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=Text=
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                                                                                    -JUL 12' 1989
c.
                    "
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  '                        -
*
                            -  Docket.Nos; 50-352.-
2
                                    '
-JUL 12' 1989
              ,                                    ;50.-353
"
                          ' Philadelphia Electric Company.
Docket.Nos; 50-352.-
                          ' ATTN: Mr. C. ~ A. McNeill', ~Jr.
'
                                            . Executive Vice' President
-
                                                Nuclear-                                                                         - !-
-
      ,,
'
                  ,
;50.-353
                          . Correspondence ~ Control Desk
,
                                P. O. Box.7520' ,.
' Philadelphia Electric Company.
                                Philadelphia, PA. 19101-
' ATTN: Mr. C. ~ A. McNeill', ~Jr.
                              Gentlemen:
. Executive Vice' President
                          -Subject: Combined Inspection 50-352/89-80 and 50-353/89-80
Nuclear-
                                                                ~
- !-
                              This: refers to your letter dated May 8,1989,:in response to our = letter
. Correspondence ~ Control Desk
                              dated March 23, 1989
,
                          'Thank'you for.'qforrring es of'the corrective and preventive. actions' documented
,,
                                in your letter'       .  Those setions will be examined during a~ future inspection of-
P. O. Box.7520' ,.
                        .your licensed program.
Philadelphia, PA. 19101-
                        ;Your cooperation with us is appreciated.
Gentlemen:
                                                                                                Sincerely,
-Subject: Combined Inspection 50-352/89-80 and 50-353/89-80
                                                                                                . Original Signed BY8
This: refers to your letter dated May 8,1989,:in response to our = letter
                                                                                                  P. K. Eopen
~
                                                                                                Jacque P. Durr, Chief
dated March 23, 1989
                                                                                              . Engineering ' Branch
'Thank'you for.'qforrring es of'the corrective and preventive. actions' documented
                                                                                                Division of Reactor. Safety.
in your letter'
                        .cc,w/ enc 1:
Those setions will be examined during a~ future inspection of-
                              J. S. Kemper,'Sr., Senior Vice President - Nuclear Construction
.
                              G. _M. Leitch, Vice President - Limerick Generating Station
.your licensed program.
;Your cooperation with us is appreciated.
Sincerely,
. Original Signed BY8
P. K. Eopen
Jacque P. Durr, Chief
. Engineering ' Branch
Division of Reactor. Safety.
.cc,w/ enc 1:
J. S. Kemper,'Sr., Senior Vice President - Nuclear Construction
G. _M. Leitch, Vice President - Limerick Generating Station
S. J. Kowalski, Vice' President - Nuclear Enginee' ring
i
i
'
'
                              S. J. Kowalski, Vice' President - Nuclear Enginee' ring
.
                                        .
D. R. Helwig, General Manager - Nuclear Servcies
                              D. R. Helwig, General Manager - Nuclear Servcies
M. J. McCormick, Jr.,: Manager - Limerick Generating Station
                              M. J. McCormick, Jr.,: Manager - Limerick Generating Station
W.' T. Ullrich, Manager .
                              W.' T. Ullrich, Manager . Limerick Unit 2 Startup
Limerick Unit 2 Startup
                              A. S~. MacAinsh, Manager '- Limerick Quality Division
A.
l0                             G. A Hunger, Jr. , Director - Licensing Section
S~. MacAinsh, Manager '- Limerick Quality Division
l                             T. B. Conner, Jr. , Esquire
l0
                              E. J. Bradley, Esquire, Assistant General Counsel
G. A Hunger, Jr. , Director - Licensing Section
                              H..D. Honan,-Branch Head -~ Nuclear Engineering Licensing
l
                                  -
T. B. Conner, Jr. , Esquire
                                      .
E. J. Bradley, Esquire, Assistant General Counsel
                              Public Document Room (PDR)
H..D. Honan,-Branch Head -~ Nuclear Engineering Licensing
l                             Local Public Document Room (LPDR)
-
L                              Nuclear Safety Information Center (NSIC)
.
                              NRC Resident' Inspector
Public Document Room (PDR)
                              Commonwealth of Pennsylvania
l
Local Public Document Room (LPDR)
Nuclear Safety Information Center (NSIC)
L
NRC Resident' Inspector
Commonwealth of Pennsylvania
m
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                                                                  0FFICIAL RECORD COPY                     RL LIM 89-80 - 0001.0.0
0FFICIAL RECORD COPY
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RL LIM 89-80 - 0001.0.0
          ..'''
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                -
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                        :o                                 PDC         ,
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= _ - _ _ _ - _-__ - - _ _ _ _ - _ _ - _ __ _
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    .           .
.
              '
.
  .                                                      JUL 121983
'
                                                                -
JUL 121983
      '
.
                  Philadelphia Electric Company               2
-
                  bec w/ encl:
'
                  Region I Docket' Room (with concurrences)
Philadelphia Electric Company
                  "                                                                       ,
2
                    onoscu. cat ^.cristant, DRMA (w/o encl)                                 .
bec w/ encl:
                  Section Chief, DRP
Region I Docket' Room (with concurrences)
                  tiente Conner (SALP 'evvi is Only)
" onoscu. cat ^.cristant, DRMA (w/o encl)
                  P/,0 (2) SALP Reporte-Gn.ly
,
                  J. Dyer, EDO
.
                                                                        .
Section Chief, DRP
                W
tiente Conner (SALP 'evvi is Only)
                RI:DRS           RI)RS
P/,0 (2) SALP Reporte-Gn.ly
                Prividy         {{pr
J. Dyer, EDO
                                  s
.
                07/11/89         07/II/89
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                                              0FFICIAL RECORD COPY   RL LIM 89-80 - 0001.1.0
RI:DRS
                                                                    07/11/89
RI)RS
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07/11/89
07/II/89
0FFICIAL RECORD COPY
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07/11/89
-
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          ,.                                             --                         _
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                                                                                                                                              -. .-
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                                                                      : PHILADELPHIA ELECTRIC COMPANY
*
l-                                                                                                                                                 j
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                                                                                  LIMERICK GENERATING ST ATION
*
j.                                                                                           P. O. BOX A
.
                                                                                  SAN ATOG A. PENNSYLVANIA A 19464
: PHILADELPHIA ELECTRIC COMPANY
                                                                                      (215) 3271200 sat. 2000
l-
                  ~
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          M. J. M cCO M MIC K. 'J a.. P.E.
LIMERICK GENERATING ST ATION
j.
P. O. BOX A
SAN ATOG A. PENNSYLVANIA A 19464
(215) 3271200 sat. 2000
M. J. M cCO M MIC K. ' a.. P.E.
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.-3.fl'.".'.."l."$*.".m...
'May 8, 1989
-
!
!
        6 .-3.fl'.".'.."l."$*.".m...                                                                                        'May 8, 1989  -
6
                                                                                                                      Docket Nos. 50-352
Docket Nos. 50-352
50-353
o
o
                                                                                                                                    50-353
License No.
                                                                                                                    License No. NPF-39
NPF-39
                                                                                                      Construction Permit No. CPPR-107
Construction Permit No. CPPR-107
                                          U.S. Nuclear Regulatory Commission
U.S. Nuclear Regulatory Commission
                                          ATTN:       Document Control Desk
ATTN:
                                    -Washington, D.C.                       20555
Document Control Desk
                                                  SUBJECT:               Limerick denerating Station,-Units 1 and 2
-Washington,
                                                                        Response:to Observed Weaknesses Noted in
D.C.
                                                                        Special Maintenance. Team Inspection
20555
                                                                        Report No. 50-352/89-80, 50-353/89-80
SUBJECT:
                                                          NRC letter dated March 23, 1989, transmitted Special
Limerick denerating Station,-Units 1 and 2
                                          Maintenance: Team Inspection Report No. 50-352/89-80, 50-353/89-80
Response:to Observed Weaknesses Noted in
                                            for the Limerick Generating Station, Units 1.and 2.                             .This letter
Special Maintenance. Team Inspection
                                          also requested that we address the noted weaknesses contained in
Report No. 50-352/89-80, 50-353/89-80
                                            the report and outlined in Appendix 3.- The letter requested a
NRC letter dated March 23, 1989, transmitted Special
                                          written response within.45 days to the noted items. Attached to
Maintenance: Team Inspection Report No. 50-352/89-80, 50-353/89-80
                                            this letter is our-response to each observed weakness.
for the Limerick Generating Station, Units 1.and 2.
                                                          If you have any questions or require additional
.This letter
                                            information, please do not hesitate to contact us.
also requested that we address the noted weaknesses contained in
                                                                                                            Very truly yours,
the report and outlined in Appendix 3.-
                                                                                                        Ql         41 0
The letter requested a
                                                                                                                                  v
written response within.45 days to the noted items.
                                                                                                            M. V. McCormick, Jr.
Attached to
                                                                                                            Plant Manager
this letter is our-response to each observed weakness.
                                            DBN: kap
If you have any questions or require additional
                                            Attachment
information, please do not hesitate to contact us.
                                            cc:   W.   T. Russell, Administrator, Region I, USNRC
Very truly yours,
                                                  T. J. Kenny, USNRC Senior Resident Inspector
Ql
                                                                                                                          ,
0
                                                                          ,,
41
  .                                 /                       <
v
  pyw iu v                                             -
M. V. McCormick, Jr.
                _ _ _ _ _ _ _ - _ _ _ _ _ _ . _       _        _ _ _ .         _                   _                                             }
Plant Manager
DBN: kap
Attachment
cc:
W.
T.
Russell, Administrator, Region I, USNRC
T. J. Kenny, USNRC Senior Resident Inspector
,
,,
.
/
<
pyw iu v
-
_ _ _ _ _ _ _ - _ _ _ _ _ _ . _
_ _ _ .
_
_
}
_


