IR 05000320/1977032
| ML19220B738 | |
| Person / Time | |
|---|---|
| Site: | Crane  |
| Issue date: | 09/20/1977 |
| From: | Coleman W, Davis A, Rebelowski T NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML19220B716 | List: |
| References | |
| 50-320-77-32, NUDOCS 7904270281 | |
| Download: ML19220B738 (12) | |
Text
U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT Region I Report No.
77-32 Docket No.
50-320 License No. CPPR-66 Priority
--
Category B1 Licensee:
Metrooolitan Edison Comoany Box 542 Reading, Pennsylvania 19603 Facility Name:
Three Mile Island Nuclear Station, Unit 2 Inspection at:
Middletown, Pennsylvania Inspection conducted':
-st -19, 1977
7 M 97
Inspectors:
-
'
~
,factorInspector da'te signed P.
k 971(W/
00h9 W. E. Coleman, Re ctor Inspector date signed d a al ~, Reactor inspector du h7 aQ 7. A. RedeP wp:i
'date signed 9/'4 / 7 7 _
Approved by:
A
_,
A. B. Davis, Chief, Reactor Projects cate/sig..ed Section No.1, RO&NS Branch Inspection Sumary:
Inspection on August 8-19, 1977 (Recort No. 50-320/77-32)
Areas Insoected:
Routine, unannounced inspection of preoperational hot functional testing plant status; pipe and hanger supports; test results verification; startup and test quality assurance program audits; circular followup; precper-ational procedure review and previously identified unresolved items. The inspection involved 131 inspector hours onsite by three NRC inspectors.
Results: Of the eight areas inspected, no items of roncompliance were found in seven areas; one item of noncompliance was identified in one area (Infraction-Failure to initiate test exceptions or test change r.otices when test procedures were not followed-Paragraph 4.b).
Region I Form 12
-
i l
(Rev. April 77)
81 245
DETAILS 1.
Persons Contacted Metrocolitan Edison Ccmoany
- Mr. J. Hilbish, Station Nuclear Engineer
- Mr. J. Se.elinger, Superintendent for Technical Support General Public Utilities Serv;ce Corocrat;on (GPUSC)
Mr. A. Cominquez, Test Engineer
- Mr. R. Fenti, Site Lead QA Auditor Mr. J. Garrison, Test Engineer Mr. C. Gatto, Engineer Mr. T. Hawkins, Assistant Startup Test Superintendent Mr. S. Levin, Project Engineer Mr. C. McMullin, Test Engineer
- Mr. M. Nelson, Technical Engineer Mr. I. Porter, Engineer Mr. J. Roberts, i.ngineer
-
- Mr. R. Toole, Test Superintendent Mr. J. Ulrich, Test Engineer UE&C
Mr. D. Ryne, Senior Engineer Mr. G. Schmidt, Piping Supervisor The inspector also interviewed other licensee rep. asentatives and employees including members of the technical engineering and operational staff.
- Denotes those present at the exit interviews.
l 2.
Licensee Action on Previous Inspector'Findinos (Closed) Unresolved item 320/76-14-01, Implementation of preventive naintenance and surveillance.
Administrative Procedure 1016 has been revised. The implementation of preventive maintenance is contained in AP 1027 and is scheduled to begin 90 days prior to
. operating license issuance.
This item is resolved.~
,
-
-
L 81-346 I
,
I
,
(Closed) Unresolved item 320/77-03-07, Recording cause for main-tenance activity.
AP 1026, Corrective Maintenance and Machinery History has been revised to include on line 3 of Attachment 1, Work Request Approval, a descrintion of the malfunction and cause of the malfunction (if known)....
This item is resolveo.
(Closed) Inspector Follow item 320/77-09-05, Unit 1/ Unit 2 Inter-face. Superintendent Operating Memo #2 dated April 15, 1977, gives detailed instructicns for the sampling of extraction steam for radioactivity and the actions to be taken if contamination is found. This item is resolved.
(Closed) Noncompliance item 320/77-14-02, Failure to maintain i
'
oreper closure of Diesel Generator.
The inspector verified the licensee's cce ective action for this item during the performance of the preoperational testing on the diesel generators.
(Closed) Unresolved item 320/77-16-03, Preoperational charter for PORC. Superintendent Oparating Memo #3 dated May 23, 1977, addresses the clements of a PORC charter as contained in the FSAR Chapter 16 and requires the PORC to cor. duct business in accordance with those requirements from the date of the memo until the Operating License i
is issued. This item is resolved.
(Closed) Unresolved item 320/77-26-01, Record Storage.
