IR 05000289/1972020
| ML19210B687 | |
| Person / Time | |
|---|---|
| Site: | Crane  |
| Issue date: | 01/30/1973 |
| From: | Folsom S, Heishman R, Howard E NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML19210B686 | List: |
| References | |
| 50-289-72-20, NUDOCS 7911110153 | |
| Download: ML19210B687 (14) | |
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U. S. ATOMIC ENERGY _ COMMISSION
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DIRECTORATE OF REGL*LATORY OPERATIONS
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RO Inspectica Report No.:
50-289/72-20 Docket No.:
50-2E
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Licensee: Metropolitan Edison Company License No.: CPPR-
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Reading, P.ennsylvania, 19603 B
Category:
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Middletown, Pennsylvania I cation:
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Type of I.icensee:
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- j Type of Inspection, Routine, Announced
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.I Dates of Insp~cetion:
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Dates of Previous Inspection:
. November 9, 1972
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/.30 2.3 Prin ipal Inspector:
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Dhte Seth A. Folsom, Reactor Inspector
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E. M. Howard, Chief, Facility Con-Date
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I struction & Engineering Support Br.
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h J. H. Tillou, Acting enior Reactor DaCC
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NT C.* McCabe, Reactor Inspector
//,8c'/73 Reviewed By:
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R. F. Heishman, Senior Reactor Inspector, Fac.-
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111 ties Construction & Engineering Support Br.
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SUMMARY OF FINDINGS
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Enforcement Action None
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Licensee Action on Previousiv. Identified Enforcement Matters
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A.
Procedures on Cable Separation Between Console and Soreader Room
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l A procedure has been prepared for the use of Quality Control inspectors
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which includes the separation and identification criteria for cable be-tween the control room console and the spreader room.
This item was identified at a site inspection on March 9,1972, and was listed as a nonconformance in a letter to the licensee on April 14, 1972. The pre-paration of this procedure fulfills the commitments made in the licensee's letter of May 12, 1972. This ites is resolved.
(Report Details, Paragraph 15)
B.
Program Controls for Appendix B Criteria I, II, XVI, XVIII
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The UE&C Quality Control organization has been placed directly under
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v the control of the GPU Quality Assurance organization. A program of indoctrination, training and retraining is in effect. Deficiency Re-ports are being completed and followed up, and a formal auditing pro-gram is being conducted. These deficiences were identified at a site inspection on May 31 - June 1, 1972, and were listed as noncomformances in a letter to the licensee on August 22, 1972.
The corrective measures taken fulfill the commitments made in the licensee's letter of September 11,
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1972.
This item is resolved.
(Report Details, Paragraph 12)
l Design Channes I
None
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Unusual Occurrences None
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Other Significant Findings A.
Current Findines 1.
Organization Channes A number of changes have been made in the licensee's site quality control - quality assurance organization.
The principal changes include:
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(a) The Home Office QC Supervisor has resigned from UE&C.
i (b) Mr. J. E. Wright has been named GPU Three Mile Island QA Manager, reporting to Mr. B. G. Avers, Manager of Quality Assurance, GPU. The UE&C Quality Assurance and Quality Control organization will be under the direct supervision of Mr. Wright.
(c) Mr. M. J. Stromberg, previously GPU Site QA Representative,
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j has been redesignated GPU Site QA Auditor with responsibility
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for third level auditing of Site QC/QA activities.
(Report Details, Paragraph 5)
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B.
Status of Previousiv Reoorted Unresolved Items
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1.
Ultrasonic Testing of Primary Svstem Pressure Vessel Welds j
The progrma for ultrasonic testing of all primary welds on the i
reactor pressure vessel, steam generators and pressurizer has been completed.
This item is resolved.
(Report Details, Paragraph 2)
2.
Radiograohv on Grinnell Pioing e
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The radiographs were delivered to the site, and the pfpe welds were re-radiographed in those instances where previous radiographs did not meet the requirements. This item is resolved.
(Report Detai'Is, Paragraph 3)
3.
Ultrasonic Testinz Procedure on Stainless Steel Valves Procedures have been developed for the UT examination of Class I stainless steel valves. This resolves the previously unresolved item relating to the development of a procedure, but the program of verifying the wall thicknesses of all safety-related valves is continuing.
(Report Deta'ils, Paragraph 4)
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4.
