IR 05000346/1973004
| ML19319C092 | |
| Person / Time | |
|---|---|
| Site: | Davis Besse  |
| Issue date: | 11/14/1973 |
| From: | Dickerson M, Hayes D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML19319C089 | List: |
| References | |
| 50-346-73-04, 50-346-73-4, NUDOCS 8001310459 | |
| Download: ML19319C092 (12) | |
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U. S. ATOMIC ENERGY COMMISSION DIRECTORATE OF REGULATORY OPERATIONS
REGION III
Report of Construction Inspection RO Inspection Report No. 050-346/73-04 Licensee:
Toledo Edison Company Edison Plaza 300 Madison Avenue
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Toledo, Ohio 43652 l
Davis-Besse Nuclear Power Station License No. CPPR-80 Oak Harbor, Ohio Category: A Type of Licensee:
PWR (B&W) - 873 Mwe Type of Inspection:
Routine, Announced s
Dates of Inspection:
October 16, 17, and 18, 1973 Dates of Previous Inspection: July 10 - 11, 1973
)M.W.Dickersonh%-
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//V 373 Principal Inspector:
(Date)
Accompanying Inspectors: None Other Accompanying Personnel: None
'/[7.5 Reviewed By:
D. W. Hayes
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Senior Reactor Inspector
'(Da te,)
Reactor Construction Branch O
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SUMMARY OF FINDINGS Enforcement Action
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A.
Violations No violations of AEC requirements were identified during the inspection.
B.
Safety Matters No safety matters were identified.
Licensee Action on Previously Identified Enforcement Matters A.
Design Documents Did Not Have the Required Approvals (R0 Inspection Report No. 050-346/73-03)
During the referenced inspection the contractor, A. Bently & Sons (Bently), for installation of the reactor pressure vessel supports, I
was unable to produce approved documents used in their construction i
activities relative to the supports.
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During this inspection, the steps taken to correct this noncompliance as stated in the Toledo Edison Company (TECO) letter dated September 20, 1973, were reviewed by the inspector and determined to be acceptable.
This matter is considered resolved.
S.
Failure to Control Design Documents as Required (R0 Inspection Report No. 050-346/73-03)
During the referenced inspection, it was established that one copy of each drawing issued by the Bechtel Corporation (Bechtel) at the site, was apparently transmitted offsite by the Babcock and Wilcox Company, without records to account for this transmittal.
During this inspection, the steps taken by the licensee to correct this noncompliance as stated in their letter dated September 20, 1973, were reviewed by the inspector and determined to be acceptable.
This matter is considered resolved.
Design Changes
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No new design changes were identified.
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Unus sal Occurrences No unusual occurrences were identified.
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Other Significant Findings
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. A.
Current Findings
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The licensee indicated that, as of October 1, 1973; (1) construc-
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tion was 52% complete, and (2) engineering was 87% complete.
These figures represent a decrease from those reported during i
i the last inspection and are a result of a new scheduling i
(Forecast No. 3) of activities for the Davis-Besse plant.
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B.
Unresolved Matters f
No new unresolved matters were identified.
C.
Status of Previously Reported Unresolved Matters 1.
Cleanliness - Construction Area (R0 Inspection Report No.
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050-346/73-03)
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During the previous inspection, cleanliness of the construction
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areas within the reactor building, except for the reactor l
containment area, were considered to be inadequate.
Examination of these areas, during this inspection, established that cleanliness was much improved.
This matter is considered-closed.
2.
CRD Undervoltage Trip Assembly Deficiency (R0 Inspection
i-Report No. 050-346/73-03)
Documentrary evidence that the subject deficiencies (encountered l
'at another site) had been satisfactorily corrected was reviewed
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by the inspector and determined to be acceptable.
This matter
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is considered resolved.
(Paragraph 1)
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Apparent Corrosion of Stainless Steel Components and Stainless
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Components in Contact With Carbon Steel Hangers and Connectors
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(RO Inspection Report No. 050-346/73-03)
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As a result of the observed conditons, as discussed in the referenced report, an investigation into both the conditiot.s and their cause
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was undertaken by TECO.
The1results of this investigation were
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insufficiently complete for review at the-time of.this inspection.
This matter remains'open.
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4.
Reactor Coolant Pipina (R0 Inspection Reports No. 050-346/72-06,
No. 050-346/73-02. and No. 050-346/73-03)
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A manufacturer's data report is now available for all reactor
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coolant piping.
