ML18093A609
| ML18093A609 | |
| Person / Time | |
|---|---|
| Site: | Salem  |
| Issue date: | 01/21/1988 |
| From: | Bicehouse H, Pasciak W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML18093A608 | List: |
| References | |
| 50-272-87-37, 50-311-87-37, IEB-79-17, IEB-87-001, IEB-87-1, NUDOCS 8802030157 | |
| Download: ML18093A609 (11) | |
See also: IR 05000272/1987037
Text
Report Nos.
Docket Nos.
0. S. NUCLEAR REGULATORY COMMISSION
REGION I
50-272/87-37.
50-311/87-37
50-272
50-311
License Nos.
Priority ----
Ca tegory _ _;;c;,___
Licensee:
Public Service Electric & Gas Company
P. 0. Box 236
Hancocks Bridge, New Jersey 08038
Facility Name:
Salem Generating Station
Inspection At:
Hancocks Bridge, New Jersey
Inspection Conducted:
December 14-18, 1987
Inspector:
Approved by:
date
I dat
Ins~ection Summary:
Ins ection on December 14-18, 1987 (Combined Re art Nos.
50- 72/87-37 and 50-311/ 7- 7
Areas Inspected: Routine, unannounced safety inspection of the licensee's
water chemistry control program including management controls, plant water
chemistry systems and implementation.
Results:
No violations or deviations were identified. The licensee was
implementing a generally effective water chemistry control program.
However,
weaknesses were noted in the licensee
1s controls of inline chemistry
instruments needing licensee attention and correction *
8802030157 880125 .
ADDCK 05000272
G
Details
1.
Persons Contacted
During the course of this routine inspection, the following personnel
were contacted or interviewed.
1.1 Licensee Personnel
- J. Zupko, Jr., General Manager, Salem Operations
- R. Dolan, Chemistry Engineer, Salem
- R. Dulee, Principal Engineer, Quality Assurance
- G. Raggio, Station Licensing Engineer, Salem
- J. Trejo, Radiation Protection and Chemistry Manager
Other licensee personnel were also contacted or interviewed during
the inspection.
1.2
NRC Personnel
2.
Scope
K. Gi~son, Resident Inspector
R. Summers, Project Engineer
- Attended the exit interview on December 18, 1987.
This routine safety insp~ction reviewed the licensee's water chemistry
control program.
The purpose of the inspection was to review the
licensee's program to control corrosion and out-of-core radiation field
buildup, ensure long-term integrity of the reactor coolant and secondary
pressure boundaries and minimize fuel leakage caused by corrosion-
induced failures. The licensee's program in these areas was reviewed
relative to requirements, commitments and industry practices provided in
the licensee's Technical Specifications, Updated Final Safety Analysis
Report (UFSAR), NRC Regulatory Guides, Bulletins and Information Notices
and industry-consensus standards provided by the Electric Power Research
Institute (EPRI) and the American Society for Testing and Materials
(ASTM).
3.
Previously Identified Item
(Closed) 25-00~13 TI-Trial Use of Water Chemistry Inspection Modules
This inspection completed a series of inspections of the licensee's water
chemistry control program which involved the trial use of two inspection
modules *
4.
3
Plant Description
The inspector reviewed the design and operating history of two units.
Salem Unit 1 (Salem-1) is a four-loop Westinghouse Pressurized Water
Reactor (PWR) rated at 1079 MWe which began commercial operation in June,
1977.
Salem Unit 2 (Salem-2) is also a four-loop Westinghouse PWR rated
at 1106 MWe which began commercial operation in October 1981.
Both units
employ Westinghouse Model 51 Steam Generators and have operated on All-
Volatile Treatment (AVT) since initial operation.
