IR 05000341/1979002
| ML19284A746 | |
| Person / Time | |
|---|---|
| Site: | Fermi  |
| Issue date: | 02/06/1979 |
| From: | Hayes D, Phillips H, Wescott H NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML19284A745 | List: |
| References | |
| 50-341-79-02, 50-341-79-2, NUDOCS 7903150345 | |
| Download: ML19284A746 (15) | |
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U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT
REGION III
Report No. 50-341/79-02 Decket No. 50-341 License No. CPPR-87 Licensee: The Detroit Edison Co:tpany 2000 Second Avenue Detroit, MI 48226 Facility Name:
Enrico Fermi Nuclear Station, Unit 2 Inspection At:
Fermi Site, Monroe, MI Inspection Conducted:
Ja ry 9-12, 1979
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Inspectors:
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H. M. Wescott
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Approved By-
. W. Nay s, Chief
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Projects Section
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Inspection Summary Inspection on January 9-12, 1979 (Report No. 50-341/79-02)
Areas Inspected:
Followup or allegation previously identified in NRC Report No. 50-341/78-05 dated April 4, 1978 and similar allegation made on January 5, 1979; followup on previously identified noncompliances/
unresolved matters; followup on core spray pump 50.55(e) report; safety related structures, procedures and work; safety related structural welding, procedures and work; reactor internals, procedures / work and records; safety related components, procedures and work.
This inspection involved 72 inspector-hours onsite by three NRC inspectors.
Results: Seven areas were inspected.
No items of noncompliance, devi-ations or unresolved items were identified during this inspection.
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DETAILS Persons Contacted Detroit Edison Company
- E.
Hines, Assistant Vice President and QA Manager
- T.
A.
Alessi, Senior QA Engineer
- A.
Alexiou, Assistant Project Superintendent
- C.
R.
Bacon, Field Project En gineer
- R.
W.
Barr, Project QA Department C. Carter, QA Engineer P. Cribbs, QA Engineer
- W.
M.
Everett, Project Superintendent
- E.
Grilang, Assistant Superintendent D. Lehnert, Engineer - Mechanical
- C.
J. Miller, Senior QA Engineer J. E. Norton, QA Engineer
- G.
Vangof f, Electrical Field Engineer
- H.
A. Walker, Site Project QA Engineer
- W.
White, Assistant Project Fbnager and Plant Superintendent Daniels International Construction
- J. T.
Blixt, Project QC Manager
- J.
G.
Bolt, Project QA Manager
- C.
W.
Kostblade, QC Engineer R. Madden, Acting Documentation Supervisor
- D.
Seifert, Project Manager General Electric E. Baker, Lead Engineer T. Diebold, QC Inspector
- W.
A. Konkle, Site Manager, HED Comstock J. Wiegand, QC Supervisor D. Ord, Inspector
- Denotes those attending the exit interview.
Licensee Action on Previous Inspection Findings (Closed) Unresolved Matter (50-341/76-02): Applicable ASME Code for inservice inspection.
In 1976, when above inspection was made, ASME-2-
Section XI, 1971 edition was referenced as the requirement for inservice
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inspection.
The present requirement stated in Amendment 15 to the FSAR references ASME Section XI 1974, summer 1975 addenda and covers class 2 and class 3 items for the preservice inspection.
(Closed) Unresolved Matter (341/77-05):
Reinforcement steel placement procedure did not contain acceptance criteria concerning spacing tolerances.
The inspector reviewed Utley-James, Inc. Reinforcement Steel Placement Procedure No. 4, Rev. 2 attachment No. I which contained acceptance criteria for reinforcement spacing.
Additionally, concrete work is completed.
This t:atter is closed.
(Closed) Unresolved Matter (341/77-08-03):
Review of Wismar & Becker Contracting Engineers QA/QC manual indicated (1) no provisions for stop work orders (2) no provisions for timely resolution of audit findings and (3) no provisions fcr deficiency reporting per 10 CFR 50.55(e).
