IR 05000289/1993006
| ML20035F332 | |
| Person / Time | |
|---|---|
| Site: | Crane  |
| Issue date: | 04/12/1993 |
| From: | Eapen P, Gregg H NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML20035F327 | List: |
| References | |
| 50-289-93-06, 50-289-93-6, NUDOCS 9304210164 | |
| Download: ML20035F332 (7) | |
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U.S. NUCLEAR REGULATORY COMMISSION
REGION I
REPORT NO.
50-289/934)6 DOCKET NO.
50-289 LICENSE NO.
DPR-50 LICENSEE:
GPU Nuclear Corpontion P.O. Box 480 Middletown, PA 15057 FACILITY NAhE:
Three Mile Island - Unit 1 INSPECTION AT:
Corporate Engineering Office, Parsippany, New Jersey, and TMI-1 Nuclear Station, Middletown, Pennsylvania INSPECTION CONDUCTED:
February 8 - 12,1993 (corporate);
and March 16 - 19,1993 (site)
E!73 INSPECTOR:
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H. I. Gregg, Sr. Ae/ctor Engineer Efate'
Systems Section, EB, DRS (2./f ]
APPROVED BY:
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f Dr. P. K. Eapen, Chfef, Systems Section Date Engineering Branch, DRS Areas Inspected: Design modifications in process and completed, corporate and site activities in support of TMI-1, and overall communications between corporate and site engineering.
Results: Design modifica6ons are intended to enhance nuclear safety, improve equipment performance, and reduced radiation exposure. Engineering has been aggressive in performing design bases document reconstitutions. Licensee's task action item commitments and engineering evaluation request performance were notably improved. Drawing improvements continue to be implemented.
9304210164 930414 PDR ADOCK 05000289 PDR G
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1.0 DESIGN CIIANGES AND ENGINEERING SUPPORT (37700)
The objectives of this inspection were to review the licensee's corporate and site engineering activities in support of design changes and modifications, and to assess the licensee's safety j
perspectives related to these changes. Other new and ongoing corporate and site engineering
programs were also assessed from a safety and performance perspective.
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2.0 PRE-OUTAGE AND OUTAGE DESIGN MODIFICATIONS
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Several selected modifications installed during cycle 9 and to be installed in the 10R outage were reviewed by the inspector. Follow-up review of the effectiveness of several prior
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modifications was also performed. The modifications are discussed below:
Spent fuel pool partial reracking (BA-412076) replaced all eight old wall and base e
mounted storage racks with six new free-standing high density storage racks dunng i
cycle 9. The inspector determined that the first effort to straighten the slightly J
i misaligned C-1 rack did not fully enable fuel movement as originally intended and
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described in prior NRC inspection report 50-289/92-20. The licensee plans additional repositioning of this rack.
Spent fuel handling bridge upgrade (BA-412580-002) addressed a site need by l
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installing a motor system to permit bridge and trolley motion in 1/16 inch increments.
This was to facilitate removal and insertion of bowed or twisted fuel assemblies.
e Erosion / corrosion program (BA-128148). The inspector found the licensee's erosion / corrosion program to be effective, formalized, and procedurally controlled to enable continuing implementation. The program is continually updated and reflects all evaluations and performed activities.
e Heater drain pipe replacement (BA-412638). This modification intends to replace several sections of feedwater heater drain piping identified in the erosion / corrosion inspection evaluation as having significant reduction in wall thickness. Replacement piping will be 316L stainless steel that has superior erosion resistance than the thinned carbon steel piping.
Once-through steam generator tube sleeving (BA-412622). Sleeving of 125 additional e
lane wedge tubes, in each generator adjacent to the 125 lane wedge tubes sleeved in
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the last outage, will be performed in the 10R outage. This modification will complete the licensee's lane wedge sleeving program for the most highly prone to failu:e tubes i
as described in prior NRC inspection report 50-289/91-28.
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Reactor coolant pump vibration monitoring (BA-412616). Replacement of IRD l
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seismic velocity pickups with Bentley Nevada pickups and installation of Bentley l
Nevada dual-plane monitors in the control rooms provide an upgraded and fully j
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com; * vibration monitoring system. Vibration monitoring can be performed from contr m indication and from plant computer output.
