IR 05000275/1982016

IE Insp Repts 50-275/82-16 & 50-323/82-09 on 820329-0402 & 0510-14.Noncompliance Noted:Class I Matl Released for Const Prior to Satisfying Established Matl Receiving,Handling & Processing QC Procedures

ML20054L783
Person / Time
Site:	Diablo Canyon
Issue date:	06/11/1982
From:	Burdoin J, Eckhardt J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V)
To:
Shared Package
ML20054L770	List: IR 05000275/1982016 ML20054L769 ML20054L775
References
50-275-82-16, 50-323-82-09, 50-323-82-9, NUDOCS 8207080476
Download: ML20054L783 (8)

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U. S. NUCLEAR REGULATORY C0fHISSION

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REGION V

50-275/82-16 Report flo. 50-323/82-09 Docket f!o. 50-275, 50-323 License No. DPR-76, CPPR-69 Safeguards Group Licensee: Pacific Gas and Electric Company P. O. Box 7442 San Francisco, California 94120 Facility Name: Diablo Canyon Units 1 and 2 _

Inspection at: Diablo Canyon Site, San Luis Obispo County, California & Corporate Office Inspection conducted: May 10-14, 1982 Inspectors: . [' r 4 6/N/8C

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i . Burdoin, Reactor Inspector D6te Signed Date Signed Approved by: ( / .# 6 ////80

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Date Signed J H. Eckhardt, Acting Chief l eactor Projects Section 1 l Summary:

Inspection during the period of May 10-14, 1982 (Report Nos. 50-275/82-16 and 50-323/82-09)

Areas Inspected: Announced inspection by regional based inspector of construction and modification activities including: a site tour, licensee actions on previous identified items, modifications to piping and electrical supports resulting from the revised annulus spectra, and TMI task action item Tne inspection involved 34 inspection hours by one inspecto Results: One item of noncompliance was identifie The licensee released for construction Class I materials prior to satisfying established material receiving, handling and processing quality control procedures (paragraph 3.b).

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8207080476 820614 PDR ADOCK 05000 RV Form 219 (2)

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DETAILS 1. Individuals Contacted Pacific Gas and Electric Company (PG&E)

• D. Etzler, Project Superintendent

• A. Rockwell, Resident Electrical Engineer

• J. A. Anmon, Resident Mechanical Engineer

• F. M. Russell, Resident Civil Engineer K. A. Nilson, Mechanical Field Engineer I. M. Zakaria, Electrical Field Engineer

• J. R. Bratton, Lead QC Engineer i J. J. Nystrom, QC Inspector I D. A. Stetson, QC Inspector R. W. M. Cook, Electrical Inspector C. H. Issel, Electrical Inspector M. J. Mello, Mechanical Inspector Various other engineering and QC personnel, H. P. Foley Company (Foley)

• A. E. Moses, Project Manager

• V. H. Tennyson, QC Manager

• J. L. Thompson, QA ",gineering Group Supervisor L. C. Fryckman, QC Inspector Pullman Power Products Corporation H. W. Karner, QA/QC Manager J. C. Schultz, Drafting Supervisor P. R. Busic, Lead Designer Pipe Hanger Department

• Denotes attendees at exit meeting on May 14, 1982.

2. Site Tour A tour of the Class 1E cable storage yard and selected areas of the Unit 2 plant was made. These areas included the reactor coolant (RC)

Pump 2-1 area and the annulus area of the containment. In the cable storage area, all Class 1E cables were stored on reels, wound in an orderly fashion. The cable reels sere neatly wrapped with plastic and cable ends were sealed with tape for protection against the weather and intrusion of moisture. In the RC Pump 2-1 area the newly installed fire protection system was examined. The containment sump in the annulus area of the containment was inspecte .. _ _ .. -.

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a 9t A tour of Unit 1 cont;ainment wSs made in company with P. J. Morrill of Region V and H. E. Schierling, Special NRR Project Engineer for the reverification program,'daring his site visit to the'Diablo Plan , ,.

