IR 05000289/1990011
| ML20043E711 | |
| Person / Time | |
|---|---|
| Site: | Crane  |
| Issue date: | 06/01/1990 |
| From: | Eapen P, Gregg H NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML20043E709 | List: |
| References | |
| 50-289-90-11, NUDOCS 9006130310 | |
| Download: ML20043E711 (9) | |
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U. S. NUCLEAR REGULATORY COMMISSION
REGION I
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Report No. 50-289/90-11 Docket No. 50-289 l
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License No. OPR-50
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Licensee: GPU Nuclear Corporation P. O. Box 480
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Middletown, Pennsylvania 17057 Facility Name: Three Mile Island Unit 1 Inspection At: Middletown, Pennsylvania and Parsippany, New Jersey Inspection Conducted:
May 3-15, 1990 Inspector $ r f M 0 h u A,
$-3 /- 90 Harold Gr g,
eniorfgactorEngineer date 8///94
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Approved b :
h/06P.K.Eapen, Chief,SpecialTest w
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L 4 rograms Section, EB. DRS Inspection Summary:
Routine unannounced inspection on May 3-15, 1990 (Inspection Report 50-289/90-11).
Areas' Inspected: Design, design changes and modifications, installation and
testing of modifications, on site and corporate engineering interface, i
l technical support of site activities, engineering organization and its capability, staffing and management support.
l-Results: No violations were identified.
Design modifications and testing of
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modifications were appropriately performed and engineering and technical support of activities was effective. One unresolved item was identified
' involving a requirement to be placed on mechanical maintenance procedures.
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9006130310 900604 PDR ADOCK 05000289
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Details 1.0 Individuals Contacted 1.1 GPU Nuclear Corporation (TMI-1 Site)
- R. Barley
' Manager, Plant Engineering (Mechanical)
J. Bashista Mechanical Engineer T. Basso -
Mechanical Engineer G. Broughton Director, Operations and Maintenance J. Caputo Senior Designer, Engineering Services R. Gloviano Manager, Technical - Functions
- K. Harkless
. Engineer, Independent Safety Review Group
- R. Harper Plant Materiel Director l
C. Hartman Manager, Plant Engineering (Electrical)
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- R. Knight Licensing Engineer
- C. Patton Start-Up and Test Manager C. Payne Document Control Specialist
- L. Porter Project Engineer, Technical Functions
- M. Press Quality Assurance Lead Auditor (
P. Snyder Manager, Plant Materiel Assessment R. Stoehr Mechanical Engineer R. Summer Lead Mechanical Engineer
- G. Skillman Plant Engineering Director
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1.2 GPU Nuclear Corporation (Corporate Office)
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- A. Asarpota Manager, Projects TMI-I
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L. Budin Supervisor, Design and Drafting A. Edelson Project Engineer
- J. Flynn Engineering Services Director J. Mataychick-Project Engineer i
- R.
McGoey Manager, PWR Licensing L
- P. Moor Projects Director TMI-1 E. Pagan PWR Licensing Engineer
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- M. Radvansky Manager, Engineering Services / Design and Drafting
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l T. Richter Project Engineer
- C. Shorts Manager, Projects TMI-1 D. Slear Plant Systems Director
- R. Wul f Manager, Plans and Schedules 1.3 U.S. Nuclear Regulatory Commission R..Brady Resident Inspector D. Johnson Resident Inspector l}
- F.
Young Senior Resident Inspector
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- Denotes those present at exit meeting on May 11, 1990
- Denotes those present at exit meeting on May 15, 1990
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2.0 Scope The scope of the inspection was to review the engineering support of design modifications and their installation and testing to assure that the requirements of the design change were satisfied and that required calculations, safety evaluations and testing were included in the design modifications.
Cooperation between site and corporate engineering, interface between plant engineering and
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other site organizationr. capabilities of the engineering organizations, staffing
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and management support of engineering were also assessed.
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3.0 Engineering and Technical Support 3.1 Design and Testing of Modification (37700 and 37828)
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3.1.1 Plant Engineering Design Change Activities Selected completed and in process Design Change Request corrective actions and support of surveillance activities were reviewed by the inspector and included:
Relocation of flow indicators and reconfiguring piping in the seal water
flow to the Reacter (Rx) coolant pumps, to resolve problem of inaccurate Rx pressure boundry leak rate. Good engineering determination of problem cause and resolution were made.
