IR 05000322/1980008
| ML19327A266 | |
| Person / Time | |
|---|---|
| Site: | Shoreham File:Long Island Lighting Company icon.png |
| Issue date: | 06/18/1980 |
| From: | Durr J, Mcgaughy R, Lester Tripp NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML19327A265 | List: |
| References | |
| 50-322-80-08, 50-322-80-8, NUDOCS 8008050093 | |
| Download: ML19327A266 (10) | |
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U. S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT
REGION I
Report No.
50-322/80-08 Docket No.
50-322 License No.
CPPR-95 Priority Category B
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Licensee:
Long Island Lighting Company 175 East Old Country Road Hicksville, New York 11801 Facility Name:
Shoreham Nuclear Power Station, Unit No. 1 Inspection At:
Shoreham, New York Inspection Condu d:
May 19-22, 1980 Ob A
Inspectors:
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E. Nar ow, Reactor Inspector
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/?b AAW 110 V Y. l$$0 R.p.Paolino,ReactorInspector date 0,
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~G. A. Walton, R~eactor Inspector
date si 4 4 2 6/9f9n Jt P. Dur, Reactor Inspector
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bf/3ff0 f.. E. Tripp, Chief, Engineering Support
'date Section No. 1, C&ES Branch Approved by: N/1/ [//bw
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"R'.W.McGauggyghief,ProjectsSection, date
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RC&ES Branch Inspection Summary:
Inspection on May 19-22, 1980 (Report No. 50-322/80-08)
Areas Inspected:
Routine, announced inspection by four regional based inspectors and a regional based section chief of work activities and quality verification records of instrument cable and components; and the status of outstanding items.
The inspection involved 67 inspector-hours on site.
Results:
No' items of noncompliance were identified.
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Region I Form 167
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(August 1979)
80080500' 3
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DETAILS 1.
Persons Contacted Long Island Lighting Company R. DiRoche, QA Specialist
- T. F. Gerecke, Engineering QA Manager J. M. Kelly, Field QA Manager T. Koch, QA Engineer J. McCarthy, Assistant Instrument Supervisor
- M. H. Milligan, Project Engineer
- W. J. Museler, Construction Manager (Unico)
E. J. Nicholas, Section Supervisor, Field QA M. G. Smith, QA Engineer Stone and Webster Engineering (S&W)
- T. T. Arrington, Superintendent Field QC
- R. W. Condike, QA Engineer
- J. Hassett, Senior QC Inspector J. A. Smith, Construction Manager R. Perra, Chief Inspection Supervisor, FQL W. C. Taylor, Assistant Superintendent, FQC Cou'rter & Company W. Bell, Training Coordinator, SQA J. Makris, Administration Supervisor
- Denotes persons in attendance at the exit interview.
The inspector also in.terviewed other licensee and contractor personnel during the inspection.
2.
Plant Tour The inspector observed work activities in progress, c pleted work and con-struction status in several areas. Work items were examined for obvious defects and for noncompliance with regulatory requirements and licensee commitments.
Specific activities and completed work observed by the inspec-tor included installation of pipe supports, cable terminations, general housekeeping, rework of the transfer canal plugs and condition of the con-trol rod drive control mechanisms.
No items of noncompliance were identified.
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3.
Qualifications of QC Personnel The inspector reviewed personnel files of a random selection (approximately 20%) of S&W FQC and Courter SQA personnel.
The records were examined to determine whether the education, experience and qualifications of QC per-sonnel were adequate for their assigned duties and conformed to the require-ments of ANSI N45.2.6.
The inspector also examined eye examination records and certificates of qualification to determine whether they were complete, current and acceptable for the person's assigned duties.
The inspector noted that two of the courter SQA inspectors'had
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been certified as Level II QC inspectors. Their records did not show any experience as QC' inspectors although they had been qualified for and had previously worked as NDE inspectors. The inspector tiscussed the work ass'ignments and prior experience of these men with Courter SQA supervisory personnel and was informed that their prior experience did include QC inspection.
Their assignments since having been qualified a Level II inspectors, in November 1979, had been primarily on "line walk" inspection of piping.
This item is unresolved pending review by en NRC inspector of additional information to be obtained concerning the men's previous experience as well as a similar review of the personnel records of the other QC inspectors.
(50-322/80-08-01)
4.
Welding Quality Trends The inspector discussed welding quality trends with representatives of the licensee and examined the results of the licensees analyses of these trends.
The number of noncompliance identified increased during 1978.
This appears to be a normal occurrence since there was a similar increase in the number of welders during 1978.
