IR 05000329/1977013
| ML19326D309 | |
| Person / Time | |
|---|---|
| Site: | Midland |
| Issue date: | 01/10/1978 |
| From: | Cook R, Hayes D, Naidu K NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML19326D301 | List: |
| References | |
| 50-329-77-13, 50-330-77-15, NUDOCS 8006090743 | |
| Download: ML19326D309 (19) | |
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U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT
REGION III
Report No. 50-329/77-13; 50-330/77-15 Docket No. 50-329, 50-330 License No. CPPR-81, CPPR-82 -
Licensee:
Consumers Power Company 1945 West Parnall Road Jackson, MI 49201 i
Facility name: Midland Nuclear Power Plant, Units 1 and 2 Inspection at: Midland Site, Midland, MI Inspection conducted: November 29-December 2, and December 5-8, 1977
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Inspectors:
R. J. Cook
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Approved by:
D. W. Hayes, Chief
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Projects Section
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Inspection Summarv
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Inspection on November 29-December 2, and December 5-8, 1977 (Report No. 50-329/77-13; 50-330/77-15)
Areas Inspected: Work activities and quality records related to concrete placement Unit 1; procedures, quality records and work activities related to the installation of safety related components Units 1 and 2; procedures and quality records related to containment structural steel, safety related
structural steel and welding activities Units 1 and 2.
This inspection involved a total of 81 inspector-hours onsite by two NRC inspectors.
Results: No items of noncompliance or deviations were identified.
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J DETAILS Persons Contacted Consumers Power Company (CPC)
- W. Bird, Section Head, Quality Assurance Engineering
- J.
Corley, Quality Assurance Superintendent
- D. Keating, Field Quality Assurance Engineer P. Kiner, Field Quality Assurance Engineer T. Black, Field Quality Assurance Engineer M. DeWitt, Field Quality Assurance Engineer
- P. Jacobsen, Quality Assurance Engineer
- B.
Peck, Construction Supervisor Bechtel Power Corporation (Bechtel)
- J.
Boos, Project Field Engineer B. Cheek, Lead Civil Quality Control Engineer J. Behress, Head Piping and Mechanical Quality Control Engineer
- G. Richardson, Lead Quality Assurance Engineer
- H.
Foster, Assistant Project Field Quality Control Engineer A. Boulden, Head Welding Quality Control Engineer
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S. Marrow, Head Receipt Inspector R. Maes, Craft Superintendent J. Miller, Material Storage and Maintenance Engineer J. Hill, Material Storage Supervisor Other personnel were contacted during the course of the inspection.
- Denotes those present at the exit interview.
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Functional or Program Areas Inspected
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SECTION I Prepared by:
R. J. Cook Reviewed by:
D. W. Hayes, Chief Projects Section 1.
Observation of Structural Concrete Activities (Unit 1)
The RIII inspector observed the concrete placement for the service water intake (SWI) structure slab No. 2 and preplacement activity for parapet wall No. 13 and determined that work and inspection activities were being accomplished according to applicable specifications; codes and drawings in the following areas.
a.
Placement Preparation (1) Forms were properly secured, leak tight, and clean.
(2) Rebar and other embedments were properly placed according to applicable drawings C-80 and associated drawings for the SWI pour and drawings C-207, C-271, 7-s C-299, and C-275 for the parpet wall.
b (3) Preplacement inspections had been completed prior to placement.
b.
Delivery and Placement (1) Mix C-2 was specified and delivered to the SWI pour No. SWI (634.5)b.
(2) Duration of concrete mixing and transportation was with-in the specified limits.
(3) The piping material for pumping concrete was acceptable.
(4) Testing was being performed at specified intervals at the placement site using calibrated equipment and met acceptance criteria; samples were being collected at the end of the line.
(5) Temperature of the concrete was within specified limits i
for cold weather placement.
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(6) Adequate crew and equipment were being utilized during concrete placement.
Vibrators were observed to be
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properly used and the free fall was limited to less than five feet.
(7)
Inspections were being performed by qualified persons.
During the inspection, the licensee performed specialized training in concrete test acceptance criteria for those personnel intimately involved in concrete placement.
