IR 05000320/1979009
| ML19208B090 | |
| Person / Time | |
|---|---|
| Site: | Crane  |
| Issue date: | 06/21/1979 |
| From: | Paolino R, Lester Tripp, Walton G NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML19208B089 | List: |
| References | |
| 50-320-79-09, 50-320-79-9, NUDOCS 7909190041 | |
| Download: ML19208B090 (14) | |
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U.S. NUCIEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT Region I Report No. 79-09 Docket No. 50-320 License No. DPR-73 Priority -
Category C Licensee: Metropolitan Edison Company Post Office Box 542 Reading, Pennsylvania 19602
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Fac'ility Name: Three Mile Island, Unit 2 Inspection at: Middletown, Pennsylvania Inspection conducted: April 13-30, 1979 Inspectors: M *Naj S/lY[79 G. Walton, Reacter Inspector date signed
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? f R.~Paolino, Reactor Inspector ddte signed
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8fh 6/N/7 9 A. Finkel Rehetor Inspector dAte signbd
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'S. Chaudhary, Reactor Inspector
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date signed Approved by:.4 W h [
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I /7d Ia Tripp, Chief, Engineering Support Section date signed No. 1, RC&ES Branch Inspection Summary:
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Inspection on April 13-30, 1979 (Report No. 50-320/79-09)
Areas Inspected: Special, announced inspection by regional based inspec-tors of modifications being made on several systems to provide long-term cooling of the reactor core in a safe condition. The function of this inspection was for surveillance of the licensee and contractor activities on the modifications which are being made under " emergency conditions".
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The inspection involved 225 inspector-hours on-site by four NRC regional
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based inspectors.
Results: No items of noncompliance or deviations were issued. The attached report details the surveillance activities.
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DETAILS 1.
Persons Contacted General Public Utilities E. Allen, QA Engineer J. Artuso, Consultant W. Gunn, Construction Manager D. Kelly, Engineer S. Levin, Project Manager R. Liscom, QA Engineer S. Morris, Civil Engineer J. Wright, QA Site Manager
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Burns and Roe Mr. Broline, Project Engineer 0. Michejda, Civil Engineer Morrison Knudsen H. Jorgenson, Field Representative, Diesel Generator Catalytic J. Kondras, Assistant Engineer, Document Control J. Wasson, Electrical Construction Supervisor Kestinghouse
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D. Cowfer, QC Engineer W. Meyers, QC Manager In addition to the above, numerous other contacts were made with personnel from GPU, Burns and Roe, Westinghouse, and Catalytic.
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2.
System Modifications As a result of the incident on March 28, 1979, the licensee has initiated several system modifications to the existing plant.
The modifications are being made to achieve long-term cooling of the reactor core, a redundant decay hest removal system, a storage area to dispose of high level auxiliary building waste, a redundant off-gas filtering system, decontamination of water in auxiliary building using an ion-exchange process and a make-up system for reactor coolant.
The inspector has reviewed the licensee's Quality Assurance program and the major subcontractors' quality assurance involvement for the Sbb b32 i
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system modifications. These QA programs recognize the uniqueness and urgency for completion of system modifications and are specifi-cally tailored to these needs. Where quality standards can not be met, these events will be documented by the licensee and subjected to further disposition regarding their acceptability.
The licensee's QA program applies the QA criteria of 10 CFR Appendix B commensurate with the specified system requirements and is compatible with the licensee's QA program previously accepted by NRC. The licensee has established a QA organization at the site specifically responsible for the system modification QA activities. This staff is experienced in all QA disciplines and associated technical fields such as: mechanical, electrical, civil, welding and non-destructive examinations. The licensee's QA Manager and several.of the QA engineers were brought in from the Forked River facility.
The licensee has lead QA responsibility for the system modifications and is providing surveillance over the activities of their subcontrac-tors, Westinghouse and surns and Roe. Westinghouse has established a QA program to control QA activities associated uith design, procurement ani vendor component fabrication related to the backup decay heat removal system modification. Westinghouse is also providing system installation procedures and on-site technical supervision.
Burns ard Roe is respon.,1ble for esta'lishing A signs for the other system modifications. Burns and Roe is implet.enting design control QA practices to assure that appt'priate quality standards are specified and verified for design adequacy. The licensee's QA program will provide surveillance for the activities for these systems, including procurement, fabrication, installation and
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testing.
