IR 05000312/1972006
| ML19309A207 | |
| Person / Time | |
|---|---|
| Site: | Rancho Seco |
| Issue date: | 02/05/1973 |
| From: | Dodds R, Garvin L, Spencer G NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V) |
| To: | |
| Shared Package | |
| ML19309A189 | List: |
| References | |
| 50-312-72-06, 50-312-72-6, NUDOCS 8003260912 | |
| Download: ML19309A207 (13) | |
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U. S. ATOMIC ENERGY C0:0!ISSION DIRECTORATE OF REGUTATORY OPERATIONS l
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REGION V
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i RO Inspection Report No.
nsn nq19/7 Ant'
- Licensee:
sorv.,m nen wn i c 4,,n 1 ne414e, n4
,.v4,.e Docket No. nsn-n119
%evamonen_ cn14fnrn4, License No. (s) CPPR-56 1 1 Priority
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Facility: Rnneho Seco Unit No. 1 Category A-3 Location: c1nv Station. Siternmento County. Calif.
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l Type of Facility:
963 Mwe (2772) PWR. Et,W Type of Inspection:
Routine. unannouncad
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Dates of Inspection:
December 18-21. 1972 Dates of Previous Inspection:
nnunmwor 1s_17 toy 9 Principal Inspector:
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j I. Y. Do'dds,' Reactor Inspector
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e 2/PI73 Accompanying Tr spectors:
W-i L. M Carvin, III, Reactor Inspecto'r '(Date)
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Construction
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(Date)
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Other Accompanying Personnel: None i
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Reviewed by:
A uAD&O^ t G. S. Spenced, Chief, Reactor Construction (Date)
and Operations Branch 8003 260 Y/M
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SUMMARY OF FINDINGS
Enforcement Action A.
The E9018 coated electrodes used in welding the upper lateral support structures for the steam generators were not always being stored in a heated oven and held at a temperature of at least 250*F prior to use, or redried if not used within one hour.
(Paragraph 3)
B.
A portable warmer containing low hydrogen clectrodes was unplugged in a work area.
(Paragraph 9.d)
C.
The radiographic procedures used for examination of pipe welds had not been approved as required by the QA program.
(Paragraph 8.)
Licensee Action on Previously Identified Enforcement
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None required as a result of the last construction inspection in September, 1972.
Design "hanges
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None identified u
Construction Deficiencies
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Nothing to report.
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Other Significant Findings Current Findings A.
Steam Generator Lateral Support Structures - The records show that the lateral support structures for the steam generators have been satisfact-orily repaired in accordance with the licensee's report dated July 24, 1972.
(Paragraph 3.)
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B.
Electrical Penetrations - Examination of records relating to the installation of electrical penetrations disclosed that the licensee had not discovered any internal shorts in the penetrations.
The penetrations were supplied by Conax rather than the Viking Company.
C.
Reactor Coolant Pumps (Guide Vancs) - The reactor coolant pumps were manufactured by Bingham Pump.
Bingham did not manufacture the Main Yankee pumps. The guide vanes were installed at the manufacturer's shop and not in the field.
Bingham's pumps have not yet experienced any guide vane failures.
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D.
Control Rod Drive Pressure Tubes - The records relating to the examination and modification of the control rod drive pressure tubes were not
'yet available for review.
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E.
Valve Wall Thickness Measurements - About 20 valves still had not yet
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arrived at the site and were all that were left to be measured for i
conformance to wall thickness specifications.
F.
Reactor Vessel Instrument Nozzles and Internal Structure Modifications -
The instrument tubes and flow vanes have been removed. The installation of new tubes was just starting.
(Paragraph 10.)
G.
Weld Filler Material Control - The procedure for the control of low hydrogen electrodes has been modified to require the electrodes to be
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destroyed if out of the holding oven or portable electrode warmers for more than four hours rather than rebaking the electrodes. The
portable warmers have been checked and found to maintain a holding temperature of 250'F providing the lid remains closed. However, many instances were noted during tours of the facility where the lids of the warmers were open and the electrodes partially exposed.
(Paragraphs
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4. and 9.d)
H.
Documentation of Essential Welding Variables - The program for the documentation of checks of essential variables on weld joints has been modified to require a daily recording of the preheat temperature-on an attachment form to the field welding checklist. Use of the
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attachment form had just been initiated, therefore, compliance with the new program could not be verified.