The inspector reviewed procedures to assure that such provisions were incorporated into the revised procedures (1) QA manual,Section I, paragraphs 3.1.1.10 and 4.2.2.7 have been revised to address stop work authority, (2) QA manual,Section XVIII, paragraph 5 addresses correc-tive action regarding audit findings, and (3) Wismer & Becker incorporated Daniel International 50.55(e) Reporting Procedure, AP-II-08, into the WEB manual.
(Closed) Noncompliance (341/77-10-04).
No p.
cedures to assure that documentary evidence that scfety related items conform to procurement requirements are available on site prior to use or installation.
Further, document packages for seismic and other required certifi-cations for Class IE equipment could not be produced to show conformance to requirements.
The inspector reviewed Project Procedure Manual (PPM) Part I, paragraph No. B.l.5.18, which now requires documentation as described above.
The matrix form to assure the field of equipment acceptability is now on site and are in the QC records file.
(Closed) Unresolved Matter (341/77-11-01): Procedure AP-IX-05 which required hold items be segregated except where impractical.
The term
" impractical" was not clear. Procedure AP-V-09 " equipment and material storage and maintenance" specified the use of locator cards. Headings on locator and daily receiving summary forms had been changed but procedure did not reflect form change.
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The inspector reviewed Edison QA audit of Daniel International
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warehousing and storage areas (Audit No. F2S8-1161, October 10, 1978).
This audit covered ninety two items.
The inspector verified segregated hold areas for items on hold in building No. 20 and a separate area for rejected items in building No. 21.
Procedures had been revised to include user procedures and revised forrs.
(0 pen) Unresolved Matter (341/78-02-07)
In April 1977 iicensee performed only one audit of Daniel quality control.
The one audit pertained to the electrical contractor.
No followup action had been performed as of Februrary 19/8.
Subsequently, the inspector found that Edison QA had p2rformed an audit of Daniel QC in March 1978.
This item remains open pending final followup of open audit findings.
(Closed) Unresolved Matter (78-03-04):
Pipe hanger, G413349-6 was bent.
Embeds immediately above the hanger were mislocated.
No hold tag was on the hanger, however, a deficiency report (DDR) 1335A had been issued.
The inspector reviewed the DDR and found that the piping was Level II.
The inspector also reviewed the nonconformance system during NRC inspection dated July 31, 1978, report No. 50-341/78-11.
NCR's reviewed had received appropriate review and approval.
The inspector has no further questions on this matter.
(Closed) Unresolved Item (50-341/78-05-01):
Tagging and segregation of cable tray and conduit supports.
The inspector examined Comstock activities and determined that items for repair and acceptable items were identified and segregated.
(Closed) Unresolved Item (50-341/78-05-02):
Improper storage cable tray and conduit supports.
Examination of the storage area revealed that dunnage had been placed under electrical cable trays and supports.
(Closed) Unresolved Items (50-341/78-05-03): Quantitative acceptance criteria not available for receipt inspection.
AWS Dl.1-75 has had supplementary design change notices added to the requirements which do define acceptance standards for welds.
(Closed) Unresolved Item (50-341/78-05-04): Uncertified welders used to fabricate electrical trays and supports.
The inspector has ascer-tained that this problem with vendors has been rectified and all vendor welders have been certified for the past 4 years.
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(Open) Unresolved Shtter (50-341/78-05-06) : Class lE electrical supports with unacceptable welds not identified nor corrective action documented.
This item has been carried forward f rom the spring of 1978 due to certain allegations made at that time.
Another allegation of similar nature was made in January, 1979 and this item remains open pending verification of quality to a licensee Design Change Notice (DCN 984).
Details, paragraph 5,Section II.
(Closed) Unresolved Item (50-341/78-05-05):
Installation welds for Cable Tray Supports do not meet AWS D1.1-75.
This item has been closed by the issuance of licensee DCS's to the procurement documents which amend the requirements of AWS Dl.1-75.
(0 pen) Noncompliance (341/78-09-04): QA audits of purchasing relating to procurement of essential components, QA Level 1 were not available.
The inspector reviewed Edison Audit EF2 45020 dated November 28, 1978.