This was done to insure that the information U. S. Testing possessed for concrete placement was compatible with the applicable specifications and the requirements of Bechtel QC.
c.
Aggregate and Cement Storage (1) Cement storage appeared to be adequate.
(2) Aggregate storage was in separated piles, piles appeared to be stored in acceptable heights.
d.
Curing The RIII inspector noted that heated enclosures were used to protect the placed concrete from the cold weather conditions. Heat was supplied from portable heaters.
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e.
Batch Plant Operation
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(1) Measuring equipment appeared to be calibrated as indicated by attached calibration stickers.
(2) Temperature was being maintained within specifications for cold weather conditions.
(3) QC inspectors were present in the batch plant during the production of concrete.
(4) Generation and control of batch records appeared to be adequate.
In the areas inspected, no items of noncompliance or deviations were identified.
2.
Review of Containment Structural Concrete Quality Records (Unit 1)
The RIII inspector reviewed the pertinent work and quality records associated with two Unit I containment wall pours from elevation 754'-5" to 764'-7" and 764'-7" to 774-9".
Consumer Power Company QA overview records for Unit I containment wall pours from 7-~ )
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elevations 744'-3" to 754'-5" and 754'-5" to 764'-7" were also reviewed.
It was determined that the records reflected work accomplished consistent with applicable requirements in the following areas, a.
Preplacement Preparation Preplacement records designated C1.20-338 and C1.20-400 indicated that preplacement inspections were performed and identified no adverse findings.
b.
Deliverv and Placement (1) Placement records designated C1.30-338 and C1.30-400 indicated that the mix specified was delivered and placed.
(2) Records of batches delivered were on file and retained with the above referenced placement records.
(3) The placement records noted above indicated that required tests of placement were taken and that concrete which met the specifications was placed.
(4)
Inspection records did not identify adverse conditions O
relative to segregation, consolidation, and temperature.
(5)
Records of the inspection personnel indicated that they were qualified.
c.
Curing Curing records designated C1.40-338 and C1.40-400 indicated that the placement was properly cured and that the forms were removed after the specified interval.
d.
Rebar Splicing (1)
Rebar splicings were performed according to the pertinent drawings.
(2) The rebar splicing technique was qualified by users tests.
(3) Rebar splicing records designated C6.00-611 indicated required tests for splicings were performed and deter-mined acceptable.
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(4) Results of it.spection records did not identify adverse
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conditions.
(5) Rebar splicing records indicated that the Cadweld crew and inspection personnel were qualified.
e.
Concrete Materials (1)
Batch plant inspection and material control records designated C4.10-159 and C4.10-162 indicated that the material meets applicable specifications.
(2)
Inspection records indicated that the established require-ments were met relative to the control of material receipt, handling, and storage.
(3) Material test laboratory surveillance records designated SC1.05-41 and SC1.05-43 indicated that audits of the test-ing laboratory activities had been performed.
f.
Batch Plant Operation Production records for the placements identified no adverse findings.
(_,f No items of noncompliance or deviations were identified in the
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above areas.
s 3.
Observation of Work and Storage Activities for Safety Related Components (Units 1 and 2)
The RIII inspector observed and reviewed relevant records pertaining i
to storage, installation, and protection of Unit 1 primary coolant i
pumps, Units 1 and 2 primary coolant pump motors, decay heat
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removal heat exchanger 2E-60B, makeup pump 1P-58B, decay heat removal
pumps IP-60B and 2P-60B, and four outside diesel fuel oil storage tanks.
The inspector determined the following activities for the above I
components met applicable requirements.
a.
Storage and Protection i
(1)
Storage environment protection for primary coolant pumps, primary coolant pump motors, and diesel fuel oil storage tanks.
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Cleanliness preservation and protection for all above listed components.
(3) Surveillance during storage for primary coolant pump motors and decay heat removal heat exchanger.
b.
Installation (1) Review of QC inspection procedures revealed provisions for ensuring that component placement locations are made
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relative to applicable prints and surveyor markings for Bechtel installed equipment.
(2) Component placement and mountings for makeup pumps and decay heat removal pumps were examined.
