IR 05000289/1978019
| ML19322A235 | |
| Person / Time | |
|---|---|
| Site: | Crane  |
| Issue date: | 12/06/1978 |
| From: | Bettenhausen L, Haverkamp D, Keimig R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML19322A231 | List: |
| References | |
| 50-289-78-19, NUDOCS 7902050110 | |
| Download: ML19322A235 (16) | |
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Il U.S. NUCLEAR REGULATORY COMMISSION
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0FFICE OF INSPECTION AND ENFORCEMENT Region I
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Report No. 50-289/78-19 Docket No. 50-289 License No. OPR-50 Priority
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Category C
Licensee:
Metropolitan Edison Comoany P. O. Box 542 Reading, Pennsylvania 19603 Facility Name:
Three Mile Island Nuclear Station, Unit 1 Inspection at:
Middletown, Pennsylvania Inspection conducted:Novemb r 7-9 and 13-17,1978 Inspectors:
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//- /- /8 R.Hkeramo e
pector date signed 24,Y en n rbI aN7f
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H.' e h nhause'n,'Reacfor Insoector d' ate ' signed
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i D. L. Caphton, Chief, Nuclear Support date signed Secti t
0 $ NS Branch
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Approved by:
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unief71e2 Projects date signed R.
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Seceion to. 1, R0 & P ranch
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Inspection Summary
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Inspection on November 7-9 and 13-17,1978 (Report No. 78-19)
Areas Inspected: Routine, unannounced inspection by two regional based inspectors and a supervisor of post refueling startup testing; post refueling plant operations; surveillance of core performance and reactivity; recent plant operations including shift logs and records and facility tour; and licensee followup actions concerning selected previous inspection findings, licensee events, and IE Circulars.
The inspection involved 67 inspector-hours onsite by two NRC regional based inspectors and 6 hours6.944444e-5 days <br />0.00167 hours <br />9.920635e-6 weeks <br />2.283e-6 months <br /> by one NRC supervisor. On November 20, 1978, one inspector attended a licensee /NRC (NRR) meeting to discure proposed STS implementation, which involved 6 hours6.944444e-5 days <br />0.00167 hours <br />9.920635e-6 weeks <br />2.283e-6 months <br /> onsite.
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Results: Of the seven areas inspected, one item of noncompliance was found in two areas (Deficiency - failure to comply with administrative controls for procedure implementation and changes, Paragraphs 4 and 5).
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i R::gion I Form 12 (Rev. April 77)
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DETAILS 1.
Persons Contacted Metropolitan Edison Company Mr. T. Acker, Shift Foreman
- Mr. R. Barley, Unit 1 Lead Mechanical Engineer
- Mr. H. Crawford, Unit 1 Nuclear Engineer Mr. T. Crouse, Shift Foreman Mr. J. Hilbish, Station Lead Nuclear Engineer Mr. G. Kunder, Unit 1 Superintendent - Nuclear Support
- Mr. J. O'Hanlon, Unit 1 Superintendent Mr. V. Orlandi, Unit 1 Lead Instrumentation and Controls Engineer Mr. M. Ross, Unit 1 Supervisor of Operations Mr. M. Shatto, Unit 1 PORC Secretary Mr. W. Zewe, Shift Supervisor The inspector also talked with and interviewed several other li-censee employees during the inspection.
They included control room operators, technical and engineering staff personnel and general office personnel.
- denotes those present at the exit interview.
2.
Licensee Action on Previous Inspection Findings (Closed) Unresolved Item 289/77-09-03: Issuance of snubber func-tional testing procedure.
The inspector reviewed Surveillance Procedure 1303-9.9, " Functional Testing of Hydraulic Snubbers,"
Original.
The inspector determined that previous comments were satisfactorily incorporated in the procedure.
(Closed) Noncompliance 289/78-16-01: Failure to update emergency procedures. The licensee's corrective measures have been com-pleted, as described in MEC letter to NRC: Region I, serial GQL 1481, dated September 6, 1978. The inspector had no further ques-tions concerning this item.
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3.
Post Refueling Startup Testing a.
