IR 05000289/1973015
| ML19256D482 | |
| Person / Time | |
|---|---|
| Site: | Crane  |
| Issue date: | 10/02/1973 |
| From: | Brickley R, Brunner E, Spessard R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML19256D481 | List: |
| References | |
| 50-289-73-15, NUDOCS 7910180811 | |
| Download: ML19256D482 (13) | |
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U. S. ATOMIC ENERGY COMMIO3 ION J
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DIRECTORATE OF REGULATORY OPERATIONS
REGION I
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j RO Inspection Report No.:
50-289/73-15 Docket No.:
50-289
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Licensee:
Metropolitan Edison Company License No.: CPPR-40 i
Three Mile Island - Uni 1 Priority:
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B.1
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,c Location:
Middletown, Pennsylvania
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ll Type of Licensee:
B&W 871 MWe PWR-
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Type of Inspection:
Routine"
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Dates of Inspection: September 19-21, 1973
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j Dates of Previous Inspection:
August 29, 1973 Reporting Inspector:
dc.2,.Ld.,
/0/ !73 f
R.'L. Spessyfd, Reactor Inspector Date
Accompanying Inspectors:
Id N.
E
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R. H. Brickley, Reac h Inspector Date
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Date
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I E. J. Brunner, Chief, Facility Test and Startup Brar. h (Mgt. Interview Only)
Otner Accompany
'ersonnel:
W. A. Ruhlman, Reactor Inspector (Mgt. Interview Only)
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Reviewed By: N
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/p/3 /,3 E.A.Brunner, Chief,FacilityTest and Startup Branch
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f ey SUMMARY OF FINDING 3 Enforcement Action
None i.
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Licensee Action on Previously Identified Enforcement Items
None required relative to test and startup activities, i
i Unusual Occurrences
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Other Significant Findings de'
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l A.
Current Findings
'1.
Nuclear Service River Water Pump 1C Motor Failure (R0 Inspection Report No. 50-289/73-11) - Licensee's investigation revealed
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(_g motor failure was caused by heat generated by the motor and stator
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j rubbing together.
The apparent cause of failure was the guide bearing taking the ihrust and the thrust bearing having no thrust
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j allowing the rotor to " wobble',' due to play in the thrust bear-ings. Motor is to be repaired in accordance with vendor (W)
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specifications and tested in accordance with AE (GAI) specifica-tions. Additionally, a new or replacement motor has been ordered.
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I 2.
480 Volt Switchgear Malfunctions (R0 Inspection Report No. 50-289/
73-11) - Licensee's investigation revealed that GAI did not re-quest ES switchgear with the same design feature utilized at TMI-l
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on any other domestic power reactor under GAI's design cognizance.
The licensee was unable to obtain similar information from Westing-house and was info aed by the inspector that no further action was necessary, as this information would be obtained by other Subsequent to this RO inspection, RO:HQ learned during means.
telephone discussions with Westinghouse representatives that TMI-l was the only power reactor with ES switchgear utilizing this unique design feature (Requested by GAI).
3.
Core Flood Tank Stop Valves Malfunctions (RO Inspection Report No. 50-289/73-11) - Licensee's investigation to determine generic applicability has not been completed.
Item will be reviewed during a subsequent RO inspection.
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E.
Status of Previously Reported Unresolved Items 1.
Criterion II, Appendix B,10 CFR 50 (R0 Inspection Report No.
50-289/73-10) - Item is resolved based on revision of Test Instruction No. 19.
(Paragraph 5.d)
2.
Criterion XI, Appendix B, 10 CFR 50 (R0 Inspection Report No.
50-289/73-10) - Item is resolved based on revision of Test
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Instruction No. 19.
(Paragraph 5.d)
3.
Criterion XV, Appendix B,10 CFR 50 (R0 Inspection Report No.
50-289/73-10) - Item is resolved based on revision of Test Instruction No. 7.
(Paragraph 5.b)
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4.
Scheduled Audit No. 11 (R0 Inspection Report No. 50-289/73-10) -
Item is resolved based on"further review of the licensee's program.
