IR 05000320/1979012
| ML19263E991 | |
| Person / Time | |
|---|---|
| Site: | Crane  |
| Issue date: | 08/07/1979 |
| From: | Paulino R, Lester Tripp, Walton G NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML19263E990 | List: |
| References | |
| 50-320-79-12, NUDOCS 7910190205 | |
| Download: ML19263E991 (14) | |
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U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT Region I Report No. c;n 19n/70 12 Docket No. 50-320 License No. DPR-73 Priority Category C
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Licensee:
Metrooolitan Edison Comoany P. O. Box 542 Reading, Per.nsylvania 19640
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Facility Name:
Three Mile Island, Unit 2 Inspection at:
Middletown, Pennsylvania Inspection conducted:
May 1-31, 1979 Inspectors: AfW&
Su. 31979
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G. Walton, Reactor Inspector
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'datf! signed Ab~ '
Cruf 3 / 9 79
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hR.Paolino,RedctorInspector date signed Y Nu* -
0us3,1979 hA.Finkel,ReadtorInspector date signed ka2T5b2btM
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Czur3 l'179 5. Chaudhary, Reactor Inspector
'date signed Approved by:
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2.bd
$7[7f L. Tripp4 Chief, Engineering Support Section #1, date signed
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RC&ES Branch Insoection Summary:
Insoection on May~ 1-31, 1979 (Report No. 50-320/79-1 2)
Areas Insoected:
Special, announced inspection by regional based inspecton of modifications being made on several systems to provide long term cooling of the reactor core. The function of this inspection was for surveillance of s
the licensee and contractors activities of the modifications which are being made under " emergency conditions." The inspection involved 378 inspector-hours on site by four NRCiregional based inspectors.
Results: No items of noncompliance or deviations were issued.
The attached report details the surveillance activities.
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OETAILS 1.
Persons Contacted This report is a continuation of surveillance activities conducted by the Reactor Construction and Engineering Support Branch of Region I at Three Mile Island, Unit 2.
See inspection repcrt 50-320/79-09 for listing of persons contacted.
2.
Systerr Modifications As a result of the incident on March 28, 1979 at Three Mile Island, Unit 2, the licensee has initiated several system modifications to the existing plant.
This report covers the surveillance activities,of the Reactor Construction and Engineering Support Branch of Region I during the month of May, 1979.
A.fescription of the modifications and applicable codes are described ir. I&E Inspection Report No. 50-320/79-09.
This report covers the inspectors surveillance of these modifica-tions.
a.
Modification For Water Solid Goeration of Steam Generator "B" TS-3C Insoector Surveillance Inspected the installation and termination of the
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13.2/4.16 KV transformer for the recirculating water pumps which are rated at 2250 horsepower (ECM-083).
The inspector inspected the 13.2 KV transformer installa-tion switchgear 2-5 Cubicle 5-4 in the pump house.
The cubicle 5-4 was modified to accept the power cable from the 13.2 KV transformer.
This transformer will supply power for the 2250 horsepower circulating pumps.
Inspected and traced the electrical cable for the
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installation of the "B" power to the closed cooling water pump cubicle SC-P-lc from the MCC-2-418.
The power for this system is off the 2-4 bus of the white diesel system.
Inspected the electrical installation of the 700 horse-
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power high pressure pump motor for the water circulattag through the "B" steam generator.
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Performed visual inspection of pipe welding activities.
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Detail audit of the tie-in-weld from 12" LTB-2 to the
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20 inch feedwater line. Material thickness is 1 7/8 inchtgick,withafullpenetrationweld.
The preheat was 50 F min.
The weld was magnetic particle inspected at root, and final surface.
Visual inspection was performed at 1/2 T, and final.
The weld rod was E7018, 3/32 inch and 1/8 inch diameter.
The welding procedure used was SP4-200 C/S N100.
It was noted that this procedure was not qualified for a thickness of 17/8 inch.
Catalytic subsequently requalified the weld procedure to include material thicknesses of 17/8 inch.
Reviewed drawing M148, Revision 4.
This requires
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radiography of all welds that cannot be hydrostatically examined.
Visual examination of assemblies:
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1005, 77-128-J 6" sch. 40 A106B; 1005, 78-3-A 8" sch. 40 A106B; Reviewed post weld heat treatment charts for the feed-
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water tie-in, and feedwater flanges 1-8 and 1-g.