Procedure Review The inspector reviewed the completed test procedures listed below to verify that startup testing was conducted in accordance with approved procedures.
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RP 1550-01, " Controlling Procedure for Physics Testing,"
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Revision 2 (TCN 78-158), begun April 27, 1978 RP 1550-02, "Zero Power Physics Testing," Revision 3 (TCN
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78-162 and 78-179), completed May 1, 1978 RP 1550-04, " Power Imbalance Detector Correlation,"
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Revision 1 (TCN 78-178)
RP 1550-08, " Core Power Distribution Verification,"
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Revision 2 (TCN 78-153)
The only discrepancy identified was a missing signature ah.
date far the final step 7.32 of Procedure RP 1550-01.
A licensee representative stated that proper notation would be made.
The inspector had no further questions concerning this item.
b.
Test Results Review The following physics test results were reviewed and compared with Technical Specifications and with acceptance criteria detailed in the procedures.
Power Imbalance Detector Correlation was accomplished at
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75% full power by introducing imbalances with Axial Power Shaping Rods and comparing measurements from the full in-core detectors, the minimum in-core detector system and the out-of-core detectors.
Correlations met the accept-ance criteria.
The shutdown reactivity margin as determined in RP 1550-
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02 was computed to be 1.07% a k/k with a conservative estimate for withdrawn control rod.
The inspector inde-pendently computed this result and determined that it meets Technical Specification 3.5.2.1.
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Core power distribution limits did not meet original
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acceptance criteria in that radial and total power dis-tribution were greater than predicted by more than 10%.
A reanalysis and Technical Specification Amendment No. 40 lead to changes in criteria to 11% for radial and 13.5%
for total power.
These criteria were met by the physics testing.
The physics testing met all acceptance criteria, as modified by Technical Specification Amendment 40.
No items of noncompliance were identified.
4.
Post Refueling Plant Operations The inspector reviewed the following completed work requests and operating and surveillance procedures, which were associated with plant operations during or following the 1978 refueling outage.
Work Request 22625 dated February 8, 1978 (DH-P-1A/B Shaft
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Replacement)
Work Request 22416 dated December 29, 1977 (RC-P-lC Seal
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Inspection / Replacement)
Work Request 22415 dated December 29, 1977 (RC-P-1B Seal
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Inspection / Replacement)
Work Request 23626 dated April 27,1978 (MU-V-16B Packing
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Replacement)
Work Request 22317 dated December 29,1977 (Letdown Cooler MU-
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C-1B Replacement)
Operating Procedure (0P) 1102-1, " Plant Heatup to 525*, Re-
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vision 28 (TCN 78-150), completed April 27, 1978 OP 1102-2, " Plant Startup," Revision 25 (TCN 78-152,78-154,
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and 78-183), completed May 21, 1978 OP 1103-2, " Filling and Venting Reactor Coolant (RC) System,"
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Revision 18, completed April 18, 26, and 28,1978 OP 1103-6, " Reactor Coolant Pump Operation," Revision 13,
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l completed April 27, 1978
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OP 1103-8, " Approach to Criticality," Revision 8, completed
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June 30,1978 OP 1104-4, " Decay Heat Removal System," Revision 16, completed
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April 25 and 28, and June 22, 1978
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OP 1104-2, " Makeup and Purification System," Revision 26,
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completed June 27, 1978 Surveillance Procedure (SP) 1301-9.2, " Control Rod Program,"
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Revision 11, completed April 26, 1978 SP 1301-4.4, " Borated Water Storage Tank," Revision 5, completed
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March 16 and April 13 and 27, 1978 SP 1301-4.6, " Station Storage Batteries - Required Interval
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Weekly," Revision 3, completed April 6,13, 21, and 28,1978 SP 1301-4.8, " Primary Coolant Isotopic Iodine Analysis,"
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Revision 1, completed March 31 and April 7, 14, 21, and 28, 1978 SP 1301-5.7, " Spent Fuel Pool," Revision 2, completed March
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21, April 24, and May 21, 1978 SP 1301-5.7, " Station Batteries," Revision 1, completed March
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15, April 21, and May 25, 1978 SP 1301-4.16, " Emergency Power System," Revision 12 completed
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April 13 and May 11, 1978 (EGY-1A) and April 17 and 19, and May 13 1978 (EGY-18)
The work requests and procedures were reviewed to verify the following items.