(Paragraph 4)
l 5.
UE6C Instrument Shop's means for cleaning test gauges and for i
verifying their cleanliness (R0 Inspection Report No. 50-289/
73-06) - Item is resolved based on corrective action taken by
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the licensee.
(Paragraph 6)
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No change in other items.
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Management Interview An exit interview was conducted on September 21, 1973 at the conclusion of the inspection.
Items discussed and personnel in attendance were as follows:
Licensee Representatives Mr. R. Klingamen, Plant Superintendent, Met Ed'
Mr. J. Herbein, Assistant Plant Superintendent, Met Ed Mr. J. Barton, Startup and Test Manager, GPUSC Mr. G. Miller, Test Superintendent, GPUSC Mr. R. Burns, Assistant Project Manager, Engineering, GPUSC Mr. M. Stromberg, Site Auditor, GPUSC hr. 1. Sturgeon, QA Specialist nr. G. Roshy, QA Specialist
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-3-RU:I Representatives Mr. L. Spessard Mr. R. Brickley Mr. E. Brunner Mr. W.,Ruhlman
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A.
Test Instructions
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l Inspection findings relative to review of certain recently revised
l Test Instructions and the licensee's implementation of certain Test Instructions were discussed.
(Paragraph 5, 6, and 8)
B.
Site QA Audit Program
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Inspection findings relativeatb Scheduled Audit No.11,12, and 13
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and planned audits of preoperational tests were discussed. (Para-
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l graph 4)
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C.
Decay Heat Closed Cycle Cooling Mater System Turnover to Met Ed s
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(_)
Inspection findings relative to the turnover package for this system and the licensee's commitment to revise generic procedure TP 250/2
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were discussed.
(Paragraph 7)
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D.
Preoperational Test Procedures Inspection findings relative to the review of TP 301/3C and TP 310/4, the review of TP 201/5 test results, and the review of previously reported deficiencies were discussed.
(Paragraph 2)
E.
Initial Fuel Procedures and Instructions Licensee representatives were informed of the discussion held with their representatives regarding RO policy on the contents of initial full loading procedures.
(Paragraph 3)
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DETAILS
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1.
Persons Contacted Metropolitan Edison Company
R. Klingaman, Plant Superintendent
J. Colitz, Station Engineer l
W. Potts, QA Engineer
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W. Cotter, Mechanical Engineer
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D. Barry, Instrument Foreman R. Harper, Instrument Foreman E. Daniels, QC Assistant
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B. Rittle, Electrical Maintenance Fo' reman
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M. Ross, Shift Supervisor
General Public Utilities Service Corporation
"J. Barton, Startup and Test Manager
,s G. Miller, Test Superintendent
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R. Toole, Assistant Test Superintendent M. Nelson, Technical Engineer S. Levin, Unit #1 Project Engineer
i W. Gunn, Site Project Manager J. Renshaw, Proj ect Engineer R. Claussen, Lead Engineer - Instrument & Controls M. Stromberg, Site Auditor T. Sturgeon, QA Specialist United Engineers and Constructors E. Mc Devitt, Lead Startup Enginnar G. Mitchell, Startup and Test Engineer G. Somdahl, Instrument Supervisor 2.
Preoperaticnal Test Procedures a.
Status of Test Procedure Preparation, Review, and Accroval
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Preoperational' Test Procedures Approved for Performance-52%
Preoperational Test Procedures Awaiting Final Approval
- 6%
Preoperational Test Procedures Under Review by TWG & DOT
- 9%
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-5-Preoperational Test Procedures Written and Undergoing-12%
In-house Review
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I Preoperational Test Procedures Not Started-21%
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b.
Status of Preoperational Testing i
l Preoperational Tests Completed and Accepted
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Preoperational Tests Completed and Under Review
- 7%
Preoperational Tests in Progress-11%
i Preoperational Tests Not Started-73%
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c.
