ML20077J356

Responds to NRC Re Violations Noted in IE Insp Repts 50-454/83-17 & 50-455/83-14.Corrective Actions: Integrated Hot Functional Test Procedure Revised & Rev 3 Issued

ML20077J356
Person / Time
Site:	Byron
Issue date:	06/21/1983
From:	Farrar D COMMONWEALTH EDISON CO.
To:	James Keppler NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
Shared Package
ML20077J352	List: ML20077J356 ML20077J358
References
6797N, NUDOCS 8308160292
Download: ML20077J356 (10)

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)- Ons First NLtional Ptsza, CNcago, Illinois C/ ' '- Address Reply to: Post Office Box 767.

Chicago, lilinois 60690 p

June 21,-1983 i

Mr. James G. Keppler, Regional Administrator

- Region III U.S. Nuclear Regulatory Commission 799 Roosevelt Road Glen Ellyn, IL 60137 7

Subject:

. Byron Station Units 1 and 2 Response to IE Inspection Report Nos. 50-454/83-17 and.50-455/83-14 NRC Docket Nos. 50-454 and 50-455-4

' Reference (a):

J.

F. Streeter letter to Cordell Reed dated May 24, 1983.

i -

Dear Mr. Keppler:

Reference (a) provided the results of an inspection conducted by Mr. M. A. Ring of your office during the periods of March 30, 31, April 1,

?

5-8, 18-22, 26-29, and May 4, 1983, of activities at our Byron Station.

- During that inspection, certain activities appeared to beLin noncompli-ance with NRC requirements. 'The Attachment to this letter provides the

. Commonwealth Edison Company. response to the Notice of Violation as I

appended to Reference (a), and reflects our consideration of the specific

- examples documented.in paragraphs 2 and 3 of the inspection report as requested.

Additionally, Reference (a)-indicated Region-III's: concerns regarding the numerous examples of our failure to follow our' admini-strative procedures during the development of the hot functional' test procedure, and the apparent inadequacies of our administrative ~ procedures

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- which allowed the hot-functional test procedure to.be approved with numerous examples of the test procedure not adequately: addressing FSAR testing-commitments.

These-matters were considered'in the development of our response as requested,.and we believe that the corrective actions i

stated sh'ould prevent such recurrence.

j

. To.the best of my knowledge and belief, the statements contained j

in the Attachment are true.and correct.

In some respects these statements.

3

- are not based on my personal knowledge but'upon-information. furnished by

' other Commonwealth Edison employees.

Such information has been: reviewed t

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- in accordance with Company practice and-I'believe-it to be reliable.-

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J. G. Keppler 2-June 21, 1983 i

Please address any questions that you or your staff may have concerning this matter to this office.

Very ruly yo

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ennis L. Farrar Director of Nuclear Licensing EDS/1m i

Attachment cc:

Region III Inspector - Byron

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ATTACHMENT Response to Notice of Violation J

VIOLATION 1 10 CFR 50, Appendix B, Criterion V states, Activities affecting quality shall be prescribed by documented instructions, procedures, or drawings, of a type appropriate to the circumstances and shall be accomplished in I

accordance with these instructions,-procedures, or drawings.

Instructions, procedures, or. drawings shall include appropriate quantitative ai qualita-4 tive acceptance criteria for determining that important activities have been satisfactorily accomplished."

Criterion XI, states, in part, "A test program shall be established to assure that all testing required to demonstrate that structures, systems

-and components will perform satisfactorily in service is identified and performed in accordance with written test procedures which incorporate the t

-requirements and acceptance limits contained in applicable design documents..."

Section 2.4.3 of the Byron Startup Manual assigns Project Engineering the responsibility to review and approve all pre-operational and startup tests, provide test acceptance criteria, and ensure test objectives are

- properly stated and met by acceptance criteria.

Contrary 1to the above, the applicant approved and issued for performance Test Procedure 2.63.10,." Integrated Hot Functional," without performing an

-adequate review of the procedure'as evidenced by incomplete or missing acceptance criteria, data not designated as acceptance-criteria,

- misleading typogrLahical errors, incomplete testing provisions, and incomplete objectives.

- RESPONSE TO ITEM 1 CORRECTIVE ACTION TAKEN AND RESULTS ACHIEVED:

l An extensive review was conducted of Revision 2 to.the Integrated ~ Hot Functional (IHF) Test procedure and the applicable FSAR commitments.

