IR 05000275/1979013
| ML16342B061 | |
| Person / Time | |
|---|---|
| Site: | Diablo Canyon  |
| Issue date: | 07/05/1979 |
| From: | Dodds R, Hutson T, Kirsch D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V) |
| To: | |
| Shared Package | |
| ML16341C963 | List: |
| References | |
| 50-275-79-13, 50-323-79-08, 50-323-79-8, NUDOCS 7908200235 | |
| Download: ML16342B061 (18) | |
Text
U, S, NUCLEAR REGULATORY COMHISSION OFFICE OF INSPECTION AND ENFORCEIKNT
REGION V
Report.No.
Docket No.
50-275/79-13 50-323 79-08 50-275 50-323 CPPR-39 License No.
CPPR-69 Safeguards Group Licensee:
Pacific Gas and Electric Com an 77 Beale Street San Francisco CA 94106 Facility Name:
Diablo Can on Units l. and
'nspection at:
Diablo Can on Site San Luis Obis o Count California and Cor orate Offi Inspection conducted:
June 4-20 1979 Inspectors:
D. F. Kirsch, Reactor Inspector D te Signed T.
W. Hutson, Reactor Inspector Da e Signed Approved By:
Summary:
R. T. Dodds, Chief, Reactor Engineering Support Section Date Signed a
e igned Ins ection durin eriod of June 4-7 and 20, 1979 Re ort Nos.
50-275/79-13 and 50-323/79-08 d~yd:R 1,
dd d
by Rd yb d
inspectors of construction activities including:
licensee action on previous inspection findings; licensee action on IE Bulletins and Circulars; licensee action on 50.55 (e) items; safety related component support modifications; pipe supports and restraints; and nonconformance reporting system.
The inspection 'involved 45 inspector hours by two NRC inspectors.
Results:
Of the six areas inspected, no items of noncompliance or Bev>atsons were identified.
RV Form 919('P)
V906eoQ ~5s
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DETAILS Persons Contacted Pacific Gas and Electric Com an PGRE
- R.
- N
- D
- F
- V
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- J
- J B.
- J R.
M.
R.
R.
W.
D.
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D. Etzler, Project Superintendent R. Tressler, Assistant Station Construction Superintendent A. Rockwell, Resident Electrical Engineer N. Russell, Resident Civil Engineer L. Killpack, Resident Mechanical Engineer E. Leppke, QA Supervisor Arnold, Coordinating QC Engineer A. Holley, Mechanical Engineer Marver, Project Administrative Assistant R. Stevenson, Project Administrative Engineer A. Kelmenson, Assistant Licensing Engineer V. Williamson, Licensing Engineer A. Young, Electrical Engineer E. Bacher, Senior Mechanical Engineer A. Raymond, QA Director L. Polley, Assistant to Project Engineer R. Bratton, QC Engineer Sokoloff, Civil Engineer D. Kerr, Welding Engineer Leiske, Inspection Engineer S. Dobrzenski, QA Engineer J.
Dodd, Level III HDE Examiner J. Foat, QC Engineer'ullman Power Products Kello 2.
D. Geske, QA Manager L. F. Myrick, Welding Supervisor V. E. Pilkington, QC Inspector T. Meyers, Welding Engineer
- Attended Exit Interview of June
=7, 1979
- ~Attended Exit Interview of June 20, 1979 General The licensees punch list of incomplete Unit 1 work items was examined.
It was apparent that the licensee had applied a significant effort to assure, that the punch list adequately reflects work items which are in progress or incomplet The inspectors examined the status of comprehensive design reviews, design review gA audits, engineering equipment releases and as-built completion at the corporate office on June 20, 1979.
The licensee was continuing to apply efforts to assure the completion of these items prior to fuel load.
IE Bulletin 79-02 was discussed with responsible engineering personnel.
The licensee was in the process of preparing the necessary evaluations and response.
3.
Licensee Act'ion on Previousl Identified Enforcement Items a.
0 en Infraction:
Failure to translate racewa su ort desi n bases into instructions, rocedures and drawin s.
275/79-06-0
, 79-06-02 and 323/79-04-01, 79-04-02 On May 22, 1979, the licensee submitted a report, under the provisions of 10 CFR 50.55 (e).
The inspector evaluated the report and conducted, selective examinations to verify implementation of the indicated corrective actions.
Numerous class
raceway support installations in all areas of the plant were examined.
It appeared that the installing contractor had installed saddle bolts on the applicable raceways even though the design details did not specifically require saddle bolt installation.
Furthermore, in the course of the inspections, the inspector did not observe any other raceway supports with the saddle bolts missing.
In a response to the item of noncompliance, dated June 4, 1979, the licensee detailed additional corrective actions to achieve full compliance.
The licensee's home office and field engineering departments examined all raceway support details to establish a list of details for which saddle bolting requirements had been omited.
New support details were issued by Engineering showing that the minimum bolting requirement was one bolt in each saddle to cross-member connection.
l The inspector examined the procedure for the Unit 1 raceway saddle bolt inspection program and observed that it appeared adequate in scope and content.
