IR 05000320/1977006
| ML19220B642 | |
| Person / Time | |
|---|---|
| Site: | Crane  |
| Issue date: | 03/08/1977 |
| From: | Robert Carlson, Narrow L, Sanders W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML19220B625 | List: |
| References | |
| 50-320-77-06, 50-320-77-6, NUDOCS 7904270159 | |
| Download: ML19220B642 (14) | |
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II:I Form 12 (J 75) (Rev)
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U. S. NUCLEAR REGULATORY CCFCilSSIO i OFFICE OF INSPECTION AND DiFORCDiDif
REGION I
IE Inspection Report No:
50-320/77-06 Docket No:
50-320 Licensee:
Metropolitan Edison Company License No:
CPPR-66 Box 542 Priority:
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Reading, Pennsylvania 19603 Categcry:
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B i
Safeguards i
Group:
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Location:
Middletown, Pennsvlvar.ia (TMI-2)
Type of Licensee:
Ty)
of Inspection:
Routine, Unannounced Dates of Inspection:
February 7-10, 1977 Dates of Previous Inspection:
February 2-4, 1977 3![
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Reporting Inspector:
L. Narrow, Reactor Inspector
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DATE Accccpanying Inspectors:
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W. Sanders, Reactor Inspector
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DATE Af 6&R 3hh-7 G. Walton, Reactor Inspector DATE
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DATE Other Accompanying Ferso:.nel:
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2)
Reviewed By:
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R. W. McGaughy, Chief, Construction Projects Section
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Reactor Construction and Engineering Support Branch
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,O SUMMARY OF FINDINGS Enforcement Action
_ Infractions
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A.
77-06-01 Failure of site QA to establish inspection requirements in order to assure conformance to specifications.
(Details, Paragraph 3)
B.
77-06-02 Failure to perform nondestructive examination as required by procedures during weld repair on the main steam line.
(Details, Paragraph 4)
Licensite Action on Previously Identified Enforcement Items The following items have been resolved:
A.
Failure to properly inspect safety related orifice plates.
(Details, Paragraph 5)
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B.
Failure to perform audits of document control and to mainta'-
document control.
(Details Paragraph 6)
Design Changes None.
, Unusual Occurrences None.
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_0ther Signi#icant Findings A.
Current Findings 1.
Unresolved Items 77-06-03 Discrepancies between information recorded in the data package for modification of the surveillance specinen holder tubes and the requirements of B&W Specification CS-3-23.
(Details. Paragraph 7)
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2.
Acceptable :tems_
Cleanliness and physical protection of reactor internals.
a.
(Details, Paragraph 8)
Inservice inspection program, selected inservice inspection procedures and observation of preservice examination of a 5.
(Details, Paragraph 9)
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(Details, Weld history records of four class 1 pipe welds.
c.
Paragraph 10)
Hyd:ostatic test procedure for thc secondary s'de of the(Details, d.
steam generator and associated piping.
Previously Reported Unresolved Items B.
i The following items have been resolved:
(Details, Paragraph 12)
Modification of ASCO solenoid valves.
1.
Voids in the fuel transfer canal wall.
(Details, Paragraph 13)
2.
i (Details, Internal connections in GE Type AKD-5 switchgear.
3.
Paragraph 14)
C.
Deviations _
None.
Exit Interview _
10, 1977.
An exit interview was held at the site on February Persons Presen_t i
, General Public Utilities Service Corporat on_
R. F. Fenti QA Auditor R. W. Heward, Project Manager S. Levin, Project Engineer M. J. Stromberg, Senior Site Auditor R. L. Wayne, Construction QA Manager J. E. Wright, Site OA Manager L
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United Enoineers and Constructors J. J. Carrabba, Construction /QC Superintendent R. Dourte, Assistant Field Supervisor, QC Burns & Roe G. T. Harper, Jr., Site Project Ergineer A. 5, Dam, Project Engineer Babcock and Wilcox T. A. Skrzyoiec, Site Manager A.
Scope of Inspection
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The inspector stated that the inspection was conducted to review the status of outstanding items and QC program for the reactor
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internals and the preservice inspection program.