                                                                                _ _ _- __ -
_ _ _- __ -
  .
*
          *
.
    -
-
        s
s
    .
.
      -
-
                                                                  Attachment 1
Attachment 1
                                                                  Page 1 of 11
Page 1 of 11
                                                          NRC Inspection Report
NRC Inspection Report
                                                                  50-352/89-80
50-352/89-80
                                                                  50-353/89-80
50-353/89-80
          Item 1
Item 1
          NRC Observed Weakness
NRC Observed Weakness
              Communications with offrite engineering organizations could be
Communications with offrite engineering organizations could be
          improved (Ref. II.4.1 {pg. 12}).
improved (Ref. II.4.1 {pg. 12}).
          Response
Response
              Regarding the general issue of communications between the
Regarding the general issue of communications between the
          station and the offsite engineering organization, an update to the
station and the offsite engineering organization, an update to the
          response provided to NRC Inspection Report 50-352/88-20 is provided
response provided to NRC Inspection Report 50-352/88-20 is provided
          below.
below.
              -The Engineering Work Request (EWR) process, implemented at
-The Engineering Work Request (EWR) process, implemented at
          Limerick in 1989 has provided engineering support for station
Limerick in 1989 has provided engineering support for station
          requests in such areas as Licensee Event Reports (LERs), Equipment
requests in such areas as Licensee Event Reports (LERs), Equipment
          Qualification (EQ) evaluations, potential deportability and
Qualification (EQ) evaluations, potential deportability and
          operability evaluations, and specific design related questions. The
operability evaluations, and specific design related questions.
          EWR process is being tracked and trended along with the                           !
The
          Non-Conformance Report (NCR) and Engineering Review Request Form
EWR process is being tracked and trended along with the
          (ERRF) processes using the Nuclear Engineering Task Tracking (NETT)
!
          system. Over 600 individual Limerick requests have been responded
Non-Conformance Report (NCR) and Engineering Review Request Form
          to by Engineering between January and April 1989.
(ERRF) processes using the Nuclear Engineering Task Tracking (NETT)
              The status of the tracking and trending is reported monthly in
system.
          the Senior Management Report (SMR) and includes information
Over 600 individual Limerick requests have been responded
          regarding timeliness of responses, total requests processed and the
to by Engineering between January and April 1989.
          current backlog of requests. This report is discussed monchly with
The status of the tracking and trending is reported monthly in
          the nuclear group vice-presidents and their direct reports.
the Senior Management Report (SMR) and includes information
              Six deu cated engineering personnel have been located onsite and
regarding timeliness of responses, total requests processed and the
          additional engineering resources are located at the
current backlog of requests.
          Architect / Engineer's (A/E's) Pottstown, Pennsylvania office.   An               i
This report is discussed monchly with
          Engineering project management staff, located at the site,                         {
the nuclear group vice-presidents and their direct reports.
          coordinates and tracks each individual request using the NETT                     j
Six deu cated engineering personnel have been located onsite and
          process and ensures effective communications between the station and               ]
additional engineering resources are located at the
          the offsite engineering organizations.     Members of the staff attend           j
Architect / Engineer's (A/E's) Pottstown, Pennsylvania office.
          the daily routine plant meetings (e.g. morning meeting, TRIPOD,                   j
An
          PORC) and provide needed support.     Our goal is to locate                       i
i
          approximately ten individuals from the engineering organization at                 I
Engineering project management staff, located at the site,
{
coordinates and tracks each individual request using the NETT
j
process and ensures effective communications between the station and
]
the offsite engineering organizations.
Members of the staff attend
j
the daily routine plant meetings (e.g. morning meeting, TRIPOD,
j
PORC) and provide needed support.
Our goal is to locate
i
I
approximately ten individuals from the engineering organization at
the site by the end of December 1989.
l
l
          the site by the end of December 1989.
The station engineering personnel have been trained on how to
              The station engineering personnel have been trained on how to
properly complete an EWR to ensure that station requests for
          properly complete an EWR to ensure that station requests for
engineering support clearly identify needs and expectations.
          engineering support clearly identify needs and expectations.     This
This
          will help provide effective use of the EWR thereby,providing
will help provide effective use of the EWR thereby,providing
          effective communications.                                                         l
effective communications.
                                                                                            i
l
                                                                                              :
i
                                                                                              1
:
                                                                                            !
1
                                                                                            t
!
                                                                                            j
tj


                                                                                                              _ _ _ _ _ _ _ - _
_ _ _ _ _ _ _ - _
  .
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    *
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      .  . -                                                                                                                   l
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        ,                                                          Attachment 1
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                                                          NRC Inspection Report                                                 .
Attachment 1
                                                                  50-352/89-80                                                   .
,
                                                                  50-353/89-80                                                 )
Page 2 of 11
o                                                                                                                                 i
NRC Inspection Report
l                                                                                                                                   l
.
.               Periodic meetings between station and engineering management                                                       1
50-352/89-80
.
50-353/89-80
)
i
o
l
l
.
Periodic meetings between station and engineering management
1
!
!
          were held on a bi-weekly basis during the outage and are presently                                                       !
were held on a bi-weekly basis during the outage and are presently
            scheduled to continue to be held on a monthly basis after the                                                       1
!
          outage. These meetings have been effective in prioritizing and                                                       j
scheduled to continue to be held on a monthly basis after the
                                                                                                                                  '
1
            resolving problems which require engineering support.
outage.
                Potentially reportable issues identified by the offsite                                                         i
These meetings have been effective in prioritizing and
            engineering organization are communicated to the station regulatory
j
          personnel by way of a Deportability Evaluation Form (REF). Station                                                     .
resolving problems which require engineering support.
          management can then evaluate the need for compensatory or other
'
            required actions, to make any required notifications, and to request
Potentially reportable issues identified by the offsite
          additional engineering support utilizing the EWR process. This
i
          mechanism has provided effective communications between the offsite                                                   l  1
engineering organization are communicated to the station regulatory
            engineering organization and station personnel such that potential
personnel by way of a Deportability Evaluation Form (REF).
            deportability / equipment operability concerns are raised to station                                                   !
Station
          operations personnel in a timely manner.                                                                             !
.
                Some examples of recent effective engineering support and
management can then evaluate the need for compensatory or other
          com.nunication between the offsite engineering organization and
required actions, to make any required notifications, and to request
          station personnel especially in the area of maintenance include 1)
additional engineering support utilizing the EWR process.
            investigation and evaluation of the jet pump riser nozzle crack and
This
          design of modifications to install crack monitoring equipment, 2)
l
          development of the test procedure and design of the required
mechanism has provided effective communications between the offsite
          modifications for the main turbine torsional testing, 3)
1
            investigation and evaluation of indications on the Low Pressure
engineering organization and station personnel such that potential
          Turbine blades, 4) design of a modification to relocate the
deportability / equipment operability concerns are raised to station
          Suppression Pool Temperature Monitoring System (SPTMS) temperature
!
          probes, 5) the project task force which is reviewing and resolving
operations personnel in a timely manner.
          problems identified during the review of the 10CFR50 Appendix R
!
            related fire protection issues, and 6) the establishment of periodic
Some examples of recent effective engineering support and
          Service Water System Reliability Group meetings involving
com.nunication between the offsite engineering organization and
          engineering and station personnel.
station personnel especially in the area of maintenance include 1)
                In conclusion there is clear evidence that there are improved
investigation and evaluation of the jet pump riser nozzle crack and
          communications between the offsite engineering organizations and the
design of modifications to install crack monitoring equipment, 2)
          station staff.
development of the test procedure and design of the required
                                                                                                                                    I
modifications for the main turbine torsional testing, 3)
                                                                                                                                    l
investigation and evaluation of indications on the Low Pressure
                                                                                                                                I
Turbine blades, 4) design of a modification to relocate the
                                                                                                                                i,
Suppression Pool Temperature Monitoring System (SPTMS) temperature
                                                                                                                                    j
probes, 5) the project task force which is reviewing and resolving
                                                                                                                                l
problems identified during the review of the 10CFR50 Appendix R
                                                                                                                                    i
related fire protection issues, and 6) the establishment of periodic
                                                                            _ _ _ _ _ _ _ _ _ _ _ _ _ - _ _ _ _ _ _ -
Service Water System Reliability Group meetings involving
engineering and station personnel.
In conclusion there is clear evidence that there are improved
communications between the offsite engineering organizations and the
station staff.
I
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                                                                        Attachment 1
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                                                                        Page 3 of 11
Attachment 1
                                                              NRC Inspection Report
Page 3 of 11
                                                                        50-352/89-80
NRC Inspection Report
                                                                        50-353/89-80
50-352/89-80
            Item 2
50-353/89-80
            NRC Observed Weakness:                                                                   .
Item 2
                      The operability of the HPCI room unit coolers was a concern in
NRC Observed Weakness:
            view of the ESW piping corrosion and no periodic performance test
.
            for these coolers.         (Ref. II.4.2 (pg. 14})
The operability of the HPCI room unit coolers was a concern in
            Response
view of the ESW piping corrosion and no periodic performance test
                      During the Unit 1 Second Refueling Outage the NRC inspector
for these coolers.
            observed several activities related to Emergency Service Water (ESW)
(Ref. II.4.2 (pg. 14})
            system valve and pipe replacements including the High Pressure
Response
            Coolant Injection (HPCI) system room unit cooler supply piping.
During the Unit 1 Second Refueling Outage the NRC inspector
            This planned modification work was-being done to increase supply
observed several activities related to Emergency Service Water (ESW)
            piping sizes to several ESW components to allow for aging
system valve and pipe replacements including the High Pressure
            degradation of this piping. During this pipe replacement,
Coolant Injection (HPCI) system room unit cooler supply piping.
            significant pipe corrosion was observed in the removed piping. The
This planned modification work was-being done to increase supply
            NRC inspector questioned the future operability of the HPCI room
piping sizes to several ESW components to allow for aging
            unit coolers in light of the observed corrosion.
degradation of this piping.
                                                                                                                                            4
During this pipe replacement,
                      During the pipe replacement work, pipe friction coefficients
significant pipe corrosion was observed in the removed piping.
            were estimated and incorporated into a computerized ESW system flow
The
            network model. Engineering and the Architect / Engineer analyzed the
NRC inspector questioned the future operability of the HPCI room
            ESW model using the new data and new piping sizes and determined
unit coolers in light of the observed corrosion.
            that a successful two unit ESW flow balance could be achieved.
4
                      The two unit flow balances were performed during the Unit 1
During the pipe replacement work, pipe friction coefficients
            Second Refueling / Unit 2 Tie-In Outage and proved ESW is capable of
were estimated and incorporated into a computerized ESW system flow
            providing adequate flows to all components in both units including
network model.
            the HPCI room coolers for all six acceptance criteria modes. An
Engineering and the Architect / Engineer analyzed the
            additional mode proved both ESW loops could independently support
ESW model using the new data and new piping sizes and determined
            eight diesel generators while providing the required' flows to both
that a successful two unit ESW flow balance could be achieved.
            units' safety related heat exchangers.
The two unit flow balances were performed during the Unit 1
                      To ensure the ESW system will continue to meet its required
Second Refueling / Unit 2 Tie-In Outage and proved ESW is capable of
            demands and support operability, several actions have been and will
providing adequate flows to all components in both units including
            be taken. A solution to the general ESW piping corrosion issue is
the HPCI room coolers for all six acceptance criteria modes.
            described under item 3 of this attachment. Quarterly flow balancing
An
            of the ESW system will be performed and piping and components will                                                             ,
additional mode proved both ESW loops could independently support
            be periodically inspected. In addition, the Technical Specification
eight diesel generators while providing the required' flows to both
            required quarterly ESW pump performance test will be performed and
units' safety related heat exchangers.
            pump capacity performance will be monit: red and evaluated. A
To ensure the ESW system will continue to meet its required
            further description of the quarterly flow balancing and component
demands and support operability, several actions have been and will
              inspection program is described below.
be taken.
                                                                                                                                            ,
A solution to the general ESW piping corrosion issue is
                                                                                          _ _ _ _ _ _ _ - _ _ _ _ _ -
described under item 3 of this attachment.
Quarterly flow balancing
of the ESW system will be performed and piping and components will
,
be periodically inspected.
In addition, the Technical Specification
required quarterly ESW pump performance test will be performed and
pump capacity performance will be monit: red and evaluated.
A
further description of the quarterly flow balancing and component
inspection program is described below.
,
_ _ _ _ _ _ _ - _ _ _ _ _ -