Systems disturbed during the refueling outage were returned to
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service in accordance with approved procedures.
The control rod withdrawal sequence and rod withdrawal author-
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ization were available and in effect prior to the startup after refuelin.
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Weekly, biweekly, or monthly surveillance tests were performed
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during the refueling outage as required by Technical Specifi-cations.
The inspector noted the following examples of noncompliance with administrative controls for procedure implementation and revision.
Changes had been made to OP 1103-2 (completed April 18, April
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26, and April 28,1978) and OP 1104-2 (completed June 27, 1978).
The changes, although minor in nature, were not approved, reviewed and documented as required by SAP 1001.
OP 1104-2 (completed June 27,1978) had been used for multiple
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startups and shutdowns of the makeup and purification system performed on April 25, April 28, June 22, and June 27, 1978, vice completing applicable portions of the procedure for each evolution.
In addition, OP 1104-2 did not indicate full com-pletion of all required steps for system startup on June 27, 1978.
OP 1104-4 (completed April 28 and June 22, 1978) did not
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indicate completion of steps in Enclosure (1), Startup Valve Checklist, as well as other steps in the procedure.
In addition, the procedures required completion of an Enclosure (2) which did not exist.
OP 1103-8 (performed for the post-refueling approach to criti-
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cality on April 28,1978) could not be located and was apparently lost.
The inspector stated that the above items, and a similar item described in paragraph 5 were considered collectively as an item of noncompliance, deficiency level of severity (289/78-19-01).
Except as noted above, the inspector's findings were acceptable.
5.
Surveillance of Core Performance and Reactivity The inspector reviewed one month samples of data sheets from the procedures listed for the time periods noted below to verify that axial power imbalance, quadrant power tilt and reactivity anomaly were within Technical Specification limits.
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SP 1301-1, " Shift and Daily Checks" Revision 23, for September
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1978 SP 1301-9.5, " Reactivity Anomaly," Revision 16, for the period
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August 28, 1978 through October 31, 1978 The inspector noted that the data sheet, P. 4.0, Enclosure (2)
to SP 1301-9.5, performed on October 31, 1978 contained an apparently erroneous entry for Step 3.a., the power correction to reactivity.
The listed value was not used in the computation of reactivity anomaly, however, another value (the correct value) was used.
The incorrect, listed value was not discovered in the subsequent check and approval on October 31, 1978.
The final calculated value for reactivity was verified to be correct by the inspector.
The inspector stated that failure to log correct data and identify the erroneous data during review was considered another example of an item of noncompliance, described in paragraph 4 (289/78-19-01).
Except as noted above, the inspector's findings were acceptable.
6.
Review of Plant Operations a.
Shift Logs and Operating Records The inspector reviewed the following logs and records.
Shift Foreman Log, Control Room Log Book, Control Room
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Operator's Log Sheets, Primary Auxiliary Operator's Log-Tour Readings, Primary Auxiliary Operator's Log-Liquid Waste Disposal Panels, Secondary Auxiliary Operator's Log Sheets, and Auxiliary Operator Log Sheets-Out-Building Tour, dated August 14-November 12, 1978 Shif t and Daily Checks, dated August 9-November 1,1978
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Jumper, Lifted Lead, and Mechanical Modifications Log
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(active and cleared); entries made during August 16-November 14, 1978, and selected active entries Fire System Removal from Service Notification Log; entries
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made during August 15-November 14, 1978 Applications for Apparatus to be Taken Out of Service;
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-those active on November 15, 1978, and those cleared, dated October 21-November 15, 1978
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Do Not Operate and Caution Tag Log; entries made during
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August 16-November 14, 1978 Transient Cycle Log Book; entries made during August 16-
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November 14, 1978 Unit 1 Operations Department Memo 78-11
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Station Superintendent's Operating Memos 5 and 6
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The logs and records were reviewed to verify the following items.