Sesmic Integrity of Batterv Room Lighting Fixtures The battery room fluorescent lights are being relocated to avoid l
possibility of damage to batteries in the event of a seismic in-cident. This item is resolved.
(Report Details, Paragraph 6)
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Cadwelding on Ring Girder Repair Work The requirements on cadwelding have been made more rigid and the i
defective cadwelds replaced. A re-examination in the containment j
ring girder repair area showed all cadwelds meeting requirements.
This item is resolved.
(Report Details, Paragraph 7)
6.
Seismic Classification of Main Steam Line
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The' main steam line is Class I seismic between the steam generators
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and the main steam isolation valves. This item is resolved.
(Re-port Details, Paragraph 8)
7.
Electronic Verification of Safeguards Cable Routing The routing of safeguards cables is being verified on a sampling m!q)
basis, using electronic signal tracing equipment.
(Report Details,
Paragraph 9)
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8.
Separation Barriers Between Terminals and Redundant Cables Barriers are shown on the cable tray construction drawings, but
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will not be' installed until the cabling is essentially cceplete.
This item is resolved.
(Report Details, Paragraph 10)
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9.
Overheating of Crimoed Connections at Switchgear Cabinet.
The vendor's representative completed a joint inspection with the licensee following repairs.at the site, and certified the quality of the repaired equipment. This item is resolved.
(Re-port Details, Paragraph 11)
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Management Interview
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The management interview was held on January 5,1973, with licensee and contractor personnel.
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Personnel Attending
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General Public Utilities (GPU)
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Mr. B. G. Avers, Manager, Quality Assurance Mr. M. J. Stromberg, Site QA Auditor i
Mr. J. A. Renshaw, Quality Assurance Specialist
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Mr. D. H. Reppert, Licensing Engineer Mr. T. Hreczuch, Mechnical Engineer United Engineers & Constructors (UE&C)
Mr. V. E. Cichocki, Construction QA/QC Coordinator
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The following items were discussed:
A.
The inspector explained that for record purposes this inspection would include the items covered on December 28 and on January 3 - 5.
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The licensee acknowledged this information.
J B.
The inspector stated that the extensive changes that had been made at the site in restructuring the cuality control and quality assur-ance organizations had been reviewed.
It was noted that the size of the organization had been increased considerably since the last
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inspection. The licensee was asked if it was planned to include the new organization in the FSAR. The licensee stated that this would be done as soon as the re-organization was considered to be c omplete.
0 Report Details, Paragraph 5)
C.
The inspector stated that during this inspection he had examined the following:
Observation of work cn the placement of containment tendons.
0 Report Details, Paragraph 13)
Electronic verification of safeguard cable routing.
(Report Details, Paragraph 9)
Progress of repairs on containment ring girder repairs.
(Re-port Details, Paragraph 14)
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Records and field observations in connection with the resolution of previously identified inspection items.
The licensee acknowledged this information.
D.
The inspector stated that the following previously identified items had been reviewed and were now considered resolved:
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1.
Ultrasonic testing of welds on the reactor pressure vessel, steam generators and pressurizer.
(Report Details, Paragraph 2)
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Deficient radiography on Grinnell piping.
(Report Details,
Paragraph 3)
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3.
Development of a procedure for ultrasonic testing of stain-i less steel valves.
(Report Details, Paragraph 4)
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Quality Assurance procedures on cable separation between
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console and spreader room.
(Report Details, Paragraph 15)
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5.
Questionable seismic integrity of battery room lighting fix-tures.
0 Report De' tails, Paragraph 6)
6.
Cadwelding on ring girder repair defective.
(Report Details, Paragraph 7)
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Seismic clas'sification of main steam line.
(Report. Details,
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Paragraph 8)
8.
Separation barriers between terminal arrays and adjacent re-dundant cables.
(Report Details, Paragraph 10)
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9.
Failure of crimped connections, overheating at switchgear cabinet.,(Report Details, Paragraph 11)
10.
Controls for quality program, in accordance with Appendix B, Criteria I, II, XVI, XVIII.
(Report Details, Paragraph 12)
E.
The inspector stated that he had observed that the containment ring girder repair work was nearing completion and asked when the docu-mentation covering the entire repair job would be available for his examination. The licensee stated that there was a current project to assemble all records, photographs and dccumentation pertaining 15B6 13B
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to this job. Upon completion of the repair work, this documentation would be thoroughly audited by the QA audit group. At that point, following needed corrections, the complete package would be available to the inspector.