The number of noncompliances decreased sharply during 1979, while the number of welders leveled off and then decreased slightly indicating a probable learning curve effect.
The inspector had no further questions concerning this matter.
5.
Instrument Components / Systems - Work Observations The inspector examined work performance, partially completed work and com-pleted work pertaining to safety-related instruments to determine whether the requirements of applicable specifications, work procedures drawings and instructions have been met in areas relating to material requirements, iden-
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tification, installation, personnel qualification and testing.
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For this determination the inspector examined the following items associated with the suppression pool level, pressure and temperature instrument installation.
Pressure Transmitter Nos. 1Z93*PT-003A, 1Z93*PT-0038,
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1Z93*PT-004A and 1Z93*PT-004B
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Level Transmitter No IZS3*LT-0018
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Temperature Element Nos. 1Z93*TE-111X, and 1Z93 TE-112W
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Material Specification SH1-406
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Installation Specification for Instruments (SH1-343) and
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Electrical (SH1-159)
Line Nos. 1Z93 K1001-ICN9-2, 1Z93 K1004-ICN9-2, 1Z93 K1007-ICN9-2
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Reference drawing Nos. FK-1F, FM-250, FK-1C, FV-7A and FK-1A, 1B,
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4C, 4D
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Engineering Design Change Request Nos. F-13110, F-13784 and
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P-3416 Weld Specification No. 081-AA
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Purchase Order Nos. 310073, 310869 and 310890
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Quality Assurance Directives Nos. QAD-9.31, QAD-9.32
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Quality Assurance Procedure Nos. QAP-10.5, Revision 1 and
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QAP-8.3, Revision 1
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Socket Weld Instrument Fittings per 11600.02-7.83-2A Instrument Valves per 11600.02-7.83-4A
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Flex Metal Hose Assembly per drawing 76229 revision C
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No items of noncompliances were identified.
6.
Instrument Components / Systems - Quality Record Review The inspector reviewed pertinent work and quality records for selected instrument components of the suppression pool level, pressure and tempera-ture instrument installation to determine whether records met established procedures and whether the records reflect work accomplishments consistent with NRC requirements and licensee commitments noted in SAR chapter Nos. 1, 3, 6, 7, 8 and 17 (including pertinent codes and standards referenced therein) for the followin receipt inspection, materials certifi-cation, nonconformances, g areas: installation and testing.
Documents examined for this determination include:
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Material receiving Report Nos. MRR-79-07642, MRR-78-10962 and
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MRR-79-08598
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Material Certifications
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Welder qualification records for the following welders identified by
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code:
LE, ABN, AAN and PS Purchase Order Nos. 310870 and 310869
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Quality Control Instruction No. FSI-F9.1-078
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Weld' Material Requisition and Control Fora Nos. 16985, 16886, 16922,
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16923 and 16924
' Field Weld sheets for 1Z93* K1001, K1004, K1007
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The inspector determined that the above documents were legible, complete and readily retrieveable.
No items of noncompliance were identified.
7.
Instrument Cables / Terminations - Quality Record Review The inspector reviewed pertinent work and quality records for safety related cables associated with the suppression pool instrumentation noted above to determine whether records meet established procedures and accomplishments consistent with NRC requirements and licensee commitments noted in chapters 1, 3, 6, 7, 8 and 17 (including codes and standards referenced therein) for the following areas:
size, type, terminations, routing, bend radius, pull ten-sion, inspections, nonconformances, legibility and retrievability of records.
For this determination the inspector examined the following:
Cable pull tickets for cable nos. 1Z93BBX030, 1Z93BBX031, 1Z93BBX032,
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1Z93CSX006 and 1Z93C5X005 Megger and continuity test records for cables noted abcve
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Quality Control Inspection Reports for the above listed cable numbers.
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The reports provide inspection verification of routing, separation, cleanliness, support, wire size, lug size / type, bend radius, termina-tion and tool identification Engineer Orsign Change Requests Nos. F-12987 and F-27144
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The records appeared complete and current, were legible and easily retrieveable.
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No items of noncompliance were identified.
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8.
Review of Nonroutine Events Reported by the Licensee Inaccordancewith10CFR50.55(e),onDecember 11, 1978 the licensee sub-mitted a report of a deficiency in welding of Schedule 160 small bore soc-ket weld fittings.
The fillet welds joining the fittings to the pipe did not meet the requirements of ASME III for fillet leg length.
The inspector reviewed the licensees dispositions of this deficiency.
The corrective action included a 100 percent reinspection, repair where required, liquid penetrant and visual examination of the repair.
