IR 05000272/1978031
| ML18078A992 | |
| Person / Time | |
|---|---|
| Site: | Salem  |
| Issue date: | 01/30/1979 |
| From: | Bateman W, Mcgaughy R, Toth A NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML18078A991 | List: |
| References | |
| 50-272-78-31, NUDOCS 7903140019 | |
| Download: ML18078A992 (15) | |
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U.S. NUCLEAR REGULATORY COMMISSION
.OFFICE OF INSPECTION AND ENFORCEMENT
50-272/78-31.
Regfon I Report Ne. 50-311/78-51 50-272 Docket No. 50-311
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DP R -70 License No. CPPR-53 Priority ---------
Category -------
B Licensee:
Public Service Electric and Gas Company 80. Park Place Newark, New Jersey 07101 Faciltty Name:
Salem Nuclear Generating Station, Unit l and Unit 2 Inspection at:
Hanco.cks Bridge, New Jersey Inspection conducted:
Dec~m~7r 11-13, and 18-21, Inspectors: J /},_ -f:i(
1978
.., Approved by:
- . A. D. Toth, Reactor Inspector
\\.A* 12.
. {lJ.f/A. !Ji-drw.a1,-
W. H. Bateman, Reactor Inspector
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G. A. Walton, Reactor Inspector
,/[bu~ *
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R. T. Paolino, Reactor Inspector S. b. Ebneter, Chief, ES Section #1 Reactor Construction ftnd Engineering Support B. /? lv Jltitltw*,1.;K
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R. W. McGaughy, CJr!efJProjects Section * ***.*. *
Reactor Constructioi!"& Engineering Support B Inspection Summary
. 'date signed I /to/1t-J
/date signed
. **/q/7 ~ie'S i gne date signed Unit l.. irispection an*oecember 19-21~ 1978 (Report No. 50-272/78-31)
Areas Inspected: Routine, unannounced inspection by a regional based inspector of the piping post weld heat treatment practices. A meeting was also held to discuss the same subjec The inspection involved 4 inspector-hours on site by NRC inspecto '
ults:
No items of noncompliance were identified in the one area inspecte Region I Form 12 (Rev. April 77)
vnro 3 1*4 eo t'\\ *,tt_
spection Summary
Unit 2 Inspection on December 11-13, and 18-21, 1978 (Report No. 311/78-51)
Areas Inspected: Routine, unannounced inspection by 5 regional based inspectors of test procedures for the containment structural integrity test; work activities for the containment structural integrity test and for weld repairs on steam generator supports; and quality verification records for the containment structural integrity test and for weld repairs on steam generator structural steel suppor The inspectors al so performed pl ant tour-ins*pections, reviewed 1 icensee action on previous inspection findings, and performed follow-up act1on as necessary to resolve questions which arose during the course of inspection of the above areas. A meeting was held to discuss post weld heat treatmen The inspection involved 118 inspector-hours onsite by 5 NRC regional office based inspectors and 2 hours2.314815e-5 days <br />5.555556e-4 hours <br />3.306878e-6 weeks <br />7.61e-7 months <br /> onsite by an NRC Region I superviso Results:
No items of noncompliance were identifie.. DETAILS Persons Contacted
- Publ it* Service** Electrit *and* Gas Company
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- .. *R. *A.* Auld,* Assistant Chief Structural Engineer
. *R. W. Cephas, QA Specialist
- S. Chawaga, Site QC Division Head L. P. torletto, Senior Engineer J. M. Destefano, Site QA Engineer R. Dierkes, Lead Engineer (Note 1)
. *R. T. Griffith, Senior Staff QA Engineer (Note 1)
. *C. P. Johnson, Startup Engineer *
. *K. J. Kieper, Materials test Engineer
. *W. Kittle, Site QA Engineer
K. S. Kraska, Engineer {Note 1)
- H~ S. Lowe, Site QA Engineer
. *J. A. McAdams, Materials Test Engineer
- D. L. Mclaughlin, Senior Construction Engineer {Note 1)
- E. H. Meyer, Site QA Division Head (Note 1)
G. C. Moran, Assistant Materials Division Chief B. M. Radimer, Senior Construction Engineer J. E. Rogozenski, Principal Engineer E&C Department {Note 1)
- F. C. Shen, Principal Staff Engineer (Structural)
. *P. E. String, QA/QC Coordinator
- W. P. Treston, QA Engineer United Engineers and Constructors O. Brown, Acting Site Surveillance Supervisor W. Copeland, QC Electrical Supervisor W. L. Johndrow, Assistant Project Superintendent R. A. Jorgensen, QC Records Supervisor
- M. Ju~ster, Test Engineer J. McFadden, QC Engineer F. 0 1Donnel, Welding Engineer
- R. J. Phelps, Field Superintendent - QC
- D. C. Snyder, Project Engineer F. Twogood, Test Engineer
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Insulation Consultants and Management Service, In M. Stine, QA Man.ager
- denotes those present at the exit interview.
