IR 05000329/1981016
| ML20030D712 | |
| Person / Time | |
|---|---|
| Site: | Midland |
| Issue date: | 09/01/1981 |
| From: | Danielson D, Erb C, Ward K NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML20030D706 | List: |
| References | |
| 50-329-81-16, 50-330-81-16, NUDOCS 8109150563 | |
| Download: ML20030D712 (11) | |
Text
U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT
REGION III
Reports No. 50-329/81-16; 50-330/81-16 Docket Nos. 50-329; 50-330 Licenses No. CPPR-81; CPPR-82 Licensee: Consumers Power Company 1945 W. Parnell Road Jackson, MI 49201 Facility Name: Midland Plant, Units 1 and 2 Inspection At: Midland Site, Midland, MI Inspection Conducted: August 12-14, 1981
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Inspectors:
M. Erb
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K. D. Ward
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D. H. Danielson, Chief
//M Materials & Process Section Inspection Summary Inspection on August 12-14, 1981 (Reports No. 50-329/81-16; 50-330/81-16)
Areas Inspected: Review of preservice inspection (PSI) work activities, nondestructive examination (hTE) personnel certifications, and data; con-tainment (Structural Steel Welding) observation of work activities, review of quality records; reactor coolant loop piping - visual examination (VT)
of welds and special welding applications; other safety-related piping -
welding material control and welder qualifications; review of flued head type penetrations; status of internals work in reactor pressure vessel, status of one 50.55(e) item. The inspection involved a total of'37 inspector-hours onsite by two N9C inspectors.
Results: No items of noncompliance or deviations were identified.
810915056's 810903 PDR ADOCK 05000329 G
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DETAILS Persons Contacted Consumers Power Company (CPCo)
- T. Cooke, Project Superintendent
- D. Turnbull, Q.A. Superintendent
- L. flowell, Mechanical Supervisor
- M. Scheffer, Section Head
- J. Decker, NDE/ Welding Supervisor
- J. Walton, Senior Engineer H. Allen, Q.A. Engineer Bechtel Power Corporation (Bechtel)
- E. Smith, Project Field Q.C. Engineer
- M. Dietrich, Project Q.A. Engineer
- W. Creel, Lead Q.C. Engineer
- R. Ash, Field Contracts Administrator R. Amos, Q.C. Engineer Babcock and Wilcox Construction Company (B&W)
W. Lee, Manager W. Hall, NSS Systems Engineer The inspectors also contacted and interviewed other licensee and contractor employees.
- Denotes those attending the exit interview.
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Licensee Action on Previous Inspection Findings (0 pen) Deviation (329/80-01-02; 330/80-01-03):
"No positive way of cracking design changes and assuring that completed work is modified in accordance with design changes and no procedure for handling design changes made after com-g pletion of work."
CPCo is in the process of reviewing the criteria from
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Bechtel for making changes.
(0 pen) Unresolved Item (329/80-17-02; 330/80-19-02):
" Radiographic linear indications of welds in two borated water storage tanks." A decision has been made by CPCo to have all questionable radiographic velds reradiographed.
(0 pen) 50.55(e): Snubber Bracket Bolts for Lateral Supports to Primary Coolant Pump, - Units 1 and 2, a total of 207 of 384 bolts of varying sizes were found by the licensee to be outside the specified hardness range.
Aptech, a licensee consultant and B&W are making enginaering studies on the-2-
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loads to these bolts under emergency conditions. The metallurgical quality of these bolts particularly in the above 2 " diameter sizes should be i
established before assigning emergency loads.
NCR-M-01-9-0-081 is out-
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standing on this item.
l Functional and Program Areas Inspected The functional and program areas inspected are described in Sections I and II.
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Section I Prepared by K. D. Ward Reviewed by D. H. Danielson, Chief Materials and Process Section 1.
General CPCo received four allegations concerning B&S NDE work from an individual previously employed at the Midland Site (File 16.0, Serial 98FQA80, dated April 11, 19S0). Three of the allegations were closed (Reference NRC Report No. 30-329/80-27; 50-330/80-28 and No. 50-329/81-06; 50-330/81-06).
