IR 05000275/2009006

IR 05000275-09-006, on 01/01/2009 - 06/30/2009 for Diablo Canyon Power Plant; Steam Generator Replacement Inspection (50001)

ML092020097
Person / Time
Site:	Diablo Canyon
Issue date:	07/20/2009
From:	Vincent Gaddy NRC/RGN-IV/DNMS/NMSB-B
To:	Conway J Pacific Gas & Electric Co
References
IR-09-006
Download: ML092020097 (11)

Text

UNITE D S TATES NUC LEAR RE GULATOR Y C OMMIS SI ON uly 20, 2009

SUBJECT:

DIABLO CANYON POWER PLANT - NRC INSPECTION REPORT 05000275/2009006

Dear Mr. Conway:

On June 30, 2009, the U.S. Nuclear Regulatory Commission (NRC) completed an inspection at your Diablo Canyon Power Plant, Unit 1. The enclosed report documents the inspection findings that were discussed on June 29, 2009, with Mr. Jim Becker and members of your staff.

This inspection examined activities conducted under your Unit 1 license as they relate to safety and compliance with the Commission's rules and regulations, and with the conditions of your Unit 1 license. Within these areas, the inspection consisted of selected examination of procedures and representative records, observations of activities, and interviews with personnel. This inspection covers Unit 1 steam generator replacement activities.

Based on the results of this inspection, no findings of significance were identified.

In accordance with 10 CFR 2.390 of the NRCs Rules of Practice, a copy of this letter will be available electronically for public inspection in the NRC Public Document Room or from the Publicly Available Records (PARS) component of the NRCs document system, ADAMS.

ADAMS is accessible from the NRC Website at http://www.nrc.gov/reading-rm/adams.html (the Public Electronic Reading Room).

Sincerely,

/RA/

Vince G. Gaddy, Chief Project Branch B Division of Reactor Projects Docket: 50-275 License: DPR-80

Pacific Gas and Electric Company -2-

Enclosure:

NRC Inspection Report 05000275/2009006 w/Attachment: Supplemental Information

REGION IV==

Dockets: 50-275 Licenses: DPR-80 Report: 05000275/2009006 Licensee: Pacific Gas and Electric Company Facility: Diablo Canyon Power Plant, Unit 1 Location: 7 1/2 miles NW of Avila Beach Avila Beach, California Dates: January 1, 2009 through June 30, 2009 Inspector: M. Brown, Resident Inspector, Project Branch B, DRP Approved By: V.G. Gaddy, Chief, Project Branch B, Division of Reactor Projects-1- Enclosure

SUMMARY OF FINDINGS

IR 05000275/2009006; 1/1/09 - 6/30/09; Diablo Canyon Power Plant; Steam Generator

Replacement Inspection (50001)

This report covered a 6-month period of inspection by the resident inspector. No findings of significance were identified. The NRCs program for overseeing the safe operation of commercial nuclear power reactors is described in NUREG-1649, "Reactor Oversight Process," Revision 4, dated December 2006.

NRC-Identified and Self-Revealing Findings

None.

Licensee-Identified Violations

None.

REPORT DETAILS

4OA5 Other Activities

.1 Steam Generator Replacement Inspection

a. Inspection Scope

This inspection report discusses NRC inspection activities related to the Diablo Canyon Power Plant, Unit 1, steam generator replacement project.

These steam generator replacement inspection activities are not part of the normal baseline inspection program, but are performed on an as-needed basis. Therefore, no sample size is specified. The inspector completed the entire procedure for steam generator replacement (50001).

Inspection Activities Documented in Other Inspection Reports:

A significant portion of these inspection efforts were completed and documented in prior NRC inspection reports, as listed below:

• Permanent plant modifications, NRC Integrated Inspection Reports 05000275/2009002 and 05000323/2009002, Section 1R18

• Temporary modifications, NRC Integrated Inspection Reports 05000275/2009002 and 05000323/2009002, Section 1R18

• Maintenance risk assessments and emergent work controls, NRC Integrated Inspection Report 05000275/2009002 and 05000323/2009002, Section 1R13

• Radiation protection, access, storage radiological safety plan, and ALARA program controls, NRC Integrated Inspection Report 05000275/2009002 and 05000323/2009002, Sections 2OS1 and 2OS2

• Inservice inspection, welding, and nondestructive examinations, NRC Integrated Inspection Report 05000275/2009002 and 05000323/2009002, Section 1R08

• Outage operating conditions, NRC Integrated Inspection Report 05000275/2009002 and 05000323/2009002, Section 1R20

• Identification and resolution of problems, NRC Integrated Inspection Report 05000275/2009002 and 05000323/2009002, Section 4OA2

• Operability evaluations, NRC Integrated Inspection Report 05000275/2009002 and 05000323/2009002, Section 1R15

• Post installation verification and testing, NRC Integrated Inspection Report 05000275/2009002 and 05000323/2009002, Section 1R22 and NRC Integrated Inspection Report 05000275/2009003 and 05000323/2009003, Section 1R19 The results of the security-related inspection activities will be documented in NRC Inspection Report 05000275/2009401 and 05000323/2009401.