I.
Tendon Strand Slippage (Containment Building) - An inspection of the short tendons that had slipped and had to be restressed disclosed some strand slippage in H-50.
(Paragraph 5.)
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High Pressure Injection Makeup Pump - The material certification records; for the high pressure injection system makeup pump did not indicate acceptance of one of the radiographs of the suction nozzle weld.
(Paragraph 6.b)
K.
Pressurizer Relief and Safety Valves - The records of the manufacturers tests of the pressurizer relief and safety valves did not clearly show that the valves were " popped" at the required settings.
(Paragraph 6.f)
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L.
Pipe Welding (Radiographic Examination) - The records relating to _ the radiographic examination of pipe welding could be misleading and do not clearly establish which film has been rejected because of density variation.
(Paragraph 8.)
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Status of Previously Reported Unresolved Items No outstanding unresolved items following the last construction inspection.
Management Interview The results of the inspection were discussed with Messrs. Mattimoe, McMahon, Stinchfield and other members of the SHUD and Bechtel staffs. The following acknowledgements and commitments were made during the discussion.
Inspection Findings Relating to Previously Identified Items of Interest A.
Steam Generator Support Structure - The licensee was informed that RO has no further questions regarding the repair of the steam generator lateral support structures which was performed in accordance with the
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licensee'a report dated July 24, 1972.
(Paragraph 3.)
B.
Documentation of Inspection Checks of Essential Welding Variables -
It appears that the program as modified for including the documentation
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of checks of essential welding variables, once fully implemented, should'
furnish sufficient evidence to show that the welding of Class I piping i
was being performed in accordance with the applicable procedures.
C.
Control of Weld Filler Metal - It appeared that the modified procedure for the control of issued' filler metal for pipe welding was consistent
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with the applicable codes. However, since the welders have formed the habit of leaving the lids of electrode warmer cans open, the low hydrogen electrodes held in these cans did not appear to meet the AWS Dl.0-69 code storage temperature requirements for structural steel welding.
The licensee's contractor stated that their inspectors will be instructed to require welders to keep the lids of the warmer cans closed for E90 series electrodes.
(Paragraphs 3. and 9.d)
Licensee Commitments and Comments i
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A.
-Filler Material Control - As stated above, a meeting will be held with the welding inspectors and they will be specifically instructed to require welders to keep the lids of warmer cans for E90 electrodes
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closed for better environmental control of the filler metal. Construction
practices for use of the warmers for other electrodes will also be
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examined. The practice of issuing a full days supply of E9018 electrodes for T-1 steel welding'will be examined and corrective measures instituted to comply with the AWS code for structural steel.
(Paragr.aph 3. and 9.d)
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B.
Protection of Stored and Installed Equipment - The entire program for heater control will be examined and measures will be established to ensure that equipment heaters are on.
The West high pressure injection-system pump will be checked for cleanliness and cleaned if necessary since the ' discharger pump cover seal was found to be damaged. (Paragraph,6.a)
C.
Records of Class I Equipment - (1)- The radiographs of the high pressure injection system makeup pump will be examined. co determine the
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acceptability of the auction nozzle welding and (2)l additional informa-i tion will be obtained to show that the pressurizer safety and electromatic relief valves were tested at rated pressures.
(Paragraphs 6.b and f)
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D.
Radiographs'of Weld Joints - The records relating to the radiographic examination of pipe welding will be examined and measures taken to permit independent film interpretation.
(Paragraph 8.)
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REPORT DETAILS Section I - Prepared by R. T. Dodds i
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Principal Persons Contacted
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Sacramento Municipal Utility District (SMUD)
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J. Mattimos Assistant General Manager, Chief Engineer
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V. McMahon Quality Assurance Director
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W. Friedrich Quality Assurance Engineer
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J. Hiltz Resident Engineer
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J. Wheeler Electrical Engineer
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L. Smith Mechanical Engineer
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Bechtel Corporation (Engineering and Construction Management)
W. Stinchfield Project Manager
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W. Chapla Project Quality Assurance Engineer
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j 1J. Wait QA Engineer
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T. Sauerbrun Nuclear Field Engineer
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i Bechtel Corporation (Construction)
J. Vander Knyff Project Superintendent
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E. Dore Project Field Engineer
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B. Boyd Welding Department Superintendent
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l P. Singh Field Engineer (Electrical Penetrations)
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R. Harris Welder
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E. Callaway Field Engineer (Mechanical Equipment)
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g G. Nelson Walder
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j B. Jarvis Field Electrical Engineer
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J. McGraw-Field Engineer (Mechanical)
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2.