Thgse welds were stress relieved for 2 hours2.314815e-5 days <br />5.555556e-4 hours <br />3.306878e-6 weeks <br />7.61e-7 months <br /> at 1100 -1150 F.
Perici: Sed a detailed review of Catalytic Welding Procedure
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SP-4200-CS(N)-100, Revision 6.
This procedure is applict.ble for welding on carbon steel.
The inspector met :t. May 15, 1979 with the Catalytic Welding Engineer and GPU, Quality Assurance, and identified six (6)
areas which did not appear to meet applicable code.
These were:
(1) Paragraph 2.01 states, "When the production welds are to be radiographically examined, the welder shall be qualified by radiographic examination or by guided bend test.
Inspectors Comments:
Even if the production weld doesn't get radiographically examined, the welders test coupon must be radiographed or examined by a guided
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bend test.
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(2) Paragraph 1.0' states, "The specification is suitable for welding in accordance with the require-ments of the ASME Code,Section III.
The specifi-cation is also suitable for welding to ANSI 831.1, 931.3, 331.7, and AWS D1.1.
Inspectors Comments:
The applicable year and addenda for each code must be identified because code editions do change requirements.
(3) Paragraph 4.09 states, " Welding materials for qualification testing do not require certification of compliance."
Inspectors Comments:
This needs to be clarified, because procedure qualification does require a certificate of compliance because it is a welding essential variable.
(4) Paragraph 4.05 states, " Concavity on the root side of a single welded circumferential butt weld is permitted when the resulting thickness of the weld is at least equal to the thickness of the thinner of the two members being joined."
Inspectors Comments:
USAS 831.7, 1969 Edition allows this only if credit of reinforcement up to 1/32 inch is used.
In some cases the welding procedure allows greater reinforcemert.
(5)
Inspectors Comments:
Paragraph 4.04 which states allowaole reinforcement, does not comply with the 1977 Edition of USAS B31.1.
(6) Inspectors Comment:
This welding procedure is qualified for weld thickness of 1/16' inch minimum to 1 3/4 inch maximum without post weld heat treatment.
However, post weld haat treatment for material thicknesses greater than 1/2 inch is mandatory for compliance with USAS 831.1, 1977 Edition.
Catalytic requested a meeting with the inspector to discuss the above comments.
The meeting was held at Catalytic's home office in Philadelphia, Pennsylvania on June 4, 1979.
Attendees from General Public Utilities,
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and NRC attended the meeting.
At the meeting Catalytic committed to make changes to the procedures and submit them to GPU for review.
It was subsequently determined that the necessary changes would affect eight (8)
procedures used by Catalytic at the site.
These pro-cedures will be reviewed after GPU performs a review of the procedures and the effect the procedure changes may have on any existing welds which were welded using these procedures.
Reviewed the hydrostatic test procedure.
The inspector
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noted the test pressure requirement was 950 psig for 10 min.
The design pressure was 650 psig.
The inspector questioned the validity of the 950 psig when USAS B31.1 requires the hydrostatic test pressure be performed at 1.5 times design pressure.
(650 psig x 1.5= 97f 'sig.)
The inspector was informed that the system conta...ed one 400 psig valve (LTB-V-48) located on the discharge side of the purj.
This was br.cught to the attention of NRC/NRR for disposi-tion.
It was determined by Burns & Roe and accepted by NRR that the valve would meet the intended service.
The basis for this is the valve was designed for 400 psig at higher temperatures.
At the temperatures this system will operate the vals* would be rated higher.
The hydrostatic test procedura war changed to read 1000 psig.
Reviewed results of hydrostatic test performed at 1000
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psig which 10 minutes holding time.
Visual examination of chemical pot tank, Item 2-BR-CPF-
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1, material A106 Grade 8.
Installation of the 13.2 KV transformer cabic -ay
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supports.
The inspector had some concerns regarding the methods used to support the output cables, cable trays, and grounding of the cable trays.
The inspector discussed these concerns with NRC/NRR personnel.
The licensee subsequently corrected the above to the satis-faction of NRR and the inspector.