        . _ .
. _ .
                    _ _ _ _ _ , _ _
_ _ _ _ _ , _ _
                                                    s
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*
                s
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    .
-
      .              .                                                                Attachment 1-
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                                                                                        Page-4 of 11
.
                                                                              NRC Inspection Report
Attachment 1-
                                                                                      -50-352/86-80
.
                                                                                        50-353/89-80
.
                                    Routine ESW flow balances tests RT-1-Oll-251-0 and
Page-4 of 11
                  RT-1-011-252-0 will be performed quarterly. The procedures were
NRC Inspection Report
                  based on the flow balances performed as part of the two unit flow                                               '
-50-352/86-80
                  balance test program. They have been''specifically-designed to
50-353/89-80
                  closely monitor ESW components with marginal performances observed
Routine ESW flow balances tests RT-1-Oll-251-0 and
                  in'the two unit flow balance test program. .-Every quarter, potential
RT-1-011-252-0 will be performed quarterly.
                  ' problem' components will be tested.               Included in this category.will
The procedures were
                  be all Residual Heat Removal (RHR) system. pump seal coolers, RHR
based on the flow balances performed as part of the two unit flow
                  motor oil coolers, the Unit 1 HPCI room coolers, and the Unit 2
'
                  Reactor Core Isolation Cooling (RCIC) system room coolers. These
balance test program.
                  . components are more'likely to become ' problem' components because of
They have been''specifically-designed to
                  their piping configurations. The remaining components will be
closely monitor ESW components with marginal performances observed
                  tested a minimum of once during each cycle as part of the scheduled
in'the two unit flow balance test program. .-Every quarter, potential
                . quarterly tests. Acoustic flow monitors will be used to verify the
' problem' components will be tested.
                  accuracy of the procedure. Acoustic flow testing will be performed
Included in this category.will
                  on any component with unusually high differential pressure (DP)
be all Residual Heat Removal (RHR) system. pump seal coolers, RHR
                  readings and on coolers with a past history of fouling. This
motor oil coolers, the Unit 1 HPCI room coolers, and the Unit 2
                  redundant verification will ensure that we maintain a close watch on
Reactor Core Isolation Cooling (RCIC) system room coolers.
                  potential problems.
These
                                    Every refueling outage, Maintenance will perform visual
. components are more'likely to become ' problem' components because of
                  inspections of ESW and Service Water pipe and components via the
their piping configurations.
                  Preventive. Maintenance Program.               Once again, ESW components
The remaining components will be
                  identified to have a. potential problem such as RHR seal coolers,
tested a minimum of once during each cycle as part of the scheduled
                  Unit'l HPCI room coolers.and Unit 2 RCIC room coolers will be
. quarterly tests.
                                                ~
Acoustic flow monitors will be used to verify the
                  inspected each refueling outage. In addition, any component that
accuracy of the procedure.
                  experienced poor performance in the quarterly flow balances will be
Acoustic flow testing will be performed
                  inspected. The piping associated with the inspected coolers will
on any component with unusually high differential pressure (DP)
                  also be inspected. Flow balances will establish a constant
readings and on coolers with a past history of fouling.
                  reference point of ESW flow versus total system dynamic head. Each
This
                  quarter this will be compared with past results and the data
redundant verification will ensure that we maintain a close watch on
                  obtained will be used to monitor pipe fouling. Low DP readings on
potential problems.
                  heat exchangers during the flow balances could also indicate low
Every refueling outage, Maintenance will perform visual
                  flow conditions due to flow restrictions. The computerized ESW
inspections of ESW and Service Water pipe and components via the
                  system flow network model will be utilized in the ESW monitoring
Preventive. Maintenance Program.
                  program. The monitoring program will enable us to predict system
Once again, ESW components
                  performance and potential problems. The monitoring program will be
identified to have a. potential problem such as RHR seal coolers,
                  continually evaluated and modified as necessary to ensure continued
Unit'l HPCI room coolers.and Unit 2 RCIC room coolers will be
                  system operability.
inspected each refueling outage.
                  Item 3
In addition, any component that
                  NRC Observed Weakness:                                                                                           l
~
experienced poor performance in the quarterly flow balances will be
inspected.
The piping associated with the inspected coolers will
also be inspected.
Flow balances will establish a constant
reference point of ESW flow versus total system dynamic head.
Each
quarter this will be compared with past results and the data
obtained will be used to monitor pipe fouling.
Low DP readings on
heat exchangers during the flow balances could also indicate low
flow conditions due to flow restrictions. The computerized ESW
system flow network model will be utilized in the ESW monitoring
program.
The monitoring program will enable us to predict system
performance and potential problems.
The monitoring program will be
continually evaluated and modified as necessary to ensure continued
system operability.
Item 3
NRC Observed Weakness:
l
L
L
'
'
                                    A comprehensive solution to the ESW piping corrosion issue was
A comprehensive solution to the ESW piping corrosion issue was
                                                                                    '
not yet well defined.
                  not yet well defined. (Ref. II.4.2 {pg. 15})
(Ref. II.4.2 {pg. 15})
                                                                                                                                    i
'
                                                                                                                                    <
i
<
l
l
t-                                                                                         - - - - . - - - - - - - - - _ _ - - - -
t-
- - - - . - - - - - - - - - _ _ - - - -


                . _ -       -   - _ - - - _ -           -     ._                           -             .__ _ _ - - _ - _
. _ -
                                -
-
                      ..   .
- _ - - - _ -
                            ~
-
                        .
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                                                                                                Attachment 1
-
,                                                                                   .
.__ _ _ -
                                                                                              .Page 5 of 11
- _ - _
                                                                                      NRC Inspection Report
..
                                                                                                  50-352/89-80                 ,
.
                                                                                                  50-353/89-80
-
                              Response
~
                                          Based.on observations of service. water system components prior
.
                              to-commercialfoperation of Unit 1, a service water / circulating water
Attachment 1
                              (cooling tower) chemical treatment program was developed. The
,
                              program was developed to limit corrosion, deposition and
.
                              microbiological fouling in circulating water, service water.and
.Page 5 of 11
                              portions of ESW. This treatment system was installed and made
NRC Inspection Report
                              operational shortly after commercial' operation (after receipt of the
50-352/89-80
                              required NPDES permit from the Pennsylvania Department of
,
                              Environmental Resources). Provisions for corrosion rate monitoring,
50-353/89-80
                              using corrosion coupons, were included in the scope of this
Response
                              installation. It was recognized that, although reductions in
Based.on observations of service. water system components prior
                              corrosion rates were expected, further corrosion protection could.be
to-commercialfoperation of Unit 1,
                              achieved with clean pipe surfaces. We therefore began to
a service water / circulating water
                              investigate cleaning alternatives in parallel with instituting the
(cooling tower) chemical treatment program was developed.
                              corrosion treatment program and periodically monitoring the
The
                              effectiveness of the program using the corrosion coupons, an
program was developed to limit corrosion, deposition and
                              instantaneous corrosion monitor, and individual component
microbiological fouling in circulating water, service water.and
                              inspections (conducted as components are isolated and opened due to
portions of ESW.
                              maintenance activities).
This treatment system was installed and made
                                          Due to the amount of piping involved in these systems, and the
operational shortly after commercial' operation (after receipt of the
                              isolation / availability constraints and outage schedule limitations
required NPDES permit from the Pennsylvania Department of
                              associated with mechanical cleaning, chemical cleaning techniques
Environmental Resources).
                            .were pursued. A chemical cleaning technique was identified and
Provisions for corrosion rate monitoring,
                            . testing was' conducted, using samples of service water piping removed
using corrosion coupons, were included in the scope of this
                              from Limerick. Although this two step chemical cleaning process
installation.
                              (deposit softening followed by mild acid wash) was demonstrated to
It was recognized that, although reductions in
                              be effective in a similar application at another utility, it was not
corrosion rates were expected, further corrosion protection could.be
                              effective in removing Limerick's deposits. Investigations into
achieved with clean pipe surfaces.
                              chemical cleaning techniques continued into cycle 2 for Unit 1. An
We therefore began to
                              alternate cleaning program has been identified similar to the
investigate cleaning alternatives in parallel with instituting the
                              previously_ tested two step program, which based on recent successful
corrosion treatment program and periodically monitoring the
                              application in a similar application has proven effective. We plan
effectiveness of the program using the corrosion coupons, an
                              to test this program using ESW piping samples removed during the
instantaneous corrosion monitor, and individual component
                              second Refueling Outage.
inspections (conducted as components are isolated and opened due to
                                            In addition, during a design review prior to the Unit 1 First
maintenance activities).
                              Refueling Outage, we recognized that due to normal aging (corrosion
Due to the amount of piping involved in these systems, and the
                              degradation) of the pipe, there would not be sufficient system flows                             j
isolation / availability constraints and outage schedule limitations
                              to support 2 unit operations and some ESW supply piping would need                               '
associated with mechanical cleaning, chemical cleaning techniques
                              to be replaced. During the First Refueling Outage, sections of
.were pursued.
                              piping in the 'A' loop of ESW were replaced with larger diameter
A chemical cleaning technique was identified and
                              piping.           Inspection and testing of the piping replaced during this
. testing was' conducted, using samples of service water piping removed
                              outage indicated that a corrosion problem existed in small ESW
from Limerick.
                              lines, specifically the one-inch diameter piping to the RHR pump
Although this two step chemical cleaning process
                              seal coolers and RER motor oil coolers, but was not evident in the
(deposit softening followed by mild acid wash) was demonstrated to
                              larger diameter piping inspected or replaced.
be effective in a similar application at another utility, it was not
                                                                                                                                l
effective in removing Limerick's deposits.
_______________                                     _.
Investigations into
                                                                                                                                ;
chemical cleaning techniques continued into cycle 2 for Unit 1.
An
alternate cleaning program has been identified similar to the
previously_ tested two step program, which based on recent successful
application in a similar application has proven effective.
We plan
to test this program using ESW piping samples removed during the
second Refueling Outage.
In addition, during a design review prior to the Unit 1 First
Refueling Outage, we recognized that due to normal aging (corrosion
degradation) of the pipe, there would not be sufficient system flows
j
to support 2 unit operations and some ESW supply piping would need
'
to be replaced.
During the First Refueling Outage, sections of
piping in the
'A'
loop of ESW were replaced with larger diameter
piping.
Inspection and testing of the piping replaced during this
outage indicated that a corrosion problem existed in small ESW
lines, specifically the one-inch diameter piping to the RHR pump
seal coolers and RER motor oil coolers, but was not evident in the
larger diameter piping inspected or replaced.
l
_______________
_.
;


