IR 05000329/1978013

IE Inspec Repts 50-329/78-13 & 50-330/78-13 on 780724-0908 During Which 2 Items of Noncompliance Were Noted:Welds with Unequal Outside Diameters Were Accepted & Safety Related Control Rod Drive Primary Breakers Were Not Well Protected

ML20062E293
Person / Time
Site:	Midland
Issue date:	11/03/1978
From:	Cook R, Haynes D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
To:
Shared Package
ML20062E289	List: IR 05000329/1978013 ML20062E285 ML20062E290
References
50-329-78-13, NUDOCS 7812060070
Download: ML20062E293 (6)

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U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT

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REGION III

Report No. 50-329/78-13; 50-330/78-13 Docket No. 50-329; 50-330 License No. CPPR-81; CPPR-82 Licensee: Consumers Power Company 1945 West Parnall Road Jackson, MI 49201 Facility Name: Midland Nuclear Power Plant, Units 1 and 2 Inspection At: Midland Site, Midland, MI t

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Inspection Conducted: July ,24-28, 31, August 1-4, 7-11, 14-18, 21-26, 28-31, September 1, and 5-8, 1978 Inspector:

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R. J. Cook

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Approved By: D. W. Hayes, Chief /I/~ E[-7$f Projects Section '

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Inspection Summary Inspection on July 24-28, 31, August 1-4, 7-11, 14-18, 21-26, 28-31, September 1, and 5-8, 1978 (Report No. 50-320/78-13; 50-330/78-13)

Areas Inspected: Assembly of decay heat removal pumps; holdown bolting techniques for steam generators and reactor vessels; lifting and setting of Unit 1 pressurizer, weld preparations for steam generator nozzles, in-place storage conditions for electrical equipment; welding and fitting of decay heat removal and make up feed systems; curing of concrete in Unit 1; a typical weld material in Unit I reactor vessel; settlement of diesel generator foundations and structures; and review of damage sustained by the LP turbine rotors and possible impact on test schedules. This inspection effort involved a total of 141 inspector-hours by one NRC inspector.

i Results: Of the twelve areas inspected, no apparent items of noncom-pliance or deviations were identified in 10 areas; two apparent items of

noncompliance w(Te identified in two areas (infraction - failure to supply adequate storage protection for safety related electrical breakers

- paragraph 6; infraction - failure to identify welds as nonconforming which did not meet the visual inspection requirements of the existing

, Technical Specification - paragraph 7). ,

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DETAILS Persons Contacted Consumers Power Company W. Bird, Section Head, Quality Engineering J. Balazer, Lead Electrical Engineer J. Corley, Project QA Superintendent D. Keating, Field QA Engineer P. Kyner, Field QA Engineer D. Miller, Site Manager B. Peck, Construction Supervisor M. Schaeffer, QA Engineer B. Wollney, Field QA Engineer

[ Bechtel Power Corporation *

L. Dreisbach, Project Field QA Engineer H. Foster. Project Field QC Engineer G. Richardson, Lead QA Engineer Those persons listed above attended at least one of the five exit interviews conducted during the report period. Numerous other principal staff and personnel including craftsmen were contacted during the reporting perio Inspection Areas Site Tours At periodic intervals generalized tours of the facility were per-

,~ formed by the Resident Inspector. These tours covered essentially every area of the site. These tours were intended to assess the state of cleanliness of the site; construction and installation activities; storage conditions of equipment and the potential for fire or other hazards which might affect personnel or equipmen . Decay Heat Pumps

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The licensee had identified that "D" decay heat removal pump (serial No. 69080) had been received with the casing assembled in reverse orientation. The pump was returned to B&W Canada In for reassembly. The reassembly was witnessed bya member of

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the licensee QA organization. The orientation and compatibility of decay heat removal pumps and pump pedestals was examined by

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the Resident Inspector and found to be matched. The orientation of the impeller within the pumps serial No. 69082 and 69083 was verified by the inspector. Access to the other two decay heat removal pump impellers was not available during this inspection period. The licensee stated that the Resident Inspector would be informed when the examination for the impeller orientation for the remaining pumps would be availabl . Steam Generator and Reactor Vessel Hold Down Bolting The methods employed for setting the hold down bolts for steam generator and reactor vessels were examined. It has not been completely established at this time whether a " turn of the nut" method or another alternate method would be employed. The inspec-tor informed the licensee that regprdless of the method employed, the bolt pre-loading requiremente- should be substantiate (329/78-13-02; 330/78-13-02) Lif ting and Setting of Unit 1 Pressurizer The lifting and placing of the pressurizer for Unit 1 was witnessed by the inspector. During the " upending" operation the pressurizer bumped against the transporting carriage. This bumping created a gouge area at the surge nozzle to leser head weld and a gouge area on the lower head between the surge nozzle and the head to shell weld. B&W generated Noncompliance Report No. 421 which identifies these damaged areas. Corrective action has not been complete . Unit 1 Steam Generator Hot Leg Nozzle Weld Preparation The inspector witnessed partial aspects of removing the lifting lugs from both steam generators in Unit 1 and the subsequent in-place machining operations for the hot leg side weld prepar-ation. The inspector encouraged the licensee to use only highly qualified personnel for specialized operation . In Place Storage of Control Rod Drive (CRD) Breakers On August 16, 1978, the inspector noted that boxed electrical equip-ment stored in place above the control room on the 674 ft. elevation had been rained upon the previous night because the temporary polyethylene roof covering the area had become dislodged from the containment wall. It was later determined that these boxes con-tained Control Rod Drive (CRD) Voltage Regulators, CRD Transformers and CRD Primary Breakers. The CRD Primary Breakers, designated ;

