IR 05000312/1973002
| ML19309A183 | |
| Person / Time | |
|---|---|
| Site: | Rancho Seco |
| Issue date: | 04/16/1973 |
| From: | Dodds R, Garvin L, Spencer G NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V) |
| To: | |
| Shared Package | |
| ML19309A179 | List: |
| References | |
| 50-312-73-02, 50-312-73-2, NUDOCS 8003260892 | |
| Download: ML19309A183 (12) | |
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i U. S. ATCMIC ENERGY CO: MISSION
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j DIF.ECTOPATE CT KIGUIATORY OPEPATIONS
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REGION V
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RO Inspection Report No.
050-0312/73-02
' Licensee:
sacramenco Miiniefont neitiev nisertee Docket No. 0s0 0112 Sacramento. California License No.(s) CPPR-56
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Priority Facility:
Rancho Seco Unit No. 1 Category
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Location:
Clay Station, Sacramento County, Calif.
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T7Pe of Facility:
963 Mwe (2772) PWR. MU
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Type of Inspection: Routine. Unannounced Dates of Inspection:
March 15,16,19 and 20,1973 Dates of Previous Inspection:
Februarv 2 8. March 1-2.
1973 Principal Inspector:
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i R.' T. Dodds, Reactor Inspector (D' ate)
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t Accompanying Inspectors:
(4A b
/6!M L. J4 Garvin, III, Reactor
'(Da t'e)
Inspector (Construction)
(Date)
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Other Accomp'anying Personnel: None
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/ d / 73 Reviewed by:
w_.LwcA G. S. SpenNer, Chief, Reactor-Construction (Date).
and Operations Branch
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SUMMARY OF FINDINGS
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Enforcement Action
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None Licensee Action on Previously Identified Enforcement
A.
Care of E9018 Wwid Electrodes - Personnel were reinstructed to follow the procedure on the care of E9018 electrodes for the welding of T-1
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carbon steel. The procedure only allows the removal of a single electrode at, a time and requires any electrode out of the portable
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warmer for more than one-half hour to be rebaked for one hour at
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750-800* F.
(Paragraph 3)
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Care of Low Hydrogen Electrodes - A field directive has been issued to personnel, with copies posted at veld filler metal dispersal rooms,
wphasizing the requirement that the lids of the portable rod warmers
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shall.be left closed and the warmer activated in work areas.
(Paragraph 3)
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Radiographic Inspection Procedures - The procedures for radiographic examination of welding were verified to have been approved as stated in the licensee's letter dated March 5,1973.
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_ Design Changes l
None identified.
Construction Deficiencies
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A.
Steam Generator Wald Records - The documentation deficiency relating
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j to the filler metal used for the repair of welds in ela steam generators
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(B&W topical report BAW-1402) has been satisfactorily dispositioned by
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the licensee as " accept" on a nonconformance report in accordance with the QA Program.
(Pa agraph 4)
Other Significant Findings
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Current Findings A.
- Painting Practices - The licensee has instituted a satisfactory QA Program to control all painting of equipment, walls and liner place
in the reactor building.
(Paragraph 5)
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B.
Limitorque Valve Motor Operators - The licensee has inspected and
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replaced, as necessary, the limit switches in 55 of 91 Limitorque valve motor operators, types SMB-00 and SMB-000. All motor operators were being inspected regardless of whether or not they were in the suspect serial number range.
(Paragraph 6)
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C.
Valve Wall Thickness - Records reviewed showed that only nine of the j
valves for the primary system pressure boundary piping had not arrived
at the site and were all that were left to be confirmed to meet l
minimum wall thickness specifications.
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D.
Reactor Vessel Instrument Nozzles and Internal Structure Modifications -
I The instrument nozzle tubes and flow vanes have been replaced.
(Paragraph 14)
E.
Control Rod Drive Pressure Tubes - The tubes have been installed on the reactor vessel head, but the records of actual measurements of tube walls were not yet available at the site for review. However, letters of certification were available and were reviewed.
Status of Previously Reported Unresolved Items A.
Usage of Portable Electrode Warmers - The procedure now states and a field directive has been issued to personnel with copies posted at weld filler metsl dispersal rooms, emphasizing a requirement that the
i lids of portable warmers be kept closed and the warmers activated in work areas.
(Paragraph 3)
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B.
Radiographs of High Pressure Injection System IIakeup Pump - The high pressure injection system pumps have been returned to the manufacturer for impeller modifications. The nozzle in qu'estion has been raradiographed and the film reviewad and accepted by Bechtel.
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Pressurizer Safety and Electromatic Relief Valves - Additional documentation was obtained from the supplier to show that the
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pressurizer safety valves had been tested to actuate at their equivalent set pressure of 2500 psig. However, the test of the electromatic relief valve was performed at 2000 psi instead of 2300 psig as noted by the inspector. This discrepancy has been documented on a nonconformance report and was being dispositioned accordingly.