- As a result, the IHF Test procedure was revised and Revision'3 was issued.. Corrective actions taken to address and resolve each specific example identified in Reference (a) are as follows:

3a.

A Test Change ~ Request (TCR) was written to: Revision 2 of the IHF Test and this change was1 subsequently incorporated into Revision

~

3 to include the Component Cooling data-taken'as acceptance criteria. - See ~ Step 4.12 o f Revision 3.

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A TCR was written to Revision 2 of the IHF Test and subsequently incorporated into Revision 3.

Included as acceptance criteria (Step 4.10.& 4.11) was the capability of the Steam Dumps:and Residual Heat ~ Removal System to cool down the plant in accordance g

-with Section 5.4.7.lt of the FSAR.

Procedural steps have -been reviewed.and approved by the Project Engineering Department.

3c.

A TCR-was written to Revision 2 of the IHF Test and subsequently

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4 incorporated into Revision 3-to correct typographical errors.

In addition, Revision 3 was'-reviewed to eliminate typographical errors.

3d.

A TCR was written to Revision 2 of the IHF Test and subsequently incorporated into Revision 3 to include Essential Service Water t

data taken as acceptance criteria.

See Revision 3 of the IHF Test, Step 4.13.

Additional components serviced by Essential Service Water were added to Revision 3 of the IHF Test.

3e A TCR was written to Revision 2 of the IHF Test and subsequently l

included into Revision 3 of the IHF Test to include the Auxiliary Feedwater Pumps and regulating valves as part of the Remote Shutdown Panel test section and' acceptance criteria, thus meeting

'the test objective as stated.

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. 3f.

A TCR was written to Revision 2 of the IHF Test and subsequently included into Revision 3 of the IHF Test, to include acceptance 4

. criteria for the Chemical and Volume Control Purification System (Step 4.14.)

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3g.

A TCR-was written to Revision 2 of the IHF Test and subsequently

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incorporated into Revision 3 to include acceptance criteria l

(Steps 4.16 and 4.17) for-the Steam Generator Safety Valves and the Steam Generator Pressure Operated Relief Valves lift a

setpoints.

The pressure gauges used to'take' data are-listed in Section7 of the IHF Test, Revision 3 special equipment.

0ther equipment used will be listed in the sequence of~ events,.if-

.necessary.

3h.

Table 14.2-24 of the Byron FSAR was amended-(Amendment No. 42,

~ May.1983) to verify -the degassing capability Lof the radioactive 4

waste gas system during startup testing.

31.

A TCRJwas written to Revision 2 of the IHF _ test and subsequently e

. incorporated into' Revision-3, Step 4.7cand-4.18-to add. Steam i

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-Generator B, C~and D level, Pressurizer' level,-Pressurizer!

pressure high' deviation and centrifugal-pump driven seal ~

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injection flow as acceptance. criteria.

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. CORRECTIVE ACTION TAKEN TO PREVENT RECURRENCE:

a.

A matrix will be developed tracking particular preoperational and startup test program requirements against specific test program commitments.

The matrix will be compiled through a re-review of the Byron FSAR, SER, Regulatory Guides, NRC Technical Bulletins and Notices and Industry Standards.

The commitments will be

. referenced to the appropriate systems and preoperational test number.

This' matrix will be used by the Test Review Board (TRB) during initial and pre-test reviews to ensure that all require-ments are established, and during post test review to verify that all acceptance criteria were met.

b.

In addition to the procedure review and approval by the Test Review Board members, an individual other than the cognizant System Test Engineer will check for and correct misleading typographical errors after the tests are typed.

c.

Test deficiencies will-be written as necessary to document 1) testing commitments identified in the FSAR which are not included in a specific preoperational or startup test and 2) changes necessary to a reference document such as the FSAR to accurately reflect the test program.

d.

A test checklist will be prepared to provide a detailed listing of areas to be covered during review of initial, pre and post preoperational test reviews.

DATE WHEN FULL COMPLIANCE WILL BE ACHIEVED:

August 15, 1983 i

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- VIOLATION 2

.10 CFR 50, Append'ix B, Criterion XIII states,.in part, that " Measures shall1be established to control the handling, storage, shipping, cleaning

- and-preservation of material.and equipment...to prevent damage or deterioration."