B.
_ Inspection Findings
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The inspector summarized the results of the inspection as listed in the Summary of Findings.
the information.
In each case the licensee _ acknowledged i
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DETAILS
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Persons Contacted General Public Utilities Service Corporation R. F. Fenti, QA Auditor W. T. Gunn, Project Site Manager S. Levin, Project Engineer P. A. Levine, QA Auditor M. J. Stromberg, Senior Site Auditor J. E. Wright, Site QA Manager R. Toole. Startup and Test Superintende1t United Engineers and Construction T. Butchkoski, Instrument Clerk R. P. Dourte Assistant Superintendent, Field QC J. Godleski, QA Engineer F. Kovalik, Office Engineer D. Lambert, QC Supervisor
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J. O'Lonner, QC Document Engineer J. Schmidt, Records Supervisor J. C. Spinck, Lead QA Engineer Gi,1bert Associates E. Reynolds, NDE Engineer purns & Roe G. T. Harper, Site Project Engineer Conam H. Munoz, NDE Inspector M. Zeisse, NDE Inspector 2.
General At a pre-inspection meeting with the licensee's representatives the inspector discussed the scope of the inspection. The licensee's representatives stated that cleaning of the secondary side of the heat exchanger and associated piping had been completed and filling (_
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of the system was in progress in preparation for the hydrostatic test.
Progress af electrical work was satisfactory and no problems were anticipated in keeping pace with the schedule for turnover of systems for testing. Two additional inspectors had been assigned to field QC.
The licensee's representatives were asked if any significant problems affecting construction, not otherwise reported, had occurred since the previous inspection and they stated that there had been none.
The inspector asked if any problems, particularly with respect to quality of the work had been observed, as a result of the reduction in tne work force in June,1976.
He was informed that no such problems had been observed.
The inspector late audited the logs of Deficiency Reports (DRs) and unsatisfactory reports for the period March through October,1976.
There were no indications of any unusual effects during this period.
i During a later discussion with the liter.see's representatives the inspector informed him of possible problems with black Lexan spools in coils for GE HFA relays.
The previous investigation of the HFA relays had shown only two w'th black Lexan spools neither of them in safety related circuits.
During a walk through inspection of the site the inspector observed that reinforcing steel had been placed in preparation for concreting the block out in the reactor building wall at elevation 305.
Pre-placement inspection for this pour had not been made and the inspector discussed with field QC personnel the methods of cleaning and inspecting the concrete surfaces prior to placing concrete.
3.
Failure of Site QA to Establish Proper Inspection Requirements The inspector was informed that site QA had reviewed all (seventy-nine) purchase orders for owner purchased services or equipment which had been placed prior to about December,1976 under Specification 2555-999. Of these orders forty-one were considered to be not within QA/QC scope (not safety related) and thirty-eight were considered to be questionable, that is, inspection requirements to be established by site QA. The thirty-eight purchase orders had been reviewed by site QA, inspection check plans had been established or been identified as not required and the equipment placed on hold as received or released when the proper documentation was made available.
The inspector audited a selected group of these purchase orders and observed that in some cases inspection check plans were not provided k_
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to assure that specification requirements had been met.
As examples:
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P.O. C-0193 to Bettis Corporation (Dynatrol) required modification a.
of two previously purchased manually operated 20-inch butterfly valves (Tag Nos. NS-V83A and B) to pneumatic cylinder operated, b.
P.O. C-0194 to Bettis Corporation (Dynatrol) required modification of two previously purchased manually operated 20-inch butterfly valves (Tag Nos. NS-V84A and 8) to electric motor operated.
The Burns and Roe (B&R) valve list and specification 2555-103 " Station Butterfly Valves" Attachment III classify these valves as Seismic Class I.
Receiving Checklist / Inspection Reports (RC/IR) dated March 11, 1976 (P.O.C-0193) and July 20,1976 (P.O.C-0194) show no documentation required, there was no evidence that inspection checklists had been
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prepared for these purchase orders and the valves had been released for construction. This is contrary to the requirements of Sp2cification 2555-103, Paragraph 3.3.1 of which states, in part, "For valves with motor or air operators... specific conside' ; tion and calculation of earthquake loading is required."