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D.
Equipment Heater Control - The QC instruction relating to the storage of electrical equipment has been modified to require verification
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Management Interviev
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The results of the inspection were discussed with Messrs. Mattimoe, McMahon,
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Stinchfield and other members of the SMUD and Bechtel staffs. The following acknowledgements and commitments were made during the discussion.
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Inspection Findings Relating to Previously Identified Items of Interest A.
Painting-Practices - The-licensee's QA program and audits of painting practices were acknowledged. Further, the records of painting performed since September 1973 substantiate adherence to the program and refute
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significant charges contained in the letter of allegations on painting
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practices.
(Paragraph 5)
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B.
The licensee's actions (completed and scheduled) on items identified during the inspection of December 18-21, 1972 were acknowledged to be satisfactory.
Licensee Commitments and Comments A.
Cleaning Solvents - The results of qualification tests and chloride analysis will be obtained for cleaning solvents as required by the i
contract specifications and/or the contract will be changed to
- acknowledge the manufacturer's certifications of conformance.
(Paragraph 8)
B.
Pipe Hangers and Supports - The procedures for pipe hangers and supports will be updated to document current practices and the dispositioning of inspection records.
(Paragraph 15)
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C.
Radiographs of Primary Pipe Welds - The radiographic report forms will be revised to include sketches and sufficient information in order to make the forms self-explanatory by April 1973.
(Paragraph 12)
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REPORT DETAILS,
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Section I - Prepared by R. T. Dodds l
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Principal Persons Contacted Sacramento Municipal Utility District (SMUD)
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J. Mattimoe 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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R. Daniels Electrical Engineer
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E. Bryan Electrical Technician
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,Bechtel Corporation (Engineering and Construction Management)
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W. Stinchfield Project Manager
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W. Chapla Project Quality Assurance Engineer
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J. Wait QA Engineer
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R. Andresen QA Engineer
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E. Conley Senior Field Engineer (Painting)
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Field Enginee'r (Systet Cleaning)
R. Franquero
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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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D. Gammon Welding Supply Issue Room Attendent
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j W. Burgess Pipe Fitter (Cleaning Room)
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M. Rosen Senior Engineer (Mechanical)
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Klaas Bros., Inc. (Painting Sub-Contractor)
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M. Miquelon QA Supervisor
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2.
Status of Construction
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The status of construction was reviewed with the licensee. The percent i
of construction completed was estimated to be 85% based upon manpower
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hours expended compared to predicted manpower hours. Only 700-1000
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i closure welds remained to be completed in the several piping systems.
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The current schedule of significant target dates was as follows:*
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- RO:V estimates construction at least two weeks behind schedule because installation of reactor vessel internals v,as two weeks behind schedule (critical path schedule ' item).
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Cold Hydrocest August 1973 Containment Leakage Rate Test Septcaber 1973
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Start Hot Functional Testing September 1973
Initial Fuel Loading December.1973
Initial 100% Power March-April 1974
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Commercial Operation May 1974
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3.
Control of Welding Electrodes
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QC Instruction No. 301 G was modified effective February 22, 1973 to
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require "... storage of welding filler metal shall be under conditions
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as outlined in the AWS : specification applicable to the filler metal
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as purchased and/or the Bechtel Welding Standards." It was further noted that the procedure for the control of E9018 electrodes for the
'j welding of T-1 steel specifically states that (1) "... electrodes shall be used within 30 minutes after removal from a holding oven. A small quantity of electrodes... stored in a small portable holding oven...may be drawn one at a time by the welder." and (2) " Electrodes that are taken from a holding oven and exposed for times longer than the
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allowed 30 minutes shall be rebaked..."
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Discussion with attendants at the two filler metal issue rooms disclosed that welders were informed personally and by a field
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directive of the importance of controlling the coated electrodes. The
directive dated February 12, 1973, requires "... portable rod warmers when moved from the rod room are immediately plugged into a power
source upon arrival at their destination. In addition, the portable
rod warmer lids shall be closed at all times except for the removal
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L of weld rod..."
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4.
Steam Generator Filler Metal Documentation
,The incomplete documentation of the weld filler metal used in the fabrication and repairs of the steam generators described in Report i
BAW-1402 dated January 1973 (transmitted by licenses with letter datad
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February 16,1973) was verified to have been dispositioned as " accept"
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on a nonconforming report in accordance with the licensee's QA program.
The deficiency was accepted following metallurgical engineering
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evaluation and approval by (1) the Engineering Review Board, (2)
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l 3echtel, Materials and Fabrication Quality Control Services, (3)
State of California Code Inspector, and -(4) Bechtel and SMUD Project Engineers.
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Acceptance of the documentation deficiency was based on the following:
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Chemical properties test had been run on all the repair weld a.