The fourth allegation has not been resolved to date.
CPCo management in Jackson, Michigan is now reviewing the allegation.
CPCo contracted Nondestructive Test Engineering (NDT-Eng.) a Division of Hartford Steam Boiler Inspection and Insurance to review approximately 64,000 radiographs of shop film on a sampling plan. The radiographs are of shop welds, castings, and other material radiographed off site. The review started July 1981, and may be completed the first part of 1982.
To date, approximately 3,700 films have been reviewed and the following discrepancies were found.
a.
Missing procedures b.
Missing shooting sketches c.
Missing readers sheets d.
Incomplete fusion e.
Slag f.
Linear indications g.
Inclusions h.
Gas pockets i. Film rejected for plus or minus allowable density ranges.
The inspector reviewed radiographs of the following shop welds that NDT-Eng. personnel had reviewed. The radiography was performed by ITT Grinnell Industrial Piping, Inc., in accordance with ASME,Section III, 1971 Edition, Summer 1973 Addenda.
System Weld No.
Date Rt'd IFCB-17-5603-6-3
"A" 1/4/77 1FCB-39-5603-6-1
"B
3/22/77 1HCB-16-5603-6-2
"C" 2/24/77 1HCB-16-5603-6-2
"A" 2/24/77 1HCB-16-5603-6-2
"C" 2/24/77 1-CC6-2-5603-7-5
"B" 10/20/77 1-CCB-2-5603-7-5
"E" 10/20/77 1-CCB-2-5603-7-5
"M" 10/20/77-4-
l The inspector also reviewed the following NDT-Eng. personnel NDE certifications in accordance with SNT-TC-1A, 1975 Editon.
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Name RT S. Tucker II M. Flores II J. Polson II J. Moreno II B. Card II
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2.
Preservice Inspection References:
NRC Report No. 50-329/79-20; 50-330/79-21 (PSI)
NRC Report No. 50-329/80-03; 50-330/80-03 (PSI)
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NRC Report No. 30-329/80-17; 50-330/80-18 (PSI)
NRC Report No. 50-329/80-27; 50-330/80-28 (PSI)
NRC Report No. 50-329/81-02; 50-330/81-02 (PSI)
NRC Report No. 50-329/81-06; 50-330/81-06 (PSI)
a.
NDE Personnel Certifications i
The inspector reviewed the following B&W NDE personnel certifica-tions in accordance with SNT-TC-1A, 1975 Edition:
Name
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B. Goranowski II II D. Ives I
b.
Observation of Work Activities, Review of Data Reports and Audits
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The inspector observed the work and had discussions with personnel during a liquid penetrant examination on welds 2-CCA-9, 2-CCA-10, and 2-CCA-10A.
The inspector reviewed data reports and determined that they demonstrated that the QA/QC requirements were met.
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The inspector also review CPCo audit No. M-01-21-1 of GEO Construction Testing (formerly Peabody Testing) on NDE activities dated May 13-18, 1981, and an audit in which CPCo contracted
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Southwest Research Institute to audit B&W during their eddy current examit.ation dated June 29, 1981.
No items of noncompliance or deviations were identified.
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3.
Containment (Structural Steel Welding) Observation of Work Activities and Review of Quality Records The inspector observed several RPV upper lateral supports where joint preparation and alignment were complete and welding had not started, also where welding was in progress.
The following procedures were reviewed:
Becthel, QC and Documentation Procedure of Welding and Nondestructiv.e Examination, WD-1, Revision 4, March 1976.
Bechtel, Welding Standard Welding Fabrication and Quality Control Documentation Requirements, WD-2, Revision 6, April 13, 1976.
Bechtel, Welding Standard, Performance Specification WQ-NF-1, Revision 0, September 26, 1973.
The inspector reviewed the following welder certifications.
Name No.
Name No.