RO:I Review of PreoperatfEnal Test Procedures
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The inspector discussed his review of the following preoperational test procedures:
O TP 301/3C - Nuclear Instrumentation Pre Op Calibration (Power Range)
TP 310/4 - Safeguari Annunciator and Alarm Test The inspector found that the deficiencies identified during the review of TP 301/3C had been corrected in the latest revision to the procedure. There were no deficiencies identified during the review of TP 310/4.
d.
Status of Previously Reported Test Procedure Deficiencies (1) TP 160/3 Reactor Building Purge System Funct'ional Test
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This system will be run by UE6C withour filters installed
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for a period long enough to insure that any debris is removed.
In addition, quality control will inspect the system for cleanliness prior to the turnover to Met Ed.
This item is resolved.
(R0 Inspection Report No. 50-289/73-11,' Paragraph
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2.c. (4))
(2) TP 301/3A Nuclear Instrumentation Pre Op Calibration (Source Range)
Revision 1 has been issued resolving the three previously c'
reported deficiencies.
(R0 Inspection Report No. 50-289/
i-73-04, Paragraph 9.c. (4))
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RO:I Review of Preoperational Test Results TP 201/5 Core Flood Flow Test - The inspector reviewed the com-pleted test package as accepted by the licensee and is satisfied with the documentation of performance and results.
3.
Initial Fuel Procedures (IFP) and Instructions (IFI)
a.
Status of Preparation, Review and Approval
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Approved
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i Under Review 95%
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Written 95%
To be Written 5%
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There are a total of 39 peccedures and 26 instructions planned.
The IFP's cover those items applicable to the initial core
loading only.
These procedures are reviewed by the " Initial l
Fuelir.g Group" consisting of representatives from Met Ed, B&W, j
Q.A., and GPU.
The final approval is made by the GPU Site i
Project Manager.
The IFI's cover those items of a repetative g3 s_/
nature that will be done during the operating life of the plant.
These instructions may be converted to plant operating procedures i
at a later date; therefore, they are submitted to the Met Ed
operating staff for review.
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The inspector discussed, with the licensee's representatives, RO policies concerning the detailed content of initial fuel loading procedures.
Unofficial copies of 34 IFP's and 20 IFI's for re-view by the RO:I staff were obtained.
4.
GPU-QA Audits of Startup and Test Activities The inspector reviewed facility records pertinent to Scheduled Audits i
No. 11, 12 and 13.
These records included: audit schedules and agenda,
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audit checklists, audit report finding forms, and the written audit reports.. Additionally, the inspector conducted discussions with GPU-
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QA and GPU startup.representativcs relative to the audit findings and the resolution of these findings.
The inspector verified by review of facility records and procedures that corrective action documented on individual audit report finding forms had been completed for find-ings relative to Test Instruction No. 2, 14, and 17 and Criterion VI, Appendix B, 10 CFR 50.
The inspector concluded that the performance of these audits and the documentation, evaluation and resolution of the results of these audits were in accordance with Appendix A of the
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-7-QA Plan for Startup and Test Three Mile Island Nuclear Station - Units 1 and 2.
The licensee representatives were informed by the inspector i
that previous RO:I findings relative to scheduled Audit No. 11 were resolved.*
During a previous RO Inspection,** a QA representative indicated that a list of the preoperational tests to be witnessed in accordance with
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the audit program would be developed.
During this RO inspection, the
inspector observed that a list consisting of 21 preoperational tests selected for audit had been prepared, that formal arrangements with
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GPU startup to coordinate and1 ting of these tests had been accomplished,
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and that approved checklists to audit these tests existed.
Additionally,
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two other preoperational tests had been recently audited by GPU-QA.
5.
Tent Instructions
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The inspector conducted a reffew of the following recently revised Test Instructions:
TI-2 Test Plan TI-7 GPU Startup Problem Report TI-14 Training and Qualifications of Test Personnel i
O T1-19 centre 1 ef Test Reui ment P
During this review, the, inspector made th'e following observations
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which were discussed with cognizant licensee representatives:
a.
TI-2 Test Plan Revision 1 to TI-2 dated August 10, 1973 was approved on August 22, 1973 in accordance with the Test Manual. This revision in-cluded requirements relative to accomplishing changes to the Authorized Test Plan and resolved a finding identified by GLT-QA during scheduled Audit No. 11.
b.