. Note l: Present at meeting on December 19, 1978 to discuss technical details of the PSE&G report dealing with the post weld ~eat ** *
treatment test dat Other Accompanying Personnel Wolfgang Laudan, IE:HQ, RCI Pl ant Tour The inspectors observed work activities in-progress, completed work, and plant status in several areas of Uriit 2 during general inspection of the plant. The inspectors.examined work items for any obvious defects or noncompliance with regulatory requirements or 1 icense conditions. Particular note was* taken of presence of quality control inspectors and quality control evidence such as inspection records, material identification, nonconforming material identification, and equipment calibration tag The inspectors interviewed craft personnel, supervision, and quality inspection personnel as such personnel were availabl~ in the work area Particular attention was directed toward the structural integrity test (SIT) procedure and performance of same, SIT associated instru-mentation, and gathering and recording of ~IT test results. Where more detailed *inspectfon of an area was conducted, the inspection scope and finding~ are described in other paragraphs of the repor No items of noncompliance were identified during the tour-inspectio No plant tour of Unit 1 was conductedr Licen~ee Action on*Pt~Vioos Inspection Findings (Unit 2)
(Closed) Unresolved Item {77-26-06) Approval of calibration proce-dures. The inspector examined a December 13, 1978 instruction from the licensee Controls Field Engineer (reference C-2-UE-267) which
establishes procedure approval requirements for calibration procedures for devices used for UE&C testing purpose The document assesses the impact of the previous lack of approvals, and reaches a satis-factory conclusion regarding validity of previous calibration activitie This item is resolve (Ciosed} Unresolved Item (78-31-01) Structural int_egrity test pro- -
cedure deviation from FSA Items a, b, e and f were reviewed during inspect ion 311 /78-46 and were determined to be res_o l ved at that tim Item d is also considered to be resolved, based upon the FSAR change discussed in the licensee's November 1, 1978 letter to NRC; which clarifies that linear motion transducers will be placed at the equipment hatch, but not the personnel hatche Item c is considered to be resolved in that subsequent to NRR/licnesee telephone agreements, the licensee has now placed a crack pattern at the containment base/wall intersection and has included monitori_ng of this area in the test procedure This item is -resolve (Closed} Unresolved Item (78-39-02) Accumulator design temperatur The inspector examined a document from the Westinghouse responsible site mechanical engineer to the PSE&G site QA en-ginee It reassures_
that the design of the accumulators was adequate for*the 50% F lower operating temperature, based upon discussion with the responsible Westinghouse design staff. This has been accepted byPSE& The inspector had no further question _This item is resolved. __
(Open NoncomDl ianee and Unresolved Itms: (311/77-Z6-06,03,09, and Ht;-
272/~8-31-oq: -(References 31~/78-26, _ _zs.:.£[ ~ and 31) Exceeding the heating/cool mg ~ates and maximum temp~r9ture for local post weld hea."t tr:ated (PWHT} pipe weld Representatives of PSE&G met with Region I rn~pect~rs to discuss the tec~nical details of the-PSE&G report -
deal mg--~, t_h _ t~e._}9~_t_ ~el d _heat treatment test data. That report ; s tn res~onse~\\t'a~:a'.nf.ften10~af-n'ori"compl iance transmitted in the letter to PSE&G on Janu*ary*10, 1978.
The NRC inspectors requested the following information to complete the review of the report: The hardness test values for the field welds selected as representative of the three categorie *. The basis for *comparison of the hardness values and the expected riorriinal hardness for the materia.
Material certification or chemistry tests verifying the test pipe materia.
Justification of the low tensile and elongation test results and the possible effect on the facility des.ig.
The number and identity of the weld joints with questiona.ble post weld heat.treatmen.
The basis used to define the limits of the post weld heat treatment test conditions and the analysis of the test result.