The licensee is evaluating the present technique of shimming and grouting of pump base supports.
c.
Protection After Installation Installed decay heat removal pumps and decay heat removal heat exchangers were found protected against adverse external conditions.
The licensee is presently evaluating the need for maintaining (
specialized environmental conditions on heat exchangers and 1 _ (s,}
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vessels which are completely installed.
In the areas inspected, no items of noncompliance or deviations were identified.
4.
Review of Procedures for Safetv-Related Piping (Units 1 and 2)
The RIII inspectors reviewed the procedures utilized by the construction contractor, Bechtel Corporation, for activities relative to safety related piping and valves and in-line component installation.
It was determined that adequate procedures exist to control the following
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activities according to applicable requirements.
a.
Quality Control procedures identify items where QC inspec-tion is required.
b.
Material receiving inspection Report No. R-100 contains provisions to document the following aspects (where applicable)
of receipt inspection:
.(1)
Piping material is in conformance with purchase specific-ations and any special requirements.
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(2) Marking and identification are as specified.
(3) As-received cleanliness and protection meets requirements.
(4) Receiving inspection reports are generated as required.
c.
Procedure for Storage and Maintenance of Equipment and Materials No. FPG-4.000 and QC Procedure PQCI-S-1.00 covers storage and issue of piping, valves, and in-line components and contains requirements to verify the following:
(1) Segregation of sizes and types of material.
(2) Storage identification.
(3) Storage condition and protection.
(4) Confirmation of issue of specified material.
(5)
Storage and issuance records are generated as specified.
d.
Master QC Instruction Nos. P-1.00, P-1.10, and P-1.30 and Specification Nos. 7220-:1-204(Q), 7220-M-214(Q), and 7220-(N M-326(Q) cover handling of piping valves and in-line com-
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ponents and include provisions to assure adequate protection during receipt, storage, issuance, and installation.
In addition they assure that the following neet applicable requirements:
(1) Location.
(2) Fit-up clearances.
(3) Type, size, location, and adjustment of hangers and restraints.
(4) Nondestructive examination and inspections.
(5) Control of cold spring.
(6)
Installation records generated during work performance, f.
The above listed procedures address post-installation cleaning of safety-related piping including the following:
(1) Types of cleaning materials and use of these materials.
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(3) Adequate record keeping requirements.
No items of noncompliance or deviations were identified in the above areas.
5.
Review of Procedures for Safety-Related Piping Welding Activities (Units 1 and 2)
The RIII inspectors reviewed the procedures utilized by Bechtel for welding activities relative to safety-related piping and determined that the Master Quality Control Instruction lio. W-1.00 covered the
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following areas:
a.
Provisions to indicate the drawings and engineering specific-ations and appropriate hold points.
b.
Provisions to ensure that welding procedures are qualified
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to applicable requirements. Welding procedures are qualified at Bechtel, San Francisco Oi'fice.
c.
Provisions to assure that welding personnel are properly qualified.
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d.
Provisions to utilize nondestructive examination procedures which conform to applicable codes and standards.
The pro-cedures are written by Bechtel's Material Quality Services Department and transmitted to Bechtel's Engineering Department
at Ann Arbor, Michigan.
e.
Provisions to assure that nondestructive examination personnel j
are qualified to applicable requirements.
f.
Provisions to control contaminants in the use of penetrant testing.
g.
Provisions to assure that the following activities are j
documented:
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(1) Weld location, system, and weld number.
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(2) Welder's name and identification.
(3) Weld procedures used which also includes procedures used for repair.
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(4) Weld filler material used.
(5) Nondestructive test examination requirements.
(6) Nondestructive examination personnel name.
(7) Nondestructive examination results.
(8) Additional inspection requirements.
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Provisions to require procedures for the following heat treatment activities where applicable:
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(1) Preheat.
(2)
Interpass temperature.
(3) Post veld controlled cooling.
(4) Stress relieving.
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Provisions to require procedures for the following NDE activities where applicable:
(1) Evaluation of weld quality by the use of specified NDE
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Procedures.
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(2) Evaluation of weld quality by visual examination.
(3) Evaluation of radiography quality.