AP 1024, Control of TMI QC Records has been revised by PCR 77-571 to contain-the requirements for storage of QC records for Unit 2.
This item is resolved.
(Closed) Unresolved item 320/77-26-10, Revise purpose and scope of AP 1012. AP 1012 Shift Relief and Log Entries have been revised to
-
address shift relief in the purpose and scope section.
This item is resolved.
(Closed) !inresolved item 320/77-10-O', Document on Diesel Generate.
fusable licks. The inspector reviewed the result of a test conducted on August 19, 1977.
Two fusable links were tested for separation temperature. The links sperated at 165.5*F.
This item is resolved.
3.
Plant' Status
.
During this inspection various plant conditions exited.
The follow-ing sumnarizes these changes.
(
.
e i
-
81 347
,
_ {
.
August 9, 4:00 p.m. com.enced pressurizer heatups August 10, 0:30 a.m. bubble in pressurizer August 11, 6:00 a.m. commenced heatup to 250 August 12, 6:30 a.m. at 250 August 15, 7:30 a.m. comenced heatup to 250 August 15, 3:00 p.m. at 350 August 15, 8:30 p.m. comenced heatup to 450 August 15,11:45 p.m. at 450 August 16, 5:15 p.m. comenced heatup to 532*
August 17, 0:30 a.m. at 532*
On August 18 at 6:30 p.m. a plant cooldown was comenced to allow cleanup of phosphates that had entered the steam generator.
The plant cooldown was in progress on August 19, 1976.
4.
Hot Functional Testina (HFT) - TP600/23 The licensee's hot functional test program consists of a sequence of tests performed on the reactor coolant system and various auxiliary systems as these systems are brought to the hot condition for the first time. The test program establishes base line data to measure system and component perfonnance during integrated operation.
The reactor coolant system (RCS) is heated to the hot conditions of 532*F, 2150 psig using heat from the reactor coolant pumps (RCPs),
maintained at 532 F for testing and then cooled down.
The licensee's HFT procedure, TP600/28, sequences and controls the heatups and cooldown evolutions and specifies the meaurements required at the established temperature plateaus of 250, 350*, 450*, and 532*F.
-
The RCS was at 120"F at the start of this inspection.
a.
Purpose The purpose of the inspection during HFT is to verify, through independent observations, evaluation and record review, that testing is conducted in acccrdance with the established pro-cedures and control.
Inspector witness of testing during the i'
inspection included observations made in the control room, the reactor building' and other areas in the plant.- - 81-248
b.
Test Witnessed The it.spector witnessed portions of the following hot functional tests and meaurements.
TP 273/3 Emergency Feedwater Pumos Functional Tests (1)
TMTX 59.71 The inspector witnessed the preparations, test run and reviewed results of the opere tion Erergency Feedwater The tect included flows at 10 and 25% of Pump 2 B.
system design with the automatic actuation of bearing cooling water.
The test preparations included a review of prerequisites The test run established dis-and test crew briefings.
charge pressures of 1550 psig at point 1 and 1510.psig at The bearing point 2 as plotted on pump flow curves.
temperature remained less than 160*F during the test run.
Additional test results for the 2A pump were reviewed and appear to meet the established criteria of +10% flows No significant vibration was f rom pump flow curves.
Prior noted in the pump or suction or discharge piping.
to the performance of the test run the hanger setting No inadequacies were group verified supports settings.
i dentified.
(2) TP 600/28 Control Frocedure for lift The licensee experienced difficulty in establishment (a)
Three of minimum oxygen req'uire,aents Jaring heatup.Problems days were required to establish chemistry.
were encountered with the RCPs.
RCP-2A dropped off A phase overload is being inve.ti-line, after start.
An oil leak in RCP 2B occurred and was torrected.
gated.
The inspector observed the accumulation of data fcr RCPs in areas of shaft vibration, seal injection, seal return and seal pressures and Core Flood Tank The operating procedure 2102-i.1, Unit Heatup, data.
as modified for HFT was the controlling document for operating personnel.
(b) The licensee failed to adhere to the Test !1anual T1-
-
9 instructions that requires the writing of an exception to the chemistry prerequisites if they are BAW 2050, February 18, 1974, Section 2.3.
not met.
8.2 specifies that LiOH for Control shall be within I
'
_
l
-
si as
-
a range of 0.2 to 2.0 ppm prior to heating Reactor Coolant system above 250 F.
On August 15, 1977, the licensee exceeded 250*F with a LiOH concentration of
.09 ppni at @938 hours.
'
Another example of failure to adhere to Test Manual Instruction TI-9 was also noted for TP 600/5.
