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UNITED STATES OF AMERICANUCLEAR REGULATORY COMMISSION

BEFORE THE ATOMIC SAFETY AND LICENSING BOARD

In the Matter of ))

METROPOLITAN EDISON COMPANY ) Docket No. 50-289) (Restart)(Three Mile Island Nuclear )

Station, Unit No. 1) )

LICENSEE'S TESTIMONY OF

T. GARY BROUGHTON, GERALD J. SADAUSKAS

AND LUTHER L. JOYNER

IN RESPONSE TO

SHOLLY CONTENTION NO. 6(a)

(INTEGRATED CONTROL SYSTEM)

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OUTLINE

The purposes and objectives of this testimony are to

respond to Sholly Contention 6(a), which asserts that prior tocontinued operation of TMI-1, a failure modes and effects

analysis (FMEA) of the Integrated Control System (ICS) shouldbe completed. The testimony shows that an ICS FMEA has beenperformed. The function snd operation of the ICS are also

described and the results of the ICS FMEA and complementary

evaluations of field data from B&W operating plants areaddressed.

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IINTRODUCTION

This testimony, by Mr. T. Gary Broughton, Control and

Safety Analysis Manager, GPU; Mr. Gerlad J. Sadauskas, Group

Leader, Instrumenticion Engineering, GPU; and Dr. Luther L.

Joyner , Principal Engineer, Power Systems and Controls Unit,

Babcock & Wilcox Company, is addressed to the followingcontention:

SHCLLY CCNCENTION NO. 6(a), /-

It is contended that the short-term actionsidentified in the Commission's Order and Noticeof Hearing dated 9 August 1979 are insufficientto provide the requisite reasonable assurance ofoperation without endangering public health andsafety because they do not include the followingitems:

Completion of a failure mode anda.effects analysis (FMEA) of theIntegrated Control System.

RESPONSE TO SHOLLY CONTENTION NO. 6(a)

BY WITNESS JOYNER: |

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Sholly Contention 6(a) states that a failure modes and

effects analysis (FMEA) of the Integrated Control System (ICS)should be completed prior to continued operation of TMI-1.Sueb an analysis has been performed.

The B&W ICS provides a coordinated response from the

reactor / steam generator / turbine system during power operation

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see Figure 1. This results in a design which can readilyrespond to changes in demand for generated power and can

accommodate various pertubations and maintain the unit in astable power condition. During load changes or system upsets

during power operation, the ICS applies signals to the majorcontrol variables (feedwater flow, steam pressure, reactor

power and reactcc coolant temperature) to achieve optimum

overall plant response without challenge to the safety systems.

The system is designed to provide automatic control during

power operation, and to accept step load changes up to 10% and!ramp load changes up to 5% rated power per minute. When load |

demand changes, the controls automaticall:7 adjust steam flow to

the turbine and feedwater flow to the steam generators to

maintain a constant steam pressure at the turbine throttle.

Simultaneously, the system positions groups of regulating

control rod assemblies to adjust reactor power and maintain a

constant average coolant temperature over a load range of 15 to100 percent power.

While the ICS was not involved in initiating the TMI-2accident and subsequently functioned as designed, a detailed

FMEA has been performed for the ICS - see Reference 1. The ICS

FMEA determined the expected effects upon the B&W nuclear steam

system from single failures of ICS inputs, outputs and internalmodules. The analysis was complemented, as shown in Reference

1, with an evaluation of field data from all B&W cperating'

plants, and a computer simulation to confirm the effects of

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various ICS failures on associated equipment.|The overall conclusion of the FMEA was the reactor core

remains protected throughout any of the ICS failures studied.

For those postulated ICS failures that could cause reactor

trip, the safety systems operate independently of the ICSmalfunction.

The overall conclusion from the operating experience

evaluation was that ICS hardware performance has not led to a

significant number of reactor trips. The ICS has prevented

more reactor trips than it has caused and thus its net effecthas been a reduction in the number of challenges to the Reactor |

Protection System.|

BY WITNESSES BROUGHTON AND SADAUSKAS:

The B&W ICS FMEA was reviewed by GPU and found to be

applicable to the TMI-l ICS. The TMI-1 safety systems which

would be actuated following ICS failures would operate indepen-dently of the ICS malfunction. The FMEA did not identify anychanges required at TMI-l to ensure the public health andsafety. Implementation of the FMEA recommendations, which will

result in improved reliability, improvec control systemperformance and reduced consequences of malfunctions, is

addressed in the TMI-l Restart Report (Supplement 1, Part 3,Question 12).

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BY WITNESSES BROUGHTON, SADAUSKAS AND JOYNER:

In summary with regard to Sholly Contention 6(a), an ICSFMEA has been completed.

Reference

1. Report BAW-1564, " Integrated Control System (ICS)

Reliability Analysis," August, 1979.

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FIGURE 1

INTEGRATED CONTRCL SYSTEM

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UNIT LOAD

DEMAND

CONTRCL

i f

INTEGRATED

p _ _ _ _. _, MASTER # _ _ _ __ _ _. qCONTROL

| |1 4 Il l I| l iI I I| 1 II i f I f I F

TURBINE STEAM REACTORCONTROL GENERATCR

CCNTRCL'

CONTRCL

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T. GARY BROUGHTON

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Business Address: GPU Service Corporation100 Interpace ParkwayParsippany, New Jersey 07054

Education: B. A. , Mathematics, Dartmouth College,1966.