The Commonwealth Edison Company Quality Assurance Program contains in Quality Requiremsnt QR 2.0 a commitment to the regulatory position of

- Regul'atory Guide 1.39, Revision 2 which endorses the requirements of ANSI N45.2.3-1973.

Section 3.2.1 of ANSI N45.2.3 states, "The work areas shall be kept sufficiently clean and orderly that construction activity 3-can' proceed in an efficient manner that will produce and maintain quality in conformance with specified requirements.

Where large accumulations of materials occur on a nonroutine basis, such as the stripping of concrete

. forms, the_ material shall_be promptly removed or stored neatly.

Garbage, trash, scrap, litter, and other excess materials shall be collected, removed from the job site, or disposed of in accordance with specified requirements or planned practices.

Such excess material shall not be allowed to accumulate and create conditions that will adversely affect quality."

I Contrary to the above, the applicant's program for maintaining

. cleanliness and housekeeping was not being adequately implemented as evidenced by the following examples:

a.

On' April 6 and 7, 1983, the inspector.noted many loose pieces of lagging and considerable garbage and trash strewn about the MSIV rooms, and a coating of lagging dust covered almost everything in the

-B and C MSIV rooms.

The A and D MSIV rooms had staging built.such that instrument valves could not be operated and loose boards were leaning against valve handwheels and generally strewn about.

b.-

On April 20 and 28,'1983, the inspector noted considerable food stuffs (soda cans, banana peels, orange peels, candy bar. wrappers and small food tins), loose boards, and cigarette packs.in' the. area of the_ Unit-2 Diesel and Motor Driven Auxiliary Feed Pumps.

. c.

On April 28, 1983, the inspector noted that the.SG,"C" cubicle walkway had numerous' pieces of rags, pop cans,' cigarette butts,

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flexitallic' gasket and genernl-construction material.

RESPONSE TO ITEM 2' CORRECTIVE ACTION TAKEN AND RESULTS-ACHIEVED Byron Site Instruction #23, Rev. 3 dated June 3,_1982 details the

, Housekeeping Plan to-be-implemented by the Project Construction Department..This instruction identifies specific areas of the-building, their~ appropriate cleanliness ~ zone as defined in ANSI'

.N45.2.3-1973,'and acceptance criteria for surveillances of:the

~ Housekeeping Plan.

Form SQP.18-2.27.is: Used to document'a monthly surveil' lance of -housekeeping activities' performed per ' Byron Sitei

' Instruction-#23..

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The following details the action taken with respect to the specific

, examples identified in Reference (a):

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' Example 2A:

MAIN STEAM ISOLATION VALVE ROOMS The attached form SQP 18.2-27 (Attachment 1) documents that a surveil-lance of the MSIV Rooms was performed on April 4, 1983 identifying i

that.the area needed cleaning.

The same form indicates that the area j

was_ cleaned to appropriate acceptance criteria on April 8, 1983.

1 The operability of valves is part of the Pre-Preop Test walkdown

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performed by the System Test Engineer.

Items' identified on this

.[

walkdown are resolved on a case by case basis.

j Example 2B:

UNIT 2 DIESEL AND MOTOR ORIVEN AUXILIARY FEED PUMPS 1_ contains the April and May Form SQP 18-2.27 surveil-j lances.

The April surveillances indicate that the Auxiliary j

Building, Elevation 383' and the Auxiliary Feed Pump Diesel Day Tank Room were clean.

Example 2C:

STEAM GENERATOR "C" CUBICLE

' Steam Generator "C" Cubicle is part of the normal Reactor Building j

housekeeping surveillance.

The April and May surveillances indicate that the Reactor Building housekeeping was acceptable.

A special cleanup was made of Steam Generator "C" Cubicle on May 10,-1983 as 4

part of the preparations for Hot Functional Testing.

j CORRECTIVE ACTION TAKEN TO PREVENT RECURRENCE:

1

- As stated in our response to the above specific examples, the established Housekeeping Plan defined in the Byron Site Instruction l

1. 23 has identified areas deficient in housekeeping and documented the correction of these deficiencies.

In our judgment, the implementa-tion of this Housekeeping Plan is adequate to keep site work areas sufficiently clean and orderly as required:by ANSI N45.2.3-1973.

l DATE'WHEN FULL COMPLIANCE WILL BE ACHIEVED r

Complete

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