TI-7 GPU Startup Problem Report Revision 3 to TI-7 dated September 4,1973 was approved on Sep-tember 19, 1973 in accordance with the Test Manual. This revision included a requirement for applicable design agency review when the final design of plant safety related functions is affected.
The pre tous RO:I finding relative to this matter is resolved.***
R0 Inspection Report No. 50-289/73-10, Management Interview Item H
RO Inspection Report No. 50-289/73-10, Management Interview Item G
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RO Inspection Report No. 50-289/73-10, Management Interview Item F G
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TI-14 Training and Qualification of Test Personnel Revision 2 to TI-14 dated September 14, 1973 was approved on September 14, 1973 in accordance with the Test Manual.
This revision clarified requirements relative to training and qualification of Shift Test Engineers and resolved a finding
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by GPU-QA during Scheduled Audit No. 13.
d.
TI-19 Control of Test Equipment i
Revision 1 to TI-19 dated August 17, 1973 was approved on Sep-tember 3, 1973 in accordance with the Test Manual. This revision
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included requirements relative to applicable design agency review
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i of permanently installed test equipment, definition and control
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of test devices, and cleaning an'd cleanliness control.
The previous RO:I findings rM ative to these matters, as appropriate, i
are resolved.*
(Refer to Paragraph 6 for inspection findings relative te implementation of cleaning and cleanliness control requirements)
6.
Control of Test Equipment p
V An inspection was conducted of the United Engineers and Constructors
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(UE&C) and Metropolitan.,Idison Company (Met Ed) instrument shops to determine the implementation of TI-19, Control of Test Equipment.
The inspector's observations and discussions revealed the following:
a.
UE&C Instrument Shop (1) Equipment has been obtained and is being used to clean vacuum and pressure gauges.
(2) Cleanliness Control Tags, as required by Appendix I of Test Instruction #19 are attached to gauges prior to issue.
(3) Appendix II - Cleaning and Cleanliness Control of Test Instruction #19 has been issued.
(4; An instrument checkout log is being maintained.
(5) A sto_ age area was erroneously posted as a " clean area".
(6) Segregation of instruments by use (air, oil, & water) has not been fully implemented at this time.
- RO Inspection Report No. 50-289/73-10, Management Interview Items C and E 1449
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O-9-Items (1), (2) and (3) resolved a previously reported deficiency.
(R0 Inspection Report No. 50-289/73-06, Managemer.t Interview Item G.4)
Item (5) was discussed with the licensee s representative.
It was pointed out that erroneously posted areas could lead personnel to ignore the requirements of a correctly posted area.
The licensee's
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representative stated that the sign would be removed.
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Item (6) remains open and will be reviewed during a future in-
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spection.
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b.
Met Ed Instrument Shon
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(1) Personnel have been instructed to comply with the requirements
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of TI-19.
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(2) Calibration Lables and Cleanliness Control Tags are on order.
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(3) Gauges have been marked " Air" and " Water" use only.
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(4) Equipment has been ordered for cleaning of gauges.
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(5) Gauges have been segregated as to use (air, oil, & water).
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Items (1) through (5) remain open and will be reviewed during a future ins,7ction.
7.
Deca-Heat Closed Cycle Cooling Water System Turnover to Met Ed TI-5 System Turnover establishes administrative control relative to turning systems over from the construction group through startup test, then to the owner (Met Ed).
It also provides a method of accounting and completing incomplete work items and coordinates the turnover procedures of QC 16 (16-2) and TP 250/2.
The inspector reviewed the turnover package for the Decay Heat Closed Cycle Cooling Water System to determine compliance with TI-5, and the following. observations were made and discussed with licensee representatives, as appropriate :
a.
The turnover package was accepted by Met Ed on August 14, 1973.
b.
The turnover package, which consisted of 6 separate folders identified by MTX Number and Title, contained the necessary construction related records, as required by TP 250/2, eg.,
Correspondence, Instrument Calibration, Electrical Test,
Pressure Test, Flush, and Preliminary Operational Test.