The audit contained tne results of auditing:
(1) QA manual requirement QAP 5 Document Control, para. 5.0.1, and Section 10.5.3.3.1.2 of Project Procedure >knual, Part 1, Section 10.
A finding was recorded regarding an approved bidders list, (2) Q AP No. 1, paragraph 1.8.1, 1.8.5 and 1.8.7.
A finding was recorded regarding indoctrination and training, (3) PPM Part 1, Section 10, paragraph 10.5.3.3.1.2.
No instructions for use of qualified vendors list and (4) PPM does not give Daniel International Construction Company directions to assure purchase orders are placed with qualified vendors. Audit EF2 45018 (Nov. 78) covered training and indoctrination, QAP No. 1 and purchasing _nspection, QAP No. 11.
The inspector noted that no audit had been performed on QAP No. 6.
Procurement document control.
Also the entire audit file was unavail-able on site.
These files will be reviewed at the Troy office during a subsequent inspection.
(Closed) Noncompliance (341/78-09-11):
Daniel International auditor qualification records were not on site as required.
The inspector verified that the auditor's qualifications records were now on site.
A certification was also in the file to demonstrate compliance with ANSI N45.2.23.
(Closed) Noncompliance (341/78-09-13). An approved bidders list was not established maintained nor distributed as required by.
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Procedure No. 7.
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The RIII inspector reviewed an approved bidders list which had been established.
Edison memo, dated September 6, 1978, M. C. Tonilas to-5-
R. W.
Barr, Subject:
Bidder's List, indicated that the list had been distributed and was in use.
(Closed) Unresolvad Matter (341/78-11-01):
Structural steel welding at 607 elevation 300 Az appeared to have lack of fusion.
The RIII inspector reviewed this matter and found that the weld was inspected by Daniel International subsequent to NRC identification and they found that the weld had been made by an offsite vendor.
Excessive convexity, lack of f usion and overlaps were also obsec /ed by DI inspectors.
Edison QA review of Inland Ryerson drawing sheet 438 showed that the weld was not required per the drawing.
This matter is considered closed.
(Closed) Unresolved Item (341/78-15-01): Licensee was not assuring that welding voltages and travel speeds were verified and documented.
Review of Reactor Controls, Inc., "QC Welder Surveillance" sheets established that the welding voltage and travel speed was being recorded as of September 27, 1978.
(0 pen) Unresolved ibtter (341/78-18-01):
Jet pump welds appeared to be made by different processes. Workmanship on one weld on jet pump No. 8 was questioned.
Excessive weld spatter was observed on jet pumps 6,11, 15,18 and 19.
The RIII inspector reviewed GE letters dated December 6 and 12, 1978 subject:
Letter of clarification on jet pump mixers (1) different processes were used per GE specification P50YP102, Rev. 5 allosed different processes, (2) the weld quality on jet pump No. 8 was the result of straightening the elbow to nozzle joint by adding straightening beads.
The inspector reviewed GE field deviatior disposition request dated November 17, 1978 and inspection records attached which documented weld spatter removal and final inspectior..
F2ragraph 4.7 of the specification stated "The weld and base metal shall be free of solidified slag and weld spatter, as determined by visual inspection." The inspector had no further questions on this matter.
Welding records were not sent to site by General Electric Company.
The licensee stated that an audit of NDE and welding on jet pumps would be performed in lieu of transmitting the records to site if this was acceptable to the NRC.
The inspector stated that either action would satisfy the concern but that this matter would remain open pending review and evaluation of the audit findings.
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(0 pen) Unresolved Matter (341/78-18-04):
Calibration of scales, batch plant admixture measuring devices were inadequate, however, concrete work was complete.
The licensee committed to review similar areas pertaining to calibration. Approximately 75% of the areas had been audited. This item will receive final review when this audit is completed.
(0 pen) Unresolved obtter (341/78-18-06):
File 6.4 record of minus 2 psig test was not immediately available for review.
The inspector requested the above record during the previous inspection.
Again, the record was available for review.
This matter will receive broader review during a subsequent inspection.