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The licensee acknowledged the request for information and stated it would be made available for revie The inspector selectively reviewed the Salem Unit 2 PWHT charts to corroborate the licensee's findings and conclusions for the basis of the PWHT test pip The foll~wing PWHT charts were reviewed:
- 2MS-14-l
- 2MS-PEN-4-228 2MS-5-l 2MS-5-3
- 2MS-6A-l 2MS-6-l
- 2MS-7-l 2MS-7-5 2MS-8-l
- 2MS-12-l
- Rejected by the licensee as not meetfog the applicable cod The inspector's findings were consistent with those of the license These items remain open pending completion of the licensee's correc-tive actions and the NRC's revie.. Containment Structural Integrity Test (CSIT) (Unit 2)
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The inspectors reviewed procedures and records.and observed work in progress relative to the CSI The inspectors evaluated the above items with regard to codes, sta.ndards, and commitments delineated in the 1icensee 1 s Final Safety Analysis Report (FSAR) Section 5.5.1 and licensee procedures and documents as listed below:
( 1 )
(2)
(3)
(4)
DTP-30-SIT-l, Revision 0, Reactor Containment Structural Integrity Test Salem Nuclear Generating Station Unit No. 1 Report on Structural Integrity Test of Containment Letter from C. P. Johnson, PSE&G Startup Engineer, to Distribu-tion entitled, "Containment Structural/Integrated Leak Rate Testing Unit No. 2 Salem Nuclear Generating Station" PSE&G Detail Specification No. 69-7437, Containment Building Strain Gage Installatio The following paragraphs $Ummarize the reviews and observations made by the inspectors: CSIT Procedure - DTP-30-SIT-l, Revision 0
. Paragraph 3 of this inspection report closed out the outstanding unresolved item relating to this procedur The inspectors reviewed the procedure to ensure (1) sufficie~t itistrumenta-tion was installed to obtain required data, (2} maximum rate of pressurization and depressurization was specified,.(3)
crack pattern mapping and crack growth criteria were specified, (4) pressurization to 1.15 times design pressure was to occur in a minimum of 4 equal pressure inc.rements, and (5) acceptance criteria and predicted values of strain and building growth
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- a were specified. At the inspectors* request, a paragraph discussing crack patterns and a map showing location of same was added to the.procedure prior to its approva The approved procedure contained the steps required to comply with NRC requirements aad licensee commitment Test* Instrumentation The inspectors observed the physical installation and location of linear variable differential transformers (LVDT 1s), INVAR wires, rosette strain gauges, test pressure*gauges, dewcells, and RTD 1 s. * A 11 rebar strain gauges were embedded in concrete and could not, therefore, be observe All parameters required
.to be measured as specified in the test procedure were appropri-ately instrumente Particular attention was given to the
- location of the LVDT support structures to ensure isolation from the containment wal Test personnel were questioned as to the accuracy and range of
- LVDT 1s and strain gauge LVDT linearity data was reviewed as well as applicable s*train gauge dat The inspectors witnessed calibration checks of se~eral LVDT 1s using gauge blocks of different thicknes Final zeroing of LVDT 1 s and strain guages, just prior to pressurization of containment was observed ori a sample basi The accuracy, range, calibration, and physical location of all the instrumentation was verified to be consistent with test procedure requirements, approved jobsite procedures, and good engineering practic Crack Patterns Crack patterns were located on the exterior of containment in **
accordance with test procedure and Regulatory Guide 1.18 requirement The area of each crack pattern exceeded the Regulatory Guide 1.18 requirement of 40 square feet. A grid network of l foot squares was superimposed on the crack pattern area as an aid for transcribing crack details. The licensee used six groups of people per shift to measure and transcribe crack data. All but one group had one member with crack
g mapping experience from Salem Unit l CSI The inspectors atterided the briefing of the crack pattern personnel and found it to be sufficiently comprehensiv The licensee sandblasted the surface o'f the containment structure at the crack pattern areas to remove a coating of Modac in
- order to expose the actua T concrete surface; During the