Thfe matter is considered closed.
(Paragraph 2)
Manaaement Interview-uA..
The following persons attended the management interview at the i
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conclusion of the inspection.
h Toledo Edison Company (TECO)
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G. J. Sampson, Vice President - Power j
L. E. Roe, Chief Mechanical Engineer
J. D. Lenardson, Quality Assurance Engineer
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G. W. Eichenauer, Field Quality Assurance Engineer i
i E. C. Novak, Nuclear Project Engineer
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Bechtel Corporation (Bechtel)
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H. A. ' Ablondi, Project-Quality Assurance Engineer
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Matters discussed and comments, on the part of management personnel, werefas follows:
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The' inspector reviewed the status of previously unresolved l
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matters described in the summary section of this report.
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.During this review, the satisfactory resolution of the
previous violations for use of an unapproved design document
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and'for failure to contro1' design drawings was also discussed.
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j 2.
The inspector requested that a controlled copy of the latest i
revision of the TECO Quality Assurance Manual be provided to l
. Region III.
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The licensee acknowledged the comments and stated that a' controlled
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copy of the TECO QA manual would be provided.
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mU REPORT DETAILS Persons Contacted
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The following persons, in addition to individuals listed under the Management Interview Section of this report, were contacted during the inspection.
Toledo Edison Company (TECO)
K. M. Cantrell, Quality Assurance Engineer W. G. Moring, Quality Assurance Engineer
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E. M. Wilcox, Quality Assurance Engineer M. D. Calcamuggio, Power Plant Electrical Engineer Bechtel Corporation (Bechtel)
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S. R. Boesel, Project Field Engineer
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J. E. Banchich, Office Engineering Assistant J. J. Ford, Quality Assurance Engineer Babcock & Wilcox Company (B&W)
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J. W. Marshall, Field Quality Control Superviso-
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A. Bently & Sons Company (Bently)
R. G.. Sanders, Quality Assurance / Quality Control Engineer Michigan Testing Engineers, Incorporated (MTE)
D. (NMI) Ponke, Quality Control Supervisor Results of Inspection
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1.
CRD Undervoltage Trip Assembly Deficiency (RO Inspection Report No. 050-346/73-Q3)
j Documentation at the site (B&W letter of September 13, 1973, which transmitted Diamond Power Speciality Corporation letter of August 29, 1973, including an electrical inspection report dated April 11, 1973)
-established that the CRD undervoltage trip assembly had been modified by the replacement of the 15 ohm trip coil with a 24 ohm coil.
It also established that, for the Davis-Besse control rod drive system, no additional modification to the circuit was required (to add a
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five-ampere fuse) since the circuit already provided overcurrent
protection in the form of a teu-ampere fuse. This matter is considered resolved.
2.
Reactor Coolant Piping (R0 Inspection Reports No. 050-346/72-06, No. 050-346/73-02, and No. 050-346/73-03)
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A manufacturer's data report (Form ND-1) for all 12 reactor coolant
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pipe spools has'now been received at the site.
This includes a data report for pipe spool No. A33-1 for which a stress analysis
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report had not been completed at the time of the previous inspection.
The pipe spools and.the respective date of the manufacturer's data report reviewed by the inspector are listed below.
- Spool Spool
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No.
Date No.
Date
A24-1 5/8/73 A67-3 5/8/73
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i A24-2 5/8/73 B44-1 5/8/73 A32-1 5/8/73 B56-1 5/8/73 A33-1 7/18/73 B59-1 5/8/73
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A67-1 5/8/73 B61-1 5/8/73 A67-2 5/8/73 B67 5/8/73
3.
Reactor Pressure Vessel Supports and Steam Generator Supports I
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Welding
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i (1) Implementation of Quality Assurance Program A review of the TECO, Bechtel, and PX Ex<
.aring Company, i
Incorporated, line and QA organizations ame functional relationships indicated that applicable quality require-
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ments were met relative to welding of the reactor pressure vessel and. steam generator supports.