The inspectors performed daily surveillance of the entire modification, talked with electricians, welders
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and fitters, and monitored GPU Quality Assurance personnel.
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b.
Redundant Decay Heat Removal (DHR) System TS-15 Inspector Surveillance Examined the DHR mechanical system which is being stored at
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the north end of the island.
Heaters were energized on the 4160 volt motor / pumps and wiring was in progress by the electrical craft.
The licensee has stated that no system test of the DHR system is plann,.d.
The present plans are to complete the piping and have the DHR system ready to hook up, but not hookcd up until it is needed.
The inspector informed NRC/ lR of the licensee plans not to perform a system test.
NRR informed the inspector that they would evaluate to determine whether a system test is necessary at this time.
Attended a meeting with Westinghouse, GPU and Authorized
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Nuclear Inspector (ANI) to discuss the ANI jurisdiction boundary.
It was determined that the ANI jurisdition extends out to the second isolation valve.
Their inspection, there-fore, will extend to the first isolation valve in the modi-fication.
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Reviewed the hole layout for core drilling of concrete
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through the fuel handling ouilding.
This drilling will involved drilling (8) eight, three inch diameter holes, one (1) 3 1/2 inch diameter hole, two (2) 10 inch diameter holes, and one (1) twelve inch diameter hole.
These holes are located at elevations 293' 10 3/8" to 297' 5 3/8".
The inspector reviewed ECM 53475-182, Revision 2, for core boring approval.
Witnessed partial drilling of the 3 1/2 inch dianeter hole
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in the fuel handling wall.
Witnessed activities such as pipe placement, fit-up weld 1g,
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etc. of pipe in the fuel handling building.
These inspections performed by the inspector were by closed circuit television.
Reviewed radiographs of weld TS-15 Weld 22.
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Reviewed " Industrial Inspection Industries Inc." Radiographic
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Procedure GP-RT-1 "", Revision 1, dated 2/3//9.
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c.
Spent Fuel Pit Modifications WG-6
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Inspector Surveillance Visual inspection of assembly WG-6 M128-2T HT-M5667 A312-
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A182.
Witnessed welding on 2 inch diameter pfling.
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On May 31, the inspector audited the weld rod controls in
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the fuel handling building.
One portable rod warmer was found disconnected that contained E7018 cov2 red electrodes.
The rods were room temperature.
This was brought to the licensee's attention and the following corrective action was taken.
Catalytic welding supervision will instruct craft foreman and responsible supervision on requirements for weld rod control.
In addition, Catalytic is instructed to perform inspection twice a week to assure compliance.
On June 1, the inspector reaudited the fuel handling building and found the weld rod controls acceptable.
The inspector reviewed GPU, QA inspection reports for comp.1-
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ance.
The following reports were reviewed:
W-125, W-123, W-093, W-062, and W-047.
They were found acceptable.
d.
Redundant Off-Gas Filtering System WG-1 Inspector Surveillance
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Review of electrical ECM3475-141-WG-1--add to MCC 2-31C
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compartment 43 alarm for auxiliary building HVAC system.
Review of electrical ECM3475-004-WG-1.
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Visual inspected tN cables and trays associated with the
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modification.
Witnessed.ne termination of electrical cables to the control
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boxes.
Inspected cable of Unit IIA.
WMG 6-31T, WMG 33C, WMG 30C,
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WMG 29C, and WMG 31C.
Power cable in tray 5010.
Inspected panel PDPSA, cable WMG 115PA and WMG 88C.
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Performed surveillance activities for control used to cut
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into the existing stack.
e.
Decontamination System for Water From The Auxiliary Building WG-2 Insoector Surveillance Visual examination of cable installation.
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Examined the camera (TV Control) installation which fill be
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used to monitor the waste processing in the chemical cleaning building.
This c" '.am was in a trouble shooting mode and a possible reince.. ion of the camera location was under study.
Inspected the chenical cleaning monitor installation cable
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trays T 1, 2, 3, 4, 5, and 6.
Inspected the cable, trays, and motor (30 HP) installation.
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Visual examinution of welds WG-1-8, WG-1-9, and WG-1-10.
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Welder identification and qualification for symbols 198 and
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67154.
Reviewed MDR-004 which identified deficiencies in globe
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valves received from Obert G&C, Torino, Italy. This MOR identified deficiencies in 26 valves of 75 inspected.
