IR 05000323/2008006

IR 05000323-08-006, on 10/10/07 - 04/30/2008, Diablo Canyon Power Plant, Steam Generator Replacement Inspection (50001)

ML081650518
Person / Time
Site:	Diablo Canyon
Issue date:	06/13/2008
From:	William Jones Region 4 Engineering Branch 1
To:	Conway J Pacific Gas & Electric Co
References
IR-08-006
Download: ML081650518 (16)

Text

June 13, 2008 John Senior Vice President - Station Generation and Chief Nuclear Officer Pacific Gas and Electric Company Diablo Canyon Power Plant P.O. Box 770000 San Francisco, CA 94177-0001

SUBJECT: DIABLO CANYON POWER PLANT NRC INSPECTION REPORT 05000323/2008006

Dear Mr. Conway:

On April 30, 2008, the U.S. Nuclear Regulatory Commission (NRC) completed an inspection at your Diablo Canyon Power Plant, Unit 2. The enclosed report documents the inspection findings that were discussed on March 28, 2008, with Mr. Jim Becker and members of your staff and again on April 30, 2008.

This inspection examined activities conducted under your Unit 2 license as they relate to safety and compliance with the Commission's rules and regulations, and with the conditions of your Unit 2 license. Within these areas, the inspection consisted of selected examination of procedures and representative records, observations of activities, and interviews with personnel. This inspection covers Unit 2 steam generator replacement activities.

Based on the results of this inspection, no findings of significance were identified.

In accordance with 10 CFR 2.390 of the NRC's "Rules of Practice," a copy of this letter will be available electronically for public inspection in the NRC Public Document Room or from the Publicly Available Records (PARS) component of the NRC's document system, ADAMS.

ADAMS is accessible from the NRC Website at http://www.nrc.gov/reading-rm/adams.html (the Public Electronic Reading Room).

Sincerely,

/RA/

William B. Jones, Chief Engineering Branch 1 Division of Reactor Safety

Docket: 50-323 License: DPR-82 UNITED STATESNUCLEAR REGULATORY COMMISSIONREGION IV612 EAST LAMAR BLVD, SUITE 400ARLINGTON, TEXAS 76011-4125 Pacific Gas and Electric Company - 2 -

Enclosure:

NRC Inspection Report 05000323/2008006 w/attachment: Supplemental Information

REGION IV==

Dockets: 50-323 Licenses: DPR-82 Report: 05000323/2008006 Licensee: Pacific Gas and Electric Company Facility: Diablo Canyon Power Plant, Unit 2 Location: 7 1/2 miles NW of Avila Beach Avila Beach, California Dates: October 10, 2007, through April 30, 2008 Inspectors: M. Brown, Resident Inspector, Diablo Canyon J. Nadel, Reactor Inspector, Engineering Branch 1 Approved By:

W.B. Jones, Chief Engineering Branch 1 Division of Reactor Safety

- 2 - Enclosure

SUMMARY OF FINDINGS

IR 05000323/2008006; 10/10/07 - 04/30/2008; Diablo Canyon Power Plant; Steam Generator Replacement Inspection (50001)

This report covered a 7-month period of inspection by a resident and a regional inspector. No findings of significance were identified. The NRC's program for overseeing the safe operation of commercial nuclear power reactors is described in NUREG-1649, "Reactor Oversight Process," Revision 3, dated July 2000.

A. NRC-Identified and Self-Revealing Findings

No findings of significance were identified.

B. Licensee-Identified Violations

None.

REPORT DETAILS

4OA5 Other Activities

.1 Steam Generator Replacement Inspection

a. Inspection Scope

This inspection report discusses NRC inspection activities related to the Diablo Canyon Power Plant, Unit 2, steam generator replacement project.

These steam generator replacement inspection activities are not part of the normal baseline inspection program, but are performed on an as-needed basis. Therefore, no sample size is specified. The inspectors completed the entire procedure for steam generator replacement (50001), with the exception of the post installation verification and testing inspections. These inspections are planned and will be documented at a later date as referenced below.

Inspection Activities Documented in Other Inspection Reports:

A significant portion of these inspection efforts were completed and documented in prior NRC inspection reports, as listed below:

• Temporary modifications, NRC Integrated Inspection Reports 05000275/2007005 and 05000323/2007005, and 05000275/2008002 and 05000323/2008002, Sections 1R23 and 1R18, respectively

• Maintenance risk assessments and emergent work controls, NRC Integrated Inspection Report 05000275/2007005 and 05000323/2007005, Section 1R13

• Radiation protection, access, storage radiological safety plan, and ALARA program controls, NRC Integrated Inspection Report 05000275/2008002 and 05000323/2008002, Sections 2OS1 and 2OS2

• Inservice inspection, welding, and nondestructive examinations, NRC Integrated Inspection Report 05000275/2008002 and 05000323/2008002, Section 1R08

• Outage operating conditions, NRC Integrated Inspection Report 05000275/2008002 and 05000323/2008002, Section 1R20

• Identification and resolution of problems, NRC Integrated Inspection Report 05000275/2008002 and 05000323/2008002, Section

==4OA2

• Post installation verification and testing, planned for NRC Integrated Inspection Report 05000275/2008003 and 05000323/2008003, Sections 1R22, and 1R19==

• The results of the security-related inspection activities will be documented in NRC Inspection Report 05000275/2008402 and 05000323/2008402.

In addition to the above, as part of this inspection effort, the inspectors reviewed additional activities to ensure proper

(1) design and planning and

(2) removal and replacement, as provided below:

Engineering and Technical Support. The inspectors reviewed engineering and technical support activities prior to, and during, the replacement outage. The inspectors reviewed the following temporary modifications:

• Temporary 480V power to containment

• Removal of containment heating, ventilation and air conditioning duct over equipment hatch

• Removal of containment equipment hatch missile shield bumpers

• Removal of containment equipment hatch awning The inspectors verified the technical adequacy of the temporary modifications, including 10 CFR 50.59 related documents.