In addition to the above, as part of this inspection effort, the inspector reviewed additional activities to ensure proper

(1) design and planning and

(2) removal and replacement, as provided below:

Engineering and Technical Support and Permanent Design Modifications.

The inspector reviewed engineering and technical support activities prior to, and during, the replacement outage. The inspector reviewed the following modifications:

• The complete scope of design changes associated with all the hard (physical plant) and soft (documentation) changes for the replacement of all four Unit 1 steam generators

• Unit 1 and Unit 2 Tavg and T-feedwater range program

• Use of alternate methodologies for Units 1 and 2 steam generator replacement projects The inspector verified the technical adequacy of the modifications, including 10 CFR 50.59 related documents.

Lifting and Rigging. The inspector reviewed engineering design, modification, testing, and analysis associated with steam generator lifting and rigging. This included:

(1) crane and rigging equipment;

(2) steam generator component drop analysis;

(3) safe load paths;

(4) load lay-down areas; and

(5) heavy load haul path. The inspector verified that the licensee had properly evaluated the potential impact of load handling on the reactor core and spent fuel, including cooling and support systems. This review also included the potential impact to underground electrical lines, fluid piping, and sewer systems that were traversed by the heavy haul route.

The inspector conducted reviews of the preparations and procedures for:

(1) crane and rigging inspections;

(2) testing;

(3) equipment modifications;

(4) lay-down area preparations; and

(5) training. The related activities and equipment included:

• Area preparation for the outside systems

• Outside lift system

• Self-propelled modular transporter travel through fuel handling building

• Single point lift system

• Hatch transfer system

• Upending/downending device

• Temporary lifting device inside containment

• Reactor cavity decking

• Steam generator removal, installation of the replacement steam generators, and transport of the old steam generators to the storage facility The inspector directly observed portions of the movement of each installed steam generator, including in the order of removal:

(1) inside containment temporary lifting device lifting and rigging,

(2) downending,

(3) traversing through the hatch transfer system,

(4) single point lift system movements,

(5) self-propelled modular transporter travel from the sundeck through the fuel handling building to the outside lift system

(6) lifting the outside lift system, and

(7) self-propelled modular transporter travel from the outside lift system to the old steam generator storage facility. The inspector also directly observed portions of the installation of the replacement steam generators, which were moved from the replacement steam generator storage facility into containment in reverse order to the old steam generator movements discussed above. The inspector observed a sample of various other activities including the initial lifts, heavy haul routes, and use of the hatch transfer system equipment.

Radiation Protection Program Controls. In addition to the health physics inspections, which are referenced in Section 1.a of this report, the inspector performed the following radiation protection-related inspections:

(1) direct inspection of radiation protection personnel coverage and control, as low as reasonably achievable, and dosimetry control activities along load movement path of old steam generator from containment to the old steam generator storage facility; and

(2) direct inspection of radiation protection controls and procedure adherence to the old steam generator storage facility.

Steam Generator Hold Down Bolts and Major Structural Modifications. The inspector examined the old steam generator hold down bolts for degradation. The inspector also reviewed documentation and performed direct inspections related to permanent structural modifications made to facilitate steam generator replacement. It should be noted that even though these modifications were treated as permanent, all outside rigging and handling equipment was removed after the replacement of the Unit 1 steam generators. These modifications included the outside lift system platform and the outside lift system tower base frame.

Foreign Material Controls. The inspector directly observed the cutting and grinding of primary and secondary side main steam line piping as well as the foreign material exclusion boundaries and controls in place for the remaining reactor coolant system piping. The inspector also verified foreign material control measures for the reactor coolant system hot and cold legs after old steam generator removal. The inspector also performed engineering reviews of the foreign material controls and reviewed corrective action documents related to foreign material exclusion.

Containment Access and Integrity. Final containment close-out and testing inspections were performed by the resident inspectors and documented in NRC Integrated Inspection Report 05000275/2009002 and 05000323/2009002. It should be noted that no physical modification or cutting was performed on the containment hatch opening during the Unit 1 steam generator replacement outage.

b. Findings

.

No findings of significance were identified.

4OA6 Meetings, Including Exit

The inspector presented the inspection results to Mr. J. Becker, Site Vice President, and other members of the licensee's management staff in person on June 29, 2009. The licensee acknowledged the information presented. Some proprietary information was reviewed during this inspection but no proprietary information was included in this report.

ATTACHMENT: Supplemental Information

SUPPLEMENTAL INFORMATION

KEY POINTS OF CONTACT

Licensee Personnel

J. Becker, Site Vice President

W. Guldemond, Director, Site Services

S. Ketelsen, Manager, Regulatory Services

K. Peters, Station Director

M. Somerville, Manager, Radiation Protection

T. Swartzbaush, Manager, Operations

J. Welsch, Director, Operations Services