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Replacement of 3/4"-2" Steam Generator (SG) skin valves and other valves
of this type which had been the source of problem leaks at the body to yoke joint.
The old valves were 600 class bolted "T" pattern globe valves
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and the new valves are 1500 class "Y" pattern globe valve of the bonnetless type.
The inspector verified that a seismic evaluation of the new increased weight valves was considered.
Continuing packing upgrade to change out asbestos packing with graphite
filament end rings, and radially wrapped and preformed grafoil center rings.
The packing upgrade also includes the use of live load packing in motor operated valves (MOVs) in feedwater and condensate-systems. Good initiatives were shown in elimination of asbestos and use of live loading.
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Use of new John Crane style split mechanical seal on heater drain pump
HD-PIC, to facilitate maintenance without removing bearings.
There was good engineering-maintenance interface to provide input to the vendor to further improve the seal.
Several leaking packing seals have been replaced with standard type mechanical seals on closed cooling and decay heat closed cooling pumps. A high level of engineering expertise was evident in mechanical seals.
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Control Rod Drive Mechanism (CRDM)' change modification to install replacement
gaskets on 14 leaking CRDM flanges and installation of modified split nut rings on these assemblies. This involved remote camera viewing of the underside of the CRDM flanges and reactor head to find the leaking flanges and boron crystal buildup on the head and flanges. Engineering was fully-involved with this effort.
Support of the BR outage SG tube eddy current testing and the eddy current
testing performed for the first time on steam generator plugs.
Plug testing was done in response to B&W information concerning pure water stress corrosion cracking of Inconel 600 plug material.
The plug testing resulted in removal of all plugs from two questionable heats (except for 1 plug that couldn't be removed and was rewelded) and 8 plugs with indications from a third heat, all replacement plugs were of recommended Inconel 690 material. Good engineering involvement and a conservative approach was evident in this effort.
Review of Plant Engineering actions regarding Generic Letter GL89-04
guidance on IST programs and Information Notice IN88-70 on Check Valve Inservice Deficiencies. A thorough re-evaluation of the IST program was made by the licensee's staff and resulted in additional valves placed in the program, forward and reverse check valve testing and disassembly inspections in accordance with the GL. The engineering actions have been thorough and conservatism and a high' degree of knowledge of IST was exhibited. The licensee's responses have been drafted and are presently being reviewed for release.
3.1.1.1 Review of Problem Areas Several problem areas identified by NRC and self identified by the licensee were reviewed during the inspection and are described in the following paragraphs.
A high and increasing backlog of engineering evaluation requests (EER) and
inappropriate actions in several EERs was identified as a weakness in a recent NRC maintenance inspection. Action is presently being taken by the licensee and a list of Mechanical items was broken down by personnel assignment and chronology of the item. The data is being reviewed by the new manager of Engineering and is to be resolved with the personnel, however, it is in the preliminary action stage. During discussions held during the inspection the Manager of Plant Engineering stated he intends to have EER reduction results by July 1990.
The licensee self identified that a large number of FCR/FCNs are associated
with plant modifications.
Site and TF engineering recognize that excessive numbers of changes could result in project delays and effect quality of the work and have initiated efforts to reduce the FCR/FCNs.
Recommendations have been made, meetings were held regarding the problem and implementation of recommendations are underwa _
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The licensee' determined that meetings at Corporate (Projects and E&D) have
not been as well attended by site engineering as deemed appropriate. As a-result the meetings are being rescheduled from Fridays to Thursdays to facilitate travel and the agenda will provide more of a description of the item to be presented so that plant engineering can better determine the need for attending.
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During the review of a prior closed-out inspection item 89-13-03' relating
to' work performed on MOVs that would require re-establishing torque switch base values or that would require an engineering evaluation, the inspector identified an item of concern. The electrical corrective maintenance procedure 1420-LTQ-1 defined thn conditions that would require evaluation,
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similar procedures 1410-V-13 and 1410-V-40 for mechanical valve packing corrective maintenance did not have similar requirements-nor.was the mechanical engineer knowledgeable of the electrical procedure change.
This shows some lack of communication which appears to be an exception
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rather than the rule because good _ communications were evident throughout
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the inspection. This item is unresolved pending the licensee's updating-of the mechanical maintenance procedures to incorporate appropriate rebase requirements similar to the electrical procedure (50-289/90-11-01).