Status of Construction Project construction was estimated to be 77% complete as of December
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20, 1972. The percentage of completion was recently revised downward and was based on the latest project cost forecast. The installation of mechanical equipment was approximately 94% complete. The reactor vessel instrument tubes and flow vanes have been removed. The installa-tion of the replacement tubes was well underway. About 60% of the required wire and cable have been pulled and about 50% of the required connections have been made.
3.
Steam Generator Lateral Support Structures The records pertaining to the repair of the lateral support structures
(T-1 steel) for the steam generators by AMCO Industries, Inc., El Cajon, California were examined. Defect removal was verified by dye penetrant examination. Acceptance of repair included both radiographic (where possible) and magnetic particle inspections by Decisive Testing
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Incorporated and Magnaflux Corporation respectively. Chemical and physical tests of the filler metal w2re performed by the user.
Bechtel inspection of the repair was accomplished pursuant to the Source Inspection Data Report. All items in the SIDR had been signed off, signifying acceptance of the repairs. The support structures
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were accepted at the site following completion of the Receiving Inspection Data Reports.
The certificates of conformance for the bolts used in the structures included actual chemical, physical and magnetic partical inspection test results.
Installation of the support structures at the site was in progress.
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During observation of welding operations, a discussion with one of the welders disclosed that enough filler electrodes were usually issued to last a full shift. The electrodes were kept in portable warmer cans, however, the lids to the warmers were usually left open and about 1-1/2 inches of the welding electrode tips were exposed to the atmosphere.
Several of the electrodes (E9018) were checked and found to be warm to the touch but not too hot to handle (estimated to be about 120-140*F).
The-records show the portable warmer cans will maintain an oven temperature of 250'F with the lid closed. A check of the area during the lunch hour on December 21 disclosed that a welder had left 3 electrodes on a work bench out of the portable warmer can.
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The above practices pertaining to electrode control appear to be contrary to Section 408 of AWS Dl.0-69 for Welding in Building Construction (applicable code.for structural steel welding) which requires low hydrogen E90 electrode to be stored in ovens held at 250*F, prior to use, and must be redried if not used within one hour after removal from the oven.
4.
Weld Filler Material Control Bechtel stated in a letter to SMUD dated November 15, 1972 that the procedures for the control of filler metal have been modified to l
require low hydrogen coated electrodes to be destroyed if out of holding ovens or rod warmer cans for more than four hours. Further,
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the portable rod warmer containers have been checked and found to maintain a holding temperature of 250*F and are required to be I
i operating when in the work area.
- Quality Control Instructica 301-F requires the rod room attendant to maintain a log of portable containers issued and received from the welders. At the completion of the work day, the portable warmers
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and unused electrodes are to be returned to the rod room attendant.
The electrodes are then removed from the warmers and stored at 200* - 350*F in dry rod ovens.
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A special tour was made of the construction site to audit weld filler material control in the field and the principal issue room prior
to and following the start of the days activities on December 19, 1972. Storage of warmer cans and electrodes and the issue of filler material were found to be in conformance with the filler material control program.
5.
Tendon Strand Slippage j
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i An inspection by Bechtel on November 3, 1972 disclosed that tendon i
H-50 showed evidence of some strand slippage. The tendon was restressed
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in accordance with VSL Data Instruction. The other 15 tendons previously reported showed no evidence of slippage. According to a Bechtel report, the horizontal tendon H-50 will be inspected within 3 months after the i
containment building structural test has been performed. Life off
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readings will be made. to verify that the tendon load falls above the predicted 46 strand load survey.
6.
Othcr class I Components j
Samplings of the records pertaining to material fabrication, storage
and installation of the following Class I components were examined.
('~'g Storage and installation was also observed as indicated.
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Reactor Coolant Pumps Three of the four reactor coolant pumps and motors have. been
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received at the site. Installation of the pump internals for the first pump was in progress and a portion of the activity was observed during the inspection. Special cleaning and access
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control procedures were in effect to preclude contamination of components.