(0 pen) Unresolved >btter (341/78-18-07):
Dravo Boss weld surface roughness was excessive.
Such e surface condition would interfere with final penetrant inspection. The RIII inspector was informed that this same problem existed throughout the plant.
As a result this matter was left unresolved pending review of QA Level I systems.
The inspector reviewed Daniel International letters dated December 8 and 11, 1978 concerning visual inspection of Class 1 QA Level I piping spool attachment welds in the drywell area, cwo one inch taps and four hanger lugs on spool piece E-41-2297-2.
Maximum weave of 3/8 inch was actually up to 1 3/4 inches. Dravo specification stated root pass with E6010 but Detroit Edison Specification 3071-30 para. 13.C.1 states coated electrodes shall be low hydrogen type except E 7010 or E 7010 A-1 may be used if root is subsequently removed.
One other pipe spool was observed with similar attachments but due to lack of time no further inspection was performed by DI inspectors.
(Closed) Unresolved Item (341/78-18-10):
Licensee not assuring that welding voltage and amperage being verified and documented. Review of Wismer/Becker " Weld Process Control Sheet Traveler" established that the voltage and amperage are being recorded on the reverse side of the sheets by a QC inspector.
(Closed) Unresolved Item (341/78-18-11):
Traceability of material and parts used for on site fabrication of Level 1 pipe hangers and supports appeared to be questionable. During this inspection it was established that materials and parts used for fabrication of Level I pipe hangers and supports were traceable to material certifications at the time of receipt and storage. The storage areas are controlled as to their contents.
When plate stock is cut the material identifying symbol is transferred to the unmarked piece.
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SECTION I l'repared by H.
S.
Phillips Reviewed by D. W.
Hayes, Chief Projects Section Functional or Program Areas Inspected 1.
Site Tour The Region III inspector visually inspected all floors of the reactor building to observe general housekeeping and construction progress.
General storage and maintenance of equipment stored in place was also inspected.
Repair welding of core spray spool piece E21 3147 5A, drawing E21 31475A, was observed.
Records of inspections performed were reviewed and were acceptable down to the point of repair.
No items of noncompliance or deviations were identified.
2.
Review of 10 CFR 50.55(e) Core Spray Pump, Impellar Vanes ( 341/ 7 8-XX-04 )
Core spray pump impellar vanes (Unit
"C" Serial #701-S0807 and
"B" Serial d701-50C0b).
Purp "C" had crack on all three vanes and Unit "B" had one crack readily visible.
W6B recorded defielencies on DDR 139 and reported per 10 CFR 50.55(e) procedures.
An investigation and analysis of reported impeller casting deficiency was performed by Byron Jackson Pump Division. The manager of metallurgical engineering concluded that the subj ect pumps could be used "as is" because "It is totally inconceivable that any crack could propagate to the point of impairing the integrity of these impellers, and jeopardizing the safety related service f or which the pumps are intended."
The investigation did not recommend crack removal, however GE has recommended such action.
This item remains open pending final repair.
No items of noncompliance or deviations were identified.
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3.
Review of Open Items Project records indicated approximately forty-nine open items prior to this inspection.
The inspector informed licensee personnel at the entrance meeting that all open items would be closed where appropriate action had been taken.
The oldest items and items identified during the last inspection were given priority.
The inspector also reviewed other open items and advised the licensee that several items would be closed subject to the concurrence of the inspector who initially identified the item.
The licensee submitted a total of twenty-five items which had received final or interim action.
Seventeen epen items were closed during the inspection.
No items of noncompliance or deviations were identified.
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SECTION 11 Prepared by C. M.
Erb Reviewed by D. H. Danielson, Chief Engineering Support Section 2 1.
Observation CRD System Parts and Installation and NDT Welding of stainless sockolets to an 8" carbon steel scram discharge pipe was observed.
The pine is to ASME SA 106 Grade B and the sockolets (22) were to ASME 105. Visual and Penetrant Test was performed on these welds, with the scram discharge pipe categorized as Class 2.
ASME Code Section III 1971 edition with sunmer addenda is applicable to this part.