Visual and liquid penetrant examination identified forging laps, cracks, and pinholes.
The inspector attended a meeting with Burns and Roe and the GPU, QA Manager and the following disposition was established.
(1) Replace all defective valves.
(2) Replace all valves from Obert which will carry radio-active fluid.
(3) Will not use any additional valves from Obert unless they are qualified, i.e., liquid penetrant and hydrostatic.
(4) Leave Obert valves which are welded in non-radioactiive lines, but perform a hydrostatic tast at 2 times operating pressure.
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f.
Makeup System for Reactor Coolant TS-6B Inspector Surveillance Inspected the following electrical items associated with the
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reactor coolant pressure control system.
Charging pump (100 HP) power from 2-32A (gray) and 2-
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12A (white) diesel system.
Charging water storage tank heater (100 KW) power from
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bus 2-45 (tnite diesel).
Visual examination of assembly 1005-F21-ZBK-TS68-6.
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Reviewed radiographs of root pass for tie-in weld.
The
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licensee had rejected the welds and repair was necessary.
Reviewed the ECM for NDE requirements of the tie-in welds.
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The inspection requirements shall be in accordance with Section III, Class 2, ASME, B&PV Code.
Reviewed the radiographs of the accepted welds, which previously
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had failed radiography.
These welds had been repaired.
Performed daily surveillance of the welding activities.
In
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some areas this was performed by remote television.
Reviewed radiographs of weld TS-6B W-1, pipe to valve.
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Performed visual inspection of the 6 inch line from the
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spent fuel pit to the tie-in weld.
This inspection was made while the system was being hydrostatically pressurized at 900 psi.
g.
Diesel Generators TS-10/ll Inspector Surveillance Reviewed the following electrical ECM's.
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ECM 3475-154-TS-ll, Connect existing CW-P-1E breaker in
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switchgear 2-5 to serve as incoming breakers for alternate power.
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ECM 3475-024-TS-10, Install neutral grounding system to
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gray diesel generator.
Inspected substation 2-38A and 2-48A and auxiliary transformer
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2A and 28.
Inspected switchgear AKD-6 and PDP-58.
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Inspected the installation and modifications made to the 2-3
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bus (gray diesel) and 2-4 bus (white diesel).
The two diesels will tie into the 2-3 and 2-4 bus through the condensate booster pumps breakers positions CO-P-2A and CO-P-28.
The inspector noted that the electrical cables for output of
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the gray and white diesels were in the same cable trays in the turbine building.
This was discussea with the licensee and NRC/NRR and the licensee subsequently corrected the above by providing cable separation.
3.
General a.
The inspector discussed the following items of concern with the licensee and NRC/NRR.
These items are generic to several of the modifications.
(1) Power and control instrumentation cable installation in the same cable trays and there was not separation.
(2) There were ' separation problems within the electrical control equipment between power and instrumentation / control cables.
(3) QCIR E-001, Auxiliary and Fuel Handling Building HVAC p oblems 5001, 5002, and 5003.
Power c tble over 21/2 inch diameter not tied in vertical traya.
The inspector was inforned by NRC/NRR that the above conditions had been corrected with the exception of power and control instrumentation separation within the equipment cabinets.
This would be evaluated during testing and if no signal interference was identified a decision would be determined by NRR as to the acceptability of the installation.
b.
The inspector performed a review of the following ECM's and QCP's which are applicable for numerous modifications.
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ECM-3475-100, Installation of electrical tray supports,
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auxiliary building.
ECM-3475-107, Installation of electronic equipment
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rack.
EMC-3475-108 Instrument panel wiring and control cable
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installation to Generator "A".
ECM-3475-085, Cable pulling from main panel feeder to
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filter Nos. 3 and 4.
ECM-3475-131, Installation of control and 1rstrument
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cable on filter units.
ECM-3475-005,.00P and Freon test of Unit 3 filter.
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ECM-3475-094, Installation of radiation monitor support
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platform.
ECM-3475-023/024, Generator "h" controller circuit
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check.
ECM-3475-053, Completion of electrical tray run, auxiliary
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building.
ECM-3475-144, Radiation monitor installation.