Experience: Control and Safety Analysis Manager,GPU Service Corporation, 1978 topresent. Responsible for nuclearsafety analysis and integratedthermal, hydraulic and control systemanalysis of nuclear and fossil plants.Supervised on-site technical support

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groups at Three Mile Island, Unit 2 i

during the post-accident period. ;

Safety and Licensing Engineer; Safety ;

and Licensing Manager, GPU Service '

Corporation, 1976 to 1978. Performed ;

and supervised nuclear licensing,.environmental licensing and safety I

analysis for Oyster Creek, Three Mile l

Island and Forked River plants.Served as Technical Secretary toOyster Creek and Three Mile IslandGeneral Office Review Boards.

Officer , U.S'. Navy,1966 to 1976.Trained at Naval Nuclear Power School,Prototype and Submarine School.Positions held include NuclearPropulsion Plant Watch Supervisor,Instructor at DlG prototype plant andEngineering Officer aboard afast-attack nuclear submarine.

Publications: EPRI CCM-5, RETRAN - A Program forOne-Dimensional Transient Thermal-Hy-draulic Analyses of Complex Fluid FlowSystems, volume 4: Applications,December, 1978, Section 6.1, " Analysisof Rapid Cooldown Transient - ThreeMile Island Unit 2", with N.G.Trikouros and J. F. Harrison.

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"The Use of RETRAN to EvaluateAlternate Accident Scenarios atTMI-2", with N. G. Trikouros.Proceedings of the ANS/ ENS TopicalMeeting on Thermal Reactor Safety,April 1980, CONF-800403.

"A Real-Time Method for Analyzing.

Nuclear Power Plant Transients", withi P.S. Walsh. ANS Transactions, Volume

34 TANSAD 34 1-899 (1980).

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GERALD J. SADAUSKAS

Business Address: GPU Service Corporation100 Interpace ParkwayParsippany, New Jersey 07054

; Education: A.A.S., Electrical Engineering, StateUniversity of New York at Farmingdale,1963.B.S., Electrical Engineering, C.W.Post College of Long IslandUniversity, 1970.Post-graduate courses, Mechanical

i Engineering, State University of Newj York at Stony Brook, 1975 to 1977.; Post-graduate courses, Electricali Engineering, Stevens Institute ofI

Technology, 1979 to present.i

Experience: Group Leader, InstrumentationEngineering, GPU Service Corporation,1980 to present. Responsible forestablishment of instrument designcriteria; preparation of conceptualdesigns, and verification of technicaladequacy of designs; responsible for

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modifications of existing plantsystems. The instrumentation section,

i is also responsible for the mea-surement of all system parameters,signal conditioning, display andprocessing of system parameterinformation.

Senior Supervising Instrumentation andControl Engineer, Burns and Roe, Inc.,1977 to 1980. Responsibilitiesincluded implementation of TMI-2lessons learned instrumentationrequirements for the Oyster Creek andRancho Seco nuclear power plants; wasinvolved in the development of a )Disturbance Analysis System forNuclear Power Plants under contractwith EPRI; involved in the developmentof an oxygen-hydrogen flame arrestorfor BWR plants; served as SupervisingEngineer for TMI-2 recovery, instru-mentation and control systems;responsible for instrumentation andcontrol engineering for the ForkedRiver plant.

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i Instrumentation and Control Engineer,Long Island Lighting Company, 1971 to1977. Duties included: responsiblefor the installation and startup ofinstrument and control systems at theShoreham nuclear plant and at theNorthport Unit 3 oil-fired plant; and,served as Construction Engineer forthe Glenwood Landing switchyard.

Electrical Engi".eer, ChemicalConstruction Corporation, 1970 to1971. Involved in installation of aCASO3 Venturi type flue gas scrubberat Boston Edison's Mystic Station.Designed potential electrical powerand control systems, includinglighting power distribution andcontrols.

Instrument Engineer, M.W. KelloggCompany, 1965 to 1971. Responsiblefor the design of instrumentation andcontrol systems for petro-chemicalplants.

Service Engineer, Bailey MeterCompany, 1963 to 1965. Serviced andinstalled electronic and pneumaticinstrument systems on oil andcoal-fired boilers, marine boilers andwaste heat boilers.

ProfessionalAffiliations: Member, IEEE and IAS.

Licensed Professional Engineer, NewYork.

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LUTHER L. JOYNERi

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Business Address: Babcock & Wilcox CompanyNuclear Power Generation DivisionP.O. Box 1260Lynchburg, Virginia 24505

Education: B.S., Electrical Engineering, ClemsonCollege, 1964 M.S., ElectricalEngineering, Clemson University, 1969.Ph.D., Electrical Engineering,Virginia Polytechnical Institute andState University, 1973.

Experience: Principal Engineer, Control AnalysisUnit and Power Systems and ControlsUnit, Babcock & Wilcox Co., 1977 topresent. Responsible for diverseproblems involved with operation andcontrol of the B&W NSS. Participatedin the failure modes and effectsanalysis and reliability study of theIntegrated Control System, includingco-authoring the resulting report,BAW-1564.

Supervisory Engineer, Instrumentationand Control Unit, Maritime Reactors,Babcock & Wilcox Co., 1976 to 1977.Responsible for design and procurementof a digital control system for amaritime nuclear propulsion plant.

Program Manager, Product DevelopmentSection, Babcock & Wilcox Co., 1972 to1976; Responsible for the research anddevelopment program for NSSdevelopment.

Professional'

Affiliations: Member, IEEE.

Registered Professional Engineer,Virginia.

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