I F.
The inspector stated that he had accompanied the licensee's QA per-
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sonnel on three occasions to observe the electronic verification of
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safeguards cable routing. He questioned the practice of notifying
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the constructor personnel, as much as a week in advance, of the
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specific identity of the cables that would be covered in the audit.
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The licensee stated that it was doubted whether this advance notifi-
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I cation could result in the correction of deficiencies prior to the audit and that he had no plans to eliminate the present practice.
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The inspector stated that the validity of the audits were made questionable by this advance notification and added that in the in-spector's' forthcoming audit of safeguards cable routing, the cables
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would be selected at random, followed by an i=sediate verification of pull-card prescribed routing.
(Report Details, Paragraph 9)
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DETAILS
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1.
Persons Contacted General Public Utilities (GPU)
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Mr. B. G. Avers, Manager Quality Assurance Mr. G. L. Kopp, QA Engineer, Electrical Mr. T. Hreczuch, Mechanical Engineer Mr. P. Levine, QA Engineer Mr. J. A. Renshaw, Quality Assurance Specialist Mr. D. H. Reppert, Licensing Engineer Mr. M. J. Stromberg, Site QA Auditor
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Mr. J. F. McConnell, Senior Engineer, Research and Development United Engineers and Constructors (UE&C)
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Mr. V. E. Cichocki, Construction QC/QA Coordinator
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Mr. R. N. Moyer, Site QC Supervisor i
Mr. R. L. Hawkins, Construction Engineer, Civil
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Mr. D. C. Lambert, QC Engineer
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Mr. C. Yohe, Lead Electrical Inspe.ctor Gilbert Associates (GAI)
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Mr. W. F. Sailer, Project Manager Conam Division of Automation Industries
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Mr. D. McGill, Operations Manager
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Mr. J. Luksic, Site Supervisor Mr. R. Lukas, Site Coordinator, In-Service Inspection Mr. D. Odegard, Ultrasonic Technician Babcock & Wilcox (B&W)
Mr. J. H. Uhl, Site Manager Mandel, Panoff and Rockwell Associates (MPR)
Mr. J. Gorman, Engineer
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2.
Ultrasonic Testine of Primary System Pressure Vep-51 Welds
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The program of UT testing of all primary welds on the reactor pressure vessel, steam generators and pressurizer has been com-i pleted.
The program was not related to the pre-baseline UT work,
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but was undertaken to provide the licensee with greater assurance of the quality of these vessels. The inspector examined the docu-
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mentation which had been assembled covering this project.
These
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records included the identification and qualifications of the Level III inspectors from Conam who performed this work. The records show-
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ed no reportable indications on these pressure vessels based on the
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j UT examination of all seams and associated metal. This item is re-solved.
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3.
Grinnell Piping Radiography
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A vendor inspection by the licensee at the Grinnell (piping sub-contractor) Kernersv111e, Pennsylvania plant identified a number of defective radiographs. All radiographs covering pipe already
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i shipped to the sice were examined by Level II and Level III NDT t
inspectors at the Three Mile Island site.
The radiographs cover-I ing 281 of the welds were found to meet the requirements. The
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radiographs on the remaining 242 welds were nonconforming and were I
re-radiographed. All welds were found to meet the requirements.
7s The problem had been in the quality of the radiographs. Deficiency
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Reports Fos. 0413 and 0415 were prepared by the licensee covering this work and were examined by the inspector.
The radiographs covering the unshipped piping (300 welds) were ex-amined at Kernerdv111e by the licensse's quality control. inspection
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team and 36 radiographs were found deficient and the welds were re-radiographed. All welds met the requirements. Deficiency Report
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No. 428 covered this work.
It is now recuired that all Grinnell radiographs be sent to the li-censee when the piping is shipped. The radiographs will be retained at the site. This item is resolved.
4.
Procedure for Ultrasonic Testing of Stainless Steel Valves The following procedures were examined:
a.
Conam NDT Procedure No. NIP-016 "UT Wall Thickness Measurement of Nuclear Piping Systec Valves" Revision 2, September 1, 1972, approved by the GPU QA Manager.
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b.
UE&C QC Procedure No. QC-10, Appendix A "QC Program for Valve Wall Thickness Checks" Revision 0, December 19, 1972.