(3') Tp 600/5 Chemical Addition and Samaling Ocerational Test The licensee heu partially compieted TP 600/5.
A review of the procedure determined that the licensee had failed to write an. exception to the test procedure in the area of prerequisites paragraph 4.1 for TP 210/12 Nuclear Chemical Addition System Functional Test MTX 15.6, prior to the performance of paragraphs 9.7.1 and 9.8.
Lithium Hydroxide Addition and ESF valve timing were perfonred
.
wiMout a review of the prerequisite tests for exception to test partially completed systems.
-
'
These examples of failure to control procedures with the required documented exception, as detailed in Test Manual T1-9, is an Item of Nonccmpliance of an Infraction severity level.
(77-32-01)
(4) TP 330/4 Integrated CRD System Test The inspector observed sections of TP 330/4 Integrated CRD System Test which included the balance of power supplies. The accuracy of the aLsolute and relative position indicator circuits and CRDM's operated in both
-
individual and assigned group tests.
,
(5) TP 600/30 HFT Checkooints The test pmcadure addresses miscellaneous tests such as Reactor P"ilding air temperatures, penetration cooling and shielo.ng concrete surface temperatures.
A review of data indicates concrete surface temperatures greater than
-
the established criteria of 150 F.
This item will be reviewed at a subsequent inspection.
(77-32-02)
%
(
..
.
.
t
-
i
-
81 250
(6) TP 401/1 Diesel Generator Functional Test The inspector ~ observed various sections of the Diesel Generator Functional Test including, overspeed trips, local and remote manual control, diesel fuel oil system operations, and air starting system oceration.
One area of concern was identified in that after five successive starts of the diesel generator without recharging of the
.
air system the air reservoir fell below the established criteria of minimum air pressure of >l50 psig.
This item is unresolved and will be reviewed upon completion of testing.
(77-32-03)
c.
Procedure Availability The inspector verified that the official copy of the approved
.
procedure, TP 600/28, was available in the control room and used by test personnel.
The inspector verified that official approved copies of the test procedures were in use for all tests witnessed.
.
d.
Crew Manning The licensee established a shift test engineer tn coordinate testing. Additionally a test enginee was assigned to cover each test procedure in progress.
The normal operations view manned the control room and con' isted of a Shift Foreman plus several control and equipment operators.
.
e.
Prereouisites and Initial Condition, Extensive prerequisites and initial system conditions were
-
contained in each test procedure (TP).
The inspector verified that prerequisites and initial 'onditions had been signed off or properely resolved by test r eptions or Test Change Noticas, except for two areas of concere scentified in TP 6(0/5 and TP
!
P]O/28.
(See paragraph 4.0, above)
The inspector verified by independent effort that se~sected prerequisites in the HFT program had been accomplisaed.
These prerequisites included system valve lineups, water chemistry specificaticns, and system operability.
(
!
..
.
'
'
i
.
-
81 351
,
..-
f.
Special Test Ecuipment The inspector verified the special test equipment required by the TP's was in use and that current calibration stickers were affixed to the equipment.
g.
Test Performance The inspector verified, through observations of testing and a sampling review of TP's, that the testing was performed as requireo by the procedures except for the Item of Noncompliance identified in paragraph 4.b above, otherwise, the TP's were found to be properly documented to indicate changes, identify problems encountered and show adherence to procedural setups.
h.
Crew Performance
"
'
The inspector c5 served that test personnel engaged in the test program were briefed at each shift change and pr'or to the performance of testing.
Test personnel actions under planned and unplanned ccnditions which were observed by the inspector, appeared to be conducted in an orderly manner.
Communications were maintained between test and operations personnel during the conduct of the testing.
i.
Data Collection The inspector verified for those tests witnessed, that all data required by procedure was recorded on the appropriate data sheets and was completed to the intent allowable, based on the test completion status.
j.
Test Results The HFT was not complete at the time of the inspectors departure from the site. A review of HFT test results as well as further test witnessing will be performed on a subsequent inspection.
.
I
.
~
i
,
.
5.
Pice Succorts and Hancers The inspector reviewed the status of pipe supports and hangers with respect to installation and settings at the initial ambient condition.
Several pipe supports and hangers were not installed at the time of this inspection. The inspector-chose a sample number of hangers and determined their installation status.
Of the bangers chosen, the not installed hangers were not required to be installed prior to the start of the HFT.
The. inspector also toured parts of the Reactor Building to determine the status of pipe hangers.
Two systems were noted to have in-complete hanger installation.
Discussions with the licensee revealed i
that these systems were not needed for HFT.