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G. Nelson 174 E. Scannell 162 G. Shaffer 061 J. Ricker 155
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The inspector made a tour of the weld testing laboratory, reviewed material certifications and instructions for purchasing, receiving, storing, disbursing and handling of welding materials. Also reviewed CPCo Project Inspection Plan and Reports (surveillance) and Bechtel print drawing No. C-367(Q), Revision 1, RPV Upper Lateral Supports, Plan, Sections, and Details.
No items of noncompliance or deviations were identified.
4.
Reactor Coolant Loop Piping - Visual and Special Welding Applications The inspector visuaily examined the 28" RC pipe to steam generator and reactor welds No. WJ4-1, 4-2, 4-3, 4-4, 5-1, 5-2, 5-3, and 5-4, reviewed the following procedures, quality records and determined that applicable welding procedures and material were used and the appearance of the weld surface was acceptable.
Bechtel, General Welding Standards GWS-FM, Revision 4, July 16, 1976.
Bechtel, General Welding Standard, Thermocouple Attachment, GWS TC, October 9, 1979.
Bechtel, Engineering Standard, Code Requirements for Postweld Heat Treatment of Field Welds, PHT-500, Revision 6, October 17, 1978.
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Bechtel, Precedure Specification of Postweld Heat Treatment of Field Welds PHT-501, Revision 7, August 1, 1979.
Bechtel, Welding Procedure Specification F1-ALH, Revision 2, October 25, 1978.
Bechtel, Welding Standard Performance Specification WQ-1, Revision 12, July 1, 1980.
Bechtel, Welding Standard Per #ormance Specification, WQ-2, April 14,.1980.
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The inspector reviewed the follouing welder certifi:ation:
l Name No.
Name No.
T. Biggs 064 V. Guoar 231 (
The inspector also review nonconformity report, dated December 6, l' :d, weld control records, welding rod certs for E-80-15-C3, PT, MT, UT ard
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l RT NDE records, repair procedures for weld no. WJ44 and WJ5-2, and d No items of noncompliance or deviations were identified.
5.
Safety-Related Piping - Weiding Material Control and Welder Qv .lication The inspector toured the receiving, storing, and distribution of welding materials including, welding electrodes, filler metal, consumable inserts, fluxes and gases. The ovens were examined and the following procedures were reviewed:
Bechtel, Control and Documentation Procedure for Welding in ASME, Section i
III, Code Applications, Revision 0, May 1, 1978.
Bechtel, Welding Standard Procedure Specification, WFMC-1, Revision 6,
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February 24, 1978 (Receiving Inspection, Storage and Disbursement).
Bechtel, Welding Filler Material Procurement Requirements, WFMF-1, Pavision 3, June 1, 1977.
The inspector reviewed the following welding certifications, including program for qualification of welders, a systea for maintaining a contin-uous record of the qualification status of t ' welders, and toured the area of yhere the bend test is performed n. the area of where the radiography may be performed for qualification of welders.
Name No.
Name No.
l C. Hyatt P-260 E. Hasse P-91 P. Leddy P-384 P. Farguaharson P-385 l
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The inspector reviewed radiographs and reports of the following field
welds in accordance with ASME Section III, 1974 Edition, Summer 1976 l
Addenda. These welds were radiographed by Peabody Testing X-Ray Engineering Company.
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ISO hjo.
M634-7 FW49 12/3/80 l
M604-9 FW341C 12/1/80 i
M613-1 FW108R4 12/2/80 l
M617-5 FW249 12/3/80 M617-4 FW125 12/3/80
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l M634-5 FW114 12/3/80 I
' M616-3 FW74 12/11/80 M613-2 FW71R3 12/4/80 M616-4 FW127R1 6/3/81 M612-1 FW92 12/8/80 M612-2 FW180 12/8/80 M617-4 FW128 12/8/80 M633-6 FW111 12/9/80 M633-6 FW112 12/9/80
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l Section II Prepcred by C. M. Erb Reviewed by D. H. Danielson, Chief Materials and Process Section 1.
Review of Penetration in Units 1 and 2 a.