Most older Westinghouse units exhibit some degree of denting in their
steam generators. The damaging consequences are most pronounced in the
outer periphery wedge and flow slot area. Units that have used all solids
(i.e. phosphate) secondary water treatment tend to experience thinning
attack. It occurs on both the hot leg and cold leg sides, at and above
the steam generator tube sheet, within the sludge pile. Units with open
tube sheet crevices are prone to Intergranular Attack/Stress-Corrosion
Cracking (IGA/SCC) within the crevice region. Models 51 and 51 A/M Steam
Generators are susceptible to primary side cracking at inner row U-bends
and at the roll transition. Models 24, 27, 33 and 51 steam generators
experience fretting wear at the anti-vibration bars (AVBs).
Salem-1 has
experienced thinning, fretting and minor denting. Salem-2 has
experienced fretting and minor denting.
During 1977, Unit-1 operated for the majority of its first fuel cycle
with leaking condenser tubes and high dissolved oxygen concentrations in
the feedwater system. Nondestructive examinations (NOE) during the first
refueling outage revealed some tube-to-tube support plate intersection
denting. Although the denting was minor, the licensee installed a
full-flow condensate polishing system, retubed the condenser (replacing
copper/nickel (90/10) tubes with AL-6X tubes) and instituted 1/3 flow
condensate cleanup system for cleanup prior to power operations.
NOE for
Unit 1 following the second fuel cycle showed no detectable increase in
the number of dented intersections. During the refueling outage, the
licensee installed a system to return steam generator blowdown to the
condenser hot well. Salem-2 began its first operating cycle in 1981 with
a full-flow condensate polishing system and copper-nickel condenser
tubes. Subsequently, the licensee retubed that condenser with AL-6X
tubing.
The following additional items were noted during review of the units
current configurations:
0
0
Low-pressure feedwater heater tubes and high-pressure feedwater
heater tubes for both units are 304 stainless steel.
The moisture separator reheaters (six per unit) are being changed
from 90/10 copper/nickel alloy to stainless steel. Salem-1 has one
remaining copper/nickel alloy moisture separator reheater and
Salem-2 has two.
0
0
0
0
0
0
0
0
0
4
Low-pressure heater drains for both units are pumped back to the
hotwell but high pressure heater and moisture separator drains are
pumped forward.
Strainers are provided in both units* Feedwater systems for
particulate removal. Auxiliary feedwater is not filtered.
Deaeration of auxiliary feedwater is not provided.
However
feedwater dissolved oxygen is routinely maintained less than five
parts per billion (ppb).
The steam generator blowdown rates are 40,000 pounds per hour
(maximum up to li % main steam flow).
Blowdown is returned to the
hotwell for both units.
Circulating condenser rate averages (annually) about 3,000 parts per
million (ppm) chloride being taken from the Delaware River estuary.
Condenser air in-leakage rate, for the units aren
1t currently known
but the licensee is planning to provide monitoring capability.
Fuel perfonnance has been good since 1980 with very few leaking pins
noted. Radiochemistry indications are nearly
11tramp
11 uranium levels
routinely.
Cation conductivities for the two units have been consistently among
the PWR industry
1s best readings.
Low pressure and high pressure turbine examinations have revealed no
corrosion-induced problems with discs and blades.
Primary-to-secondary leakage rates have been low and well within
Technical Specifications. Leaks in Salem-1 (Steam Generator No. 13)
of 20 gallons per day (gpd) and Salem-2 (Steam Generator No. 24) of
50-60 gpd were noted in recent cycles. Licensee methods of detection
are capable of detecting leakage rates from about 1 gpd.
Steam generator sludge is removed routinely during refueling
outages. Clear indications of copper (in addition to iron)
have
been not.ed in sludge analyses. Sludge piles by fuel cycle are shown
below:
5
Fuel Cycle No.
Unit
Pounds of Sludge
1
1
11
94
1
1
12
106
1
1
13
70
1
1
14
106
1
2
21
34
1
2.