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QCP-M-005, Revision 0, dated April 24, 1979 on QC
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procedures for mechanical equipment.
QCP-M-006, Revision 0, dated April 24, 1979 on QC
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p ocedure for electrical equipment.
QCP-M-007, Revision 0, dated April 24, 1979 on QC
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procedure for records and filing system.
QCP-M-Ld8, Revision 0, dated April 22, 1979 on welding
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control.
QCP-M-010, Revision 0, dated April 22, 1979 cn QC
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procedure for purchase requisitions and purchase orders.
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QCP-M-Oll, Revision 0, dated April 22, 1979 on QC
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procedure for control of weld rod, wire and consummables.
ECM-3470-150, Installation of radiation probes, temperator
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detectors, and thermistor cable for filters No. 1 and 2.
ECM-3475-152, Meggering of feeder cables from Generator
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"A" to 5 KV switchgear.
Cable pulling from auxiliary transformer to switchgear.
ECM-3475-158, Instrument panel wiring.
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Licensee QC surveillance reports numbered E-001 through
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E-017.
ECM-3475-190, Auxiliary building and fuel handling
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building temporary HVAC, transformer heater circuit.
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ECM-3475-077, Relay settings / instructions, ground trips
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associated with AKR-5A-50 breakers on 480V side of unit transformers 455-2-38 and 455-2-48.
ECM-3475-135, Cable routing measurements and correction
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of electrical drafting errors.
ECM-3475-234, Auxiliary building cleanup.
Instrument
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air to pneumatic humidity transmitter.
ECM-3475-263, Chemical lab trailer filter exhaust
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systems / sampling probe.
ECM-3475-257, New lube oil circulating pump piping to
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diesel generator "B" and gage glass to standpipes on diesel generator "A".
ECM-3475-247, Instrument installation for standby.
RC
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pressure control system.
QCP-M-001, Revision 0, dated April 10, 1979 on Receiving
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Inspection.
QCP-M-002, Revision 0, dated April 22, 1979 on Storage
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Control.
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QCP-M-003, Revision 0, dated April 24, 1979 on QC
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procedure for QC and inspection plan.
QCP-M-004, Revision 0, dated April 14, 1979 on Control
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of non-conforming conditions.
Insoector Comments b.
The inspector noted that each of the Radiation Monitoring Systems consisted of three channels; a particulate monitor, an iodine monitor, and a gaseous monitor.
These monitoring channels are mounted in series, indicating that sample flow rate passing through each channel is identical.
The inspector expresses the concern as to whether the particulate monitor sensitivity was adequate to measure 10 CFR 20, Appendix B, MPC levels at the lower flow rate used to accommodate the iodine monitor.
The iodine monitor requires a low flow rate 1-2 cpm since its efficiency is based on the absorption rate of the charcoal cartridge.
The particulate and gaseous monitor rely upon a large volume (5-10 cpm) to deposit and/or collect sufficient measureable radioactivity.
Discussions with vendor representatives at the TMI site and the licensee representatives indicate the count rate for 10 CFR 20 MPC levels would be below background count rate and, therefore, not measurable.
Tne licensee representative also indicated that the data from the particulate monitor is not used for that reason, and that only the data from the iodine monitor is used and data extrapulated from this for the particulate monitor.
The inspector also reviewed the calibration, procedures, and setpoint data itemized in letters to the licensee from Porter-Gertz dated 5/29/79 and 4/30/79 for Unit 2 alternate vent radiation monitors Nos. 1, 2, 3, 4, and 5.
The inspector noted discrepancies in the calculations which effect sensi-tivities and alarm setpoints.
Flow rates used for alarm setpoints,were 30,000 cfm and 60.000, although the installed filter fan units (4) each operated at 30,000 cfn.
Licensee representatives indicated that there would be 3 operational units at 30,000 cfm each for a total flow rate of 90,000 cfm and one standby urif t.
In addition, the constant air monitor gas channel alarm setpoint is based on a detector volume of 1390 cc, however, it appears that the detector occupies 95 percent of that volume.
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The inspector has informed NRR and IE site management of the above concerns.
4.
Exit Interview No formal exit interview has been held at this time because this inspection is continuing.
However, the inspector met daily with the GPU Quality Assurance Manager and discussed the important aspects of the ongoing modifications.
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