Hold points were noted on process sheets and the ANI is inspecting in an offsite fabrication facility in Monroe.
A radiograph to specification No. RT-3001 of an 8" scram discharge pipe was examined. This was an open butt weld with a GTAW root and SMAW completion.
An ASME steinless steel penetrameter was used with a.090" stainless steel shim which is allowable to ASME Section III 1971 edition, summer 1973 addenda.
Several carbon steel hangers for insert and withdraw lines were examined. These hangers are a scismic/ application and utilize a stainless shim on unistrut side and a stainless steel
"C" type clamp to hold each insert and withdraw line firmly to the hanger.
This design insures holding contact between similar materials yet allows endwise thermal movement.
Audits of GE installation and service engineering QA was made by Daniel AFR No. 78-03-16D and 78-10-28D, with corrective action properly implemented.
No items of noncompliance or de"lations were identified.
2.
Internals Observation of welding inside the vessel showed that 12 of the 55 in core housings have been welded in place. Welding is done to Procedure No. WPS8-43.9.2.2B Rev. 3 which requires a GTAW root and SMAW completion weld.
The in core housings are type 304 stainless steel and the vessel is clad with inconel in the weld area, so the veld joins P8 and P43 materials.
Penetrant Testing
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is performed by NDT Services.
Penetrant Test is performed 3 times, first on the root of the weld, secondly on the SMAW portion which is flush with vessel surface and the last time on the fillet part which is built by the GTAW.
No items of noncompliance or deviations were identified.
3.
Class 1 and Class 2 Valves - Ouality Records Identification, certifications and FDT results were examined for several valves both inside and outside containment as shown below:
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Type Valve Manufacturer Class S/S System ASS'E Code J" Cate Powell
V8-2165 RHR Sect. III, 197', W1971
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26" Iso Atwood & Morrill
6-682 M.S.
Sect. III, 1971 20" Check Atwood 6 Morrill 1 2-763 Feed H O Sect. III, 1971, W1971
20" Check Anchor Darling
V12-2002 Teed H O Sect. III, 1971, V1971
No items of noncompliance or deviations were identified.
4.
Repair of Torus Welds The licensee stated that repair procedures would be qualified off site by January 19, 1979 and that welder qualification of Reactor Controls personnel would then begin.
The repair weld procedure will require a 300 - 400 F preheat, which will be done by electric resistance heaters placed on the surface furthest from the welder.
This preheat would be naintained for 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> after completion of the weld.
The type 7018 electrode will be given a high temperature bake prior to use.
Block welding will be utilized, but the sequence and length of blocks was not stated.
Fifteen quenchers will be installed on the SRV lines to the torus of which five are ADS and 10 are set point type.
No items of noncompliance or deviations were identified.
Unresolved Matter (50-341/78-05-06) (Details):
Class lE electrical supports with unacceptable welc-not identified nor corrective action documented.
5.
Investigation of Allegation Concerning Welding of Cable Tray Hangers On January 5, 1975 an alleger called the NRC and stated that a
licensee Design Change Notice DCN No. 984 Rev. E had been issued
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which stated there would be "no maximum limitation on convexity of fillet welds."
This DCN also included an extensive relaxation of undercut requirenents for various standard parts containing unistrut components.
The NRC inspector stated that he would be at the site on Tuesday of the following week, and would examine the DCN and also inspect welds to determine if any of them were unacceptable to the Design Change Notice (DCN) No. 984.
1'pon arrival at the site the inspector stated to the licensee QA supervisor that the Revision E on convexity was unacceptable and the QA supervisor agreed.
Revision "E" stated that there should be no maxinun limit on convexity in fillet welds.
Fevision F, which was issued while the inspector was still on site stated that,
"the faces of fillet welds may be slightly convex or slightly concave.
Revision F further stated that any welds accepted with excessive convexity were to be reevaluated.
Revision F made no change in acceptable undercut as indicated in Revision F.
The relaxation of fillet weld size for Kellem Grip Hangers and the change in undercut requirements in DCN 984 are the result of extensive testing and are described in a letter EF2-42352.