22
24
1
2
23
14
1
2
24
19
2
1
11
94
2
1
12
94
2
1
13
82
2
1
14
105
2
2
21
0
2
2
22
24
2
2
23
49
2
2
24
12
3
1
11
59
3
1
12
35
3
1
13
35
3
1
14
70
3
2
21
5
3
2
22
14.5
3
2
23
28.5
3
2
24
12
4
1
11
24
4
1
12
47
4
1
14
35
4
1
14
47
5
1
11
46
5
1
12
30
5
1
13
43
5
1
14
41
6
1
11
29
6
1
12
21
6
1
13
62
6
1
13
62
7
1
11
24
7
1
12
29
7
1
13
46
7
1
14
41
6
Both units have conventional Westinghouse four-loop PWR designs for
the primary systems employing chemical and volume control systems
(CVCS) for chemical control, addition and cleanup.
Conventional
reactor grade primary resins are used in the eves.
The licensee
employs the "constant pH
11 (lithium hydroxide/boric acid coordinated)
operating scheme for both units. The primary system materials
include Zircalloy-4 in the fuel rods, stellite on wear surfaces,
inconel steam generator tubing and stainless steel elsewhere.
Recent channel head dose rates of 15-20 R/hr (Salem~l) and 5 R/Hr
(Salem-2) were noted.
The licensee plans to try the "elevated
lithium" operating
schem~ in one unit (see related discussion on
Task Force recommendations below).
Cobalt source reduction is also
undergoing discussion by the licensee.
In summary, both units showed designs, materials and basic operating
schemes generally consistent with industry recommendations.
The
licensee has made modifications to improve secondary water chemistry
and has shown improved steam generator performance with apparently
arrested denting in the tubes.
5.1 Organization
Figure 13.1-10 of the licensee's UFSAR describes the general
organization of licensee's chemistry function for the station.
Within the Radiation Protection/Chemistry Department, the Chemistry
Engineer is responsible for the development and implementation of
the chemistry, radiochemistry and liquid effluent monitoring
program.
The Chemistry Engineer is also responsible for plant water
treatment and control systems. The Senior Chemistry Supervisor
reports to the Chemistry Engineer and is responsible for the
sampling/analyis of plant fluid systems, data reporting, calibration
of chemical instrumentation, evaluation of laboratory and chemical
systems operation and techniques, operation of water
treatment/control systems and maintenance of fluid systems within
established limits. Three Technical Supervisors report to the Senior
Chemistry Supervisor with responsibility for laboratory systems, and
instruments. The licensee employs technicians as analysts, treatment
system operators and instrument technicians and trains them in an
Institute of Nuclear Plant Operations (INPO) accredited program.
The
inspector noted that the licensee was reorganizing the chemistry
function.
The reorganization will be reviewed in a subsequent
inspection.
No deviations from UFSAR commitments were noted in this
review.
The licensee is developing a corporate chemistry function.
At the
time of the inspection, there was little evidence of corporate
involvement in Salem Chemistry operations:
0
Senior management hadn't provided a policy statement regarding
plant water chemistry control.
0
0
0
7
Oversight functions appeared unorganized and unfocused in both
the corporate engineering and new Radiation
Protection/Chemistry Services organizations.
Systematic review/audit of chemistry activities (other than
Quality Assurance) for technical direction weren't evident.
Long-term trending and suggestions for program improvement
weren't evident.
Corporate sponsored inter-and intra-laboratory analytical
intercomparisons for chemical parameters weren't in place.
Industry practices commonly show corporate involvement, sponsorship
and participation in all the aforementioned areas.
Lack of the
above is considered a weakness in the licensee's program.
5.6 Policies/Procedures
Twelve chemistry procedures (governing specifications, routine
surveillance activities, in-line and grab sampling/analyses and
system operations) were reviewed and discussed with the licensee's
representatives to determine if:
0
0
0
0
0
critical chemical variables and limit/action levels for control
of those variables had been identified;
Resin replenishment intervals or criteria were specified;
Sampling schedules, flush lines for grab sampling normally
statement stagnant lines and locations for obtaining samples
had been provided;
Control, comparison and actions to be taken were provided for
inline monitors (conductivity, specific conductivity, pH,
hydrazine and dissolved oxygen monitors); and
investigative and corrective actions to be taken when control
or diagnostic parameters exceeded action levels were
established.