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EIM motor actuator replacements (BA-412611). The EIM actuators on four butterfly i
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i valves required to be tested to meet provisions of generic letter 89-10 will be replaced j
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by Limitorque actuators. The EIM actuators can't be diagnostic tested and safety-
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related part replacements are not available.
High pressure injection piping support upgrade (BA-412633). The licensee is
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upgradmg 31 supports, essentially all high pressure injection piping, inside
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j containment to withstand movement of the system at 554*F piping temperature. The NRC Information Notice, 89-36 concern of a check valve failure that caused high
i temperatures in a similar plant, initiated the support upgrade actions.
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i Rosemount replacements of Foxboro transmitters (BA-412623). Eleven Foxboro i
e transmitters are being replaced due to equipment obsolescence. Eight replacements j
are for monitoring steam generator level for the heat sink protection system, and three l
are for monitoring reactor coolant pressure for the engineering safeguard actuation system.
Reactor coolant pump seal leakoff provision (BA-412635). The licensee is installing a
e leakoff connection on each reactor coolant pump seal injection line intended to
i facilitate maintenance. The modification is intended to eliminate removal of four confined space inaccessible flanged spool pieces, and the resealing of these flanged-
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joints.
The inspector reviewed each of the above modification design descriptions and safety
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evaluations and found them to be well planned, technically detailed, and fully descriptive of l
the required installation. This inspector performed a detailed review of the spent fuel pool j
partial rerack modification and the erosion / corrosion program, and concluded they were
effectively performed.
3.0 SITE ENGINEERING PERFORMED MODIFICATIONS i
Several completed and in-process modifications performed by site engineering were reviewed
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by the inspector as discussed below:
Reactor coolant pump seals. The 9R outage replacement of the lower alumir.um
oxide seals (#1 film riding seals) with silicon nitride seals and the licensee's unique j
installation of 0.2 micron seal injection filters have produced excellent results. The j
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verified, from the computer data, that seal leakage since cycle 9 startup on 11/16/91
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to 3/17/93 (present) has been r 'stant at 3 gpm or less for each of the four pumps.
Re ctor coolant pump cartndge seal installation (CMR-92-114) to be performed
during the 10R outage. This modification is to replace the upper seals (#2 and #3 a
rubbing seals) with the new unitized preassembled seal package developed by the
pump manufacturer. This modification is intended to simplify seal replacement, reduce radiation exposure, and enable test verification prior to installation.
Concurrent ILRT/LLRT (CMR-91-126). The licensee is planning to perform a
combined test ILRT and LLRT at the start of outage 10R. The change modification request provides for installation of additional test connections. The concurrent ILRT/LLRT is a unique plan and will require training, significant manpower dedication, and proceduralization to be effective.
4.0 DESIGN BASIS DOCUMENTS AND SAFETY SYSTEM FUNCTIONAL INSPECTIONS The licensee's design basis document (DBD) reconstitution progress continues to be a strength. Six DBDs, reactor building spray, low pressure injection / decay heat removal, main feedwater/ condensate, instrument air, high pressure injection / makeup, and extraction steam, were completed in 1992. A total of fourteen DBDs were completed at the time of this inspection. DBD plans for 1993 include reactor building cooling / industrial cooler reactor building purge, feedwater heater (vents and drains), and control rod drive. Additionally, open items from prior DBDs are contracted out for completion in 1993.
During 1992, the licensee performed safety system functional inspections (SSFI) for high pressure injection / makeup and the low pressure injection. The DBD for the low pressure injection system was in place at the time of the inspection. This inspection was most l
effective because the DBD provided the documented system performance basis that enabled i
the inspection team to focus on safety significant issues.
5.0 ENGINEERING AND DESIGN ACTION ITEMS The inspector reviewed the status of corporate engineering action items and performance in meeting assigned closeout dates. This was a problem noted in a prior NRC inspection. The inspector determined that the missed closeouts in the prior seven months have been reduced from 14% in May 1992 (46 missed out of 334 total) to 2% in January 1993 (only 7 missed out of 360 total), and the total number of assigned items was reasonable.
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The inspector reviewed the status of the site engineering evaluation request items. This had been noted as a concern in a prior SALP report. The backlog of 950 items identified three years ago had been successfully reduced to 221 items at the time of this inspection. More importantly, there was an organized system for assignment and completion of items with
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excellent management oversight.