The licensee's field engineering organization conducted an inspection of all but 43 supports that utilize saddle brackets/bolts (ie: ~3800 supports total).
The 43 supports not inspected had been covered with fireproofing pyrocrete.
Licensee review of installation documentation for these 43 supports, inspection of the Unit 2 corresponding supports and the results of the 100% support inspection supplied reasonable
0
-3-confidence that the 43 inaccessible supports would conform to detail requirements.
The licensee's 100/ inspection program did not, identify any additional supports with missing saddle bolts.
In addition, to verify the adequacy of the field engineering jl00/ inspection,- the gC department inspected a sample of 20/
( 800 supports) for compliance to detail requirements and noted no additional discrepancies.
Performance of the raceway support inspection inventory program on Unit 2 had been scheduled for a later date.
The revised drawings are to be used as the inspection criteria.
The portion of the noncompliance, identified as 50-275/79-06-01 and 323/79-04-01.in inspection report number 50-275/79-06, is considered closed.
>lith regard to the portion of the noncompliance dealing with the failure to translate requirements necessary for support of non-class 1 raceways which cross above class 1 equipment into instructions, procedures and drawings, the licensee was in the process of evaluating design drawings and conducting a plant walkdown to identify any such discrepancies.
The licensee engineering department will then establish criteria and evaluate each discrepancy on a case-by-case basis to determine corrective actions necessary.
The portion of the noncompliance, identified in IE inspection report number 50.-275/79-06 as 275/79-06-02 and. 323/79-04-02, is open and will be examined during a future inspection.
b.
0 en Infraction:
Im ro er su or't of non-vital racewa s which cross vita racewa s
275 79-2-02 The licensee performed a review of layout and installation drawings and determined those support details which would have the maximum probability of compromising support requirements at raceway crossover points.
A weighted average random sample of these supports was inspected by Foley with the result that only two supports, of 500 total, were found unacceptable.
In addition, Field Engineering and gC have selected 500 supports of different details (from 605 total details) at random for an inspection scheduled to be performed at a later dat The balance of these supports have been scheduled for selected inspections.
The results are to be evaluated by the licensee to determine necessary corrective actions.
This item will be examined during a future inspection.
4.
Licensee Action on Previousl Identified Followu Items a
~
Closed Unresolved Item:
Racewa su ort anchor bolt s acin less than 12 nominal bolt diameters 275/79-12-01 b.
Representatives of the licensee's engineering department performed a 1005 walkdown of al'l areas of Units
'l and 2 to identify discrepant anchor bolt spacings and locations and evaluate each for acceptability.
Unacceptable installations were identified and corrected.
The K-85 and 100 areas of Unit
(where supports K-100-?-100, 115, 116, 118, and 165 are located)
were inspected by the licensee's engineering department in July, 1975, subsequent to the contractors installation and inspection of the supports, and judged as satisfactory.
The inspector also examined the contractor's quality inspection documentation for the above supports.
No items of noncompliance or deviations were identified.
~Closed Followu Item:
Roundin off of limit of thickness on the welders ualification matrix 50-275/79-2-03 Discussion with cognizant licensee and contractor personnel indicated that actual wall thicknesses stere being used on the matrix and rounded off to the nearest one-quarter inch instead of the nominal wall thickness which was recorded on the individual welder performance qualification records.
Since the last inspection, Kellogg changed the qualification matrix to use the thicknesses stated on the performance qualification records, thus making the two records correlate.
The inspector also examined the qualification records of ten welders, selected welder audit sheets and the welders
day status sheets for 1979 to verify matrix accuracy.
PGLE has written Minor Variation Report N-3904 to assure verification that no welding was performed outside the allowable limit of thickness for the specific processes.
This item will be examined further during the future reviews of the licensee's nonconformance reporting system.
e
5.
Licensee Action on 10 CFR 50.55 e
Items Cracks in ru ture restraint weldments Reference IE Ins ection Re ort 50-275/79-07, ara ra h ll The licensee submitted a preliminary 50.55(e) report on Hay 3, 1975 describing the program for investigation and the results of the investigation to date.
Actions were in progress to define the problem, establ.ish problem scope and boundaries and effect corrective actions.
The licensee had established a task force to accomplish the necessary corrective actions.
The task force was staffed by Engineering Department, Department of Engineering Research, and Field Engineering.
The task force included a design engineer, a welding engineer, the corporate Level III NDE Examiner and other personnel as necessary.
An index of all full penetration welds on the pipeway had been established.
Each weld was positiv'ely indentified and a matrix has been established for tracking the status of the weld from nondestructive examination through final acceptance.
The licensee was performing magnetic particle (surface)
and ultrasonic (volumetric) examinations of suspect welds.
The extent of the examinations appear to,meet or exceed the ANS Dl.0-69 specified NDE requirements.
The licensee had examined the heavy welds on rupture restraints inside the Unit 1 containment.
and determined that the welds were satisfactory.
The magnetic particle examinations were performed satisfactorily following minor preparation of the examination surfaces by grinding.