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Provisions to provide control of welding material in the following areas:
(1) Receipt verification and conformance to specifications.
(2) Control of. pre-issue storage conditions.
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(3) Storage identification and issue control.
(4) Post-issue control regarding identification, temper-ature and moisture.
(5) Disposition of issued but unused material.
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Provisions to cover defect repair where applicable in the
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following areas:
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i (1) Defect removal techniques.
(2) Defect removal verification.
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No items of noncompliance or deviations were identified in the
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above areas.
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I SECTION II Prepared by K. R. Naidu ililf Reviewed by D. H. Danielson, Chief Engineering Support Section 2 1.
Review of Procedures for Steel Structures and Supports (Units 1 and 2)
The RIII inspector reviewed the procedures utilized by Bechtel Corporation (Bechtel), the construction contractor, for activities relative to containment structures and supports and structural steel and supports.
It was determined that adequate procedures exist to control and assure that the following activities are per-formed according to applicable requirements.
a.
Quality Control procedures identify items where QC inspection is required.
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b.
Material Receiving Inspection Report (QCIR) No. R-100 contains provisions to document the following aspects.(where applicable)
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of receipt inspection:
(1)
Steel components are in conformance with purchase specifications.
(2) Marking or other identification is as specified.
(3) Verify documentation on the components.
(4) Visual examination to determine damage during transit.
(5)
Identification and traceability of the material.
(6) User's tests (if applicable).
(7) Release for storage.
(8) Review of Supplementary records.
(9)
Exceptions taken to specifications.
c.
Procedure for Storage and Maintenance of Equipment and Ibterials No. FPG-4.000 covers storage and issue of steel material and contains requirements to verify the following:
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(1)
Storage identification.
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Storage and issuance records, d.
Inspection procedures which cover the installation of steel structures and supports contain requirements to assure that:
(1) Type, size, location and tolerances of components meet applicable requirements.
(2) ND Examinations and inspections meet the applicable requirements.
(3)
Installation records meet established procedures.
No items of noncompliance or deviations were identified in the above areas.
2.
Review of Procedures for Structural Steel Welding Activities (Units 1 and 2)
The RIII inspector reviewed the procedures utilized by Bechtel for welding activities relative to containment structural steel and safety related structural steel.
It was determined that the Project Quality Control Inspection (PQCI) procedure W-1.00 cover the
/N following areas:
b Provisions to indicate the drawings, engineering specifications a.
and the relevant change notices.
b.
Provisions to assure that welding procedures and welding per-sonnel are qualified to applicable require =ents.
Provisions to utilize nondestructive examination procedures c.
written by Bechtel's Material Quality services department and approved by Bechtel's Engineering department (Ann Arbor).
d.
Provisions to utilize persons qualified by Bechtel's San Francisco Level III person to perform appropriate nondestructive examinations.
Provisions to utilize qualified welders; welders performing e.
AWS welding activities who do not weld during a 6 month interval are required to be requalified; welders performing ASME code welding activities who do not weld during a 3 month interval are required to be requalified.
f.
Contamination is controlled by the use of penetrants in spray cans for dye penetrant examinations.
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The following information is documented in the QC inspection record:
(1) Weld identity.
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(2) SA/ ASTM material type including grade (material to material).
(3) Material thickness.
i (4) Weld procedure used.
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(5) Filler material type, backing ring, purge gas, preheat temperature parameters, interpass temperature limitations.
(6) NDE procedura numbers.
(7) NDE sequence.
(8) Postweld heat treatment procedure including temperature / time data.
(9) Welder's symbol.
(10) HDE results.
(11) Final inspection results of the weld.
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Supplementary records including review of the following:
(1) Postweld heat treat records.
(2) NDE test reports.
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Provisions to use repair procedures.
No items of noncompliance or deviations were identified in the above areas.
3.
Review of Quality Records for Structural Steel snd Supports (Units 1 and 2)
The RIII inspector selectively reviewed the Quality Records on the following items:
Containment liner plates Penetration pipe assemblies Embedments Steel beam 14 -
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The inspector determined that records exist to confirm that quality requirements have been met in the following areas:
,s a.