,, _ _--   _
,, _ _--
                                              - - ,       , , , _ _         ,
- - ,
        .               .
, , , _ _
                            .
,
          .
_
                                                                                                          Attachment 1
.
                                                                                                          Page 6 of 11
.
                                                                                                NRC Inspection Report
.
                                                                                                          50-352/89-80
.
                                                                                                          50-353/89-80
Attachment 1
                                                  During the Second Refueling Outage, secticns of piping of the
Page 6 of 11
                                          'B'     loop of ESW were replaced for the aging concern described above.
NRC Inspection Report
                                      The new piping was passivated with a high concentration of corrosion
50-352/89-80
                                      inhibition chemicals prior to wetting. Passivation is a chemical
50-353/89-80
                                      treatment applied to the inner metal surface of the piping to
During the Second Refueling Outage, secticns of piping of the
                                        inhibit corrosion. The removed sections of pipe contain similar
'B'
                                      amounts of corrosion as contained in the 'A' loop piping removed 18
loop of ESW were replaced for the aging concern described above.
                                    months earlier with the exception of the HPCI room unit cooler
The new piping was passivated with a high concentration of corrosion
                                      piping.           The 'A' loop piping replaced during the first refueling
inhibition chemicals prior to wetting.
                                      outage was inspected and found to contain a very small amount of
Passivation is a chemical
                                      corrosion after 18 months of service. Evaluation of the corrosion
treatment applied to the inner metal surface of the piping to
                                    monitoring data and the observations made during the second
inhibit corrosion.
                                      Refueling Outage indicate that the corrosion rate within the ESW
The removed sections of pipe contain similar
                                      piping has been reduced. Samples of the deposits obtained from the
amounts of corrosion as contained in the
                                      ESW piping were analyzed and the results indicate that the fouling
'A'
                                      problem is caused by general iron corrosion products and not from
loop piping removed 18
                                      silt / mud deposition, microbiological fouling or microbiological 1y
months earlier with the exception of the HPCI room unit cooler
                                        influenced corrosion.
piping.
                                                  Based upon the chemical analysis results, ESW system
The
                                        inspections, and several tests involving the service water system
'A'
                                        (which normally supplies the ESW piping and components), we have
loop piping replaced during the first refueling
                                      determined the causes of the ESW system fouling to be the following:
outage was inspected and found to contain a very small amount of
                                                  'l . Ineffective layup practices during plant construction and
corrosion after 18 months of service.
                                                      testing phase which resulted in prolonged periods of exposure
Evaluation of the corrosion
                                                      of the piping to raw water in stagnant or intermittent flow
monitoring data and the observations made during the second
                                                      conditions. This resulted in high corrosion rates and
Refueling Outage indicate that the corrosion rate within the ESW
                                                      deposition / accumulation of the corrosion products on the pipe
piping has been reduced.
                                                      surface.
Samples of the deposits obtained from the
                                                  2. An effective cleaning program was not identified and
ESW piping were analyzed and the results indicate that the fouling
                                                      implemented coincident with the chemical treatment program.
problem is caused by general iron corrosion products and not from
                                                      This limited the effecti"oness of the chemical treatment.
silt / mud deposition, microbiological fouling or microbiological 1y
                                                  3. Although the cooling tower corrosion treatment program does     l
influenced corrosion.
                                                      provide some corrosion protection of ESW, isolation of         )
Based upon the chemical analysis results, ESW system
                                                      certain ESW components and low or intermittent flow             '
inspections, and several tests involving the service water system
                                                      conditions when in standby mode further limit this
(which normally supplies the ESW piping and components), we have
                                                      protection.
determined the causes of the ESW system fouling to be the following:
                                                  Chemical treatment of the service water and ESW systems has been
'l . Ineffective layup practices during plant construction and
                                        recently upgraded to provide enhanced dispersant and anti-corrosion
testing phase which resulted in prolonged periods of exposure
                                      chemicals.                 Initial results of this upgraded treatment program
of the piping to raw water in stagnant or intermittent flow
                                        indicate even lower corrosion rates than achieved during the                   !
conditions.
                                      previous treatment program. A study is in progress to determine the             ;
This resulted in high corrosion rates and
                                      feasibility of a targeted biocide and corrosion inhibitor program to           !
deposition / accumulation of the corrosion products on the pipe
                                      address the corrosion problems during stagnant / intermittent                   !
surface.
                                      operating conditions present in the ESW and Residual Heat Removal                 l
2. An effective cleaning program was not identified and
                                      Service Water (RHRSW) systems. A Service Water System Reliability
implemented coincident with the chemical treatment program.
                                                                                                                      :
This limited the effecti"oness of the chemical treatment.
  - _ _       - _ _ _ _ _ _ _ _ _ - _ _ _ _
3. Although the cooling tower corrosion treatment program does
provide some corrosion protection of ESW, isolation of
)
certain ESW components and low or intermittent flow
'
conditions when in standby mode further limit this
protection.
Chemical treatment of the service water and ESW systems has been
recently upgraded to provide enhanced dispersant and anti-corrosion
chemicals.
Initial results of this upgraded treatment program
indicate even lower corrosion rates than achieved during the
previous treatment program.
A study is in progress to determine the
feasibility of a targeted biocide and corrosion inhibitor program to
address the corrosion problems during stagnant / intermittent
operating conditions present in the ESW and Residual Heat Removal
Service Water (RHRSW) systems.
A Service Water System Reliability
- _ _
- _ _ _ _ _ _ _ _ _ - _ _ _ _


  ,                         ..   .
,
                                      -
..
                                          ~ . .   . ,       ,       .
.
                                                                                      -
-
                                                                                            - - - - - - - =
~ . .
    ,j>               .
. ,
    .
,
                          ~
.
                                                                                  Attachment 1
-
                                                                                  Page 7 of.ll
- - - - - - - =
                                                                        NRC Inspection' Report
,j>
                                                                                  50-352/89-80
.
                                                                                  50-353/89-80
.
                        Group, composed of onsite and offsite engineering and technical
~
                        : personnel, was initiated in December,-1988, to identify and address
Attachment 1
                        specific Service Water and ESW problems.
Page 7 of.ll
                            . These actions will provide the comprehensive solution to the ESW
NRC Inspection' Report
                        piping corrosion issue.
50-352/89-80
                        Item 4
50-353/89-80
                        NRC Observed Weakness:
Group, composed of onsite and offsite engineering and technical
                        Deletion of QC witness points in certain maintenance procedures
: personnel, was initiated in December,-1988, to identify and address
                        without specific guidance (Ref. II.4.4 {pg. 18}).
specific Service Water and ESW problems.
                        Response::
. These actions will provide the comprehensive solution to the ESW
                              The weakness identified as the process for deleting QC witness
piping corrosion issue.
                        points =was recognized by NQA during the NRC inspection and
Item 4
                        appropriate 1 corrective measures were taken at that time.     As stated
NRC Observed Weakness:
                        in the Inspection Report, the problem stemmed from the efforts to
Deletion of QC witness points in certain maintenance procedures
                        increase accountability for quality at the worker level and sharpen
without specific guidance (Ref. II.4.4 {pg. 18}).
                        the focus of QC on the more critical aspects of the work activities.
Response::
                        Without formal guidance to accomplish this, QC witness points were
The weakness identified as the process for deleting QC witness
                        inconsistently applied and, in some instances, appropriate QC
points =was recognized by NQA during the NRC inspection and
                        witness points had been deleted from certain procedures along with
appropriate 1 corrective measures were taken at that time.
                        those that were. unnecessary. During the NRC inspection, a~ review
As stated
                        was initiated by the QC Division which determined that of
in the Inspection Report, the problem stemmed from the efforts to
                        approximately 700 Maintenance Procedures, seventy-seven (77) were
increase accountability for quality at the worker level and sharpen
                        revised without the specific guidance being in place.       These seventy
the focus of QC on the more critical aspects of the work activities.
                        seven procedures were reviewed and eleven (11) required revision to
Without formal guidance to accomplish this, QC witness points were
                        reinstate the appropriate QC witness points which were inadvertently
inconsistently applied and, in some instances, appropriate QC
                        deleted. The eleven procedures including the emergency diesel;
witness points had been deleted from certain procedures along with
                        engine and motor control center preventive maintenance procedures
those that were. unnecessary.
                        identified by the NRC inspector were appropriately revised prior to
During the NRC inspection, a~ review
                        performance of any work activities utilizing them.                                 i
was initiated by the QC Division which determined that of
                              As committed to during the inspection, formal guidance for
approximately 700 Maintenance Procedures, seventy-seven (77) were
y                        determining QC points for specific work activities has been
revised without the specific guidance being in place.
l                       proceduralized. Maintenance Guideline No. 28, titled
These seventy
                        " Identification of Quality Control Witness Points" and a supplement
seven procedures were reviewed and eleven (11) required revision to
                        to the QC Inspection Program Procedure, Supplement NQA-4-SlA,
reinstate the appropriate QC witness points which were inadvertently
                        " Determination of QC Action Points", provide the formal guidance to
deleted.
                        the maintenance procedure writer and QC procedure reviewer for
The eleven procedures including the emergency diesel;
                        determining when QC witness points are to be included in the
engine and motor control center preventive maintenance procedures
                        electrical and mechanical preventive maintenance procedures.
identified by the NRC inspector were appropriately revised prior to
                        Supplement NOA-4-SlA is expected to be formally issued by June 30,
performance of any work activities utilizing them.
                        1989.
i
        _ _ - - - - - -
As committed to during the inspection, formal guidance for
determining QC points for specific work activities has been
y
l
proceduralized.
Maintenance Guideline No. 28, titled
" Identification of Quality Control Witness Points" and a supplement
to the QC Inspection Program Procedure, Supplement NQA-4-SlA,
" Determination of QC Action Points", provide the formal guidance to
the maintenance procedure writer and QC procedure reviewer for
determining when QC witness points are to be included in the
electrical and mechanical preventive maintenance procedures.
Supplement NOA-4-SlA is expected to be formally issued by June 30,
1989.
_ _ - - - - - -


