality of the modification packages and the small number of field change requests.
Bi-weekly phone conferences among corporate engineering managers of 2 loop plants was perceived as a good initiative.
Site engineering effectively responds to daily issues.
There is good engineering support for operations and maintenance activitie.0 EXITMEETINGS The inspector met with the licensee's representatives on June 18, 1993, and September 3, 1993, to summarize the findings of this inspection.
Attendees at the exit meeting are listed in Attachment 1.
The licensee acknowledged the inspector's finding ATTACHM<22IT1 Persons Contacted R
he er s
nd Electric ti n S. Adams R. Arnold R. Baker C. Forkell, Jr.
R. Jaquin M. Kennedy R. Marchionda L. Markham D. Markowski D. Morgan T. Newberry T. Schuler J. F. Smith J. H. Smith L. Sucheski T. Werner J. Widay P. Wilkens D. Zebroski M. Zweigle Superintendent, Support Services Mechanical Engineer Electrical Engineer Manager, Electrical Engineering Nuclear Safety and Licensing Engineer Director, Configuration Management Superintendent, Production Project Manager Mechanical Engineer Lead Mechanical Engineer Senior Mechanical Engineer Technical Manager Manager, Steam Generator Replacement Electrical Engineer Supervisor, Structural Engineering Director, Technical Process Plant Manager, Ginna Department Manager, Nuclear Engineering Services Structural Engineer Mechanical Engineer N clear Re ulato ommis ion
+
T. Knutson T. Moslak Resident Inspector Senior Resident Inspector
- Denotes presence at exit meeting on June 18, 1993
+ Denotes presence at exit meeting on September 3, 1993
1