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(2) Review of Quality Control System The PX Engineering QC system was determined to be acceptable for (1) qualification of weld procedures,
. welders, NDE techniques, NDE technicians; (2) identity of weld location, welder, weld procedures, NDE technicians,
NDE procedures,-and NDE results; (3) radiograph quality,
magnetic particle, dye penetrant and ultrasonic examination i
and corelation of records-to welds; (4) visual inspection of-6-
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joint preparation, environmental control, root gap,
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alignment, root pass, and completed weld; (5) weld
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preheat, interpass temperature, post weld' cooling control and stress relief; (6) defect removal technique, verification, and acceptance of repair; and (7) weld rod material receipt verification preissue storage conditons, issue control, post issue environmental control, and the disposition of unused weld rod.
Included, for each, were the QC inspector's procedural requirements.
Acceptability was established by selective' examination of the following:
(a) PX Engineering Company, Incorporated, QA Manual, Revision 1, Dated December 21, 1971.
(b) Weld procedures and welder qualification procedures.
(c) Weld repair procedure, WRP-010, dated May 16, 1972.
(d) Liquid penetrant inspection procedure, LP-010, dated January 6, 1972.
(e) Radiograph procedure, RT-012, dated August 30, 1972.
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(f) Post Weld heat treating procedure for P-1 material,
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HT-020, dated August 25, 1972.
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_(g) Ultrasonic examination of welds, UT-011, dated July 12, 1972.
I (h) Magnetic particle inspection procedure (final pass)
i MPI-012, dated August 30, 1972.
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(3) Follow-up Record Review An examination of the QC records for welding were satis-factorily reviewed for conformance with Bechtel Specifica-
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tion No. 7749C-48, Revision 0 (Technical Specification for the Furnishing, Detailing, Fabrication, and Delivery of Structural Steel for Major Component Support and Restraint Structures for Toledo Edison Company &nd The Cleveland-Illuminating Company, Davis-Besse Nuclear Power Station Unit No. 1 Construction) dated August 31, 1971,
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and-included:
(a) NDE records including UT records by the Arnold Green Testing Laboratorr, required by the repair of beam supports Nos. 1, z. 3, 4, 5, 6, 7, and 8.
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(b) Defect removal verification and acceptance of repair.
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(c) Welder qualification records.
(d) Post weld cooling control records.
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Weld rod material control records and a list of currently qualified welders were not reviewed, since they were not required to be submitted as part of the data package.
(4) Follow-up Observation of Work No observation of the welding, as performed, could be made since the RPV and SG supports had been completed
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prior to the time of this inspection, ar4 the supports were embedded in concrete during 1972.
b.
Structures and Supports (1) Implementation of Quality Assurance Program
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l A review of the TECO, Bechtel, PX Engineering Company, l
and Bently (installation contractor) QA organizations
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and functional relationships indicated that applicable
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quality requirements were met relative to the reactor
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pressure vessel and steam generator supports.
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f (2) Review of Quality Control System The PX Engineering and Bently QC systems were determined to be acceptable relative to material chemical composition, physical character, materials NDE, handling of nonconfor-mances, storage, and identification and control. No installation specifications were required, other than those containeu on drawings C-187, Revision 3, and C-lSO, Revision 1, for embeds and placement, and no NDE and inspection were required, except for the concrete within which the supports were embedded. Acceptability was determined by selective examination of the following:
(a) PX Engineering Company, Incorporated, QA Manual, Revision 1, dated December 21, 1971.
(b) Bently Quality Control Onsite Inspection Manual for Q-Listed Material, Revision 3, dated October 11, 1973.
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W (3) Follow-up Record Review s_,
An examination of the QC records for the RPV beam supports and SG supports established that they had been satisfactorily manufactured (to Specification 7749-C-48, Revision 0) receipt inspected, and installed.
Records examined included material chemical composition and physical character certifications, NDE records, receipt inspection records (including nonconformances) and installation records. The latter included 28-day concrete strength tests which exceeded the required 5,000 psi.
Installation records examined included the following com-pleted Bently checklists and report forms:
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(a) Form 5, Reinforcing Steel Placement (b) Form 6, Cadweld Check-off List (c) Form 9, Formwork Construction Report (d) Form 10, Concrete Placement Checklist (e) Form 13, Installed Inspection Report (4) Follow-up Observation of Work
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No observation of the work as performed could be made, since the RPV beam supports and SG supports had been completed prior to the time of the inspection and had been embedded during 1972.
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4.
Primary Piping a.
Welding (1) Implementation of Quality Assurance Program A review of the B&W QA organization and functional relationships indicated that applicable quality require-ments were being met relative to welding of the primary coolant piping.