Logkeeping practius and log book reviews are conducted
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in accordance with established administrative controls.
Log entries involving abnormal conditions are sufficiently
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detailed.
Operating orders do not conflict with Technical Specifi-
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cations (TSs).
Jumper Log and tagging log entries do not conflict with
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TSs.
Jumper / lifted lead / mechanical modification and tagging
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operations are conducted in conformance with established administrative controls.
Problem identification reports confirm compliance with TS
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reporting and LC0 requirements.
l Acceptance criteria for the above review included inspector judgment and requirements of applicable Technical Specifi-cations and the following procedures.
Station Administrative Procedure (SAP) 1002, " Rules for
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the Protection of Employees Working on Electrical and Mechanical Apparatus," Revision 13 SAP 1010, " Technical Specification Surveillance Program,"
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Revision 12
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SAP 1011
" Controlled Key Locker Control," Revision'16
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SAP 1012, " Shift Relief and Log Entries," Revision 8
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SAP 1013 " Bypass of Safety Functions and Jumper Con-
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trol," Revision 7 SAP 1016, " Operations Surveillance Program," Revision 12
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SAP 1033, " Operating Memos and Standing Orders," Original
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SAP 1037, " Control of Caution and DN0 Tags," Revision 1
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Findings were acceptable, as noted below.
Control Room Log Book entries continued to be explicit
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and complete.
During review of the Jumper, Lifted Lead and Mechanical
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Modifications Log the inspector noted that lifted leads
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Licensee representatives stated that the continued use/
disposition of these lifted leads would be evaluated as I
required by SAP 1013.
The inspector had no further ques-tions concerning this item.
During review of the Do Not Operate and Caution Tag Log
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the inspector noted that the status of a few log entries was not correct.
Prior to the end of the inspection these minor discrepancies were corrected.
The inspector had no further questions concerning this item.
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Plant Tour l
At various times on November 8-9 and 14-17, 1978, the inspector conducted tours of the following accessible plant areas.
Auxiliary Building
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Turbine Building
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2 Control and Service Building
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Control Room
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Diesel Rooms
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Switchgear Rooms
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Inverter and Battery Rooms
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Makeup Pump Rooms
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The following observations / discussions / determinations were made.
Control Room and local monitoring instrumentation for
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various components and parameters was observed.
Radiation controls established by the licensee, including
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the posting of radiation and high radiation areas, the condition of step-of' pads, and the disposal of protective clothing, were observed.
Radiation Work Permits used for entry to radiation and controlled areas were reviewed.
Actual radiation levels were measured and compared with posted values throughout the plant.
Plant housekeeping, including general cleanliness conditions
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and storage of materials and components to prevent safety and fire hazards, was observed.
Systems and equipment in all areas toured were observed
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for the existence of fluid leaks and abnormal piping vibrations.
Selected piping snubbers / restraints were observed for
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proper fluid level and condition / proper hanger settings.
The indicated positions of electrical power supply breakers
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and selected control board equipment start switches and remote-operated valves and the actual positions of selected manual-operated valves were observe.
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Selected equipment lockout tags, caution tags, and Do-
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Not-Operate tags were observed for proper posting and the tagged equipment was observed for proper positioning, where applicable.
Selected jumper and lifted lead markers were observed for
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proper identification and the effected wiring changes were observed for proper completion.
The Control Board was observed for annunciators that nor-
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mally should not be lighted during the existing plant conditions. The reasons for the annunciators were dis-cussed with control room operators.
The licensee's policy and practice regarding plant tours
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was reviewed.
Control Room manning was observed on several occasions
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during the inspection.
Acceptance criteria for the above items included inspector judgment and requirements of 10 CFR 50.54(k), Regulatory Guide 1.114, applicable Technical Specifications, and the following procedures.
SAP 1002, " Rules for the Protection of Employees Working
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on Electrical and Mechanical Apparatus," Revision 13 SAP 1003, " Radiation Protection Manual," Revision 12
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SAP 1008, " Good Housekeeping," Revision 4
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SAP 1009, " Station Organization and Chain of Command,"
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Revision 3 SAP 1028, " Operator at the Controls," Original
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SAP 1037, " Control of Caution and DN0 Tags," Revision 1
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The inspector's findings were acceptable.