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This is in noncompliance with 10 CFR 50, Appendix B, Criterion VII, which states, in part, " Documentary evidence that material and equipment conform to the procurement requirements shall be available at the nuclear power plant site prior to installation or use of such...."
Prior to the conclusion of the inspection site QA received a ' IX from B&R stating that "By inspection of similar operated valt.s that have been analyzed and since the referenced (NS-VP3A/B, d4A/B)
valve-valve operator combinations are of sufficiently similar geometry, weight distribution and design, specific analysis is not required and the valves are seismically qualified".
This item (77-06-01) is not resolved pending review by an NRC inspector of measures taken by the licensee to preclude repetition as well as to assure that equipment procured under other purchase orders in this group have not been similiarly misclassified.
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Failure to Perform Required NDE-Weld Repair of Main Steam Line 4.
The inspector reviewed the " Weld History Record" fo These welds had been repaired after rejectable defects After defect excavation, and prior and 2-MS-800.
iiscovered by radiography.
to rewelding, the area prepared for rewelding, had not been inspected were by either a liquid penetrant or magnetic particle method to assure defect removal as required by the General Procedure for Manual Arc Welding 9WP 100N/C-5 and the USAS B31.7 Code.
The welding proct'ure 9WP-100N/C-6 paragraph 8.3 states; Prior to l
welding, the surfa es to be welded shall be cleaned to bright c ean The cavity shall be examined by the magnetic particle or metal.
liquid penetrant method to assure complete removal of defects.
paragraph B-1-150 states, The applicable section of USAS B31.7,1969," Welds shouing Paragraph 2-724.7(b) states, "the defect is in Paragraph 2-724.7.
removed and the area prepared for repair is examined by either magnetic particle or liquid penetrant examination..."
The inspector r.9ted that the cavities had been inspected by a radio-graphic method prior to rewelding which gives some assurance those
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However, defects originally detected by radiography were removed.
the intent of the magnetic particle or liquid penetrant test is to assure smaller defects, i.e. those below the thresh ment is made.
The failure to perform the proper NDE of weld metal cavities as state in the applicable welding procedure is contrary to 10 CFR, Part 50, Appendix B, Criterion V which states, in part, " Activities affecting quality shall be prescribed by... procedures..
Inspection of Safety Related Orifice Plates 5.
Failure to properly inspect orifice plates for use in safety related
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(Inspection Report systems had been identified as a noncompliance.The inspector 50-320/76-08).
plates which had been supplied by the vendor, remaining orifice plates.
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The inspector also examined procedures TMINS-4 " Procurement of owner furnished equipment, Rev. 3, dated October 25, 1976.
Paragraph 19
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of this procedure states, "The requisition (for owner furnished equipment) shall contain wording to identify those itens being
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procured which are under QA/QC scope."
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The inspector was informed by the licensee's representative that in order to prevent recurrence of this problem, the purchase orders written against specification 2555-999 had been identified by the GPUSC project office to site QA for appropriate action.
All future purchase orders for owner furnished equipment will identify items under QA/QC sccpe in accordance with the requirements of Procedure TNINS-4.
This item is resolved.
6.
Failure to Control Specification and Procedure Chances Failure to maintain control of specification and procedure changes and to perform audits of document control had been identified as a non-compliance.
(Inspection Report 50-320/76-19)
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The inspector reviewed the licensee's corrective actions as shown
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below:
Reports of audits by QC of all engineering specifications, con-a.
struction procedures, welding procedures and QC procedures issued to and controlled by Electrical, Mechanical, Structural, Welding /
Piping Engineering, Instrumentation Receiving, Quality Control and Startup Departments.
Unsatisfactory conditions where identified on inspection reports. All such conditions had been corrected and were so reported in reports of subsequent audits.
b.
Reports of periodic audits of all departments by QC at approximately weekly intervals.
A random selection of documents were selected l
for examination during these audits.