The equipment used was an Autcmation Industries (Sperry) Reflect-oscope, No. UM-721, utilicing L EFN Pulser-Receiver with a digital i
readout module plus a unit for visual / aural alarm gating.
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t Calibration standards were provided to cover each austenitic alloy and thickness of material to be measured.
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For demonstration purposes, a 4" A11oyco Cate Valve No. MUV-89A was examined during the inspection.
The records for the wall thickness measurements were maintained on UESC forms designated THI-WT-1 through WT-9 for the different type valves being inspected.
The inspecto. made the f ollowing observations during the inspection:
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There was no documentation available for reference calibration a.
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The valve inspection record forms did n,ot require the identifi-
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cation of the particular reference calibration standard used.
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The Conan Procedure No. NIP-106 specifies a + 7% accuracy, whereas c.
the licensee's correspondence states that a + 5% accuracy"will be attained.
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These items were corrected by the licensee crior to the completion of the inspection and were verified by the inspector.
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The. outstanding item related to the development of an ultrasonic tech-j nique for measuring wall thicknesses on stainless steel valves is re-solved, but the licensee's program of verifying the dimensional require-ments of all safety-related valves is continuing.
5.
Re-Organization of OC/0A The QC/QA functions at the site have been re-organized effective October 31, 1972, with the licensee assuming responsibility f or management of th,e QC/QA functions which were previously managed by UE&C.
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The QC/QA remains a three-level program and the responsibilitie
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and functions of each level are described in the Three Mile Island QA Plans.
The vendor inspection group is now located at the site.
A' number of organizational ch'anges have been made to attain the objective of direct licensee management of QC/QA. The organization will be included in future FSAR asendments.
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The special task force.which was formed to institute changes in QC/
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QA has been disbanded.
There has been a considerable buildup in the number of QC/QA per-sonnel at the site. The total is presently 134, which includes
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GPU, UE&C, Conam, Gilbert Associates, Burns & Roe, Stearns-Roger, Babcock & Wilcox, Pittsburgh Testing Laboratories, and US Testing Laboratories.
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6.
Seismic Integrity of Battery Room Lighting Fixtures
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The seismic integrity of the lighting fixtures was believed by Gilbert Associates to fulfill the requirements at this battery room location.
There was some discussion between GAI and the li-censee on the strength of the hanging devices. The solution agreed upon was to relocate the lighting fixtures so.that any failure which
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might occur in the event of a scismic incident would not endanger the
' batteries.
The inspector examined GAI Drawing No. E-220-131, Revision 9, December 14, 1972, which included the entry, " Moved battery racks and lights on Coordinates B-3, C-3 and D-3 as per DCR 2-277.
Work to be done before hot functional." This item is resolved.
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7.
Cadwelding on Ring Girder Repair Work The ring girder repair program was nearing completion at the time of inspection. Most of the cadwelding had been completed on the exposed rebar.
The inspector examined a number of cadwelds for alignment, cleanliness, voids, presence of remaining packaging, and spacing.
No deficiencies in the cadwelding were observed.
This item is resolved.
8.
Seismic Classification of Main Steam Line The main steam line is designated as Class I seismic in the FSAR, k50b s
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Volume IV, Section 10, Figure 10-3, from the steam generators to the main sdeam isolation valves. The architect engineer's Project Manager stated that this designation has existed since the initial
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design stage, and that there was no intention to change the classifi-
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cation. This item is resolved.
9.
Electronic Verification of Safeguards Cable Routing
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Two procedures on cable routing verification were examined:
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a.
UE&C Electrical Construction Procedure ECP-12, Revision 1, September 13,1972, " Operating a Cable Fault Detector to Trace Routing of Cable," approved by H. I. Stewart.
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b.
GPU Electrical Procedure No.100, " Verification of Installed Safe-
' guard Cable - IMI-1, Revision 1. September 28, 1972, approved by H. J. Stromberg.
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The inspectors accompanied the licensee's quality assurance personnel on three occasions in the use of these procedures. The procedures are being used, and a total of 103 cables have been verified to date.
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It is planned to verify a total of 10% of the safeguards cables. The i
inspector questioned the practice of providing the constructor with a (m.
one week notification of the identity of the cables to be verified.
The licensee stated that this advance notification was insufficient to s.,
provide any influence on the audit results. The inspector reiterated his contention that this advance notification served to lessen the credibility of the audit, and added that his forthcoming audit would i
not include advahce identification.