No deviations or items of noncompliance were identifie >

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3. Licensee Actions on'Previousx1dentified Items e

' (Closed) Nonchnklia'nce'(50-255/82-07/01} Construction Work on Pipe Hanger Modifications

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This item-of~ noncompliance invo19ed instances'of construction deficiencies on four pipe supports'that had been modifie The measures taken by the licensee to correct the deficiencies on'the four hangers were inspected in the field by the NRC Inspector and.found to be acceptable. '

To assure compliance with applicable-quality control procedures and requirements, the licensee has re-emphasized to Pullman the '

necessity of strict adherence to all of the installation requirement In' addition, in an' effort to prevent similar occurrences and to assure an adequate and: uniform understanding of the installation requirements, the following actions were taken: 7 1) All contractor craft personnel have been directed in writing as well as verbally by their :qpervisors to use extreme carefin protecting all existing ' plant installation ~

2) Detailed training sessions for contractor field engineers, OC inspectors. and craft supervision were conducted on March ,

2 and 3, 1982. This training dealt with the proper information '

required to-assure complete and accurate documentation of th,e installatio ) Seven training sessions-were conducted between March 12 and 16,1982,,where typical; welded support structures were

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utilized as examples to' assure a; uniform understanding of the "fina1 visual" weld. acceptance criteria stated in ESD Number 223. .These classes were conducted for contractor QC inspecto'rs, field, engineers, superintendents, craft general foremen and craft foreme s .

lhe inspector considers i. hat 'tNo actions described above will assure full; compliance with quality assurance requirements and will prevent,similar def.iciencie l

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-3-b. (Noncompliance) Unresolved Item (50-323/82-06/01) Allegation of Improper Quality Assurance Practices by the Licensee's Electrical Contractor (Howard P. Foley Company).

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1) Allegation On December 14, 1981, the NRC Resident Inspector was contacted by an individual who alleged that-Class 1 materials received by the Howard P. Foley Company were released to construction for installation prior to receipt of proper documentation of certification of material. The details of this allegation are described in inspection report 50-323/82-0 ) Findings

Class 1 fabricated steel items for Unit 2 purchased by the Foley Company under Purchase Order 03999 when received on January 22, 1982 without supporting documentation were not processed in accordance with Foley Quality Control Procedure (QCP) 4, " Receiving, Handling and Storage", Section 4.2, and QCP-3 " Processing and Control of Deviations and Nonconformances",

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Section 1. These same Class 1 materials supposedly in a status of nonconformance were released to construction for installation which was contrary to existing QA procedure No provisions exist in the present QA procedures ~for releasing material to construction prior to receipt of documentatio It has been determined that the steel fabrications purchased

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under P.O. 03999 were installed in the condensate polishing i

system which is a Class II system. This polishing system is 1:cated in a Class II area of the' Turbine Building at i

ground elevation (85').

The contractor, at the direction of the licensee, initiated a 100% audit on March 15, 1982 of all materials purchased by the Foley Company for Diablo Canyon back to January 197 The audit, which involved over 2500 purchase orders requiring quality assurance, has revealed that.not all documentation required for Class I materials purchased under eight purchase ;

orders has been received. The receipt on site of this documentation is still outstanding and dates back several months. This t

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nonconforming material has since been released for construction.

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-4-3) Conclusions Contrary to quality control procedures 3 and 4 for receiving and processing Class I materials without proper documentation, the Class I materials received under eight purchase orders were not processed in accordance with prescribed procedures and were released for construction prior to receipt of naterial documentatio The failure to conform to existing approved procedures when receiving, handling and releasing this material for construction is an apparent item of noncompliance (50-323/82-09/01). (Closed) Unresolved item (50-275/82-07/02) Pipe Support 176-141SL T$eismic Limiter)

Two questions developed concerning pipe support 176-141SL; (1)

the support was found to have two mechanical shock arrestors (snubbers) which did not have full thread engagement of bolts on the transition tube flange, and (2) these bolts were not equipped with locking wire ) This same item (short snubber bolts) became a concern in 1978 at which time the licensee questioned Pacific Scientific, supplier of the snubbers. Pacific Scientific letter of September 8, 1978 to PG&E addressed the subject and stated that transition tube bolts included with the snubbers fell into one of three categories when installed: bolts that extended through the snubber flange, those that were flush with the flange and those that did not reach completely through the flange. Pacific Scientific has ctated that the metal thickness of the transition tube into which the shorter bolts mate is thicker than a standard size nut for the. size bolt in question. The shorter bolt engage the same number of threads as a standard size nut. The supplier has also verified by analysis and test the adequacy of the shorter bolt ) The snubbers in question were installed in 1979 and the locking devices used at that time were lock washers which is in accordance with the requirements of piping design N4SI B31.1 and B31.7. On June 4, 1980 the field procedure was changed to use safety wire on all new snubber installations and on installations which require retorquing of the bolts due to rewor This item is close ,