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i The Phase II Turnover Agreement per QC-16 was signed in accord-i c.
ance with TP 250/2.
d.
The Incomplete Work List consisted of 18 items, and each item l
had an assigned completion schedule, as required by TI-5, eg.,
7 items complete prior to Reactor Cosiant System Fill and re-l maining 11 items complete prior to Hot Functional Testing.
I The Equipment Erection Data Sheet Vibration Record that was i
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complete ' for pumps DC-PlA/B in accordance with TP 250/2 during
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the Preliminary Operational Test (MTX 71.5) did not clearly identify the location where each vibration reading was taken.
During a visual inspection of the system, the inspector observed that each location where a vibration reading had been taken was l
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identified by a white (paint) sp'ot.
Licensee representatives agreed to revise the subtftt data sheet in TP 250/2 to identify
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vibration readings taken on the pump outboard bearing or casing.
Additionally, these completed data sheets did not identify the piece of test equipment used to obtain the vibration data.
The
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p control of test equipment per TI-19 was reviewed, and the in-spector concluded that the IRD used during this test was calibr-v
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l ated, although the actual'IRD used could not be determined.
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Licensee representagiva agreed to review TP 250/2 and'to make
appropriate revisions to this. procedure to assure that all test
equipment used in conjunction with future generic tests is identified and recorded.
I The inspector iaformed the licensee representatives that these matters would be reviewed d'uring subsequent R0 inspections.
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f.
Facility records relative to GPU-QA Scheduled Audit No. 12 con-ducted August 14-15, 1973 disclosed that this turnover package
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was one of the areas included in the audit. The inspector picked one of the GPU-QA audit findings, as documented on an Audit Report Finding Form, to independently verify that corrective action had been taken. The finding selected, pertained to Criterion VI, Appendix B, 10 CFR 50, and the corrective action to prevent re-currence involved revision of QC Procedure No. QC-16. A review of Field Change No. QC-104 dated August 29, 1973 to QC Procedure No. QC-16 disclosed that the subject procedure revision was approved by the C'USC TMI QA Manager on September 6, 1973.
8.
Shift Test Engineer (STE) Log The inspector reviewed the STE log covering the period April 8, 1973
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L thcu September 19,~1973 for implementation of the requirements of 1449
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TI-17, Shif t Test Engineers Log.
The following deficiencies were
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identified:
The test procedure number does not appear in the left margin a.
for many entries.
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Corrections to entries have been made without initialing the b.
I corrected item.
The initial and final entries identifying the relieved and re-c.
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lieving STE's are not always entered.
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d.
The individual STE naking or requesting an entry is not always
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identified.
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In addition, too much blank sphce is left between the last entry and the STE's signature and between log entry periods.
(Not l
addressed in T1-17)
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The inspector noted that the above items had been identified in a (~)
recent audit conducted by GPU-QA (Scheduled Audit No. 13), and that satisfactory corrective actions had been initiated.
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MEMO ROUTE SLIP s.... aout wo.
roc e.ncure.no.
For.etion.
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ro,m AEC-95 (Rev. May 84,1947) AECM 0240 Note and retura.
For signature.
Y For inferrnation.
70 (Name and unit)
INITIALS REP' '.A KS RO Chief. FSAEB (HQ)
METROPOLITAN EDISON COMPANY RD: liq (5)
RO Files THREE MILE ISLAND 1 Central Mail & Files; Regulatory Standards (3)
INSPECTION REPORT No.
50-289/73-15
,
TO OJame and unit)
IMITtALS REMAAKS D rectorate of Licens ing (13)
The above inspection report is forwarded for
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Regional Directors, 10 (4)-
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mn information.
Distribution will be made by
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this office tc. the PDR, Local PDR, NSIC, DTIE, To (Name and unit)
WeTIALS RLatAAKS and State representatives after review by the licensee for proprietary information.
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FROM (Name and unit)
REMAAKS E. J. Brunner Region I g
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t PHONE M(1 DATE 264
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IAE OTHER SIDE FOR ADDITIONAL REMAAKS CPO : 19710 - 445-489
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