The licensee les made significant performance improvements in meeting assigned action item
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commitment dates and in completing and systematizing plant engineering evaluation request items.
6.0 DRAWING CHANGE PRACTICES
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Recent completions of drawing upgrade programs has resulted in improved drawings. The special ihree-month reassignment of the design and drafting manager to review user needs
and existing practices and to recommend further improvements was recently completed.
Recommendations for improvements were made to: 1) perform class R-2 (a grouping of lesser priority construction and as-built drawings) drawing revisions in lieu of posting changes, 2) reformatting and expediting the as-found field change notice to appropriate personnel, and 3) simplifying the post modification process for closcout (rollup) of field change notice documentation. The licensee is actively involved in the drawing change process upgrade to revise approximately 1500 R-2 drawings on a six-month interval instead of the current practice of posting six changes prior to revising the drawing.
The inspector concluded the licensee's special assignment of the design and drafting manager to study and recommend additional drawing improvements a good licensee initiative.
7.0 TECHNICAL FUNCTIONS / ENGINEERING ORGANIZATIONAL CIIANGES Recent organization changes have taken place. Changes included the appointment of a new Vice President and Director of Technical Functions, an additional Projector Engineer in the motor operated valve program, reporting of the Site Shift Technical Advisors to the Technical Functions Site Director, and transfer of eight engino.:r assignments to the newly established site systems engineering organization. The licensee's program of planned downsizing has been accomplished through vacancy eliminations, attrition, transfers, and several personnel removals.
The inspector noted good communications between corporate and site engineering management and staff. Site engineering management has continued to attend the 6:30 a.m.
and 4:00 p.ni. shift turnover briefings to gain first hand knowledge of site problems.
8.0 PROCUREMENT ENGINEERING A fully staffed nine-person procurement engineering group was established within the plant engineering organization. Individual procedures that follow the Electric Power Research
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Institute guidelines and the direction of the Nuclear Management and Resources Council have been issued for processing a requisition for material, classification of parts, technical evaluation of replacement items, commercial grade dedication, and participation in performance-based supplier audits. The fully revised administrative procedure for purchase requisition review and approval was also issued. The inspector found the licensee's storeroom parts review program has effectively dispositioned 20,000 parts, and a significant number of appropriate parts dedications have also been performed. The procurement organization consists of engineers from varied engineering disciplines. By maintaining the group within engineering, the licensee has established effective interfaces between the procurement staff and requesting engineers.
9.0 EXIT MEETING The inspector met with the licensee's representatives at the conclusion of the inspection on February 12, 1993, and March 19, 1993, to summarize the findings of this inspection.
Attendees at the exit meeting are listed in Attachment 1. The licensee acknowledged the inspector's findings.
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ATTACIIMENT 1 Persons Contacted
GPU Nuclear
+A. Asarpota TMI-1, Project Engineer R. Barley Manager, Steam Generator Programs l
+G. Beaulke Manager, Engineering Projects, TMI-1
+G. Bond Director, Systems Engineering
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- S. DiVito Design and Drafting Supervisor, TMI-1
- F. Giacobbe Manager, Plant Engineering, Mechanical
- C. Hartman Manager, Plant Engineering, Electrical and I&C R. Keaton Vice President, Technical Functions
+D. Kelly Licensing Engineer
- M. Knight Licensing Engineer, TMI-I
+J. Knubel Licensing and Regulatory. Affairs Director
+S. Kowkabany Instrumentation Manager
+M. Laggart Manager, Corporate Licensing
+R. Markowski Manager, QA Program Development
+P. Moor Engineering Projects
- M. Nelson Manager, Nuclear Safety, TMI-1
+E. O'Connor Engineering Services Director
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M. Radvansky Manager, Design and Drafting T. Richter Project Engineer
- M. Shatto Procurement Engineer, TMI-1
- G. Skillman Plant Engineering Director
+ D. Slear Director, Engineering and Design
- S. Wilkerson Manager, Systems Engineering R. Zak Senior Licensing Engineer Commonwealth of Pennsylvania
- R. Janati Department of Environmental Resources U.S. Nuclear Reculatory Commission
- F. Young Senior Resident Inspector
+ Denotes presence at exit meetings on February 12, 1993.
- Denotes pmsence at exit meetings on March 19, 1993.