Within the scope of the review, the following weakness was
identified:
0
The licensee makes routine intercomparisons of in-line and
laboratory instrument readings for process monitors providing
continuous indications of plant parameters, (e.g. conductivity,
dissolved oxygen, etc.). However, review of licensee's
procedures showed that acceptance criteria for determining that
an inline monitor was performing properly weren't provided.
At
the exit interview on December 18, 1987, the licensee indicated
8
that a contractor would develop acceptance criteria during the
next operational run by statistical review of the
intercomparisons made between the in-line monitors and the
laboratory measurements.
Other aspects of the licensee's
procedures were in reasonable agreement with EPRI and ASTM
guidance, Westinghouse-recommended practices or manufacturer's
suggested practices.
5.3 Resources
Chemistry staffing was reviewed relative to analytical/sampling,
instrument calibration/maintenance and water systems operational
responsibilities. Staffing of chemistry technicians, assistants and
workers appeared to be adequate since no backlogs of assigned work
were noted in the areas reviewed.
Laboratory and inline analytical
capabilities were reviewed relative to EPRI guidance and typical NRC
Region I utility capabilities. State-of-the-art analytical
instrumentation allowing ppb measurements to be routinely made were
noted.
Within the scope of this review, the inspector concluded that
adequate resources had been provided by the licensee to support the
licensee's basic water chemistry control program.
5.4 Audit/Review Processes
The two most recent quality assurance audits of the licensee's
chemistry program were reviewed to determine if Technical
Specification and Quality Assurance Plan requirements had been met
in the scope, coverage, management review and resolution of findings
from those audits. The inspector noted that the licensee had
contracted for additional audits by a contract chemistry
organization every six months.
During the recent refueling outage, the licensee's Maintenance
Department proposed the use of a refueling gasket material
containing a chloride/fluoride organic compound.
The inspector
noted that introduction of the gasket material into the core could
result in localized chloride/fluoride attack of the Zircalloy-4
cladding due to breakdown of the material in the heat and radiation
environment. The inspector reviewed Site Operations Review Committee
(SORC) meeting minutes to determine if the concern had been raised,
addressed and resolved.
SORC Meeting No.87-086 (October 16, 1987)
extensively discussed the potential problem and subsequent revisions
provided material controls to reduce the likelihood of gasket
material intrusion.
During periods of operation, daily and monthly reports were provided
to Station Management giving chemical and radiochemical data/trends
by the Chemistry group.
The reports were reviewed to determine if
key chemical and radiochemical parameters were identified, the
9
report received wide management distribution and significant results
were acted upon.
No concerns were identified. The reports were
a~curate and reasonable presentations of key parameters and received
wide station distribution.
6.
Sampling/Measurement
The inspector reviewed the licensee's sampling and measurement program to
determine if:
0
0
reactor coolant, steam generator and feedwater chemistry were
adequately sampled relative to Technical Specifications, UFSAR
commitments and industry consensus standards; and
surveillance of in-line instrumentation sample stream temperature
control and conditioning, quality control of inline instrumentation
accuracy, acceptance and correction criteria for conductivity and
cation conductivity measurements, sample line valve operation and
radiological control met industry-consensus standards provided by
The units' sampling and inline instrumentation was observed during plant
tours, discussed with Chemistry personnel and key procedures and records
were reviewed to complete the determination.
Within the scope of this review, the following weakness was noted:
0
The licensee's control of sample temperatures for inline
instrumentation failed to meet ASTM standards.
ASTM recommends that
sample temperatures be controlled to 25 degrees centigrade (+/-1
degree) to avoid errors associated with calculated temperature
correction. The licensee's sample conditioning used circulating
cooling water to reduce temperature from plant conditions to
measurement temperatures. However, circulating cooling water varies
seasonally in temperature from 48 degrees to 115 degrees Fahrenheit
(8-46 degrees Centigrade).