The labor force to perform these modifications is provided by Catalytic.
Detail procedures and qualification of welding activi-ties are provided byCatalytic.
Pullman Power Products (PPP) is an ASME Code shop and is fabricating piping subassemblies for several of the modifications. The inspector
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audited the PPP shop at Williamsport, Pennsylvania on April 23, 1979 and performed a visual inspection of the assemblies being fabricated.
In addition, the inspector audited the nondescrnctive examination facilities, discussed the nondestructive examination requirements with engineering, and reviewed the welding operator and welding procedure requirements. The licensee has established a QA engineer at PPP to review radiographs and perform visual examina-tion of welds.
Following is a brief description of each modification in progress on-site, the applicable code for construction and installation, and areas where the inspector performed surveillance. An identification number is assigned to eacn modification. These identification c [s 6 06._a i
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numb-rs will be used on each report and feeder report during the duration of the modifications.
a.
Modifications to Steam Generator "B" for Water Solid Operation, TS-3C
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Description:
This modification will utilize the plant cooling water system to effect cooling of steam generator "B" during water solid operation of the secondary side of the steam generator and under natural circulation of the primary water. The water will enter through the main feedwater ting, through the secondary side of the steam generator, and exit through the main steam
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line.
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This modification will involve installation of a new high pressure train consisting of a pump, heat exchanger, valves, and piping located in the turbine building basement. The loop will be connected to the main steam line at a 10" drain pot between the main steam isolation valve and the stop valve, and to the main feedwater line between the feedwater pump and 3rd stage feedwater heater. Additional piping will be required for a surge tank, chemical addition tank, and demineralizer.
In addition, the interconnections between the A and B feedwater heater trains were separated and capped off.
Connections are being.nade to the existing secondary services closed cooling water system supply and return lines for cooling the shell side of the new heat exchanger. Jumper pipes will he installed between the existing nuclear services river water
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system and the existing secondary services river water system to cool the tube side of the secondary services closed cooling water aystem.
The materials being used are carbon steel, generally SA 106, Group B, all connections are welded.
All valver are manually operated.
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The following new instrumentation is being provided:
(1) Radiation Monitor (2) Loop flow indication (3) Steam Generator Heat Exchanger, Shell Side Temperature (4) Heat Exchanger, Tube Side Temperature (5) Pump Pressure, Suction and Discharge c86 07;4 i
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-4-(6) Loop Temperature and Pressure Applicable Codes The modification is being fabricated and installed to the 1977 Edition of " Power Piping" USAS B31.1. The purchased pumps were built to ASME Section 111, Class 2.
Miscallaneous t.anks are ASME Section VIII, Division 1, and valves are built to ANSI B16.5 and B16.34.
Inspector Surveillance Installation activity for this modification began on April 24, 1978. The inspector performed the following inspections:
Visual inspection on the new heat exchanger and pump
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Visual inspection of stub tubes (3) welding on secondary
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side of heat exchanger Visual inspection of piping assembly 2-BR-LTB-11,1005 Fil
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Visual inspect?.on of fit-up to feedwater line
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Reviewed nondestructive examination reports for magnetic
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particle inspection of the weld to feedwater line. The weld was MT'ed at root, 1/2 t and final Visual inspections of the flanged (4 welds) and the tie
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in weld to the main steam
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The inspector reviewed weld procedure SP4-200 C/S-100
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In addition to the above, the inspector performed daily
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surveillance of the activity, talked with craftsmen, and
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interfaced with GPU QA inspectors, and Burns and Roe Engineers.
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The contractor, catalytic, is keeping weld history records which identify the welder, weld procedure and all essentials of welding. Except for some documentation required from Pullman Power. which has not yet been received, all areas reviewed by the inspector meet the applicable code USAS B31.1 or were specifically approved by NRR.
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Redundant Decay Heat Removal System, TS-15
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Description:
A third train for decay hest removal is being provided by modification to the existing decay heat removal (DER) system.
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-5-This involves a connection into the existing DHR downstream of valve DH-V-3 located in the fuel handling building and connec-tions into the two return lines to the cold legs located in the fuel handling building. New lines will run through the penetration room to an opening cut in the fuel handling building wall and connect to a skid located outside the building. This skid contains a neu decay heat removal heat exchanger and two fuel capacity pumps. The. discharge line for the heal axchanger will return through the opening in the fuel handling building to the return line connections. All valves will be motor operated. The secondary side of the new decay heat removal heat exchanger will be cooled by a new decay heat closed cooling water system with its own pump, piping and valves.