3.2.1 Review of Site Technical Functions Mini Mods and the Installation~
and Testing of the Mods BA 128086 (Mini Mod -059).
Radiation Monitoring system pump replacement
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.of Roots pumps which by design feature leak from the pump shaft seal, thus small quantities of containment air leakage to the intermediate
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building had the potential for increased hazards. The pumps were replaced with Eberline pumps to eliminate this source of leakage.
This installation
.was performed by plant maintenance and post installation testing was verified to have been performed by maintenance.
BA 412512 (Mini Mod 135). Connection of Main Feedwater Pump bearing oil
pressure trip signal to the plant computer as an outcome of the Safety Performance Improvement Program (SPIP) recommendation. Testing was verified to have been performed by the TF start-up and test group under master test index MTX 0948.2 BA 41258 (Mini Mod 129).
Installation of 4 isolation valves in the steam
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. lines to the heated posts supporting the MSSV piping to enable isolation L
of separate trains during power operation. This mod was installed and tested by plant maintenance and surveillance for thermal clearance was verified to have been performed.
The work packages for the above mods were complete with clearly written installation specifications, safety evaluations, work descriptions and testing l
requirements.
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3.3.1 Review of Corpcrate Office Engineering Activities The inspector reviewed several corporate engineering activities that support the TMI-1 site. These activities included projects performed by several Technical Functions departments.
3.3.1.1 Drawing Legibility program This project was performed by the Design and Draft.ing Department and was initiated early in 1989. A combined review, by corporate and site engineering, was made of 1500 R1 class control room drawings a'nd the determination was made that 500 drawings needed legibility improvements.
The project was performed in-house and was completed in May 1990.
Several before and after examples of di*awings were reviewed by the inspector and the legibility enhanced drawings were significantly improved.
Another activity in the final stage of completion was the extensive undertaking of replacing 25,000 circuit schedule drawings by placing the infrrmation in a computer data base.
The data for all cables (numbers, colors, p irs, routings,
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landing contacts, etc.) was verified to be readily accessible from the computer data base.
3.3.1.2 Engineering Projects Major Modifications Main Feedwater (FW) Flow Venturi replacement (BA 412565), to improve flow
accuracy and eliminate power output loss, Several flow transitions, one in cylce 6 and one in cycle 7 (one on each venturi), i,hought to be caused by fouling in the olti venturi's initiated this project.
The two new venturi's, one in each FW train, are 20" Leeds and Northrup Model UVT with electropolished flow elements. The new venturi assemblies are flanged to facilitate cleaning or removal and also have a flanged inspection port.
Initial flow calibration testing was done at Alden Laboratories at flows of approximately 30*f power (the limit of the test facility).
The Combustion Engineering Chem Trac process which utilizes a lithium tracing technique was used at the sitt to determine discharge coefficients at 30%, 75*;, 90*4, and 100*4 pover conditions.
Final coefficient determinations are now in process.
In depth engineering was performed on this project and a comprehensive testing program was developed and carried out.
- Instrument Air Modification (BA 412551), that was an outcome of the SPIP program.
This modification to install an additional larger capacity air compressor will improve reliability of the instrument air system and will eliminate the need for the use of service air in casualty type events.
The tie-in isolations were installed during 8R and the other components dre on site for installation during Cycle 8.
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Upgrade of Rx Coolant Pump Lube Oil System (BA 412512), to improve
reliability and maintenance. This was also an outcome of the SPIP program.
The modification replaced the mechanical joints with weld joints, replaced copper tubing with stainless steel, and provided remote lubrication capability for reliability and radiation exposure improvements.
The work for the upper reservoirs was completed in BR and the lower reservoir work is scheduled for 9R.
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Feedwater Flow Nozzle Replacement (BA 128135), was an extensive effort in
which 32 nozzles on each OTSG were replaced. This work was performed with in-house personnel and there was in depth consultation with B&W and direction of construction crews by the licensee's staff.
Cold Leg Nozzle Dams (BA 412562), was another extensive effort involving
B&W and Projects interface and control of the welding and dam contractors.
Reactor Building Permanent Maintenance Platform Installations (BA 412540)
to facilitate maintenance and reduce radiation exposure.
Projects Engineering was involved with prework walkdowns and there was interface with Plant Engineering, Quality Assurance and the Architect Engineer.
The inspector verified that seismic review was performed due to attachments made to the contain-ment structure and dynamic load consideration in event of a pipe break, and thermal growth considerations were evaluated.