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7.
In-Office Review of Licensee Event Reports (LERs)
The LERs listed below were reviewed in the Region I office promptly following receipt to verify that details of the event were clearly reported including the accuracy of the description of cause and the adequacy of corrective action.
The LERs were also reviewed to determine whether further information was required from the licensee, whether generic implications were involved, whether the event should be classified as an Abnormal Occurrence, and whether the event warranted onsite followup.
The following LERs were reviewed.
LER 78-23/3L, dated August 30,1978 (During a power reduction
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for turbine stop valve testing, incore detector quadrant tilt limit of 3.64% was exceeded for 50 minutes)
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LER 78-24/1T, dated September 1,1978 (Personnel error during
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switching and maintenance tagging operations left two nuclear river water pumps incapable of automatic start)
- -- LER 78-26/3L, dated September 15,1978 (Reactor Building per-sonnel access hatch inner door was jammed open due to worn and misadjusted drive train components)
- -- LER 78-27/lT, dated September 15, 1978 and Undate LER 78-27/1T, dated October 27,1978 ("B" Core Flood Tank level was found to be less than required due to out of calibration level transmitter)
- -- LER.78-28/lT, dated September 22, 1978 (Sodium hydroxide star-age tank was found to contain more than the maximum limit for Na0H, due to tank level / transmitter error by leaky 0-rings and calibration drift)
- -- LER 78-29/lT, dated September 28, 1978 (Fire watch was not
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established within one hour, when a temperature sensor for the
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"A" Emergency Diesel Generator Room was found to be inoperable l
during surveillance testing)
LER 78-30/3L, dated October 20, 1978 (Miscellaneous evaporator
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i heater element cladding rupture, due to crud buildup in the evaporator tank which developed a hot spot in the heater element)
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The above LERs were closed based on satisfactory review in the Region I office, except tho:e LERs selected for oniste followup.
8.
Onsite Licensee Event-Followup For those LERs selected for onsite followup (denoted in paragraph 7), the inspector verified that the reporting requirements of Technical Specifications and GP 4703 (Original) had been met, that appropriate corrective action had been taken, that the event was reviewed by the licensee as required by Technical Specifications, and that continued operation of the facility was conducted in conformance with Technical Specifications limits.
The inspector's findings regarding these licensee events were acceptable, unless otherwise noted below.
LER 78-24 described the potential use of atypical weld wire in
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the construction of the TMI-l reactor vessel. B&W letter to MEC dated August 4, 1978 provided confirmation of the generic problem to the facility and included drafts of required changes to heatup and cooldown. rates listed in Technical Specifications, assuming the atypical weld material was used.
B&W letter to MEC dated August 16, 1978 provided proposed revisions to Technical Specifications covering revised pressure-temperature curves for heatup/cooldown and inservice leak and hydrostatic testing.
MEC letter to NRC (NRR) dated August 18, 1978 stated that heatup/cooldown will be in accordance with B&W's recommended rates and P-T limits and that procedures will be revised and revised Technical Specifications will be submitted upon completion of the B&W evaluation.
The B&W evaluation was recently completed and the licensee expects to submit applicable revised Technical Specifications as soon as possible.
As an interim administrative measure, Operations Department Memo 78-11 dated August 22, 1978 was issued to provide a revised heatup/cooldown curve for facility operation. The inspector noted that formal procedure revisions have not yet been implemented.
Licensee representatives stated that OPS Memo 78-11 h'A been in effect longer than originally planned, due to deinys in obtaining the final B&W evaluation of the probl em. However, applicable procedure revisions would now be implemented expeditiously. This item is unresolved pending ccmpletion of applicable Technical Specification and procedure revision. (289/78-19-02)
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LER 78-25 described in the inability of the two inservice
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nuclear river water pumps to start on an emergency safeguards signal, due to improper switching and tagging manipulations.
The LER stated that a procedure change would be made requiring ES selector switch positions to be added to switching orders.