- inspector's observations of the crack pattern areas, it was noted that the sand-bl~sting operation had weathered the edges of the existing cracks, thus making it somewhat difficult to obtain consis.tent crack width reading The inspectors alerted test personnel of their concerns in this are The inspectors observed the initial crack survey at atmoshperic pressure just prior to the start of pressurization and expressed their concern to the licensee about the methods being used to measure crack In response, the licensee conducted additi'onal training of each crack mapping tea Test Performance The inspectors verified by personal observation that (1) the rate of pressurization of containment did not exceed the maximum rate stated in the test proc~dure, (2) all pressure plateaus were achieved and required data taken, (3) environmental conditions both inside and outside of containment were monitored for unusual activity, and (4) data obtained was compared with predicted values and any discrepancies were resolved prior to proceeding to the next pressure platea The inspectors evaluated the performance of the CSIT personnel by asking individuals pertinent questions related to their job assignmen Additionally, the overall test coordination was evaluated based on the CSIT Engineer's direction of the compu-ter data gathering, crack mapping, air compressor, valve operating, and other miscellaneous data gathering personne At the maximum test pressure of 54 psig, reached at 0519, on December 20, 1978, the inspectors made a final survey of data gathering activities. Also at this time, the inspectors made
- indepen.dent crack measurements, using a 6X optical comparator, of cracks appearing on the crack pa.tterns and on other unmapped areas of the containment dome and cylinde,..,-,.-------------------------------------------
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Based on the intervi.ews, observations, and independent measure-ments performed, the inspectors felt the test was conducted in accordance with the test procedure and that valid test data was obtaine Review of Test Records A prei iminary review of. the* test reccirds indicated that all parameters monitored met the acceptance criteria specified in the test procedure.with the exception of crack growth in the area of the equipment hatch.. The vertical and radial growth of the Salem 2 containment was less than that of the Salem l containmen The crack growth in the equipment hatch area appeared to exceed the maximum allowable of.030 inches by as much as.060 inches in certain crack Many other cracks exceeded the.030 inch growth criteria.but not by as much as.060 inche Based on the observation that the LVDT's monitoring movement of the containment wall around the equipment hatch showed no indication of unusual movement, the licensee felt crack measuring techniques caused the problem *.
The final test results and data evaluation will appear in an official structural integrity test repor The inspectors will review the licensee's final conclusions when this report is issue No items of noncompliance were identifie.
Instrumentation Cables and Terminations - Observation of Work and Work Activities (Unit 2)
The inspector examined control room penetrations numbered 870, 871, 827, 883, 910 and 911, to verify that licensee work performance and inspecfion procedures are being adhered to during installation of cable and raceway penetration fire barrier seals. * This work activity was reviewed against the requirements of procedure DCP-2215, Revision 2, entitled, "Electrical Seals" and jobsite specification 771304, Revision 0 *
In addition, the inspector examined the following vendor records and procedures to certify compliance with specification requirements:
Facility as-built drawings dated November 27, 1978, identifying each area and penetration number assignment by locatio Vendor form FR-2 used to identify each area, penetration, hatch number, and operator performing tas Vendor form DM-1 used for batch sample test listing density, cell structure, start and end of pou *
Vendor form BT-1 used for recording batch test data, QC inspection date and s.ignof *
No items of noncompliance were identifie,.
6. **instrumentation Cables and Terminations - Review of Procedures Unit*2 The inspector examined the fire endurance test report No. OAQS.AM prepared by Factory Material Research of Norwood, Massachusetts, dated May 18, 1977. This report describes the construction, test procedures, and results of fire tests conducted on ten penetration seal systems in accordance with the Standards for Fire Tests of Building Construction and Materials, ASTM-Ell9-76 (NFPA-251).
The inspector verified, by comparison, the similarity of the installed penetration seals with the penetration seals tested in the above test repor No items of noncompliance were identifie.
Instrumentation Com onents and S stems - Review of Qualit Assurance Procedures* Unit 2
. *The inspector verified that the licensee has established procedures for inspection, calibration, and testing of installed instruments and associated component Documents examined for this determination include:
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Procedure No. GTP-2, Revision 4, dated April 24, 1978, entitled,
"General rnstrument Calibration Procedure for Field Services."
Procedure No. GTP-4, Revision.2, dated December 9, 1977, entitled; "General Field Pressure Leak Test Instructions."
_ Procedure No. GTP-5; _Revision l, dated March 8, 1978, entitled, nrnstrt.imentation and Control Loop Calibration" Procedure No. GTP-8, Revision 0, dated June 21, 1977, entitled
"Cable Continuity and Integrity Testing" Procedure -No. GTP-9. Revision l, dated May 17, 1978, entitled,
"Motor Operated ValVe and Control Functional Checkout" No items of noncompliance were identifie.