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-5- (Closed) Unresolved item (50-275/82-07/03) Pipe Support 2180-18 Hanger Rod Beam Attachment A question developed concerning the ITT-Grinnell supplied spring hanger rod which was bearing on the threaded portion of the beam

attachment bolt of pipe support 2180-1 ITT-Grinnell has demonstrated through both testing and analysis for clamps of the design in question that the bolts where the hanger rod bears on the threads would not be over stresse Also, the supplier acknowledged that the bolts shipped with the figure 66 welded beam attachment are 8307 grade, A36 material, and the threaded portion extended into the rod area of the clam This item is close (Closed) Followup item (50-275/82-13/01) Missing Locking Devices

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on Snubber Missing locking devices on mechanical snubber 22-20 SL transition tube capscrews were identified. The QC records show that lock wire was installed March 9, 1981. A work order was issued to retorque capscrews and install new lockwires. This work was completed May 11 and inspected May 12, 198 This item is close . Safety-Related Pipe Support and Restraint Systems, Unit 1 The seismic verification of pipe supports to date has resulted in 121

, large bore piping hangers requiring modifications. As of this inspection, i

modifications to 90 hangers have been complete Approximately 67 small bore (2" diameter and smaller) piping hangers require modifications. Forty-five of these modifications are to provide two-way vertical restraint of the pipe. To date, modifications to

. 66 small bore hangers have been complete The inspector examined modifications to large and small bore pipe supports in Unit 1 containment and auxiliary building to ascertain by visual examination whether the pipe supports met the requirements specified by licensee's drawings, procedures, and specifications,

! The following pipe supports which had been inspected and accepted by the contractor's Quality Control were examined, and appeared to satisfy the applicable requirements of ESD-223, " Installation and Inspection of Class 1 Pipe Supports."

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-6-Large Bore Pipe Supports Small Bore Pipe Supports12-160SL 2155-172 13-34SL 57N-129R 585-23R 17G-140SL No items of noncompliance or deviations were identifie . TMI Task Action Plan Items for Unit 1 The inspection of the following TMI task action plan items was continued as a followup to inspection report 50-275/81-26 for the inspection period October 5-9, 198 II.B.1, Reactor Coolant System Vents This task action item requires the addition of Reactor Coolant System (RCS)/ Reactor Vessel Head high point vents. The modification at Diablo Canyon Unit 1 consists of the installation of redundant reactor head vent systems. Each system consists of two DC solenoid operated valves in tandem. These valves are normally closed and are energized to open. They close on loss of power. The two valves of each system are energized from a 125 volt vital batter The status of the installation of these redundant systens, as reported in inspection report 50-275/81-26, is completed except for receipt and installation of environmentally qualified electrical connections on the reactor head for the four solenoid valve The licensee is presently awaiting a response from Westinghouse to their request for additional documentation of the environmental qualifications for the reactor head vent solenoid valves and environmental qualifications requirements and documentation for the electrical conductors to these valve This item remains open, and the status will be reported in a subsequent inspection report (50-275/82-16/02). II.F.2, Instrumentation for Detection of Inadequate Core Cooling This task action item requires that the licensee shall provide a primary coolant saturation meter to provide on-line indication of coolant saturation conditions. Additional instrumentation to provide an unambiguous indication of inadequate core cooling is to include reactor-water-level indicatio ..

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-7-Attachment 1 of this task action item requires upgrading to safety grade the incore thermocouple cablirig to the control room. These thermocouples monitor core outlet temperature The following is the status of the installations of these requirements:

(1) The installation of the subcooled margin monitoring system is completed, tested and turned over to operations. The installation of this system is acceptabl (2) The installation and preliminary testing of the reactor vessel level instrumentation system has been complete Final testing will be completed during hot functional testing following fuel load. The installation of this system is acceptabl (3) A LOCA qualified enclosure for the cold junction boxes and qualified thermocouple extension cable have been delivere The enclosures have been mounted in the containment, the cold junction boxes installed and the extension cable pulle The incere thermocouples connectors at the vessel head were installed during the inspection week of May 10-14. Terminations of cabling at cold junction boxes and at containment penetrations is awaiting release from design before this work can commenc This installation was examined in the field. No items of noncompliance or deviations were identified. This item remains open, and the status will be reported in a subsequent inspection report (50-275/82-16/03).

6. Management Interview A meeting was held with the licensee representatives (identified in Section 1) on May 14, 1982. The scope of the inspection and a summary of the findings, as noted in this report, were discussed.