Containment Liner Plates Material Receiving Report (MRR) No. 2220 dated July 1, 1971, indicates that Southern Boiler and Tank Works Inc. (SBTW)
Memphis, Tennessee supplied the following liner plate assemblies which met the purchase specification C-50A.
MK D-4-18 MK D-9-8 MK RD-3-11 MK RD-3-15 MK RD-4-9 MK RD-4-10 (1) Material test reports from Armco Steel indicate that the material conforms to ASTM-A-36/69.
(2) Receiving Inspection Reports (RIR) indicate that some pieces of the Lower Dome Liner were damaged at the ends or corners.
Nonconformance Report (NCR) No. 0094 was generated to document the damage; there was no documen-tation that the damage was repaired prior to installation, g-~
The inspector req::ested the licensee to review this matter ( j with Bechtel and determine whether such records exist.
This matter wi'
itified as an unresolved item, con-sidering that
.amage occurred as early as 1971, when the control of NCR's may have been marginal and the fact that liner plates cannot be installed if the bent corners of the liner plate were not straightened.
(329/77-13-01, 330/77-15-01)
b.
Penetration Assemblies MRR No. 1898 dated November 19, 1970, indicates that SBTW supplied penetration pipe assemblies piece marks R-16-R, R-21-R, R-1-R, R-5-R, R-4-R which met the purchase specification C-50A.
(1)
Material test reports from Armco Steel Corporation indicate that the material conformed to ASTM-A-36/69.
(2)
Receiving Inspection Reports indicate that certain compon-ents were received with unapproved heat numbers. NCR 0083
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indicates that unapproved heat numbers 68212, 22281, 60215,
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83E 774 were identified on some components of the assemblies; also that certain radiographs were missing.. Records indi-cate that the missing radiographs were subsequently furnished; however, the matter of unapproved heat numbers was not addressed. The licensee informed the inspector that he will review this matter further with Bechtel. This matter is considered an unresolved item.
(329/77-13-02, 330/77-15-02)
c.
Embedments (1) HRR No. AE0-4205 dated August 31, 1977, indicates that Embed
mark 1-11B(L)-R/B1 was purchased to Purchase Order (PO) 7220-F-
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16781(Q) to reflect the requirements of specification C-233.
QCIR indicates no adverse findings in the following areas:
(a) Willste and Company Saginaw was the prime vendor.
(b)
Paragon Steel Corporation was the subvendor.
(c) Certificate of Compliance from Willste and Company that the material conforms to ASTM-A-36.
(d)
Shop inspected material.
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(e)
Identification and traceability.
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(f) Release for storage and installation.
(g)
Supplementary records.
(h) No exceptions were taken to specification requirements.
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(1) Tests reports - Ultrasonic (UT) and Radiographic furnished by NDT services Inc, Plymouth, Michigan.
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The RIII inspector reviewed the UT reports and requested certain clarifications; it was not clear whether the UT was performed under water or why water couplant was used; the enclosed Distance Amplitude Curve (DAC) was incomplete.
The Bechtel shop inspector identified as No. 355 signed the report and Bechtel was unable to explain the significance of the signature and confirm whether the signature indicated that Becthel shop inspector reviewed the test report or witnessed the test.
The licensee agreed to review this matter. This will be considered as an unresolved item.
(329/77-13-03, 330/77-15-03)
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The above embedment was observed to be installed in its intended location as a RC Pump return line embedd; QC
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preplacement inspection were in progress.
(2) MRR No. AEO-2181 dated November 30, 1976, indicates that embeds E4 plate mark Ell, D4 plate ?brk E13, E4 plate mark E14, and A5 plate mark 1/359 met the specification C-233 requirements.
The QCIR indicates no adverse findings in the following areas:
(a) Haven-Busch, the vendor, supplied the raterial certifi-cations confirming that the material conforms to ASTM-A-36.
(b) Welding material certifications were acceptable.
(c) Shop welding inspection records indicate several root passes were unacceptable; in those instances, the final passes were signed off by the vendor shop inspector without indicating whether the defects in root pass were repaired.
The RIII inspector was unable to establish whether this was an error in docu-centation or deficiency in inspection.