This system will be cooled by water from the nuclear services river water system and will require new connections.
The primary piping material is a mixture of stainless steels, type 304 and 316. All welds are fully radiographed except for weld-o-let connections 6. cri: ting de..y heat removal piping.
This exception is specially approved by NRR.
The following new instrumentation is provided:
(1) DHR pump suction pressure (2) DHR pump suction temperature (3) DHR cooler inlet pressure (4) DHR cooler discharge pressure and temperature (5) DHR flowrate Applicable Code:
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The piping connection at the existing DHR line back to and including the first valve will be constructed to USAS B31.7.
The balance of the piping will be fabricated to USAS B31.1.
The pump, valves and heat exchanger were built to ASME Section III, Class 2.
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The decay heat closed cooling water system is built to ASME Section III, Class 3 and the material is carbon steel piping with stainless steel pump, valves and heat exchanger.
Inspector Surveillance Attended a meeting on April 19, 1979 with the Quality
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Assurance Manager from GPU and the Quality Control Manager from Westinghouse and discussed the procedure for plasma arc cutting the existing line, welding, grinding and NDE of the weld-o-lets.
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-6-Visual inspection of the skid during fabrication at
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Pullman Power Products (PPP). This included the heat exchanger, pumps, valves and associated piping. After completion, the skid was disassembled at PPP for shipment.
Visual' inspection at the site of reassembly of the components.
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Reviewed welding procedure (Catalytic) SP 4200-SS(N)-102
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Reviewed Westinghouse Procedure WNSD-TMI-1, Revision 1,
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titled, Installation of Alternate Decay Heat Removal System. The inspector commented that the procedure should include dam installations for control of backing gas.' Westinghouse is presently correcting the procedure to include this.
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Installation of piping had not commenced as of April 30,
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1979.
The inspector witnessed the practice runs of the "O
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Lancing" of concrete blocks. This w:
themethodp$oposed by Westinghouse for penetrating the 5 thick ausiliary
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building wall. The concrete lancing operation uses magnesium wires encased in steel tubing and is burned with oxygen forced through the tube which creates a temperature of approximately 5000 to 6000 Fahrenheit.
The inspector expressed the following concerns regarding this operation:
(1) Heating of concrete by this operation would severely
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damage the concrete adjacent to the penetration.
(2) There was no data available on-site as to the extent of heat affected zone, and consequent dm:erioration of concrete.
(3) Effects of heat on the rebar due to prolonged lancing
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operation (e.g., (i) extent of temperature rise, (ii) change in mechanical properties, (iii) change in metallurgical composition, (iv) loss of bond due to thermal expansion, and (v) magnitude of thermal and other stresses generated by rebar in surrounding concrete had not been evaluated.
(4) The planned penetration is approximately 15' to 20' from the Unit 2 containment wall. Because concrete has a very low thermal conductivity, major portions of the enormous heat generated by the operation would be carried away by the rebars in the vicinity. This heat may affect th'e containment wall.
The extent of damage, if any, on the containment wall could not be predicted due to lack of data on such operations.
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-7-Thu lic:nsee subsequ'ntly deleted the oxygen lancing method and the present plans are to use a core drilling process to Tenetrate the wall.
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Spent Fuel ?it Modification, WG-6 The purpose of the modification is to dispose of high level auxiliary building waste. Two 25,000 gallon tanks are located in the bottom of the pit. Four d ditional 15,000 gallon tanks are installed above the tn tanks and are suspended from steel beams across the top of the pool. The tanks will draw waste from miscellaneous waste hold-up tanks. All tank are interconnected with 2" piping for filling and discharge. The discharge is
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connected to two standpipes mounted vertically in the
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fuel pool. The fuel pool may be flooded for shielding purposes when the tanks are full.
Concrete barriers are placed above the pool for shielding purposes.
All piping is schedule 40S, type 304 stainless steel.
The tanks arc.250 inch thick, type SA240-304 (15,000 gallons) and SA240-316 (25,000 gallons). The supplier is Paul Mueller Company, Springfield, Missouri.
The listing of instrumentation is not available at this time.
Applicable Code:
The tanks were fabricated to ASME B&PV Code, action VIII, Division 1, 1977 Edition. All piping is installed
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to USAS B31.1, 1977 Edition.