No other control of sample temperature
was provided. Conductivity and dissolved oxygen readings are
particularly sensitive to widely variable temperatures. Since the
licensee did not control temperatures, systematic errors in the
measurement of key chemical parameters by inline instruments were
introduced lessening the accuracy and reliability of those measurements.
At the exit interview on December 18, 1987, the licensee indicated that
sample temperature control would be improved.
7.
Implementation
The licensee's implementation of the water chemistry control program was
reviewed relative to Technical Specifications, recommendations and
guidance in NRC Regulatory Guides, licensee conrnitments in response to
NRC Bulletins and EPRI and ASTM concensus standards.
7.1
10
Surveillances
For Salem-1, (under Technical Specification No. 3/4.4.7) and for
Salem-2, (under Technical Specification No. 3/4.4.8), the licensee is
required to determine dissolved oxygen, chloride and fluoride
concentrations in the Reactor Coolant System at least once per 72
hours. Chemistry logs and other records were reviewed to determine
. if the surveillances and limits had been met for both units during
periods of operation in 1986 and 1987. Within the scope of this
review, no violations were noted.
The licensee's general chemistry sampling and analysis program for*
control and diagnostic parameters on the two units' primary and
secondary coolant loops was reviewed relative to the licensee's
procedures. Chemistry logs and other records were reviewed and
discussed with chemistry personnel to determine that sampling
frequencies and analyses as specified in the procedures had been met
and, if any unusual concentrations had been noted that they were
investigated by the licensee. Within the scope of this review, no
violations were identified.
7~2. NRC Bulletin No. 79-17
In response to NRC Bulletin No. 79-17, the licensee committed to
examinations and surveillances to ensure the integrity of piping
systems containing stagnant borated water was maintained. The
inspector briefly reviewed surveillance and sampling activities and
discussed pipe examinations with the licensee to determine whether
the commitments were being fulfilled.
No deviations were noted.
7.3
NRC Bulletin No. 87-01
In response to NRC Bulletin No. 87-01, the licensee responded to
questions concerning programs for monitoring the wall thickness in
condensate, feedwater, steam and related piping subject to
erosion/corrosion phenomena.
In addition, the licensee responded to
a questionnaire regarding typical chemical parameters in those
systems.
The inspector reviewed the accuracy and representativeness
of the chemistry values reported by the licensee on a sampling basis
and determined that the chemical data presented was representative
of plant conditions.
7.4 Task Force Recommendations
The licensee chartered and staffed several in-house special task
forces to provide recommendations to improve performance in several
areas. The inspector reviewed three task force reports for
recommendations related to improved corrosion and radiation field
buildup control and noted the following:
0
0
0
0
0
11
The licensee implemented a recommendation to increase CVCS
letdown flowrates to better utilize the cleanup system for the
primary coolant.
The licensee is considering nonchemical fuel rod cleaning and
chemical decontamination of selected primary coolant loop heat
exchangers to control radiation field buildup.
The licensee plans to implement an elevated lithium hydroxide
operating scheme in place of the current coordinated lithium
hydroxide/boric acid to maximize cobalt solubility and reduce
radiation fields.
Control of debris associated with valve maintenance were
reviewed and suggested improvements were recommended.
Recommendations for reduced primary loop cobalt alloys were
made.
The inspector noted that the recommendations were consistent with
industry-suggested improvements for radiation field control and
lauded the licensee for this in-house initiative.
8.
Exit Interview
The inspector met with the licensee's representatives (denoted in Detail
1) at the conclusion of the inspection on December 18, 1987.
During the
meeting, the inspector summarized the purpose and scope of the
inspection, identified findings and expressed concern over the in-line
instrument sample temperature control and reading intercomparison
weaknesses.
The licensee indicated a willingness to address and resolve
those weaknesses.
At no time during this inspection was written material provided to the
licensee by the inspector.
No infonnation exempt from disclosure under
10 CFR 2.790 is discussed in this report *