The licensee agreed to investigate this matter further with Bechtel and furnish details.
This is considered an unresolved (~~N item.
(329/77-13-04, 330/77-15-04)
i d.
Bechtel Shop Inspection Checklist In the above instances, a Bechtel Form G 321D was duly signed by a Bechtel Shop inspector in Section 22.0 documenting the shop inspection was included in the QA records; however, the RIII inspector was unable to determine the prerequisites to be satis-fied prior to the signoff in Sectf.on 22.0.
The' licensee informed the inspector that he would obtain documented instructions rele-vant to the prerequisites from Bechtel. This is considered an unresolved item.
(329/77 13-05, 330/77-15-05)
e.
Steel Beam (1) !!RR No. C38 indicates that a steel beam shipped from New City Steel on March 16, 1976, arrived on site on March 17, 1976.
(2) No shipping damages were identified.
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(3) Certificate of Conformances indicate that materials used conformed to ASTM-A-36-74 and ASTM-A-572-76B, Grade 50.
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No items of noncompliance or deviations were identified in the above areas.
4.
Observation of Containment Penetrations Work Activities (Unit 2)
The RIII inspector observed partially completed work and completed work activities relative to containment penetrations No. 2Z26 and 2227. The following was determined.
a.
Method of installation appeared to be consistent with work specifications.
b.
The location of the penetrations were at elevation 605'-0" angles 307 and 262 -30' respectively as indicated on drawing No. C-419 (Q), Revision 3 and were intended for the decay heat removal supply lines.
Inspection activities were being performed as required by estab-c.
lished procedures by qualified personnel.
d.
Measures were not established to protect installed penetrations from construction debris, physical damage and hostile environ-
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ments. Bechtel specification M-204 titled " Technical Specifi-
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cations for Field Fabrication and Installation of Piping for Nuclear Service," Section 5.21 in part states, " Care shall be taken in handling and installation of piping to prevent surface damage"; however, protection of installed penetrations was not addressed. Section 6.4 requires open pipe and to be capped; all open ended caps were observed to be capped.
The inspector informed the licensee that procedures should be established to protect installed penetrations. This matter is considered an unresolved item.
(329/77-13-06, 330/77-15-06)
No items of noncompliance or deviations were identified in the above areas.
5.
Review of Containment Structures Welding Records (Unit 2)
The inspector reviewed QC Inspection Plan No. C-111-111 which docu-mented the inspections for the fabrication of (Unit 2) dome subassembly plate RD-4-10 to RD-9-10.
QCIP No. C-111-111 indicates that inspec-tions were conducted in the following areas and were determined to be satisfactory:
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Weld edge preparation and fitup.
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b.
Storage and disbursement of weld filler material.
c.
Qualified welders were used.
d.
Welding requirements conformed to ASME Code Section VIII, Division 1, paragraphs UW-26 to UW-38.
e.
Single groove welds with continuous backing strips were used.
f.
Completed welds were visually inspected.
g.
In addition to visual inspections, Radiography (RT), Magnetic Particle (MP), Liquid Penetrant (LP), Vacuum Box (VB), and Leak Chase Tests (LCT) were formed; no unacceptable indications were identified.
h.
Report No. 948 indicates that VB tests could not be performed on Seams A, B and C while the components were on jigs due to jig bracing; instead MP testing was recommended and performed as indicated below.
1.
Report No. 945 indicates that 100% NT testing was performed on I
seams A, B and C to procedure MT-Y, 2 Rev. 0; no unacceptable N.)h indications were identified.
j.
NDE inspectors were qualified to perform NDE inspections.
No items of noncompliance or deviations were identified in the above areas.
Unresolved Items Unresolved items are matters about which more information is required in order to ascertain whether they are acceptable items, items of noncom-pliance, or deviations.
Unresolved items disclosed during the inspections are discussed in Section II paragraphs 3.a(2), 3.b(2), 3.c(1)(i), 3.c(2)(c),
3.d and 4.d.
Exit Interview The inspectors met with licensee representatives (denoted under Persons Contacted) at the conclusion of the inspection and summarized the scope and findings of the inspection. Licensee's comments are noted in the applicable sections of this report.
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