No items of noncompliance were id'entified.
6.
Test Results Verification The test results of completed test SP 330/2, ICS Open Loop Cali-bration, were reviewed to determine:
the licensee evaluated the test results to assure that testing
--
demonstrated that the systems met design requirements.
test results were ccmpared to acceptance iriteria by the
--
TeGmical Engineer on July 7,1977.
a review of the procedure was in conforrance with the Test
--
Manual, Test. Instruction No. 18 Revision 5.
-
the approval of Test Working Group which includes NSSS, GPU,
--
and Met Ed representative on July 21, 1977.
'-
'
The inspector also reviewed problem report 2178 which changed the
.
acceptance. criteria for the Feedwater temperature BTU limit alarm.
No inadequacies were identified during this review.
7.
Startuo and Test Ouality Assurance Procram (ST0AP)
The description and controls for this program have been reviewed and documented in Report 50-320/76-05.
The implementation of STQAP was documented in Report 50-320/77-09.
Additional review of this program follows:
'
(
.
I
-
81 3G3
,
=
i m
=
2
--
a.
Audits
_
The licensee representative, GPUSC, had conducted four audits
--
during the period from February 1 to July 1977.
During these
-
audits, thirteen items, requiring followup were identified.
"]
The. audits reviewed, areas covered, dates conducted, and numbe? of findings (items) are listed below:
77-05 OTSG Secondary Side Hydrostatic Test conducted
--
j_"
Februa ry 14-18, 1977 (two items)
.
-
77-07 Startup and Test Program, conducted during period
--
}
May 16-30, 1977 (fiveitems)
77-08 Phase I Turnover, conducted April 19 to May 17,
--
__
1977 (two items)
2:
77-11 Startup and Test Program, conducted May 31, June 1-
--
-
3,1-10,13-17, 20-24, 27-28,1977 (six items)
-
The audit findings, answers and co rective actions were reviewed.
,g The licensee had identified a total of fifteen items which
-
a required answers / corrective actions, during the conduct of the, audits.
.
The inspector noted that one item that has been
__
"
--
addressed which requires greater than sixty working days for correction.
It has been entered in the Audit Status Summaries.
No inadequacies with system has been identified.
,
8.
IE Circular Followuo
-
The inspector reviewed the licensee's followup action regarding IE Circular 77-06, Effects of Hydraulic Fluids on Cablee.
The inspector
-
determined that this Circular had been reviewed f(
applicability
-
by plant engineers and operating staff personnel. The licensee had
initiated appropriate corrective action, as described in the Circular when applicable. The inspector had no further questions at this time.
==
9.
Precoerationai Procedure Review The
-
nspector reviewed the following procedures to ascertain the
--
initial calibration of the Reactor Protection System instrumentation
'94 to verify that system operates as designed and that the response time of each nuclear instrumentation channel meets its acceptance
criteria. The tests reviewed are:
-
(
_a
-
--
M
!
-
-
I S1 P54
--
Q b
TP 600/23 (MTX 151.5) Reactor Protection System Functional
--
Test TP 301/2 (MTX 108.1,) Detector Cabling and Response Tests
--
TP 301/3A (MTX 108.2) Nuclear Instrumentation Preoperational
--
Calibration Source Range TP 301/3B (MTX 108.3) ;iuclear Instrumentation Preoperational
--
Calibration Intermediate Range TP 301/3C (MTX 108.4) Nuclear Instrumentation Preoptrationi
--
Calibration Power Range TP 301/3D (MTX 108.5) Determination and Setting of Detector
--
'
-
Vol tages All of the above tests were approved on May 5, 1977,, except TP 600/23 which was approved on March 17, 1977.
The review confimed that licensee has addressed the following items:
--
Coincidence Testing Response Time of each protective channel
--
Logic of protective system
--
Calibration of protective systems
--
Trip and alam settings of protective system
--
Additional insulation breakdown tests
--
The procedure fonnat was in accordance with Test Instructions
--
No. 18 No inadequacies were identified during this procedure review. This item is resolved.
10. Unresolved Items Unresolved items are matters for which more infomation or additional time is required in order to ascertain whether they are acceptable items of noncompliance or deviations. Unresolved items identified during this inspection are discussed in Detail 4.b(3), 4.b(5),
4.b(6).
(
.
i
.055
.
11.
Exit Interview The inspector net with licensee representat.ives (denoted in Detril 1) at the conclusion of the inspection on August 19, 1977.
The inspector sumarized the purpose and scope of inspection and the findings.
.
.
(-
.
t
I 81. 356
-.
.