This letter dated November 20, 1978 from Mr. W.
F.
Colbert to R. W.
Barr Deco explains the basis for DCN 984 which was developed by Sargent 6 Lundy to supplement AWS D1.1-1975.
The inspector examined several welds in cable ; rays in three plant areas, but found no instance where welds would be unacceptable to AVS D3.1-1975 as anended by DCN 984 Rev. F.
In a telecon the licensee stated that all class IF electrical support welding would be conforming to AUS D1.1-1975 and DCN 084 Rev. F na later than February 16, 1979.
The inspector will perform a final review of welding to DCh 984 Rev. F if possible with the help of the alleger, to insure that no unacceptable welds are installed or in stores at the site.
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SECTION III Prepared by H. M. Wescott Reviewed by D. W.
Hayes, Chief Projects Section 1.
Review of Quality Assurance Implementing Procedures The inspector reviewed the following QA procedures for welding of safety related structures to ascertain that they had been estab-lished per applicable requirements.
a.
Enrico Fermi Atomic Power Plant Quality Assurance Manual, Detroit Edison Company QAP No. 10. " Control of Special Processes," dated November 7, 1975, Revision 2.
b.
Wismer/Becker Quality Assurance and Quality Control Manual,Section IX, " Control of Special Processes," dated May 1, 1976 through Addendum 4.
c.
QAP No. 9. " Instructions, Procedures and Drawings," dated November 1, 1975, Revision 3.
d.
WB-Q-101, " Control of Weldiag Materials," dated May 6, 1978, Revision 3.
e.
WB-Q-103, " Visual Weld Examination Procedure," dated February 8, 1978, Revision 5.
f.
WB-C-lli, " Weld End Preparation," dated November 25, 1978, Revision 1.
g.
WB-C-117, " Weld Joint Fit-Up," dated September 28, 1978, Revision 5.
h.
WB-C-118, " Methods of Control and Monitoring of Preheat and Interpass Temperature," dated January 20, 1978, Revision 2.
2.
Review Qualification Records of NDE Personnel The inspector reviewed the qualification records of NDE personnel to ascertain that they were in conformance with SNT-TC-1A as follows:
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a.
Review of three (3) Wismer/Becker NDE personnel qualification records selected at random for Level I PT, Level II PT, MT and assistant RT, and Level III RT and PT.
b.
Review of six (6) reactor control Inc., NDE personnel qualification records.
All of the qualification records had been audited prior to this inspection.
Several discrepancies were noted as a result of the audit and action is being taken to update the records to conform with SN-TC-1A requirements.
3.
Review Qualification Records of Welders The inspector reviewed the qualification records of welders to ascertain that the w:1ders were qualified to the welding procedures in use and that they had maintained their qualification as follows:
a.
..eview of five (5) Wismer/Becker welder cualification and performance qualification records.
b.
Review of seven (7) Reactor Controls, Inc., welder qualification and performance records.
Review of Receiving Inspection Reports and Observation of Storage Area The inspector reviewed Wismer/Becker Receiving Inspection Reports (RIR's) and made observations in the storage area of Class 1 parts and material as follows:
a.
RIR's No.'s 2762 through 2778 including the required certifications.
b.
Randouly selected Class 1 parts from the Wismer/Becker storage warehouse and traced to the RIR's and certifications.
5.
Observation of Weld Joint Fit-Up The inspector observed weld joint preparation and fit-up as follows:
a.
Four (4) suppression pool torus support plates.
b.
Main steam hanger support steel ID No. 's 635 BK4 and 635 BK5.
c.
Trapeze hanger G 41-3'o0-G16 and E21-3145-C01.
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d.
Weld P1, cess Control Sheet No. 20762 (6EC9) Weld ID No.
B21-3258-4100 for weld fit-up and tack weld of fixtures.
In the areas inspected no items of noncompliance were identified.
Exit Interview The inspectors met v :h site staff representatives (denoted in the Persons Contacted pa agraph) at the conclusion of the inspection on January 12, 1979.
Te inspectors summarized the scope and findings of the inspection.
The licensee acknowledged the findings.
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