Replacement of the Gaseous Chlorine System (BA 41257), had considerable
projects involvement with EPA to enable removal of the gaseous chlorine safety hazard, and approval has been requested for using non gaseous compounds in the closed loop and in the open loop cooling systems.
Chemical Cleaning of OTSG (BA 128128) that is.ontemplated in 9R to
eliminate the magntU te oxide corrosion build-up on the tubes that lodge at the brocch plate support locations. This effort has a high priority and high level Projects Engineering involvement.
The cleaning process to be used, develped by EPRI and PWR NSSS vendors, is a fill and flush chemical process which places the corrosion products into solution to enable their removal. B&W will be the vendor to perform this project.
3.3.1.3 Engineering and Design (E&D) Activities Design Basis Documents (DBDs). Two DBDs were completed in 1989 for the
i pilot program. They were for the Reactor Building Emergency Cooling Water l
and the Liquid Rad Waste systems. The DBDs provide the WHY answers of the system and component design function.
The DBDs define the requirement of the system and equipment and provide the basis and background to enable l-the Why questions to be answered. Action items that result from DBDs are assigned tracking codes and those of preliminary safety concerns have assigned times for completions.
For 1990 the licensee plans to complete 5 DBDs that include Reactor Coolant System, Reactor Protection System, Main Steam System, Control Building HVAC System, and Emergency Safeguards l
Actuation System.
The inspector noted that some 30 DBDs are in the overall l
plan for TMI-1.
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Safety System Functional Assessments (SSFIs). The first out-of-house $$FIs
were performed in 1989. Two were performed and they were for the Liquid Rad Waste and the Emergency Power Distribution systems.
The inspector reviewed the SSFI reports and concluded they were well performed, had meaningful findings resulting in actions to be taken.
The inspector
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reviewed the action list of one SSFI and noted there were due dates assigned and that the listing was updated as the items were completed.
For 1990 one SSFI will be performed for the Decay Heat / Low Pressure Injection system.
For this SSFI, the licensee intends to include an additional team member from the Independent safety Review Group.
The inspector reviewed several current activities that have high E&D
involvement.
These were the support of site on the issue of SG 1evel and reduced power due to corrosion build-up on the tubes.
In this activity the inspector noted a strong interface with site engineering and operations.
Another activity of E&D involvement that appears to be a proactive under-taking is in the thermal fatigue area.
In this effort the licensee is performing extensive transient monitoring and assessment of many nozzles and pressure components to assure that usage limits are satisfactory.
3.3.1.4 Engineering Services Activities Technical Support Self Assessment (TSSA).
The inspector determined that a
TSSA had been completed March 29, 1989.
A review was made of the report and the updated action items list of January 3,1990, and verified that the licensee has completed the majority of items.
Backlog of Technical Functions Assigned Actions. The inspector reviewed
the backlog listing from December 1988 through March 1990 and noted a sizable reduction in backlog in the first half of 1989. The backlog through Farch 1990 was constant and appears manageable. The licensee's graphical backlog format has gone through several evolutions and depicts the new items coming in, items over six months, and items of earlier vintage.
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early vintage items are minimal and the others are remaining generally constant over the past 8 months, 3.4.1 Overview of Engineering and Technical Support
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The engineering staff at site and corporate was technically competent and are responsive to self identified and NRC identified issues.
Effective involvement i
was evident by site and corporate engineering for each of the inspection areas.
In the change modifications, site engineering made appropriate determinations i
of problem causes and their resolution, initiative and high levels of expertise were evident and conservative actions were taken.
Site engineering was responsive to administrative problem issues and takes rapid action to correct them.
Corporate engineering activities of major and mini projects, engineering design efforts, and engineering services in support of the site have been extensive and meaningful. There is good communications between corporate and site
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engineering and managenient is supportive in both areas. A team approach and the desire for continued improvement was evident during the inspection.
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4.0 Unresolved Items
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Unresolved items are matters about which more information is required in order to ascertain whether they are acceptable items, violations or deviations. An unresolved item is discussed in paragraph 3.1.1.1 of this report.
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5.0 Exit Meeting The inspector met with the licensee's representative at'the conclusion of the inspection on May 11,.1990 at the TMI-1 site and May 15, 1990 at the Corporate office, to summarize the findings of this inspection.
During this inspection, the inspector did not provide any written material to the licensee. The licensee did not indicate that the inspection involved any proprietary information.
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