  zgy e v             o     , , .   --
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                                                                                        Attachment'1
M.~
                                                                                        Page 8 of 11
r
            +
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                                                                                NRC Inspection Report
v
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Attachment'1
Page 8 of 11
NRC Inspection Report
+
50-352/89-80
i
i
                                                                                        50-352/89-80
50-353/89-80-
                                                                                        50-353/89-80-
' Item-5'
                    ' Item-5'
NRC Observed Weakness:
                      NRC Observed Weakness:                                                                 F
F
                      Low' Level-QA/QC involvement in the ESW piping corrosion issue.
Low' Level-QA/QC involvement in the ESW piping corrosion issue.
                      (Ref. .II.4.4 {pg. 19))
(Ref. .II.4.4 {pg. 19))
                      . Response
. Response
                            The ESW piping system corrosion problem had been previously
The ESW piping system corrosion problem had been previously
                      identified during flow balancing of the ESW system during
identified during flow balancing of the ESW system during
                      pre-operational testing. A flow network analysis was performed-to.
pre-operational testing.
                      aid in flow balancing and modifications were initiated to ensure.
A flow network analysis was performed-to.
                      that no unacceptable flow restrictions existed as the ESW piping
aid in flow balancing and modifications were initiated to ensure.
                      aged. . These modifications were identified and substantiated by
that no unacceptable flow restrictions existed as the ESW piping
                      written Safety Evaluations and Plant Operating Review Committee
aged. . These modifications were identified and substantiated by
                      revi'ews.
written Safety Evaluations and Plant Operating Review Committee
                            During the course of on going ESW piping modifications, QC-
revi'ews.
                      inspection personnel questioned the acceptability of the ESW piping
During the course of on going ESW piping modifications, QC-
                      corrosion.
inspection personnel questioned the acceptability of the ESW piping
                                                                                                    '
corrosion.
                                          However, in the absence of specific cleanliness       .
However, in the absence of specific cleanliness
                      acceptance criteria in the governing specification, and in light'of
.
                      the on-going. modifications, flow network ' analysis -and engineering
'
                      study, NQA management ' and QC supervision felt that the ESW corrosion'
acceptance criteria in the governing specification, and in light'of
                      problem was adequately identified and controlled and concluded that
the on-going. modifications, flow network ' analysis -and engineering
                      it was not necessary to issue nonconformance reports..
study, NQA management ' and QC supervision felt that the ESW corrosion'
                            In order to avoid recurrence in situations where the involvement
problem was adequately identified and controlled and concluded that
                      of the' appropriate personnel would not be as evident, supplement to
it was not necessary to issue nonconformance reports..
                      NOA-QC inspection procedures are being developed to more clearly.
In order to avoid recurrence in situations where the involvement
                      define' cleanliness acceptance' criteria for plant operating systems.
of the' appropriate personnel would not be as evident, supplement to
                      These crite ia sill include loss of cross-sectional area that could
NOA-QC inspection procedures are being developed to more clearly.
                      impair or pronibit mechanical piping system components.such as' check
define' cleanliness acceptance' criteria for plant operating systems.
                      ! valves, coolers or heat exchangers from performing their. intended
These crite ia sill include loss of cross-sectional area that could
                      function. The supplemental inspection procedures are expected to be
impair or pronibit mechanical piping system components.such as' check
                      issued by. June 2, 1989. These criteria will be used to determine
! valves, coolers or heat exchangers from performing their. intended
                      the acceptability of internal cleanliness conditions.of plant piping
function.
                      systems and if not met will be the basis for issuance of Equipment
The supplemental inspection procedures are expected to be
                      Trouble Tags (ETT's) or Nonconformance Reports (NCR's) in accordance
issued by. June 2, 1989.
                      with procedure NOA-24 " Control of Hardware Non-Conformances" (now
These criteria will be used to determine
                      NGAP NA-03N001).
the acceptability of internal cleanliness conditions.of plant piping
                            In addition, a committee has been appointed by the NOA-General
systems and if not met will be the basis for issuance of Equipment
                      Manager to revise NOA-24 (NGAP NA-03N001) to ensure that ambiguity
Trouble Tags (ETT's) or Nonconformance Reports (NCR's) in accordance
                      will not exist in the procedure regarding nonconforming conditions
with procedure NOA-24 " Control of Hardware Non-Conformances" (now
                      and the issuance of NCR's. The procedure revision is expected to be
NGAP NA-03N001).
                      completed by September 30, 1989.
In addition, a committee has been appointed by the NOA-General
              _x___________.                     _ _ _ .   - _ - _ _ . - .
Manager to revise NOA-24 (NGAP NA-03N001) to ensure that ambiguity
will not exist in the procedure regarding nonconforming conditions
and the issuance of NCR's.
The procedure revision is expected to be
completed by September 30, 1989.
_x___________.
_ _ _ .
- _ - _ _
. - .


        .,                                                                     ,                                         _-_ . - _ _
.,
                                          .
,
                                  .-
_-_
              4
. - _ _
                                            '
.
                                                                                                            Attachment 1
. -
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4
                                                                                                  NRC Inspection Report
'
                                                                                                            50-352/89-80
Attachment 1
                                                                                                            50-353/89-80
Page 9 of 11
                                                        These, or any other nonconformances that are found to be
NRC Inspection Report
                                        repetitive, shall be considered a significant nonconformance in
50-352/89-80
                                      accordance NQA-24. As such, a Corrective Action Request shall_be
50-353/89-80
                                        initiated to management attention in accordance with existing
These, or any other nonconformances that are found to be
                                      procedure NOA-25, " Corrective Actions," to request a root cause
repetitive, shall be considered a significant nonconformance in
                                      analysis and to determine corrective action to prevent recurrence.
accordance NQA-24.
                                      Item 6
As such, a Corrective Action Request shall_be
                                      NRC Observed Weakness:
initiated to management attention in accordance with existing
                                      The lack of preparation of a Maintenance Procedure to support
procedure NOA-25, " Corrective Actions," to request a root cause
                                      lapping operations for D/G crankshaft bearings. (Ref. III.S.0 {pg.
analysis and to determine corrective action to prevent recurrence.
                                      25}).
Item 6
                                      Response:
NRC Observed Weakness:
                                                        The need for a bearing journal lapping procedure was previously
The lack of preparation of a Maintenance Procedure to support
                                      identified during the construction phase of Limerick Unit 2.
lapping operations for D/G crankshaft bearings. (Ref. III.S.0 {pg.
                                      Bearing inspections were scheduled to be performed on all four Unit
25}).
                                      1 emergency diesel generators (D/G's) during the Unit 1 second
Response:
                                      refueling outage and during this inspection, journal lapping is not
The need for a bearing journal lapping procedure was previously
                                      normally required. In addition, there were no vibration problems
identified during the construction phase of Limerick Unit 2.
                                        indicating that the journal bearings would need replacing and
Bearing inspections were scheduled to be performed on all four Unit
                                        journal lapping was not expected to be necessary during the second
1 emergency diesel generators (D/G's)
                                        refueling outage. Therefore, incorporation of journal lapping
during the Unit 1 second
                                      instructions into permanent procedures was determined to be of a
refueling outage and during this inspection, journal lapping is not
                                      lower priority than revision and enhancement of other procedures
normally required.
                                      required to support the Unit 1 Refuel Outage. During the overhaul
In addition, there were no vibration problems
                                      of the D12 D/G, journal lapping was identified to be required arid a
indicating that the journal bearings would need replacing and
                                      lapping procedure was generated shortly thereafter.
journal lapping was not expected to be necessary during the second
                                                        Journal lapping instructions are expected to be incorporated
refueling outage.
                                      into the appropriate permanent Maintenance Procedure (s) prior to
Therefore, incorporation of journal lapping
                                      July 31, 1989.
instructions into permanent procedures was determined to be of a
                                                                                                                                      1
lower priority than revision and enhancement of other procedures
                                        Item 7
required to support the Unit 1 Refuel Outage.
                                                                                                                                    ]
During the overhaul
                                                                                                                                      l
of the D12 D/G, journal lapping was identified to be required arid a
                                      NRC Observed Weakness:                                                                        l
lapping procedure was generated shortly thereafter.
                                                                                                                                      1
Journal lapping instructions are expected to be incorporated
                                                                                                                                    i
into the appropriate permanent Maintenance Procedure (s) prior to
                                      Slow implementation of the PRA into the prioritization of                                    )
July 31, 1989.
                                      maintenance work.                  (Ref. III.5.0 (pg. 27J)                                    '
1
Item 7
]
l
l
                                                                                                                                      .
NRC Observed Weakness:
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _       _ _ _ _ _
l
                                                                                                                                    j
1
i
Slow implementation of the PRA into the prioritization of
)
maintenance work.
(Ref. III.5.0 (pg. 27J)
'
l
.
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
_ _ _ _ _
j


  ,     . .                                 .                               .                     ._ _ - _ _ _ _ _ _ _ - _ _ -
,
            .,
. .
              *                                                                                                                     l
.
    g 6                                                                                                                             !
.
                                                                                            Attachment 1
._ _ - _ _ _ _ _ _ _ - _ _ -
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.,
                                                                                  NRC Inspection Report
l
                                                                                            50-352/89-80                           1
*
                                                                                            50-353/89-80                           j
6
                Response:
!
                                          Several factors inhibited early extensive use of the
g
                Probabilistic Risk Assignment (PRA) in the maintenance process and
Attachment 1
                  at Limerick in general.                       These included:
Page 10 of 11
                  1)                     The lack of a comprehensive, living PRA that reflected the
3
                                          as-built plant, and,
1
                  2)                     The lack of a user friendly PRA tool that would simplify and
NRC Inspection Report
                                          expedite use of the.PRA.
50-352/89-80
                                          The following describes actions taken over the past few years to
50-353/89-80
                  eliminate these factors:
j
                  1)                     The PRA originally performed in 1980 was reviewed during the
Response:
                                          plant licensing process and updated in September 1982. Before
Several factors inhibited early extensive use of the
                                          widespread use could be made of the PRA, the system models had
Probabilistic Risk Assignment (PRA) in the maintenance process and
                                          to be revised to reflect as-built designs. Also, station
at Limerick in general.
                                          operating procedures, that were non-existent in 1982, had to be
These included:
                                          incorporated. The PRA was updated in August 1986 to reflect
1)
                                          Unit 1 as-built design and most of the emergency operating
The lack of a comprehensive, living PRA that reflected the
                                          procedures (i.e. the Transient Response Implementation Plan
as-built plant, and,
                                          (TRID) procedures). A second update was completed in November
2)
                                          1988 tict completed the incorporation of the TRIP procedures and
The lack of a user friendly PRA tool that would simplify and
                                          reflected two unit operation. Completion of this update
expedite use of the.PRA.
                                          addresses the first factor providing Limerick with a
The following describes actions taken over the past few years to
                                          comprehensive, living PRA that reflects the as-built plant and
eliminate these factors:
                                          supports applications.
1)
                  2)                     PRA applications in the past were limited due to the available
The PRA originally performed in 1980 was reviewed during the
                                          computer software that was difficult and cumbersome to use.                           In
plant licensing process and updated in September 1982.
                                          1987, the Nuclear Engineering Department PRA Branch purchased a
Before
                                          personal computer (PC) workstation that streamlined the process
widespread use could be made of the PRA, the system models had
                                          of modifying and using the PRA. The conversion of the PRA to
to be revised to reflect as-built designs.
                                          the workstation model was completed by November 1988. The PRA
Also, station
                                          work station was used to develop the PRA parameters (i.e. what
operating procedures, that were non-existent in 1982, had to be
                                          systems and equipment are PRA important and how they affect Core
incorporated.
                                          Damage Frequency) to be utilized by the station PRA programs and
The PRA was updated in August 1986 to reflect
                                          will be used by engineering to answer specific PRA based
Unit 1 as-built design and most of the emergency operating
                                          questions from the station. The PRA workstation addresses the
procedures (i.e. the Transient Response Implementation Plan
(TRID) procedures).
A second update was completed in November
1988 tict completed the incorporation of the TRIP procedures and
reflected two unit operation.
Completion of this update
addresses the first factor providing Limerick with a
comprehensive, living PRA that reflects the as-built plant and
supports applications.
2)
PRA applications in the past were limited due to the available
computer software that was difficult and cumbersome to use.
In
1987, the Nuclear Engineering Department PRA Branch purchased a
personal computer (PC) workstation that streamlined the process
of modifying and using the PRA.
The conversion of the PRA to
the workstation model was completed by November 1988.
The PRA
work station was used to develop the PRA parameters (i.e. what
systems and equipment are PRA important and how they affect Core
Damage Frequency) to be utilized by the station PRA programs and
will be used by engineering to answer specific PRA based
questions from the station.
The PRA workstation addresses the
second factor; it is the tool that was needed to simplify PRA
'
'
                                          second factor; it is the tool that was needed to simplify PRA
use and provide better responsiveness to PRA requests.
                                          use and provide better responsiveness to PRA requests.
- _ _ _ _ _ _ - _ _ _ _ -
                - _ _ _ _ _ _ - _ _ _ _ -