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rod as noted for the rod heat numbers in the B&W Report (BAW-1402).
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Chemical properties were. essentially the same as other acceptable i
material of the same msnufacture.
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The use of the carbon equivalent for extrapolation of the data to c.
the steam generator vessels was a logical approach and indicates that if these filler metals had been tested, the results would have been acceptable.
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In conclusion, the responsible parties found that the explanation and data presented in the report (BAW-1402) provides sufficient technical justification to permit acceptance of the welds in question.
5.
Painting Practices
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The QA program for the painting of equipment and the liner inside the
containment vessel was examined. Specific emphasis was placed on l
reviewing the proportioning of catalyst, preparation of painting surfaces and application of undercoat. The licensee suspended painting j
j of surfaces inside the containment building about one year ago pending the results of testing of paints to post accident environmental conditions.
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Areas and equipment in areas where the painting would not withstand
DBA conditions were being identified, and rework was being requested.
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A QA program was established and implemented in September 1972 for.all
Class I components and the equipment and liner plate inside the containment
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vessel. Records examined of painting activities since September 1972 included the following:
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Daily Field Preparation and Paint Application (Reactor Building a.
Dome Area).
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b.
Procedure Compliance Acceptance Records (WPI-4-2, Vacuum Blasting i
and WPI-5-2, Painting).
CIDR-C36.8-1 Rev. 2 (Construction Inspection Data Report - Reactor
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c.
i Building Liner Plate).
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Elcometer calibration procedure and daily test results.
Coating Material Batch Records (all records).
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Reactor Building Paint Coating Directory.
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Manufacturer's Certifications for' Paint Lot (laboratory test reports).
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Bechtel QA Audits (Feb[ua.ry 5, 1973 and March 7, 1973*).
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The only painting accepted to date inside the containment building was
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the liner dome and the now sealed liner construction opening. The (
Bechtel inspector used an E1cometer (Cardner Laboratory, Inc.) that had been calibrated with a 5 mil standard film to' check the coating on the liner plate. The average epoxy paint thickness was about 7 mils (minimum specified - 6 mils). Spot checks were al'so made by the inspector's escort of other liner plate, equipment panels and circulating air ducts. Several areas that obviously needed rework were noted. None of this work had yet been presented by the painting contractor for acceptance by Bechtel construction and/or management.
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During the tour of the paint mixing and storage facility, it was observed that mixing instructions had been placed above the agitating machines s
for the mixing of partial as well as full batches of epoxy paint. Epo,xy pigment and catalyst in storage were noted to contain receiving
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inspection acceptance tags. The cleaning of painting equipment was
^l also observed and discussed with the attendants.
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i No significant deficiencies were identified during the examination of the painting QA progrcm and records.
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6.
Limitorque Valve Motor Operators
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Replacement of suspect Jimit switches in limitorque valve motor operators,
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l Models SMB-00 and 000, was reviewed with SMUD field engineers. The licensee has identified all of the suspect limitorque valves and has inspected and replaced the limit switches on all valves at the site.
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Still to be inspected were 36 motor operators that vers not yet on site. Of the 55 motor operators inspected to date, 21 had suspect
limit switches. A good switch can easily be identified by a special
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notch that has been cut in the switch tensioning dial and by red paint
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on the end of the. cam shaft and the retaining nut, a QC practice that was established after the discovery of the problem.~ The remaining motor
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- The first of a series of weekly audits promised by the license 5,
during the inspection of March 1-2, 1973, to examine the substance of
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quality-related items in a letter received by the AEC alleging poor
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painting practices at Rancho Seco.
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operators will be inspected and switches replaced when received at the site according to the licensee.
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Equipment Heater Control a
QCINo.,30,RevisionG,approhed, February 22, 1973, entitled " Storage </
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Inspection Requirements for hiectrical Equipment" now requires a weekly '
documented check verifying 'that the ' equipment heaters were energized..
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i The primary coolant pump motors were observed to be" stored in< side a sheltered building, and the heaters were verified to be on and operating.
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Cleaning of Piping Systems, Valves and Components 9[!
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Two general QCI's have been issued for " Clean Rooms and Controlled
Areas" and "On-Site Cleanliness Control During Construction and -
Installation of NSS Components and Auxiliary Building." These procedures
were examined and were noted to include the following requirements:
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Specifications for cleaning agents.
(Restrictions on type of solvents prohibits free sulphur, chlorides and other halides.)
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Freedom from contaminants.
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Temperature requirements, d.
Evaluation of cleanliness (CIDR No. 853-1, Field Piping System).
Acceptance Records (Drawings, Flush Record Card, Cleaning Record,
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Cleaning Record Log, Cleaning Rework Clearance Tag Log, Cleaning l
Rework Record, and Inspection Request Form).