Instrumentatian com onents and S stem - Observation of Work and Work Activities Unit*2 The inspector examined completed work activities pertainin*g to. the calibration and functional checks of select safety related systems to ascertain whether the requirements of applicable test*procedures listed in item 7 above have been me This determination was based on examination of calibration/test documents for the following systems:
Primary Water Flow Control of Chemical Volume Control System -
Set No. 16-I5 per GTP-5, component FA-118 Rapid Borate Flow Indication of Chemical Volume Control System -
Set No. 16-I5, component FA-2174EI
- 22 Boric Acid Tank Level and Alarm for Chemical Volume Control System - Set No. 16-I5, component LA-1097(LT-102)
Component Cooling Surge Tank level iridication - Set No. 24-I2, Component No. 's LT-628A, LI-628A and LI-628B
- 21 Component Cooling/RHR heat exchanger outlet flow - Set N I2, "Component Nos. FA-1565, FA-5071-IB and FI-601 No items of noncompliance were identified *
-* During the review of the Unit 2 PWHT item of noncompliance (311/77-26-07, 08, 09, and 10), the licensee was requested to review the Unit l PWHT charts. This review has disclosed several instances in whi.ch the ANSI 831..7 Code PWHT requirements appear to have been exceeded in Unit 1 during the construction phase. Consequently, any re solution to the i tern of noncompl i ance for Unit 2 wi 11 neces sa ril y involve consideration for Unit *
This item is unresolved (272/78-31-01) pending completion of the licensee's corrective actions and review by the NR. Possible Sensitization of Safety Injection Pump Piping (Unit l)
The inspector *noted that the small bore stainless steel piping attachments to the safety injection pumps were made with a 410 series stainless steel fitting to a 316 series stainless stee The 410 series steel requires a post weld heat treatment (PWHT) at 1300-1400° F to develop the desired mechanical properties. This PWHT could sensitize the 316 series material and increase its susceptability to stress corrosion failur The licensee stated that this condition would be evaluated. This item is unresolved pending completion of the licensee's evaluation and review by the NRC (272/78-31-02).
11. Steam Generator Support Repair (Unit 2)
The inspector reviewed the licensee's program for corrective actions being taken on the stea*m generator support The following records were reviewed:
Deficiency Report No. 6520, Addendum 1, 2, 3, and 4 Status of Repair P~ogram
- Acceptance Standards Welder Qualification, Weld Procedure Qualification, Welding Specification 70-5050, Section C, Detail Spec. C-4
Weld rod withdrawal slips Visual and Magnetic Particle Inspection Procedure lPMT-205, Revision 3101-1 Visual and magnetic particle examination result The licensee had performed one hundred percent visual inspection of*
all steam generator supports as stated in Deficiency Report 652 The following acceptance standards were applicabl Welds shall be of proper size and length, have no cracks, and have no porosity exceeding 1/8 inch in the greatest dimensio Structural members shall not have gouges or weld undercut which exceeds 1/32 inch in dept These acceptance standards are in compliance with AWS Dl.0-6 The inspection of the steam generator supports to the acceptance standards stated above resulted in rejection of the following area No. 21 Steam Generator Support 139 areas No. 22 Steam Generator Support 162 areas No. 23 Steam Generator Support 144 areas No. 24 Steam Generator Support 132 areas The licensee is continuing repair of all rejectable area *..
No items of noncompliance were identifie. * Licensee Site Audit (Unit 2)
The inspector selected audit reports numbered 761, 78S, 786 and 793 associated with safety related components to determine if the scope, frequency, and adequacy of the audits were in accordance with PSE&G Quality Assurance Manua The inspector also verified that deficiencies identified by the licensee were corrected in a timely manne No items of noncompliance were identifie I I
1 Unresolved Items Unresolved items are matters about which more information is required in order to ascertain whether they are acceptable items, items of noncompliance, or deviations. Unresolved items disclosed during the inspection are discussed in Paragraphs 9 and 1.
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1 Management Interview At the conclusion of the structural integrity test inspection, on December 20, 1978, a meeting was held at the site with representa-tives of the licensee and contractor organizations. Attendees at this meeting included personnel whose names are indicated by notation(*)
in paragraph 1. The inspector summarized the results of the inspection as descri-bed in this report. A 1 so, on December 21, 1978, a second meeting was held with. licensee and contractor personnel to discuss instrumentation, steam g~nerator support, and piping post-weld-heat treatment inspection activities which had been conducted December 19-21, 197 The inspectors summarized results of this inspection activity as described in this repor *