2B-91A, 2B-92B, 2B-91C and 2B-92D, are classed for storage 1/ Reference Drawing No. 376 i

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requirements compatible with ANSI N45.2.2 Level A and Field Pro-cedure FPG-5.000 which requires a controlled humidity and temperature environment and protection from weathering condition This failure to provide adequate storage for safety related equipment is considered an item of noncompliance with 10 CFR 50,. Appendix B, Criterion XII The licensee initiated immediate corrective action to bring the storage environment into controlled specifications and generated Nonconformance Report No. M-01-4-8-068 to ensure that a detailed inspection of the equipment is performed after more permanent storage conditions are established. Administrative procedures for release of equipment from the warehouse to locations of installed storage have been upgraded to ensure tnat the new location offers adequate protection for the safety related equipmen I Because of the actions taken by the licensee including steps to prevent recurrence no response to the above item of noncompliance is necessar . Auxiliary Piping System Field Welding and Fabrication Essentially all phases of field fabrication of piping being installed in the auxiliary building were examined. This included fitup, welding, and physical examination of pipe and valve joints for the decay heat removal system, makeup feed system and other system joints being welded in the auxiliary buildin During the examination of 18" x 3/8" vall piping to valve welds in the decay heat removal system (designated 2HCB-611) on August 10, 1978, it was noted that the visual inspection criteria established to meet the requirements of Specification 7220-M-204, Section

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5.1.3.g for welding of unequal outside diameter piping could not be me The inability to meet the specification of Section 5.1. was brought about by the geometry of the weld preparation performed on the valve and having to include the weld reinforcement when considering a maximum transition slope of 3 to 1 and remain within the constraints of a limited weld zone. It was also noted that several other completed valve to pipe welds for smaller diameter pipe fell into this same catagory and had been accepted as to meeting visual inspection requirement Additional review revealed that the valves had been purchased with a " code allowable" weld preparation and that in actuallity it appeared that the welding was being performed within the-4-

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limitations of the applicable ASME Code. However, the applicable specifications for welding this type of joint and subsequent visual inspection requirements were not compatable with the limitations of I the ASMT Cod Therefore, accepting unequal outside diameter welds which physically

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could not have met the established criteria of Technical Specifi-cation for Field Fabrication and Itstallation of Piping, N M-294 Section 5.1.3.g is cons-dered an item of noncompliance with 10 CFR 50, Appendix B, Criteria The licensee has changed the wordiag of Specification 7220-M-204, '

Section 5.1.3.g to reflect the style of weld joint preparation being installed within the limits of the ASME Code and subsequent

j visual inspection requirements. QC personnel involved in visual examination of these welds have been given additional instructions

pertinent to this change. An overview visual examination of nominally 125 selected welds which could have the geometric 4 limitations discussed above has been performed. A portion of this overview visual examination was witnessed by the inspector.

i Because of the above actions of the licensee, no response to the item of noncompliance is necessary.

> Curing of Concrete in Unit 1 .

During the reporting period seisnic Class 1 concrete has been poured within the containment of Unit 1, i.e., Slab 2 containment and steam generator cavity walls. The adequacy of curing conditions

! have been noted at periodic interval . Atypical Weld Material Used in B&W Reactor Vessel Welds

On August _7,1978 the licensee informed the Resident Inspector

} that weld material containing less amounts of nickel and greater-

' (- amounts of silicone than originally intended may have been used .

in the Unit 1 reactor vessel. These incorrect welding materials may increase the nil-ductility transition temperature more than anticipated. The resolution cf this matter has been referred to NRR and IE headquarter persont a .

10. 50.55e Item Settling of the Diesel Generator Foundations and:

Structures I

On September 7,1978, the licer.see informed the Resident Inspector that settlement of the diesel generator foundations and structures

' was considered a reportable item under the provisions of 10 CFR ,

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50.S5(e). The licensee stated that the abnormal settlement was-5-t n

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determined through the routine surveillance survey program. The licensee stated that additional investigation to define the extent of the situation was being performed. Further review of this matter is planned (329/78-13-03; 330/78-13-03).

1 Environmental Review - Operating License Stage' Meetings On September 6, 1978, Environmental Reviewers from NRR visited the site for meetings with the licensee. The Resident Inspector attended l a portion of these meetings pertaining to archeological and socio- I economic interests. On September 7, 1978 separate meetings were scheduled between NRR socioeconomic reviewers and the Midland City !

( Planning Department, Midland County Planning Commission and the Midland County Road Commission. The Resident Inspector attended these meetings in the interest of supplyir.g first hcnd information pertinent to the review proces ' 1 LP Turbine Damage from Dersilment On August 7, 1978, the inspector was informed that the train carrying both LP turbine spindles experienced a derailment close to Lorain, Ohio which resulted in damage to the turbines. The turbines have been returned to the vendor for repairs. At this time there is no known gross impact on the scheduling of the plan . Meeting with Local Officials On August 30, 1978, a meeting was held between elected officials from the local community, regional based representatives and the resident inspector. The meeting was conducted to explain the NRC regulatory program and to introduce the resident inspector program concept to the communit ( 1 Exit Interview

'. The Resident Inspector met with licensee representatives (denoted under Persons Contacted) on July 28, August 10, August 16, August 24, and September 8, 1978. The inspector summarized the scope and findings of the inspection effort to date. The licensee acknowledged the findings reported herei ,

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