The two pump motors not in use were stored outside the assembly building. They were wrapped with heavy duty tarpaulins and heat lamps were observed to be operating inside the tarpaulins at the base of the pumps. The outdoor storage of the motors was documented on a nonconformance report as not complying with the manufacturers instructions. The pump motor heaters had been connected but a
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check of the power switch on December 19 disclosed it to be
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shut off. The examination of the inspection records disclosed that the heaters had been checked to be operating weekly with the latest check being performed the previous day. No reasonable explanation other than " sabotage" was offered as to why the heaters were off. The following records were specifically examined
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during the inspection:
(1)
Storage inspection instructions and records including pump rotation records.
(2) Pump internal and motor installation specifications and inspections.
(3) Material fabrication certifications. Several chemical and physical properties reports were checked against ASTM'
standards and found to conform to the applicable specifi-cations. It appeared to the inspector that material certifiestion had been obtained for the components and materials used for the pump casing and internals.
I (4)- The certifications of the pump motors were not yet available for review.
b.
High Pressure Injection Pumps The pump rotation, heater checkout and installation inspection records were examined. No anomalies were identified. All items on the applicable. Construction Inspection Data Reports had been completed for work performed to date. Inspection of the pump assemblies / disclosed that the cleaning seal on the discharge nozzle of P238A had been broken. All ether pipes and nozzles gN appeared to be satisfactorily sealed.
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Nkterial certification records and source inspection data reports.
- were examined. Only one anomaly was identified.. The radiographer's
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report of the radiograph of section 3-0 on the suction nozzle band
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lof the makeup pump (P236): did not indicate acceptance or rejection
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lof'that particular film.
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c.
Reactor Building Upper Dome Emergency Air Circulators The Source Inspection Data Reports, Test Results Reports, Construction Inspection Data Reports, field motor rotation and motor meggaring records, Receiving Inspection Data Reports, and material certification records were examined. Installation of the units was also examined. The wire cables to the motors had
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not yet been pulled. No anomalics were-identified during the review of records and the tour.
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d.
Primary System Pressurizer
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Portions of the following recordo pertaining to the fabrication, shipping and placement of. the pressurizer were examined.
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l (1) Construction Inspection Data Report for vessel placement.
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(2) Source Inspection Data Reports.
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(3) Receiving Inspection Data Reports.
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(4) Source Inspection Certification Telegram.
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The installation of the pressurizer was physically examined.
Clean rooms were being established at the top and bottom entry
manholes. No anomalies were identified during the review of records and tour of the. facility.
e.
Decay Heat Removal Coolers I
The Construction Inspection Data Reports, Source Inspection Data
Reports, Material Certifications and the installation of the decay
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heat removal coolers were examined. Pipe nozzles of coolers were noted to be sealed off trimaintain clean system status. No anomalies were identified during the examinations.
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Pressurizer' Safety Valves The safety valves were manufactured by Dresser Industries.
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Source Inspectors' Certification of Proof Testing, NSS Component Testing, 'R<eceiving Inspection Data' Report, Source Inspection Data-
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Report, Nuclear Test Log, Material Certifications and storage of
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. the. safety and electromatic relief valve were examined.
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The only potential anomalies identified were the valve " pop" test certifications. Steam pressure on the valve plus a hydraulic assist pressure on the spring was used to test the valves. The data presented did not clearly show that the valves had indeed been popped at their equivalent set pressures of 2500 psig and 2300 psig for safety and electromatic relief valves respectively (i.e., the only pressures listed for the safety valves were 1500 psig steam plus 685 hydroset and 2000 psig steam for the electromatic relief valve - hydroset not listed).
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Letdown Cooler Isolation Valves The Source Inspection Data Report, Receiving Inspection Data Report, B&W QA Data Sheet, Hydrostatic Test Data, Material Certifications, NDT Certificates and storage of the letdown cooler isolation valvcs were examined. The valves have been cleaned at the site and were noted to have been sealed. No anomalies were identified during the examinations.