The inspector reviewed i.onconformance report.: 371, A, 8, C, D, and E for systems 821, Ell, E41, E51 and E21.
The systems rauired several repiirs, for example, system 821 contained a total of 84 sch. 160 socket /fillat welds and 27 required repair.
The license has performed all required inspections and repairs, where required.
This item remains unresolved pending the inspectors review of the licensee's corrective actions taken to prevent recurrence of such deficiencies.
9.
Review of Deficiencies Reported by Vendors By letter dated Septembe'r 20, 1979 Transamerica DeLaval had reported a deficiency which could potentially have caused failure of the drive shaft for the engine driven jacket water pump of the standby diesel generator.
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The inspector examined Returned Material Report RMR 79-1063 showing that the three Jumps had been sent back to the vendor for rework; and N&D Report No. 2766 slowing that the pumps had been returned to the site after repair but without evidence of PQC inspections.
The N&D Report was closed out by theEquipmentSpecialist,ProjectEngineerandQAonthebasesofdocumen-tation furnished by the vendor.
The inspector had no further questions concerning this item.
10.
Licensee Action on Previous Inspection Findings (Closed) Noncompliance (78-02-01):
Failure to control weld materials in accordance with procedures.
The licensee's corrective actions were reviewed during inspections 78-06 and 78-12.
This item was closed during the latter inspection based on the licensee's actions and observations of conditions on site.
This item was reopened during inspection 79-06 due to observation of loose weld rod by the inspector during a "line walk" inspection.
Inade-quate control of weld rod was again observed by the inspector during Inspec-tion 79-07.
At that time the licensee instituted-more stringent controls of weld materials including a requirement that all used and unused materials
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be returned to the weld rod issue station and noted on the requisition slip.
Discrepancies between the amounts issued and returned if repeated were subject to withdrawal of the welders qualification.
Since May, 1979 when the new controls had been instituted, the inspector had checked for loose or uncontrolled weld rod when performing plant tours during inspections.
No loose weld rod had been identified during those inspections.
The inspector' discussed the program for control of weld materials with the licensees representatives and reviewed Unico and Field QC memoranda and IOC's establishing the program and instructing Field QC to perform surveil-lance inspections for loose weld rod, including daily inspections of Cate-gory I areas.
The inspector also reviewed QC inspectors' reports and DCO's for the past three months to ascertain the effectiveness of the program.
The inspector noted that inspections occasionally identified some loose weld rod but that overall the program was effective and that one welder had been disciplined (loss of qualifications) in June,1979 for a discre-pancy between number of weld rod issued and returned.
The inspector had no further questions concerning this item.
(Closed) Unresolved Item (78-09-01):
Calibration hole size larger in dia-meter than permitted by ASME Section III.
The inspector reviewed preser-vice inspection procedure No. 80 A 475.
The licensee's inspection contrac-tor has revised the procedure to stipulate the correct hole size, i.e., a 1/8 inch side drilled hole.
The original procedure required a 3/16 inch side drilled hole.
In addition to the procedure change the licensee has generated drawing 80C0413 which reflects the proper hole s,ize.
The inspector had no further question regarding this matter.
(Closed) Noncompliance (78-16-01):
Nonc'onformance of Reactor Building Crane Welding to specifications.
Partially completed corrective actions had been reviowed during inspection 79-02.
The inspector examined the following documents:
N&D Report No. 1925 which provided the disposition and methoo of
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repair or rework of nonconforming load bearing welds.
The disposi-tion had been approved by Engineering and QA; and weld repair was complete.
The vendor's (Whiting corporation) weld evaluation report and letter
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dated November 21, 1979 which identified the type and amount of rework to be performed and recommended that a Whiting representative be pre-sent during the rework
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QC Inspection Reports dated May 1 and 5, 1980 for final inspection of
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the weld rework MT Inspection Report for inspection of grinding to remove crack prior
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to weld repair - Whiting Drawing No. U-75447-4 The inspector also observed the conditions of a random sample of repaired welds.
The inspector had no further questions concerning this item.
(Closed) Unresolved Item (78-17-01):
The preservice inspection program is beina conducted to satisfy the requirements of 10 CFR 50.55a(g) and the 1971' Edition of the ASME B&pV Code,Section XI including the Summer 1972 Addenda.
A previous inspection had disclosed unresolved items regarding this program.
The inspector reviewed the licensee's action on these items:
Table A-1, Appendix A, Category A, omitted the requirement for e::ami-
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nation of any repairs to base material in the core belt region.