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I T.emorandum dated December 9,1976, directing that drawing control c.
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personnel be re-instructed in the requirements of GCP-1-2 on drawing, specification and document control and notes of a meeting
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for this purpose on December 14, 1976 with personnel from each of the above departttnts in attendance.
d.
Records of training classes conducted by QC lead engineers in each discipline on the audit requirements of GCP-1-2 during the period December 8,1976 to January 10, 1977.
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The inspector also audited control by the Instrumentation Department of a random selection of specifications and procedures with ro dis-crepancies identified.
This item (76-19-01) is resolved.
7.
Discrepancies Between Data packaoe and Specification - Modification of Surveillance 5cecimen Holder Tubes An inspection was made to review the quality records relative to the reactor core internals and determine if the field activities and work accomplishments are consistent with applicable requirements.
The final data package for modification of the surveillance specimen holder tubes was selected for a record review to the requirements of equipment specification B&W CS-3-23.
The review revealed discrepancies in the following categories.
a.
Cobalt limit exceeded b.
Cobalt not reported c.
Weld wire ferrite value not given (
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No evidence of heat treating as required e.
No evidence o f Ultrasonic Testing of material as required
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The above is a listing of examples which are not in accordance with B&W W CS-3-23 and do not represent a complete review.
The review was aborted after the inspector was informed by the site QA manager that the data package had not been finally accepted by them. This item is unresolved pending the licensee's final review of the data package.
8.
Cleanliness and physical protection of Reactor Internals A visual inspection was made of the Reactor Vessel internals to inspec t the conditions of storage for physical protection of the equipment and that the cleanliness protection was being maintained and controlled over the interim period awaiting final inspection.
TFc inspector noted that the internals assembly was located in the refueling pit and adequately covered with polythylene with the open edges taped together to prevent the entry of fine dust particles.
The procedure requires a final cleaning just prior to final installation.
A review of the quality related records relative to the handling and maintenance of cleanliness was made.
No discrepancies were identified.
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Preservice Inspection Prooram The inspector selected three (3) ultrasonic examination procedures for review. These were:
2305-El-B, Rev.1, Manual Ultrasonic Inspection of CRDM
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Pressure Housing Welds 2305-El-D, Manual Ultrasonic Inspection of Reactor Coolant
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and Associated System Pipe Welds 2305-El-L, Ultrasonic Inspection of Reactor Flange to Vessel
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Weld and Flange Ligaments The inspector reviewed the above listed procedures for technical This included but was not limited to the considerations adequacy.
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shown below.
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(1) The type of apparatus, including frequency range, is specified (2) The extent of coverage, beam angles, and size of transducers (
are specified (3) Calibration is acccmplished on approximate side drilled holes and scanning sensitivity is defined and is in accordance with the ASME Code (4) Evaluation, recording, and acceptance standards for flaw
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indications are specified and consistent with the applicable
'a.ble ASME Code The taspector observed the ultrasonic examination of the reactor pressure vessel upper shell to flange weld and the ligament area on the reactor vessel flange. This examination was conducted in accordance with the procedural requirements. No reco-dable in-dications were detected.
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The inspector reviewed the examination results documented for the following listed welds:
Weld RC 111 and RC 112 Clasr 1, 28" line, from Steam Generator lA
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to RC Pump 1A Weld MU-084 and MU-085, MU-086, MU-088, Class 1, 2h-inch line
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Make-Up Piping Weld RC 001 and RC 002, RC 003L, RC 004L, RC 006 RC 007, RC 008
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RC 016B, RC 017L, RC 018L, RC 019. RC 020, Cl
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from Steam Generator 18 to reactor vessel Indications were recorded in a:cordance with procedure requirements
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No discrepancies were identified by the inspector.
10. Class I Pipe Welding Records The inspector selected four (4) welds on the reactor coolant pressure boundary piping for review.
i Welds selected were on the 10 inch pressurizer surge line, Class
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1, welds WJ-3-1, WJ-3-2, WJ-3-3 and WJ 60-1.