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10. Separation Barriers Between Terminals and Redundant Cables
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Barriers are shown on electrical construction drawings where these are needed to assure separation between redundant cables.
Evidence was presented on drawings and field inspection reports where additional barriers will,be provided, but barriers will not be installed until cabling is essentially complete. This item is resolved.
11. Overheating of Crimeed Connections at Switcheear Cabinet A Deficiency Report No. DR-0451, April 11, 1972, was examined by the inspector.
The report covered Bill of Material EG-5 Engineered Safe-guards Motor Control Center.
The DR shows under " Disposition" that
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an inspection of the reported deficiencies, and to supervise needed repairs. The inspector also examined a letter to the licensee frcm the ITE Product Engineering Manager, June 2,1972, which included the statement, "This letter is to certify that the QA documentation l
for the equipment furnished on the Motor Control Center is still valid." The licensee stated that "The ITE representative went over
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the equipment piece by piece and wire by wire, and they verified, and the constructor repaired every item found." This item is re-solved.
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a 12. Program Controls for Apoendix B, Criteria I, II, XVI, XVIII The re-organization of the QC/QA at this site, together with the
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marked increase in the number of personnel involved in quality work j
has resulted in the preparation of new procedures and an' increased implementation of the pre-existing procedures.
Criterion,I and II have been implemented by the indoctrination and retraining of all quality-related personnel, covering their authority, duties and independence from the construction personnel.
Criterion XVI has been implemented by the use of UE&C Deficiency
Reports, Revision C.
Several of these completed DR's were examined
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by the inspector. These included identification of the deficiency,
' p-report describution list, disposition, verification of disposition
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O action and re-inspection.
The approvals were signed and dated,by the designated authorities.
Criterion XVIII has been implemented by the formation of a licensee QA group whose function is the planning, scheduling, conducting, i
documentation and. followup of site audits. The inspector examined the wall mounted schedule of planned and completed audits, and the documentation covering completed audits.
In addition to the pre-planned audits there were numerous spot audits of field activities.
This item is resolved.
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13. Containment Tendon Placement The inspector was informed that work had been started by Inland Ryerson, the subconstractor for the installation and tensioning of the contain-ment tendons. The progress to date was examined.
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A total of 77 vertical tendons (about 40%) had been installed at j s
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the time of inspection.
There had been no tendon tensioning to date, and none was planned until. March,1973. The inspector was assured that per his request he would be notified in advance of the start of tendon tensioning.
It is planned to fully tension each tendon the'first time, instead of the previously announced 5% tensioning followed-by full tensioning.
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The records showed that the tendon installation work had previously been stopped by the licensee principally because of the lack of cer-tain procedures.
The inopector observed the actual installation of one tendon, and saw that the job was being closely followed by the subcontractor's quality control inspectors. Some difficulty had been experienced in the tendon installation work by the snagging and tearing of the sections of Flex tube tendon sheathing.
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The containment ring girder repair work has previously interfered
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with the installation of the tendons. The tendon work is expected l
to accelerate when the ring girder. repair work is completed, which is estimated to occur about February 1,1973.
I 14. Containment Rine Girder Reoairs ()
The ring girder repair program appeared to be nearing completion.
Essentially all of the jackhm=mering, chipping, rebar installation
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and cadwelding was complete, the principal remaining effort was the placement of concete.
l The licensee stated that all documentation covering this repair work j
was currently being assembled, and that a QA audit of the records was planned at an early date to insure that all items in the procedures and their addenda had been completed and properly documented. The li-censee agreed, per the inspector's request, to notify the inspector when this package of documentation was assembled.
15. Procedures on Cable Senaration Between Console and Screader Room A meeting was held by the licensee on May 22, 1972, concerning the
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inspector's cocments on the absence of site OA procedures on the separation of cable:s between the control room consoles and the spreader room. The meeting was attended by representatives from UE&C and Gilbert Associates. It was agreed to provide field QC personnel with the needed separation, identification and installa-tion criteria in accordance with the series of Drawing Nos. S-224-
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The inspector examined a memorandum for hr. J. R. Stout, GPU Resi-i dent Electrical Engineer, to the Project Engineer, subject "TMI-l Control Room Consoles CL, CC, and CR Internal Wiring Separation."
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The memorandum covers the required 6" air space separation, the initia111ng of terminations and the related Quality Contol Forms.
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The inspector examined the use of this information by the OC in-
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spector. This item is resolved.
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