The following procedures and records were examined for compliance with AWS Dl:1-79 and procedural requirements.
(a)
Procedure for t1anual Ultrasonic Examination of Welds and Plate in Pipe Rupture Restraints (b)
Pullman-Kellogg Welding Procedure Code 7/8 and supporting procedure qualification records (c)
Welding Technique Specification AWS-l-l established to clarify the techniques to be utilized for application of Welding Procedure Code 7/8 to AWS Dl.l-79 welding operations
~
.
-6-(d)
Procedure No. 8833 XR-1 Rev 4:
Diablo Canyon Rupture Restraint General Repair Procedure (e)
Procedure No. 8833 XR-2:
Procedure for Thermal Cutting (f)
Procedure No. 8833 XR-3:
Diablo Canyon Rupture Restraint Sampling Plan (g)
Welder performance qualification documentation for five Kel.logg welders (h)
Field Process Sheets for a number of base metal and field weld repairs (i)
Procedure-for "Manual Ultrasonic Examination of Welds and Plate in Rupture Restraints
- Diablo Canyon Unit
In addition, the inspector examined three rupture restraints in various stages of repair for compliance with AWS-D1.1-79 and procedural requirements.
No items of noncompliance or deviations were identified.
The licensee appeared to have. an adequate program to identify discrepant welds and effect the necessary repairs.
This item wi 11 be examined during a future inspection.
(275/79-13-01)
6.
Licensee Action on IE Bulletins and Circulars Bulletin 79-09:
The licensee reported by letter of May 15, 1979 that the subject GE type AK-2 circuit breakers were not used or planned for use at Diablo Canyon.
This bulletin is closed.
7.
Com onent Coolin Water Heat Exchan er Su ort Modifications The inspector examined the following documents specifying the component cooling water heat exchanger support modifications.
(a)
Drawing Nos.
463683, 438200, 438299, 438321, 438297, 438306, 2264-T-V-3-39B.
(b)
Design Change Orders DCO-G-C-650 and DC-l-G-C-865.
It appeared that the licensee's engineering department had determined that concrete" anchor bolt lengths of, 3'10" were adequate for the support modifications and that the thickness of the turbine building basemat conformed to design specifications.
No items of noncompliance or deviations were identifie.
Ru ture Restraint Crushable Bum er Ga Settin s
PG5E has developed an envelope of pipe movement for each rupture restraint by reanalysis of rupture restraint gap settings.
The theoretical hot position has been included on each drawing.
A gap of one-half inch from the edge of the envelope to the crushable bumper has been specified for all rupture restraints.
The setting of the specified gaps had been completed except for eleven rupture restraints, which were undergoing additional reanalysis, and two others, which were on hold pending receipt of material.
No items of noncompliance or deviations were identifi'ed.
9.
Pi e
Su orts and Restraints Nine Unit 2 pipe supports and restraints were selected by the inspector to verify installation conformance= to Kellogg ESD-223,. Installation and Inspection of Class I Pipe Supports.'The supports inspected are listed below:
S~N.
Drawin No.
Sheet Rev.
548-20 548-20
~
947-7R 051368
'
ll
949-203R 051370 203
512-42R 049323
1 75-11SL 051399
1 49-114R 051352
1 6-129R 051351 146
'
72-16SL 051396
1 72-15SL 051396
1 Support 512-42R appeared to have one concrete anchor bolt that was cocked at an angle and the bolt head did not, appear to be'ully bearing on the baseplate.
The inspector also identified that one U-Bolt nut had stripped threads and did not appear to have sufficient thread engagement.
Hanger 6-129R did not appear to have the T-shoe gaps specified on the drawing for the top and bottom T-shoes.
The drawing specified a zero gap on the bottom and 1/8" at the top.
The gap at the top was zero and the bottom was approximately 1/4".
A modification to a support down the line
-8-appears to have caused the pipe to move and upset the specified gaps.
The contractor stated that the cocked anchor bolt, stripped nut and gap deficiencies would be investigated and evaluated.
The inspector examined the quali,ty records associated with the above listed supports to evaluate conformance with documentation requirements of ESD 223.
The records included Field Support Process Sheets, PSA Snubber Checklists, Minor Variation Reports for applicable supports and as-built drawings.
The records reviewed appeared to accurately document the status and quality of the inspected work.
The inspector will continue to examine the licensee's corrective action on discrepant pipe supports and restraints.
No items of noncompliance were identified.
10.
Nonconformance and Minor Variation Re orts The licensee's nonconformance reporting system was examined for compliance with gA program requirements.
The inspector reviewed selected NCR's and MYR's in the civil, mechanical and electrical areas initiated during the period between April 1, 1979 and June 4, 1979..
The resolution and closeout of the selected NCR's and MVR's appeared to conform to the requirements of the gA program.
No items of noncompliance or deviations were identified.
11.
Exit Interview The inspectors met with licensee representatives (denoted in Paragraph 1) on June 7, 1979 and June 20, 1979., at the site and corporate office, respectively, and summarized the inspection purpose, scope and findings.