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The record review was conducted to ascertain whether the re l
in conformance with established procedures and whether the records j
reflect work accomplishment consistent with applicable requirements
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in the following areas:
Inspection records covering visual and nondestructive inspection,
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including repair of rejectable defects Welder identification and qualification
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Personnel Qu&lification records
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Weld history records, including preheat, interpass and post weld
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heat treatment, where applicable Filler materials used
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No discrepancies were identified.
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11. Hydrostatic Test Procedure - Steam Generator The inspector reviewed the hydrostatic test procedure, Number TP 200/9 for inspection of the Toce Th ough Steam Generators, secondary side and their integral piping back to the turbine stop valves.
The sequence for performing the hydrostatic test is to raise the pressure to 1318 psig at +1400F, hold for ;? minutes and inspect, then lower pressure to 1050 (design pressure, psig and inspect for leakage.
Three pressure gauges would be used, with a 0-2000 psig + 5 psig.
No discrepancies were identified.
12. Modification of ASCO Solenoid Valve
.lletin 75-03 had identified failure of ASCO Series 8300 and 8302 y.ves to operate properly due to incorrect lower disc stem clearance and/or improper lever to lower disc stem clearance.
The licensee had previously identified one valve of this series (Tag No. WDG-V188) as having been furni.;hed by Velon Engineering Company (Velon) for this plant. The inspector examined correspondence between Velon and B&R concerning modification of this valve including a letter dated December 23, 1976 from Velon to B&R stating that ASCO had informed Velon that solenoid valve No. 830081-RV Tag ho, WDG-V188 had been modified in accordance with IE Bulletin 75-03.
This item is resolved.
13. Voids in Fur' Transfer Canal Wall By letter dated July 30, 1976 the licensee had reported as a significant deficiency in accordance with 10 CFR 50.55(e) the finding of voids in the north wall of the fuel transfer canal (reactor building secondary shield wall). The voids were located in a section of the wall which had been blocked out during the initial pour to permit installation of fuel transfer tubes. Since a similar condition had been identified at the blockouts for fuel transfer tubes in the south wall of the fuel
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handling building, the licensee had stated that an investigation of all mator blockouts in class I buildings would be conducted.
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The inspector examined the following documents:
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Engineering Change Memorandum (ECM) No. 3859 which a.
attaches a procedure for repair of the voids entitled
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" Repair Procedures for Concrete Voids Located Above the East and West Fuel Transfer Tubes in the Reactor Building
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Secondary Shield Wall" b.
Deviation Report (D'.) No. 0605 which provides a description of the deviation, requires an investigation of all poured blockouts, releases excavation of the voids after determination of the extent of the voids. The disposition had been verified and the DR had been signed by the DRB and Qr Memorandum dated February 8,1977; subject DR-0605 stating that c.
investigation of the poured blockouts had revealed that all blothouts, other than those for the fuel transfer tubes have slopes to the exterior faces of the walls to permit venting during placement of concrete in thc olockout
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This item is resolved.
14. Internal Connections - GE AKD-5 Switchaear By letter dated August 16, 1976 the licensee had reported as a significant deficiency in accordance with 10 CFR 50.55(e), the presence of defective butt splices in internal connections of GE AKD-5 switchgear.
The inspector examined the following documents:
Letters dated July 1,1976 and July 14, 1976 from General a.
Electric Company (GE) to the licensee offering to make available a field engineer to inspect these cabinets and document the inspection findings b.
GE letter dated July 20, 1976 which confirms that " pull tests" were made on all. splices in the AKD-5 switchgear. Nine hundred and ninety-two splices were tested; seven splices were found to be loose, replaced and retested.
One sub-station No. 2-2DC was not available for testing at that time.
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Report of above tests performed showing sut _ ations tested anc identification of defective splices d.
QC Inspection Report No. P-3267 of pull tests, witnessed and splices inspected in Unit Sub-Station No. 2-2DC.
One defective splice was identified and repaired.
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Memorandum dated December 16, 1976 which forwarded " splice inspection" sheet for unit sub-station No. 2-2DC and states that inspection of unit sub-stations per GE letter dated July 1,1976 had been completed.
This item is resolved.
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