        ;,,                 ,               ,
;,,
                                                                              _ _ _ _ . . _ _ . . -
,
                                                                                                    _______
,
_ _ _ _ .
. _ _ . . -
_______
'^
'^
                ; . -
;
                    '
.
                  .
-
                      '
'
                                                                            Attachment 1
.
                                                                            Page 11 of 11
'
                                                                  NRC Inspection Report
Attachment 1
                                                                            50-352/89-80
Page 11 of 11
                                                                            50-353/89-80
NRC Inspection Report
                          With the above described improvements completed in November of
50-352/89-80
                      3988, Limerick has been able to develop several programs involving
50-353/89-80
                      the PRA. Specific to the prioritization of maintenance work, these
With the above described improvements completed in November of
                      programs include Administrative Guidelines (AG) AG-42, "PRA
3988, Limerick has been able to develop several programs involving
                      Applications in Plant Maintenance" and AG-43, " Guideline for the
the PRA.
                      Performance of System Outages." Following extensive training of
Specific to the prioritization of maintenance work, these
                      Limerick personnel, these programs became effective in January 1989
programs include Administrative Guidelines (AG) AG-42, "PRA
                      and have since then been implemented.
Applications in Plant Maintenance" and AG-43, " Guideline for the
                      Item 8
Performance of System Outages."
                      NRC Observed Weakness:
Following extensive training of
                      The lack of adherence to an administrative procedure (A-26) resulted
Limerick personnel, these programs became effective in January 1989
                      in traceability problems of mechanical tools. (Ref. III.7.0 {pg.
and have since then been implemented.
                      36))
Item 8
                      Response:
NRC Observed Weakness:
                          This problem had been identified prior to the inspection and the
The lack of adherence to an administrative procedure (A-26) resulted
                      Maintenance Request Form (MRF) had been changed in late 1988 to
in traceability problems of mechanical tools.
                      allow recording of up to 15 tools versus 5 allowed on the old form.
(Ref. III.7.0 {pg.
                      On February 9, 1989, the next day following identification of the
36))
                      problem by the NRC inspector, a meeting was held with the
Response:
                      maintenance department personnel. The importance of recording all
This problem had been identified prior to the inspection and the
                      tools used during maintenance activities on the MRF was stressed in
Maintenance Request Form (MRF) had been changed in late 1988 to
                      the meeting. Continuing training for Maintenance personnel will
allow recording of up to 15 tools versus 5 allowed on the old form.
                      address the need to include calibrated tool serial numbers on the
On February 9, 1989, the next day following identification of the
                      MRF in order to provide traceability.
problem by the NRC inspector, a meeting was held with the
                          A review of all out of tolerance (OOT) tools is being performed.
maintenance department personnel.
                      Prior to January 1, 1988, Quality Assurance (QA) personnel recorded
The importance of recording all
                      all calibrated tools used on sa'.'ety related equipment in parallel to
tools used during maintenance activities on the MRF was stressed in
                      the work activity. A similar traceability problem is net likely to
the meeting.
                      have occurred prior to January 1, 1988 nor after the meeting held on
Continuing training for Maintenance personnel will
                      February 9, 1989 and therefore the review will encompass the OOT
address the need to include calibrated tool serial numbers on the
                      reports from the calibration facility received from January 1, 1988
MRF in order to provide traceability.
                      to February 15, 1989. This review will compare the OOT tool
A review of all out of tolerance (OOT) tools is being performed.
                      reports, the tool usage log and the referenced MRF's to ensure that
Prior to January 1,
                      the OOT tools are properly identified on the MRF and that the affect
1988, Quality Assurance (QA) personnel recorded
                      of the OOT tools have been evaluated. This review includes the nine
all calibrated tools used on sa'.'ety related equipment in parallel to
                      MRF's identified during the NRC inspection. Any deficiencies
the work activity.
                      identified during this review will be evaluated and corrected.               In
A similar traceability problem is net likely to
                      addition, a maintenance guideline is being prepared for the control
have occurred prior to January 1, 1988 nor after the meeting held on
                      of calibrated tools. All corrective actions are expected to be
February 9,
                      completed by September 1, 1989.
1989 and therefore the review will encompass the OOT
reports from the calibration facility received from January 1,
1988
to February 15, 1989.
This review will compare the OOT tool
reports, the tool usage log and the referenced MRF's to ensure that
the OOT tools are properly identified on the MRF and that the affect
of the OOT tools have been evaluated.
This review includes the nine
MRF's identified during the NRC inspection.
Any deficiencies
identified during this review will be evaluated and corrected.
In
addition, a maintenance guideline is being prepared for the control
of calibrated tools.
All corrective actions are expected to be
completed by September 1, 1989.
- _ _ _ _ _ _ _ _ _
- _ _ _ _ _ _ _ _ _
}}
}}

Latest revision as of 22:16, 1 December 2024

Ack Receipt of Informing NRC of Steps Taken to Correct Violations Noted in Insp Repts 50-352/89-80 & 50-353/89-80
ML20246N417
Person / Time
Site: Limerick  
Issue date: 07/12/1989
From: Durr J
NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I)
To: Corbin McNeil
PECO ENERGY CO., (FORMERLY PHILADELPHIA ELECTRIC
References
NUDOCS 8907190367
Download: ML20246N417 (2)


See also: IR 05000352/1989080

Text

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2 -JUL 12' 1989 " Docket.Nos; 50-352.- ' - - '

50.-353

, ' Philadelphia Electric Company. ' ATTN: Mr. C. ~ A. McNeill', ~Jr. . Executive Vice' President Nuclear- - !- . Correspondence ~ Control Desk , ,, P. O. Box.7520' ,. Philadelphia, PA. 19101- Gentlemen: -Subject: Combined Inspection 50-352/89-80 and 50-353/89-80 This: refers to your letter dated May 8,1989,:in response to our = letter ~ dated March 23, 1989 'Thank'you for.'qforrring es of'the corrective and preventive. actions' documented in your letter' Those setions will be examined during a~ future inspection of- . .your licensed program.

Your cooperation with us is appreciated.

Sincerely, . Original Signed BY8 P. K. Eopen Jacque P. Durr, Chief . Engineering ' Branch Division of Reactor. Safety. .cc,w/ enc 1: J. S. Kemper,'Sr., Senior Vice President - Nuclear Construction G. _M. Leitch, Vice President - Limerick Generating Station S. J. Kowalski, Vice' President - Nuclear Enginee' ring i ' . D. R. Helwig, General Manager - Nuclear Servcies M. J. McCormick, Jr.,: Manager - Limerick Generating Station W.' T. Ullrich, Manager . Limerick Unit 2 Startup A. S~. MacAinsh, Manager '- Limerick Quality Division l0 G. A Hunger, Jr. , Director - Licensing Section l T. B. Conner, Jr. , Esquire E. J. Bradley, Esquire, Assistant General Counsel H..D. Honan,-Branch Head -~ Nuclear Engineering Licensing - . Public Document Room (PDR) l Local Public Document Room (LPDR) Nuclear Safety Information Center (NSIC) L NRC Resident' Inspector Commonwealth of Pennsylvania m 0FFICIAL RECORD COPY RL LIM 89-80 - 0001.0.0 n 07/11/89 - 's907190367 890712 '. M,,OI i b .. PDR- ADOCK 05000352

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PHILADELPHIA ELECTRIC COMPANY

l- j LIMERICK GENERATING ST ATION j. P. O. BOX A SAN ATOG A. PENNSYLVANIA A 19464 (215) 3271200 sat. 2000 M. J. M cCO M MIC K. ' a.. P.E. ~ J .-3.fl'.".'.."l."$*.".m... 'May 8, 1989 - ! 6 Docket Nos. 50-352 50-353 o License No. NPF-39 Construction Permit No. CPPR-107 U.S. Nuclear Regulatory Commission ATTN: Document Control Desk -Washington, D.C. 20555 SUBJECT: Limerick denerating Station,-Units 1 and 2 Response:to Observed Weaknesses Noted in Special Maintenance. Team Inspection Report No. 50-352/89-80, 50-353/89-80 NRC letter dated March 23, 1989, transmitted Special Maintenance: Team Inspection Report No. 50-352/89-80, 50-353/89-80 for the Limerick Generating Station, Units 1.and 2. .This letter also requested that we address the noted weaknesses contained in the report and outlined in Appendix 3.- The letter requested a written response within.45 days to the noted items. Attached to this letter is our-response to each observed weakness. If you have any questions or require additional information, please do not hesitate to contact us. Very truly yours, Ql 0 41 v M. V. McCormick, Jr. Plant Manager DBN: kap Attachment cc: W. T. Russell, Administrator, Region I, USNRC T. J. Kenny, USNRC Senior Resident Inspector , ,, . / < pyw iu v - _ _ _ _ _ _ _ - _ _ _ _ _ _ . _ _ _ _ . _ _ } _