Inspector Surveillance:
The inspector performei t e following inspectf.ans commencing t
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M lding of supports to framework for hanging the
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tanks.
Welding of plug c ps on piping from tanks. This
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piping will not be used.
Positioning of tank in the spent fuel pool.
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Welding of sub-assemblies of 2-inch piping.
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In addition to the above, the inspector performed
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daily surveillance of the activity and talked with the craftsmen. All areas inspected meet the toplicable code USASB31.1.
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Redundant Off-Gas Filtering System, WG-1 This modification is a complete off gas filtering system.
It is located on top of the auxiliary building and connects to the existing stack. The system is powered with four 250 horsepower axivane fans which vent to atmosphere. The filtering system contains charcoal and HEPA filters. Six radiation monitors are provided, 2 on the inlet and 4 on the exhaust.
The filters and associated ductwork is connected to the auxiliary building roof.
Several excavations were made in the auxiliary building roof, 12 to 24 inches in width and approximately 15 inches in depth.
Applicable Code:
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None.
Inspector Surveillance:
Daily surveillance commencing April 16, 1979 of all
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activities associated with the installation.
The inspector made the following observations:
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(1) The top layer of rebars have been damaged during concrete chipping.
(2) In one of the excavation footings, a piece of
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wood was found to be embedded in the roof slab.
e (3) Footings were not soaked for any appreciable length of time before grouting.
(4) Mixing water for grout did not appear to be
" clean and potable" as required by ACI code.
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(5) In one footing, where there was some welding performed on rebar, no evidence existed to confirm that welding was authorized and/or proper technique was followed.
(6) No records existed for mix proportion of grsut (Master Builders-Masterflow 713).
(7) GPU QC/QA was monitoring the work and was obtaining some cube samples for grout per ASTM C-109.
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-9-(8) The sampled grout cubes were being cured in the desk drawer of the GPU QC Engineer (cube strength at 7 days was 4030 psi average).
The above observations were brought to the attention of the GPU, QA Manager and NRR. The QA Manager informed the inspector that he was performing inspection and/or surveillance as well as he could within the constraints of emergency schedule, and manpower he had. The above observations were also brought to the attention of Region I supervision at site. With the exception of item 3 and 4 above, the licensee had identified and docum nted the L ove concerns.
It will be necessary to resolve these concerns before NRC will allow TMI-2 to be return 2d to operation.
Visually esamined the installation of the temporary cable
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trays on the auxiliary building roof.
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The inspector reviewed ECM3475-144 pertaining to the
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installation of four (4) Radiation Monitoring Systems for auxiliary building cleanup.
The four (4) Radiation Monitoring systems are installed in three (3) prefab metal enclosures which are secured to the auxiliary building rcof.
Sample lines and air flow measurement lines were verified for compliance to drawing M145 dated April 19, 1979. The inspector noted that three monitors of identical design were counted en casters and are subject to building vibration or movement which could result in the loosening and/or severing of the hard mounted, swage lock fitted sample lines. The fourth unit is mounted on I beams; however, the I beams were not secured in place. Cognizant licensee QA/QC personnel were advised of the NRC concern with assurance of corrective actions to follow.
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The inspector reviewed and verified the requirements of
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ECM3475-084 pertaining to the fabrication, modification and installa-tion of brackets for Radiation Pro.bes No. RE-19, RE-24, RE-29 and RE-34; thermometer function boxes for thermometer No. TE-20, TE-25, TE-30 and TE-35.
One each of the above referenced units was attached to Filters No. TWG-FS-1, TWG-FS-2, TWG-FS-3 and
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TWG-F3-4.
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Decontamination Systes for Water From the Auxiliary Building, WG-2 This modification will allow processing of contaminated water from miscellaneous waste holdup tanks through new demineralizers located in the existing chemical cleaning building.
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i-10-The modification required cutting a large opening in the side of the chemical cleaning building, installation of doors and a monorail system, installation of prefilters, demineralizers, and resin filters. This requires pumps, valves and asseciated piping.
A complete new filtering system is provided in a new concrete block building adjacent to the existing chemical cleaning building for processing of gases. The system contains "HEPA" and carbon filter and radiation monitoring.
This monitoring also requires the addition of a second building adjacent to the chemical cleaning building.
This building will house the controls for the modification and television monitoring of the processing area in the chemical cleaning building.