The licensee's inspection contractor has revised the program plan 80A0482 Revision 2 to include a requirement to examine all repairs in the core belt region which exceed 10 percent in depth.
Table A-1, Appendix A, Category E-1 must be revised to include volu-
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metric examinations of the control rod housing pressure boundary welds.
The licensee's inspection contractor revised the program to include the fabrication inspection records as part of the preservice exami-nations.
Appendix E, Figure 13-1 must be revised to inc:ude a hydro-visual
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examination of the control rod drive partial penatration welds.
.The licensee's inspection contractor has revised tre program plan 80A0482 Revision 2 to include a visual examination during the system hydrostatic test.
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Appendix E, Figure 05-01 must be revised to reflect actual weld loca-
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tion and identification.
For example, weld 31-NS005-BW38 shown on the schematic does not exist on the Loop A line.
Also, during the preservice examinations, the licensee discovered an additional weld between welds B31-NS005-BWO2 and RS-1-A2-B which appears to be a shop weld.
This weld was not shown on Figure 05-01.
The licensee's inspection contractor has revised the isometric drawings to reflect the actual as-built condition.
In addition, before the preservice examinations are performed a line walk-down is performed to identify any discrepancies in the isometric drawing.
The inspection contractor also receives the fabrication drawings which reflects field changes for addition into the preservice program.
The inspector has no further questions regarding the above four items and this matter is considered to be resolved.
(Closed) Unresolved Item (78-17-02):
Potential interference of name plate with complete inservice inspection of weld.
The licensee has taken correc-tive action regarding this item by removing the nameplate from the vicinity of the weld.
In addition the licensee's inspection contractor performed an examination to determine if any interferences occur which might prevent full preservice examinations.
The inspector had no further questions concerning this matter.
(0 pen) Unresolved Item (79-07-04):
Examination of RPV feedwater nozzle.
Theinspectorobtainedadditionalinformationregarding)indicationsdetected in the nozzle / pipe weld of RPV nozzle N48 (azimuth 135..
A surface examination was performed by the inspection contractor to prepare the subject welds for preservice examinations.
This examination revealed a rejectableindicationontheoutsidesurfaceidentifiedasporosity.
To further investigate the cuality of the weld, an informational ultrasonic examination was performec by the inspection contractor on all feedwater nozzle to pipe welds.
These examinations revealed numerous indications in the weld which require further evaluation.
The data report of February 29, 1980 from Nuclear Energy Services, Inc. disclosed the following:
Nozzle weld N-4A revealed five recordable indications, one is con-
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sidered to be inside geometry, and the remainder are identified as slag indications.
Nozzle weld N-4B revealed eight indications which exceed the 50 per-
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cent recording level, one is considered to be in::ide geometry.
Six indications are identified as slag and another indication received from the inside surface could not be identified and warrants further investigation.
Nozzle weld N-4C revealed an inside signal presumed to be a gauge mark
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which must be verified by a visual examination of the inside surface.
Nozzle weld N-4D revealed two indications, one is considered to be
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inside geometry.
The'second indication is similar to the indication in N48 in that the signal appears to be a possible fusion defec ~
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The porosity defects on the outside surface were removed by grinding reinspection and visual examination.
It has been determined by the licens-ee that this area is now acceptable to ASME Section III.
It remains an open item by the licensee until 'it is determined whether the depression will interfere with the preservice examination.
The indications detected by ultrasonic will be reinspected and reevaluated for acceptance after the ASME B&PV code calibration block is fabricated.
This item continues unresolved pending the licensee's reinspection and dis-position and further review by the NRC of the disposition.
11.
General Prior to this inspection the inspector attended a meeting of the Case Load Assessment Team (CLAT) with the licensee for review of the licensee's
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revised schedule.
The licensee's tentative schedule anticipated fuel load-ing in June-September 1982.
After considering the material presented by the licensee, CLAT stated that in their opinion September,1982 would be a more realistic fuel load date.
The present schedule includes Mark II modifications and known changes resulting from studies of the TMI accident.
12.
Unresolved Items Unresolved items are matters about which more information is required in order to ascertain whether they are acceptable items, or items of noncom-pliance.
An unresolved item identified during the inspection is discussed in Paragraph 3.
13.
Exit Interview
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The inspector met with licensee representatives (denoted in Paragraph 1)
at the conclusion of the inspection on May 22, 1980.
In addition, H. B.
Kister, Chief, Reactor Projects Section #4 and the NRC Resident Ins 1ector, Mr. J. C. Higgins attended the meeting.
The inspector summarized t1e scope and finding of the inspection.
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