_ _ _- __ -

. - s . - Attachment 1 Page 1 of 11 NRC Inspection Report 50-352/89-80 50-353/89-80 Item 1 NRC Observed Weakness Communications with offrite engineering organizations could be improved (Ref. II.4.1 {pg. 12}). Response Regarding the general issue of communications between the station and the offsite engineering organization, an update to the response provided to NRC Inspection Report 50-352/88-20 is provided below. -The Engineering Work Request (EWR) process, implemented at Limerick in 1989 has provided engineering support for station requests in such areas as Licensee Event Reports (LERs), Equipment Qualification (EQ) evaluations, potential deportability and operability evaluations, and specific design related questions. The EWR process is being tracked and trended along with the ! Non-Conformance Report (NCR) and Engineering Review Request Form (ERRF) processes using the Nuclear Engineering Task Tracking (NETT) system. Over 600 individual Limerick requests have been responded to by Engineering between January and April 1989. The status of the tracking and trending is reported monthly in the Senior Management Report (SMR) and includes information regarding timeliness of responses, total requests processed and the current backlog of requests. This report is discussed monchly with the nuclear group vice-presidents and their direct reports. Six deu cated engineering personnel have been located onsite and additional engineering resources are located at the Architect / Engineer's (A/E's) Pottstown, Pennsylvania office. An i Engineering project management staff, located at the site, { coordinates and tracks each individual request using the NETT j process and ensures effective communications between the station and ] the offsite engineering organizations. Members of the staff attend j the daily routine plant meetings (e.g. morning meeting, TRIPOD, j PORC) and provide needed support. Our goal is to locate i I approximately ten individuals from the engineering organization at the site by the end of December 1989. l The station engineering personnel have been trained on how to properly complete an EWR to ensure that station requests for engineering support clearly identify needs and expectations. This will help provide effective use of the EWR thereby,providing effective communications. l i

1 ! tj

_ _ _ _ _ _ _ - _ l . . . -

s . Attachment 1 , Page 2 of 11 NRC Inspection Report . 50-352/89-80 . 50-353/89-80 ) i o l l . Periodic meetings between station and engineering management 1 ! were held on a bi-weekly basis during the outage and are presently ! scheduled to continue to be held on a monthly basis after the 1 outage. These meetings have been effective in prioritizing and j resolving problems which require engineering support. ' Potentially reportable issues identified by the offsite i engineering organization are communicated to the station regulatory personnel by way of a Deportability Evaluation Form (REF). Station . management can then evaluate the need for compensatory or other required actions, to make any required notifications, and to request additional engineering support utilizing the EWR process. This l mechanism has provided effective communications between the offsite 1 engineering organization and station personnel such that potential deportability / equipment operability concerns are raised to station ! operations personnel in a timely manner. ! Some examples of recent effective engineering support and com.nunication between the offsite engineering organization and station personnel especially in the area of maintenance include 1) investigation and evaluation of the jet pump riser nozzle crack and design of modifications to install crack monitoring equipment, 2) development of the test procedure and design of the required modifications for the main turbine torsional testing, 3) investigation and evaluation of indications on the Low Pressure Turbine blades, 4) design of a modification to relocate the Suppression Pool Temperature Monitoring System (SPTMS) temperature probes, 5) the project task force which is reviewing and resolving problems identified during the review of the 10CFR50 Appendix R related fire protection issues, and 6) the establishment of periodic Service Water System Reliability Group meetings involving engineering and station personnel. In conclusion there is clear evidence that there are improved communications between the offsite engineering organizations and the station staff. I l I i j l i _ _ _ _ _ _ _ _ _ _ _ _ _ - _ _ _ _ _ _ -

-_ _. - _ _ ._ _ _ _ _ . _ _ _ _ _ _ _ _ _ - _ _ - .. . . . . - i a Attachment 1 Page 3 of 11 NRC Inspection Report 50-352/89-80 50-353/89-80 Item 2 NRC Observed Weakness: . The operability of the HPCI room unit coolers was a concern in view of the ESW piping corrosion and no periodic performance test for these coolers. (Ref. II.4.2 (pg. 14}) Response During the Unit 1 Second Refueling Outage the NRC inspector observed several activities related to Emergency Service Water (ESW) system valve and pipe replacements including the High Pressure Coolant Injection (HPCI) system room unit cooler supply piping. This planned modification work was-being done to increase supply piping sizes to several ESW components to allow for aging degradation of this piping. During this pipe replacement, significant pipe corrosion was observed in the removed piping. The NRC inspector questioned the future operability of the HPCI room unit coolers in light of the observed corrosion. 4 During the pipe replacement work, pipe friction coefficients were estimated and incorporated into a computerized ESW system flow network model. Engineering and the Architect / Engineer analyzed the ESW model using the new data and new piping sizes and determined that a successful two unit ESW flow balance could be achieved. The two unit flow balances were performed during the Unit 1 Second Refueling / Unit 2 Tie-In Outage and proved ESW is capable of providing adequate flows to all components in both units including the HPCI room coolers for all six acceptance criteria modes. An additional mode proved both ESW loops could independently support eight diesel generators while providing the required' flows to both units' safety related heat exchangers. To ensure the ESW system will continue to meet its required demands and support operability, several actions have been and will be taken. A solution to the general ESW piping corrosion issue is described under item 3 of this attachment. Quarterly flow balancing of the ESW system will be performed and piping and components will , be periodically inspected. In addition, the Technical Specification required quarterly ESW pump performance test will be performed and pump capacity performance will be monit: red and evaluated. A further description of the quarterly flow balancing and component inspection program is described below. , _ _ _ _ _ _ _ - _ _ _ _ _ -

. _ . _ _ _ _ _ , _ _ s i

. - s . Attachment 1- . . Page-4 of 11 NRC Inspection Report -50-352/86-80 50-353/89-80 Routine ESW flow balances tests RT-1-Oll-251-0 and RT-1-011-252-0 will be performed quarterly. The procedures were based on the flow balances performed as part of the two unit flow ' balance test program. They have beenspecifically-designed to closely monitor ESW components with marginal performances observed in'the two unit flow balance test program. .-Every quarter, potential ' problem' components will be tested. Included in this category.will be all Residual Heat Removal (RHR) system. pump seal coolers, RHR motor oil coolers, the Unit 1 HPCI room coolers, and the Unit 2 Reactor Core Isolation Cooling (RCIC) system room coolers. These . components are more'likely to become ' problem' components because of their piping configurations. The remaining components will be tested a minimum of once during each cycle as part of the scheduled . quarterly tests. Acoustic flow monitors will be used to verify the accuracy of the procedure. Acoustic flow testing will be performed on any component with unusually high differential pressure (DP) readings and on coolers with a past history of fouling. This redundant verification will ensure that we maintain a close watch on potential problems. Every refueling outage, Maintenance will perform visual inspections of ESW and Service Water pipe and components via the Preventive. Maintenance Program. Once again, ESW components identified to have a. potential problem such as RHR seal coolers, Unit'l HPCI room coolers.and Unit 2 RCIC room coolers will be inspected each refueling outage. In addition, any component that ~ experienced poor performance in the quarterly flow balances will be inspected. The piping associated with the inspected coolers will also be inspected. Flow balances will establish a constant reference point of ESW flow versus total system dynamic head. Each quarter this will be compared with past results and the data obtained will be used to monitor pipe fouling. Low DP readings on heat exchangers during the flow balances could also indicate low flow conditions due to flow restrictions. The computerized ESW system flow network model will be utilized in the ESW monitoring program. The monitoring program will enable us to predict system performance and potential problems. The monitoring program will be continually evaluated and modified as necessary to ensure continued system operability. Item 3 NRC Observed Weakness: l L ' A comprehensive solution to the ESW piping corrosion issue was not yet well defined. (Ref. II.4.2 {pg. 15}) ' i < l t- - - - - . - - - - - - - - - _ _ - - - -

. _ - - - _ - - - _ - - ._ - .__ _ _ - - _ - _ .. . - ~ . Attachment 1 , . .Page 5 of 11 NRC Inspection Report 50-352/89-80 , 50-353/89-80 Response Based.on observations of service. water system components prior to-commercialfoperation of Unit 1, a service water / circulating water (cooling tower) chemical treatment program was developed. The program was developed to limit corrosion, deposition and microbiological fouling in circulating water, service water.and portions of ESW. This treatment system was installed and made operational shortly after commercial' operation (after receipt of the required NPDES permit from the Pennsylvania Department of Environmental Resources). Provisions for corrosion rate monitoring, using corrosion coupons, were included in the scope of this installation. It was recognized that, although reductions in corrosion rates were expected, further corrosion protection could.be achieved with clean pipe surfaces. We therefore began to investigate cleaning alternatives in parallel with instituting the corrosion treatment program and periodically monitoring the effectiveness of the program using the corrosion coupons, an instantaneous corrosion monitor, and individual component inspections (conducted as components are isolated and opened due to maintenance activities). Due to the amount of piping involved in these systems, and the isolation / availability constraints and outage schedule limitations associated with mechanical cleaning, chemical cleaning techniques .were pursued. A chemical cleaning technique was identified and . testing was' conducted, using samples of service water piping removed from Limerick. Although this two step chemical cleaning process (deposit softening followed by mild acid wash) was demonstrated to be effective in a similar application at another utility, it was not effective in removing Limerick's deposits. Investigations into chemical cleaning techniques continued into cycle 2 for Unit 1. An alternate cleaning program has been identified similar to the previously_ tested two step program, which based on recent successful application in a similar application has proven effective. We plan to test this program using ESW piping samples removed during the second Refueling Outage. In addition, during a design review prior to the Unit 1 First Refueling Outage, we recognized that due to normal aging (corrosion degradation) of the pipe, there would not be sufficient system flows j to support 2 unit operations and some ESW supply piping would need ' to be replaced. During the First Refueling Outage, sections of piping in the 'A' loop of ESW were replaced with larger diameter piping. Inspection and testing of the piping replaced during this outage indicated that a corrosion problem existed in small ESW lines, specifically the one-inch diameter piping to the RHR pump seal coolers and RER motor oil coolers, but was not evident in the larger diameter piping inspected or replaced. l _______________ _.