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The majority of the piping is small bore (2-inch diameter)
and is a combination of stainless steel and carbon steel.
Applicable Code:
USAS B31.1 Inspecter Sur,eillance:
The inspector began daily surveillance of welding activi-ties on April 24, 1979.
Visual examination of welds WG-1-8,'WG-1-9, WG-1-10.
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The creas inspected met the applicable code, USAS B31.1.
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Make Up System For Reactor Coolant, TS-6B A standby reactor coolant pressure control and makeup system is being added which will serve as a backup to the CVCS and maintain reactor coolant system pressure with
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the pressurizer filled solid with water. This system will consist of two 900 gallon capacity water tanks and one surge tank, nitrogen bottle, two 40 gpm positive displacement pumps, a degassed borated water supply tank valves and piping. This system will be connected to the discharge side of the high pressure makeup system downstream of valve MU-V-144C.
The modification will establish a flowpath of makeup water and pressure control through the normal makeup lines that connect to the cold leg of the reactor coolant loop.
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i-11-The following instrumentation is provided:
(1) System water pressure (2) Water level in each tank (3) Nitrogen pressure (4) Make up flow (5) Make up pump discharge pressure (6) Borated water storage tank level (7) Borated water supply temperature Applicable Code:
The water supply tanks are fabricated to ASME Section 111 Class 1.
The charging pumps are fabricated to ASME Section 111 Class 2.
The piping is installed to the rules of USAS B31.1.
The degassified water supply tank is fabricated to ASME Section VIII, Div. 1.
All component supports are installed to the rules of USAS B31.1.
All components are stainless steel and welded when possible.
Inspector Surveillance:
The inspector performed the following surveillance
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commencing on April 30, 1979:
Visual examination of assembly 1005-F21 ZBK TS6B-6
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Visual examination of the holding tanks
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All areas inspected meet the requirements of USAS B31.1.
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g.
Diesel Generators TS-10/11 For all electrical loads that previously did not require loss-of-off-site power, which now do require it, and all newly added loads which require this protection, the licensee has installed two new 2500 Kw diesel generators.
The generators have their own switchgear, batteries, and fuel tanks.
The foundation requirements for supporting the diesel generators are a series of railroad ties (31 minimum per unit) on 16-inch centers on top of 24 inches of crushed Q k,L Chb i
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-12-rock. No concrete foundation or hold down bolts were required for the generating unit.
One generating unit is designated as the " Master Generating Unit" (MPA) and contains electrical equipment required for the operation of both units. The remaining unit contains the electrical equipment required for its own control but has no fuel transfer equipment, batteries or battery charging equipment. This unit is designated
" Auxiliary Generating Unit" (MPB).
Applicable Code:
None.
Inspector Surveillance:
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The inspector performed the following surveillance commencing on April 16, 1979:
The inspector reviewed the requirements of ECM
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3475-023 and ECM 3475-024 pertaining to modifications and installation of Diesel Generator A and B.
The inspector witnessed the check out of Diesel
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Generator A control circuit for manual operation and verified the installation of the current transformers for the "A" unit.
The foundations for two 2500 Kw generators were
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inspected. The foundations / supports consist of approximately 24 to 30 inches of crushed rock within an enclosure of timber logs. On top of the crushed rock, timber logs similar to railroad ties are laid transversely for generator support.
The inspector questioned the adequacy of these supports for apporting the peerator.
The generators may enduce small
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amplitude vibratory load during operations resulting in compaction of c ushed stone. Such compaction of crushed rock may induce differential settlement of the support, thus creating a problem in generator operations. This potential problem was brought to NRR and GPU's attention.
In the preliminary meeting, NRR and GPU engineers concurred with inspectors'
concern, and GPU engineers indicated that they would pursue and resolve the matter to NRR's satisfaction.
The inspector was provided with a Westinghouse brochure recommending foundation and support for such diesel generators. The brochure recommended similar foundation and support required normally for such generators over a 2000 psf bearing capacity soil sub-base, Q0b e c. (~
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-13-The licensee subsequently filled the area around the ties with sand. This satisfies the inspectors'
Concern.
In addition to the above, the inspector performed
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daily surveillance of the installation.
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Exit Interview No formal exit interview has been held at this time because this inspection is ccntinuing. However, the inspector met daily with the GPU Quality Assurance Manager and discussed any important aspects of the ongoing modifications.
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