The inspector noted that applicable switching orders have been completed properly.
However, Station Administrative Procedure 1002 has not yet been revised, although PCR 656 was initiated on August 21, 1978.
The inspector further noted that PCR 656 was still being held for review by TMI 2 personnel due to conflicts in implementing the change as written.
Licensee representatives stated that this matter would be tracked by PORC and the differences between the unit staffs concerning PCR 656 would be resolved.
This item is unresolved pending applicable revision of SAP 1002. (289/78-19-03)
LER 78-27 described the determination that the "B" Core Flood
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Tank level was less than required due to out of calibration level transmitters.
Change / Modification 1165 has been initiated to replace the core flood tank level transmitters with those of a different design.
Replacement is anticipated to take place during the 1979 refueling outage, pending approval of C/M 1165 and availability of equipment.
This item is unresolved pending approval and completion of C/M 1165. (289/78-19-04)
9.
IE Circular Followup The inspector reviewed the licensee's followup actions regarding the IE Circulars listed below.
IEC 78-15, " Tilting Disk Check Valves Fail to Close wit'
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Gravity in Vertical Position," dated July 24, 1978 IEC 78-16, "Limitorque Valve Actuators," dated July 26, 1978
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This review included discussions with licensee personnel, review of selected facility records, and observation of selected facility equipment and components.
With respect to the above Circulars, the inspector verified that the circular was received by appropriate licensee management, a review for applicability was performed, and that action taken or planned is appropriate.
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Acceptance criteria for the above review included inspector judge-mat and requirements of applicable Technical Specifications and facility procedures.
Licensee followup to the above Circulars was acceptable, unless ethswise noted below.
.t PORC review of IE Circular 78-15 is being tracked by PORC
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Action Item (PAI) #78-40-01.
The cognizant engineer deter-mined that all tilting disk type containment isolation check valves and check valves under ISI scope were installed in a horizontal piping run, except MU-V73A-C, EF-VllA/B, EF-V13, and DH-V22A.
The valve vendor informed the licensee that these valves should function properly in a vertical piping run, unless excessive valve wear is experienced.
The vendor recomended a minor modification of each valve to assure maximum operational reliability in a vertical piping run.
The modification consists of installing a valve bonnet plug which limits the valve disk travel when open.
MU-V73A-C have been satisfactorily tested on a quart'erly basis per SP 1300-3H, and the remaining valves are infrequently operated and thus are not subject to excessive wear.
However, the licensee plans to complete the vendor recommended valve modification on each of the above valves during the 1979 refueling outage.
The inspector had no further questions concerning the licensee's actions regarding IEC 78-15.
PORC review of IE Circular 78-16 is being tracked by PAI #78-
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34-02, scheduled for completion by December 1,1978.
Generation Engineering-Electrical Section has been assigned to review the applicability of Limitorque valve actuator problems at TMI Unit 1.
This item is unresolved pending licensee completion of IEC 78-16 review and determination of necessary corrective actions.
(78-19-05)
10.
In-Office Review of Periodic Reports The periodic reports listed below were reviewed in the Region I office to verify t;at the report included information required to be reported and that test results and/or supporting information discussed in the report were consistent with design predictions and performance specifications, as applicable.
The reports were also reviewed to ascertain whether planned corrective action was adequate for resolution of identified problems, where applicable, and to determine whether any information contained in the report sMuld be classified as an Abnormal Occurenc _ _.
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The following TMI 1 periodic reports were reviewed.
August Operating Report, dated September 11, 1978
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. September Operating Report, dated October 10, 1978
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The above reports were closed based on satisfactory review at the Region I office.
11.
Unresolved Items Unresolved items are matters about which more information is re-quired in order to ascertain whether they are acceptable items, items of noncompliance, or deviations.
Unresolved items disclosed during this inspection are discussed in Paragraphs 8 and 9.
12.
Exit Interview The inspector met with the licensee representatives (denoted in Paragraph 1) at the conclusion of the inspection on November 17, 1978. The inspector summarized the purpose and scope of the in-spection and the findings.
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