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Material certification for cleaning agents - specification requires,
"In each lot of material, the Contractor shall furnish a test report to Management Inspection from his suppliers fa'cilities or
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a commercial laboratory, showing individual and' average resu.lts of all the qualification test's r6ad chloride limits."
The inspection of this area included (1) the review of the above procedures, (2) erm=4 nation of the records relating to cleaning and cleanliness control of portions of the reactor cleanup system, '(3) tour of valve cleaning facility, and (4) er==4ning cleanliness control of compo'nents and equipment during tours of the facility.
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The only anomaly noted with the requirements of the program was the certification for the Freon "TF" being used to clean valves and other
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components. The licensee had a certification from E.I. duPont stating that the Freon "TF" met the requirements of Cert. MIL 81302B (limits i
. free chlorides to 5 0.1 ppm) but did not show actual laboratory test results. These will be obtained according to the licensee.
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Calibration of Construction Test Equipment
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The program for the calibration of construction test equipment was
reviewed with Bechtel Construction. The " Equipment Calibration Control Log" contains a listing of all test equipment, including calibration
dates and required certifications. The following calibration and certification records for the past year were examined.
a.
Torque wrenches - wrenches were returned to individual manufacturers for calibration every six months.
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b.
Pressure gauges - examined records for seven gauges and determined that they had been calibrated quarterly as scheduled.
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Vacuum gauges - only four. All were being calibrated quarterly as scheduled.
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Deadweight. Tester - calibrated once per year. Last calibrated on March 12, 1973 by Teletek Enterprises.
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Section II - Prepared by L. J. Carvin, III
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10.
Persons Contacted:
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Bechtel Corporation
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B. Sniath Boilermaker
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T. J. Sauerbrun Inspector
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.H. Hayes Receiving Inspector
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B. Boyd
' Welding Department Superintendent
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R. W. Andresen QA Engineer
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J. Wait QA Engineer
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J. R. Donalson Pipe Inspector
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B. Regan Pipe Superintendent
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i R. Kimbal Field Engineer
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M. Rosen Senior Mechanical Engineer
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State of California
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C. E. Pambutau
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Inspector # 883-SMUD QA Engineer W. Friedrich
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11.
Radiographs of Primary Pipe Welds
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The licensee had made a commitment to revise radiographic report forms
for the primary pipe welds to include sketches and more information in order to uake the forms self-explanatory. These actions had not been i
completed at the time of this inspection. The licensee stated that the revision to the report forms would be complete in April 1973.
12.
Reactor Vessel Internals The reactor internals arrived on site on February 23, 1973. Due to a i
strike, they were not moved into the containment building as planned until March 10, 1973. The internals were still in their shipping packages. They will not be unpacked unti.'. clean areas are established.
External shipping package damage inspection has been completed. Bechtel source inspection had released the internals prior to shipping.
I Construction Inspection Data Report (CIDR) Number N 101-2 is to be used for the installation of the internals. This document has been approved by Bechtel, B&W and SMUD. The CIDR referenced several quality control
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instructions. These instructions included clean room preparation and use, handling of internals, the assembly and installation of internals
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and the procedure for nonconformances. The CIDR also indicated inspection points for Bechtel and B&W inspectors. No deficiencies were noted in the examination of the CIDR for the installation of the internals.
I The cranes to be used to handle the internals had been tested to 125%
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of capacity in July 1971. Since that time, these cranes had been used several times. No deficiencies had been noted during their use.
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13.
Reactor Vessel Instrument Nozzle Repair The records for the repair of the reactor vessel instrument nozzles
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and flow vanes were reviewed. The repair has been completed. The state code inspector witnessed certain areas of the repair and had i
signed the' code papers. The records for the repair included NDT and
l weld procedures used, welder qualification papers, NDT inspector's qualifications, NDT reports, mill test reports for the replaced nozzles
and weld electrodes-used, weld electrode issue records, repair procedures
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i used and field welding checklists. No anomalies were noted.
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14. Pipe Hangers l
The quality assurance / control procedures for-the installation of pipe
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i hangers were examined. QCI 303B " Installation Inspection of Process Piping, Supports and Components" defines the inspection requirements for the contractor's inspectors. This instruction includes Form PFE-009A that verifies certain inspection points including type, location and adjustment of hanger.
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During the examination of th2 program, it was noted that Form PFE-009A had been revised but the QCI had not been updated. The requirements of the new form included similar items in addition to increased frequency of inspection documentation.
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The QCI did not specify the final. location of the completed inspection
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form. After some effort, the file of completed forms was located in the hands of the startup coordinator. No provision for quality assurance review or filing of these forms had been made. The inspector expressed
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his concern about these-records. The licensee said that the QCI would be
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revised to include (1) the new form, (2) a requirement for the frequency of form use, and (3) the final filing location of the form.
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