(2) Review of Quality Control System The B&W QC system was determined to be acceptable for (1) qualification of weld procedures, welders; NDE
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techniques, and NDE technicians; (2) identity of weld location, welder, weld procedures, NDE technicians, NDE procedures, and NDE results; (3) radiograph quality, magnetic particle, dye penetrant and ultrasonic examina-tion _and corelation of records to welds; (4) visual l
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inspection of joint preparation, environmental control, root gap, alignment, root pass, and completed weld; (5) weld preheat, interpass temperature post weld cooling
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control, and stress relief; (6) defect removal technique, verification, and acceptance of repair; and (7) weld rod-material receipt verification, preissue storage conditions, issue control, post issue environmental control, and the disposition of unused weld rod.
Included, for each, were the QC inspector's procedural requirements.
Acceptability
was established by selective examination within the
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following:
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(a) B&W QA Manual for Nuclear Power Plant Components, Copy No. 3, issued to TECO February 17, 1973.
(b) B&W QC Manual for. Toledo Edison Company, NSS-14, Copy No. 3, issued to TECO February 15, 1973.
The QC manual is composed of five sections.
Section
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N technical QC procedures; Section 3, NDE QC procedures; Section 4, welding QC procedures; and Section 5 contains welding instruction sheets and procedure
qualification.
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Piping
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(1) Implementation of Quality Assurance Program
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A review of the B&W organization and functional relation-ships' indicated that applicable requirements were being met relative to receipt, storage, and installation of the
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primary coolant piping.
(2) Review of QC System
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'The B&W QC system was determined to be acceptable
relative to material chemical and physical certifications, NDE, cleanliness at receipt, protective closures, protective p
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measures, marking and identification, quarantine of nonconforming material, storage identification and control, storage protection and installation NDE. Acceptability was
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i established by selective examination of Sections 1 and 3
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procedures from the B&W QC Manual for Toledo Edison Company, NSS-14, Copy No. 3, issued to TECO February 15, 1973, as follows:
Section 1 (a) No. 9A-107, Report of Inspection - Inspection Ticket, Revision 8.
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(b) No. 9A-107-1, Receipt Inspection and Procedure for
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Tagging, Revision 6.
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(c) No. 9A-108, ASME Code Data Reports, Revision 4.
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(d) No. 9A-112, Disposition of Nonconformities, Revision 8.
j (e) No. 9A-ll7, Storage Requirements, Revision 2.
Section 3 (a) No. 9T-102A, General Procedure for Radiographic Examination, Revision 6.
l (b) No. 9T-RT-200, Radiographic Examination of Cir-
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cumferential Butt Welds Using Iridium-192, Revision 2.
(c) No. 9T-102F, General Procedure for Magnetic Particle Examination, Revision 2.
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(d) No. 7T-MT-203, Magnetic Particle Examination of Welds Using Yoke Method, Revision 1.
(e) No. 9T-102H, General Procedure for Liquid Penetrant Examination, Revision 4.
(f) No. 9T-PT-200, Liquid Penetrant Examination of
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Welds, Revision 0.
(g) No. 9T-102U, General Procedure for Ultrasonic
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Examination, Revision 0.
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UNITED STATES
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-l ATOMIC ENERGY COMMISSION j.{
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OlVISION OF COMPLIANCE f,
REGION lli
- gg 799 ROOSEVELT ROAD GLEN ELLYN, ILLINots 60137 ola) ess.asso i-050-346/73-04
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A.
RO Inspection Report No.
tiovember 14, 1973 Transmittal Date
Distribution:
Distribution:
RO Chief, FS&EB RO Chie f, FS&EB RO:HQ (5)
RO:HQ (4)
i DR Central Files L:D/D for Fuel & Materials Regulatory Standards (3)
DR Central Files Licensing (13)
RO Inquiry Report No.
Transmittal Date
Distribution:
Distribution:
RO Chief, FS&EB RO Chie f, FS&EB RO:HQ (5)
RO:HQ DR Central Files'
DR Central Files Regulatory Standards (3)
RO Files Licensing (13)
RO Files C.
Incident Notification From:
(Licensee & Docket No. (or License No.)
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Transmittal Date
Distribution:
Distribution:
RO Chief, FS&EB RO chie f, FS&EB RO:HQ (4)
RO:HQ (4)
Licensing (4)
L:D/D for Fuel & Materials DR Central Files
'DR Central 'iles RO Files RO Files
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