,, _ _-- - - , , , , _ _ , _ . . . . Attachment 1 Page 6 of 11 NRC Inspection Report 50-352/89-80 50-353/89-80 During the Second Refueling Outage, secticns of piping of the 'B' loop of ESW were replaced for the aging concern described above. The new piping was passivated with a high concentration of corrosion inhibition chemicals prior to wetting. Passivation is a chemical treatment applied to the inner metal surface of the piping to inhibit corrosion. The removed sections of pipe contain similar amounts of corrosion as contained in the 'A' loop piping removed 18 months earlier with the exception of the HPCI room unit cooler piping. The 'A' loop piping replaced during the first refueling outage was inspected and found to contain a very small amount of corrosion after 18 months of service. Evaluation of the corrosion monitoring data and the observations made during the second Refueling Outage indicate that the corrosion rate within the ESW piping has been reduced. Samples of the deposits obtained from the ESW piping were analyzed and the results indicate that the fouling problem is caused by general iron corrosion products and not from silt / mud deposition, microbiological fouling or microbiological 1y influenced corrosion. Based upon the chemical analysis results, ESW system inspections, and several tests involving the service water system (which normally supplies the ESW piping and components), we have determined the causes of the ESW system fouling to be the following: 'l . Ineffective layup practices during plant construction and testing phase which resulted in prolonged periods of exposure of the piping to raw water in stagnant or intermittent flow conditions. This resulted in high corrosion rates and deposition / accumulation of the corrosion products on the pipe surface. 2. An effective cleaning program was not identified and implemented coincident with the chemical treatment program. This limited the effecti"oness of the chemical treatment. 3. Although the cooling tower corrosion treatment program does provide some corrosion protection of ESW, isolation of ) certain ESW components and low or intermittent flow ' conditions when in standby mode further limit this protection. Chemical treatment of the service water and ESW systems has been recently upgraded to provide enhanced dispersant and anti-corrosion chemicals. Initial results of this upgraded treatment program indicate even lower corrosion rates than achieved during the previous treatment program. A study is in progress to determine the feasibility of a targeted biocide and corrosion inhibitor program to address the corrosion problems during stagnant / intermittent operating conditions present in the ESW and Residual Heat Removal Service Water (RHRSW) systems. A Service Water System Reliability - _ _ - _ _ _ _ _ _ _ _ _ - _ _ _ _

, .. . - ~ . . . , , . - - - - - - - - = ,j> . . ~ Attachment 1 Page 7 of.ll NRC Inspection' Report 50-352/89-80 50-353/89-80 Group, composed of onsite and offsite engineering and technical

personnel, was initiated in December,-1988, to identify and address

specific Service Water and ESW problems. . These actions will provide the comprehensive solution to the ESW piping corrosion issue. Item 4 NRC Observed Weakness: Deletion of QC witness points in certain maintenance procedures without specific guidance (Ref. II.4.4 {pg. 18}). Response:: The weakness identified as the process for deleting QC witness points =was recognized by NQA during the NRC inspection and appropriate 1 corrective measures were taken at that time. As stated in the Inspection Report, the problem stemmed from the efforts to increase accountability for quality at the worker level and sharpen the focus of QC on the more critical aspects of the work activities. Without formal guidance to accomplish this, QC witness points were inconsistently applied and, in some instances, appropriate QC witness points had been deleted from certain procedures along with those that were. unnecessary. During the NRC inspection, a~ review was initiated by the QC Division which determined that of approximately 700 Maintenance Procedures, seventy-seven (77) were revised without the specific guidance being in place. These seventy seven procedures were reviewed and eleven (11) required revision to reinstate the appropriate QC witness points which were inadvertently deleted. The eleven procedures including the emergency diesel; engine and motor control center preventive maintenance procedures identified by the NRC inspector were appropriately revised prior to performance of any work activities utilizing them. i As committed to during the inspection, formal guidance for determining QC points for specific work activities has been y l proceduralized. Maintenance Guideline No. 28, titled " Identification of Quality Control Witness Points" and a supplement to the QC Inspection Program Procedure, Supplement NQA-4-SlA, " Determination of QC Action Points", provide the formal guidance to the maintenance procedure writer and QC procedure reviewer for determining when QC witness points are to be included in the electrical and mechanical preventive maintenance procedures. Supplement NOA-4-SlA is expected to be formally issued by June 30, 1989. _ _ - - - - - -

zgy e v o , , . -- 7 . x. - - ---_- , M.~ r - v - r :: -g - . .

~ Attachment'1 Page 8 of 11 NRC Inspection Report + 50-352/89-80 i 50-353/89-80- ' Item-5' NRC Observed Weakness: F Low' Level-QA/QC involvement in the ESW piping corrosion issue. (Ref. .II.4.4 {pg. 19)) . Response The ESW piping system corrosion problem had been previously identified during flow balancing of the ESW system during pre-operational testing. A flow network analysis was performed-to. aid in flow balancing and modifications were initiated to ensure. that no unacceptable flow restrictions existed as the ESW piping aged. . These modifications were identified and substantiated by written Safety Evaluations and Plant Operating Review Committee revi'ews. During the course of on going ESW piping modifications, QC- inspection personnel questioned the acceptability of the ESW piping corrosion. However, in the absence of specific cleanliness . ' acceptance criteria in the governing specification, and in light'of the on-going. modifications, flow network ' analysis -and engineering study, NQA management ' and QC supervision felt that the ESW corrosion' problem was adequately identified and controlled and concluded that it was not necessary to issue nonconformance reports.. In order to avoid recurrence in situations where the involvement of the' appropriate personnel would not be as evident, supplement to NOA-QC inspection procedures are being developed to more clearly. define' cleanliness acceptance' criteria for plant operating systems. These crite ia sill include loss of cross-sectional area that could impair or pronibit mechanical piping system components.such as' check ! valves, coolers or heat exchangers from performing their. intended function. The supplemental inspection procedures are expected to be issued by. June 2, 1989. These criteria will be used to determine the acceptability of internal cleanliness conditions.of plant piping systems and if not met will be the basis for issuance of Equipment Trouble Tags (ETT's) or Nonconformance Reports (NCR's) in accordance with procedure NOA-24 " Control of Hardware Non-Conformances" (now NGAP NA-03N001). In addition, a committee has been appointed by the NOA-General Manager to revise NOA-24 (NGAP NA-03N001) to ensure that ambiguity will not exist in the procedure regarding nonconforming conditions and the issuance of NCR's. The procedure revision is expected to be completed by September 30, 1989. _x___________. _ _ _ . - _ - _ _ . - .

., , _-_ . - _ _ . . - 4 ' Attachment 1 Page 9 of 11 NRC Inspection Report 50-352/89-80 50-353/89-80 These, or any other nonconformances that are found to be repetitive, shall be considered a significant nonconformance in accordance NQA-24. As such, a Corrective Action Request shall_be initiated to management attention in accordance with existing procedure NOA-25, " Corrective Actions," to request a root cause analysis and to determine corrective action to prevent recurrence. Item 6 NRC Observed Weakness: The lack of preparation of a Maintenance Procedure to support lapping operations for D/G crankshaft bearings. (Ref. III.S.0 {pg. 25}). Response: The need for a bearing journal lapping procedure was previously identified during the construction phase of Limerick Unit 2. Bearing inspections were scheduled to be performed on all four Unit 1 emergency diesel generators (D/G's) during the Unit 1 second refueling outage and during this inspection, journal lapping is not normally required. In addition, there were no vibration problems indicating that the journal bearings would need replacing and journal lapping was not expected to be necessary during the second refueling outage. Therefore, incorporation of journal lapping instructions into permanent procedures was determined to be of a lower priority than revision and enhancement of other procedures required to support the Unit 1 Refuel Outage. During the overhaul of the D12 D/G, journal lapping was identified to be required arid a lapping procedure was generated shortly thereafter. Journal lapping instructions are expected to be incorporated into the appropriate permanent Maintenance Procedure (s) prior to July 31, 1989. 1 Item 7 ] l NRC Observed Weakness: l 1 i Slow implementation of the PRA into the prioritization of ) maintenance work. (Ref. III.5.0 (pg. 27J) ' l . _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ j

, . . . . ._ _ - _ _ _ _ _ _ _ - _ _ - ., l

6 ! g Attachment 1 Page 10 of 11 3 1 NRC Inspection Report 50-352/89-80 50-353/89-80 j Response: Several factors inhibited early extensive use of the Probabilistic Risk Assignment (PRA) in the maintenance process and at Limerick in general. These included: 1) The lack of a comprehensive, living PRA that reflected the as-built plant, and, 2) The lack of a user friendly PRA tool that would simplify and expedite use of the.PRA. The following describes actions taken over the past few years to eliminate these factors: 1) The PRA originally performed in 1980 was reviewed during the plant licensing process and updated in September 1982. Before widespread use could be made of the PRA, the system models had to be revised to reflect as-built designs. Also, station operating procedures, that were non-existent in 1982, had to be incorporated. The PRA was updated in August 1986 to reflect Unit 1 as-built design and most of the emergency operating procedures (i.e. the Transient Response Implementation Plan (TRID) procedures). A second update was completed in November 1988 tict completed the incorporation of the TRIP procedures and reflected two unit operation. Completion of this update addresses the first factor providing Limerick with a comprehensive, living PRA that reflects the as-built plant and supports applications. 2) PRA applications in the past were limited due to the available computer software that was difficult and cumbersome to use. In 1987, the Nuclear Engineering Department PRA Branch purchased a personal computer (PC) workstation that streamlined the process of modifying and using the PRA. The conversion of the PRA to the workstation model was completed by November 1988. The PRA work station was used to develop the PRA parameters (i.e. what systems and equipment are PRA important and how they affect Core Damage Frequency) to be utilized by the station PRA programs and will be used by engineering to answer specific PRA based questions from the station. The PRA workstation addresses the second factor; it is the tool that was needed to simplify PRA ' use and provide better responsiveness to PRA requests. - _ _ _ _ _ _ - _ _ _ _ -

,,

, , _ _ _ _ . . _ _ . . - _______ '^

. - ' . ' Attachment 1 Page 11 of 11 NRC Inspection Report 50-352/89-80 50-353/89-80 With the above described improvements completed in November of 3988, Limerick has been able to develop several programs involving the PRA. Specific to the prioritization of maintenance work, these programs include Administrative Guidelines (AG) AG-42, "PRA Applications in Plant Maintenance" and AG-43, " Guideline for the Performance of System Outages." Following extensive training of Limerick personnel, these programs became effective in January 1989 and have since then been implemented. Item 8 NRC Observed Weakness: The lack of adherence to an administrative procedure (A-26) resulted in traceability problems of mechanical tools. (Ref. III.7.0 {pg. 36)) Response: This problem had been identified prior to the inspection and the Maintenance Request Form (MRF) had been changed in late 1988 to allow recording of up to 15 tools versus 5 allowed on the old form. On February 9, 1989, the next day following identification of the problem by the NRC inspector, a meeting was held with the maintenance department personnel. The importance of recording all tools used during maintenance activities on the MRF was stressed in the meeting. Continuing training for Maintenance personnel will address the need to include calibrated tool serial numbers on the MRF in order to provide traceability. A review of all out of tolerance (OOT) tools is being performed. Prior to January 1, 1988, Quality Assurance (QA) personnel recorded all calibrated tools used on sa'.'ety related equipment in parallel to the work activity. A similar traceability problem is net likely to have occurred prior to January 1, 1988 nor after the meeting held on February 9, 1989 and therefore the review will encompass the OOT reports from the calibration facility received from January 1, 1988 to February 15, 1989. This review will compare the OOT tool reports, the tool usage log and the referenced MRF's to ensure that the OOT tools are properly identified on the MRF and that the affect of the OOT tools have been evaluated. This review includes the nine MRF's identified during the NRC inspection. Any deficiencies identified during this review will be evaluated and corrected. In addition, a maintenance guideline is being prepared for the control of calibrated tools. All corrective actions are expected to be completed by September 1, 1989. - _ _ _ _ _ _ _ _ _ }}