Almost all of the flued head type of penetrations were observed in l
l both Units 1 and 2 to be installed. These penetrations were supplied by Tube Turns to the requirements of ASME Section III, 1974 Edition.
Documentation '.or the following penetrations was examined and appeared
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to be accepta' ale to ASME requirements.
Ident.
Epe Size Outside Dia.
Material Comments l
1Z-38 18"x.938" 34"x.750" Carbon St.
Impacts req.
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IZ-27 10"x1.125" 16"x1.500" Dissimilar 309 elect.
1Z-35 2 "x.375" 16"x.656" Dissimilar 309 elect.
1Z-65 1 "x sched 16"x.656" Dissimilar 309 elect.
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160 1Z-71 6"x.432" 12"x.375" C.S. to Alloy H.T.
i 1Z-78 10"x.365" 16"x.656" Dissimilar WPP3P1-A.T-l AgR7 l
l The penetrations for Unit 2 appeared to have been ordered to the l
same specifications and bear the same identification except the 1
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prefix is replaced by a 2.
All the butt welds in piping were made using the open butt procedure.
In some cases the tests made by the l
fabricator, Tube Turns, were witnessed by a Bechtel inspector. The i
weld procedures and NDT results on the installation welds at the l
site were enmined and appeared to be acceptable to ASME Section III, Class 2 requirements, b.
Penetration IZ38 which is a flued head type was electronically tested by Tube Turns. However, the test report is signed by a l
Level 1 inspector. Other test reports were checked and had been
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signed by a Level 2 UT inspector. Pending resolution, this matter l
is considered to be an unresolved item.
(330-81-16-01)
No items of noncompliance or deviation were identified.
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2.
Documentation for NSS Valves The three pressurizer relief valves were supplied by Dresser Industries to ASME Se; N.on III, 1971 Edition, Summer 1972 Addenda. One of these valves is an electromatic type 25"x4", while the other two valves are setpoint type.
The Spray Control valves were 2 " inlet supplied by Rockwell Manufacturing to the same code requirements as the relief valves. However, the inspector noted that a later change to the FSAR indicated the Spray Control valves were brought to the requirements of ASME Section III, 1977 Edition, Summer 1979 Addenda.
In a telecon on August 17, 1981, the licensee explained that the Spray Control valves had been reordered from Target Rock Company to the later ASNE Code.
No items of noncompliance or deviations were identified.
3.
Status of Internals Units 1 and 2 The reactor pressure vessel for Unit I had been completely cleaned and vacuumed. At the time of the inspection, layers of clean Visqueen were being placed in the vessel, making it ready to fit the core support structure.
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2n tait 2, the core support structure is installed and work to secure
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the nozzle flange and tube flange for the CRDN's has been stopped until a corrective action has been performed with regard to clearance near
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I the flexitallic gaskets.
Installation of incore flux tubing is complete for Unit 2 and Unit 1.
This tubing, 3/4" and 1" in size is butt welded l
together, with a plug subsequently pulled past the weld to insure non-interference from drop through of the weld.
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No items of noncompliance or deviations were identified.
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Status of Modification to Reactor Pressure Vessel Supports - Unit 2 l
The licensee is preparing to de -nsion the nolddown stude in Unit 2.
Machining of the flats on the oucside vessel wall where the lateral supports will bear is proceeding with three areas complete. A second milling machine is being prepared for this machining operation.
B&W who are performing the work qualified the machine end operators on dummy pieces of plate which appeared to mock-up the vessel curvature.
For the detensioning and retensioning of the hold down studs, UT equip-ment will be used to ascertain extension figures at various loads.
No items of noncompliance or deviations were identified.
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Unresolved Items Unresolved items are matters about which more information is required in order to ascertain whether they are acceptable items, items of noncompliance, or deviations. Unresolved items disclosed during this inspection are dis-cussed under Paragraph 1.b,Section II.
Exit Interview The inspectors met with site representatives (denoted in Persons Contacted paragraph) at the conclusion of the inspection. The inspectors summarized the scope and findings of the inspection noted in this report.
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