Lifting and Rigging. The inspectors reviewed engineering design and analysis associated with major component lifting and rigging projects. This included:

(1) crane and rigging equipment;

(2) steam generator component drop analysis;

(3) safe load paths; and

(4) load lay-down areas. The inspectors verified that the licensee had properly evaluated the potential impact of load handling on the reactor core and spent fuel, including cooling and support systems. This review also included the potential impact to underground electrical lines, fluid piping, and sewer systems that were traversed by the heavy haul route.

The inspectors conducted reviews of the preparations and procedures for:

(1) crane and rigging inspections;

(2) testing;

(3) equipment modifications;

(3) lay-down area preparations; and

(4) training. The related activities and equipment included:

• Area preparation for the outside systems

• Outside lift system

• Self-propelled modular transporter travel through fuel handling building

• Single point lift system

• Hatch transfer system

• Upending/downending device

• Temporary lifting device inside containment

• Reactor cavity decking

• Steam generator removal, installation of the replacement steam generators, and transport of the old steam generators to the storage facility The inspectors directly observed portions of the movement of each installed steam generator, including in the order of removal: (1)inside containment temporary lifting device lifting and rigging ,

(2) downending,

(3) traversing through the hatch transfer system,

(4) single point lift system movements,

(5) self-propelled modular transporter travel from the sundeck through the fuel handling building to the outside lift system

(6) lifting the outside lift system, and

(7) self-propelled modular transporter travel from the outside lift system to the old steam generator storage facility. Inspectors also directly observed portions of the installation of the replacement steam generators, which were moved from the replacement steam generator storage facility into containment in reverse order to the old steam generator movements discussed above. The inspectors observed a sample of various other activities including the initial lifts, heavy haul routes, and use of the hatch transfer system equipment.

Radiation Protection Program Controls. In addition to the health physics inspections, which are referenced in Section 1.a of this report, inspectors performed the following radiation protection-related inspections:

(1) direct inspection of radiation protection personnel coverage and control, ALARA, and dosimetry control activities along entire load movement path of old steam generator from containment to the old steam generator storage facility; and

(2) direct inspection of radiation protection controls and procedure adherence at the old steam generator storage facility.

Temporary Storage Radiological Safety Plans. Temporary storage activities will be addressed in a future NRC inspection report, under Inspection Procedures 71122.02, "Radioactive Material Processing and Transportation," and 71122.03, "Radiological Environmental Monitoring Program and Radioactive Material Control Program."

Major Structural Modifications. The inspectors reviewed documentation and performed direct inspections related to permanent structural modifications made to facilitate steam generator replacement. It should be noted that even though these modifications were treated as permanent, all outside rigging and handling equipment is planned to be removed after the replacement of the Unit 1 steam generators in Refueling Outage R15. These modifications included: outside lift system platform, and outside lift system tower base frame.

Permanent Design Changes. The inspectors also reviewed documentation and performed direct inspections of the following permanent design changes, which are planned to remain permanent except as noted below:

(1) the complete scope of design changes associated with all the hard (physical plant) and soft (documentation) changes for the replacement of all four steam generators;

(2) removal of concrete curbing near equipment hatch, Units 1 and 2;

(3) removal of concrete ramps near equipment hatch, Units 1 and 2;

(4) removal and determination of the position indicator on fire protection Valve 2 FP-30 (planned to be reinstalled after Refueling Outage 1R15; and

(5) replacement of the fuel handling building doors.

Containment Access and Integrity. Final containment close-out and testing inspections will be performed by the resident inspectors and documented in NRC Integrated Inspection Report 05000275/2008003 and 05000323/2008003. It should be noted that no physical modification or cutting was performed on the containment hatch opening during the Unit 2 steam generator replacement outage.

Foreign Material Controls. The inspectors directly observed the cutting and grinding of main steam line piping as well as the foreign material exclusion boundaries and controls in place for the remaining reactor coolant system piping. The inspectors also verified foreign material control measures for the reactor coolant system hot and cold legs after old steam generator removal. The inspectors also performed engineering reviews of the foreign material controls and reviewed corrective action documents related to foreign material exclusion.

Additional Post-installation Verification and Testing. Note that post-installation and testing activities are planned to occur after the conclusion of the inspection period for this report. For this reason, these activities are planned to be inspected and documented in NRC Integrated Inspection Report 05000275/2008003 and 05000323/2008003.

b. Findings

.

No findings of significance were identified.

4OA6 Meetings, Including Exit

The inspectors presented the inspection results to Mr. J. Becker, Site Director, and other members of the licensee's management staff in person on March 28, 2008, and again on April 30, 2008, during a telephonic exit meeting. The licensee acknowledged the information presented. Some proprietary information was reviewed during this inspection but no proprietary information was included in this report.

ATTACHMENT: Supplemental Information

SUPPLEMENTAL INFORMATION

KEY POINTS OF CONTACT

PG&E personnel

J. Becker, Vice President - Diablo Canyon Operations and Station Director

S. Ketelsen, Manager, Regulatory Services

C. Dougherty, Regulatory Services

K. Schrader, Regulatory Services

T. Grozan, Regulatory Services

J. Ballard, Design Engineering

R. West, ICE Manager

J. Hodges, Supervisor, Quality Verification

K. Peters, Director, Engineering Services

A. Wells, Security Shift Supervisor

T. King, Outage Manager

R. Oldenkamp, Strategic Projects Manager

A. Kulikowski, Maintenance Manager