Section II - Prepared by L. J. Garvin, III
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Personnel Contacted s-SMUD
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R. Lawrence Mecha'ical Field Engineer
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n W. Friedrich Quality Assurance Engineer
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Bechtel Corporation R. W. Andresen Quality Assurance Engineer
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J. R. Donalson Pipe Inspector
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B. A. Boyd Welding Department Superintendent
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D. E. Gammond Weld Issue Room Attendent
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C. P. Hamilton Walder
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F. A. Pangburn Senior Field Engineer (Weld'ng)
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X-Ray Engineering R. J. Dugan Project Manager
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G.' W.- Orterry Senior Day Radiographer
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8.
Radiographic Examination of Primary System Piping Radiographic film for pipe welds were examined. Due to the diameter of the pipe and the changes in wall thickness across certain welds,
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approximately 110 radiographic films were examined. No unreported or rejectable indications were observed during the examination of the film.
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It was noted that the explanations on the radiographic reports were not sufficient to allow unassisted film interpretation. The inspector.
had to question the radiographer in order to discover which of 2 packets of film was the final accepted radior,raphs for a weld since there was only a single interpretation report for the completed weld.
The report did not identify which packet of film had been accepted.
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Both packets of film had identification markers that indicated they had been accepted by all required viewers. The inspector found that
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one of the film packets contained film that was rejectable. Another case of insufficient explanation involved the radiographic examination of welds that had large variation in wall thickness across the weld.
In these cases 3 exposures were necessary to give complete coverage of the weld. The coverage of each exposure was not apparent to the inspector. He had to question the radiographer in order to determine
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, that the coverage was complete.
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The inepector expressed his concern to the Bechtel representative about the insufficient explanation on the film reports. The Bechtel representative stated that the film and film reports would be re-examined,
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and more complete explanations would be added to the reports.
The qualifications of the radiographers and film reviewers were
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examined. All personnel were qualified and were certified as required by the ASME code.
i The radiographic procedures used for examination of the pipe welds had been qualified as required by ASME Section III and B31.7.
These procedures had been approved for use and have been used on three other
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Bechtel nuclear construction sites.
However, these procedures had not
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been approved for use on the Rancho Seco construction site. Quality Assurance Procedure number 9 requires that (1) "All Special Process procedures shall'be approved by the Quality Assurance Engineer...." and (2) " contractors submit procedures for special processes they perform
for Bechtel Vernon Project Engineering approval before use."
9.
Other Class I Piping a.
Radiographic Examination of Welds The radiographs of eight pipe welds in the makeup and purification system and four pipe welds in the main steam piping system were examined. No discontinuities that were unreported or rejectable were discovered during the examination.
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Material Certification Material certification for five pipe spools in the makeup and purification system were examined. These spools contained six different heats of steel. The material certification for these heats met the purchase order.rcquirements.
Four pipe spools in the main steam piping system were also selected for examination.
The material certifications for these spools met the purchase order requirements.
c.
Receipt Inspection Receiving reports for five makeup and purification system pipe spools and four main steam pipe spools were examined. The I
receiving reports indicated that most of the pipe had been j
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received in good condition and had been found acceptable. Two nonconforming reports had been issued for pipe that had been received with gouge marks on the beveled ends. The nonconforming reports indicated that the pipes had been repaired. These reports showed that the repairs had been accepted by both the code inspector and the field engineer.
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d.
Installation of Piping Installation records, weld electrode issue records and completed and inprogress work were examined. The installation and weld electrode issue records contained no anomalies. During the observation of work, it was noted that welders using portable electrode warmers were leaving the warmers open with electrodes extending about 1-1/2-2 inches above the top of the container.
Also noted was one warmer containing cold E7018 electrodes that was not plugged in.
These electrodes had been issued at the beginning of the shift. They were still in the building near a work area at lunch time more than 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> after 1saue. The issue record with the warmer indicated that the electrodes were to be used on pipe and pipe supports.
Both completed and partially completed welds were observed during tours of the job site. Visual examination of several
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welds was made. No rejectable indications were observed.
10.
Reactor Vessel Instrument Nozzle Repair The repair of the reactor vessel instrument nozzles had started at the time of this inspection. All instrument nozzles and flow vanes had been removed.
Installation of seven new nozzles was in progress. The
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root pass and liquid penetrant examinations had been completed.
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The records for veld electrode issue, nondestructlye examination an'd
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welder performance were examined. No anomalies were noted.
Two l
- nozzle root pass welds were visually examined. No rejectable defects
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were noted.
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