IR 05000346/1975007
| ML19319B588 | |
| Person / Time | |
|---|---|
| Site: | Davis Besse  |
| Issue date: | 05/19/1975 |
| From: | Jablonski F, Naidu K, Sutton J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML19319B576 | List: |
| References | |
| 50-346-75-07, 50-346-75-7, NUDOCS 8001270111 | |
| Download: ML19319B588 (22) | |
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l U. S. NUCLEAR REGULATORY C03DiISSION l
0FFICE OF INSPECTION AND ENFORCEMENT l
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REGION III
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j Report of Construction Inspection i
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IE Inspection Report Mo. 050-346/75-07
Licensee:
Toledo Edison Company
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300 Madison Avenue l
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Toledo, Ohio 43652 Davis-Besse Nuclear Power Station License No. CPPR-80 Unit 1 Category:
B Oak Harbor, Ohio
Type of Licensee:
Type of Inspection:
Routine, Unannounced i
Dates of Inspec. tion:
April 21-23, 1975 t
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}t Dates of Previous Inspection:
March 12-14, 1975 (Operations)
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Principal Inspector:
.~J. W.'Sutton PSe,, d
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(Date)
Accompanying Inspectors:
F.
.Nablonski 6 -/(, ~76
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(Date)
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K* R. Naidu 6~ ' O * ' ','
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I (Date)
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.l Other Accompanying Personnel:
D. W. Hayes i
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h Reviewed By:
D. M. Hunnicutt, Chief 8 / f/78
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Construction and Engineering Support Branch (Da t'e )
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SUMMARY OF FINDINGS Enforcement Action A.
Items of Noncompliance 1.
Violations None 2.
Infractions Contrary to 10 CFR, Appendix B, Criterion V, activities relative to the identification of nonconforming materials were not performed in accordance with Quality Assurance Procedure No.
6, laragraph 5.3 of the Fischbach and Moore quality Control Macual.
(Report Details,Section II, Paragraph 1.a(1)-(2))
This infraction was identified by the inspector and had the potential for causing or contributing to an occurrence with safety significance.
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3.
Deficiencies v'
None B.
Safety Matters None Licensee Action on Previously Identified Enforcement Matters A.
Use of approved instrumentation installation / fabrication planner.
(Inspection Report No. 050-346/75-01)
B.
Failure to provide and use approved instructions, procedures, and drawings during installation and fabrication of safety related components.
(Inspection Report No. 050-346/75-01)
C.
Failure to have documentary evidence of material conformance to procurement requirements prior to installation of components and structures.
(Inspection Report No. 050-346/75-01)
D.
Failure to establish and control use of inspection stamps during construction.
(Inspection Report No. 050-346/75-01)
E.
Failure to control tools used in quality related activities.
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(Inspection Report No. 050-346/75-01)
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F.
Failure to control the handling, storage, and preservation of quality s
related materials and components.
(Inspection Report No. 350-346/75-01)
G.
Failure to issue a stop-work order relative to the installation of safety related instrumentation components found to be improperly controlled.
(Inspection Report No. 050-346/75-01)
The corrective action, for the above items as outlined in the Toledo Edison Company (TECO) letter of March 26, 1975, in response to the IE:III letter and report dated February 19, 1975 and IE:III letter dated March 4, 1975 was found to have been satisfactorily accomplished and documented.
These matters are considered closed.
(Report Details, Section 1, Paragraph 1)
Design Changes None Unusual Occurrences No unusual occurrences were identified.
Other Significant Findings O
A.
Current Findings
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1.
Current Status The licensee indicated that, as of April 1, 1975:
(1) construction was 83.3% complete, and (2) engineering was 98.8% complete.
2.
Personnel Changes Toledo Edison Company (TECO)
The following has been added to the TECO QA Staff.
Mr. J. C. Buck, QA Engineer, Operations Bechtel Corporation (Bechtel)
The insrce:sr was informed as of April 23, 1975 that Mr. J.
B.
Olmstead would replace Mr. M. R. Stephens as Corporation Project Manager (Gaithersburg) for the Davis-Besse, Unit 1 Nuclear Project.
Bagwell Coatines Inc.,
Mr. C. M. Monroe, Jr. has replaced Mr. C. H. Ridgdell as Site
/N Project Manager.
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Johnson Controls Co. (Johnson) Stop Work Order The inspector was informed and shown documentation that the Bechtel Stop Work Order No. 9 issued on January 24, 1975 had been rescinded on April 15, 1975. The action was based on the results of a PQA audi. No. 184 and at a joint meeting with Toledo Edison Company, Bechtel and Johnson Controls Co.,
personnel.
Corrective action in those areas that had been found to be unacceptable, have been corrected.
The April 15, 1975 letter from 3echtel to Johnson Control Co., states that, ""Q" listed work involving ASME Section III Code and
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ANSI-B31.1 fabrication and erection, including Seismic I supports can be perfermed." This matter will be given further review during subsequent inspections..
B.
Unresolved Matters
1.
Johnson Controls Co., Sub-Vendor Inspections Johnson's QA Manager could not provide the inspector with information or a program that vould indicate that the three subvendors of Johnsonfs had b.en audited, relative to a QA Program to supply Quality related materials for use in fabricating Quality Related Instrumentation components.
g'~'s Further review of Johnson activities in this area will be (
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made during a subsequent inspection.
(Report Details,Section I, Paragraph 2)
2.
Cable Separation and Barrier Criteria The licensee could not provide the inspector with information which would indicate how cable separation would be verified and/or how barriers would be utilized to meet FSAR separation requirements.
This matter requires followup review.
(Report i
Details,Section II, Paragraphs lal, ib, Ic2, Ic3 and Id.
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3.
Electrical Nonconformance Reports
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Nonconformance reports (NCRs) reviewed by the inspector indicated
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that NCRs do not appear to be receiving adequate review for
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dispositioning purposes and that routine construction deficiencies
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are not being identified during the construction phase.
This matter will receive further review.
(Report Details,Section II, Paragraph 3)
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4.
Audits The last documented audit of F&M by TECO was April 23, 1974.
No effective audits relative to t? _ proper routing and separation of safety related power and cont al cables had been performed, by the licensce's agent.
This matter will require followup
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attention.
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C.
Status of Previously Reported Unresolved Matters 1.
Cooling Water Piping to Emergency Diesel Engine No. 2 (Inspection Reports No. 050-346/74-07, No. 050-346 # 5-01 and No. 050-346/75-03)
The inspector reviewed drawing M236H, Revision 5, dated February 10, 1975, relative to the rerouting of the cooling water pipe to the Emergency Diesel Generators.
The inspector also established that the compressed air piping reported in No.
050-346/74-07 did not relate to the Emergency Diesel Engine.
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This item is considered closed.
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2.
Hydraulic Snubbers (Inspection Reports No. 050-346/74-07,
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No. 050-346/75-01 and No. 050-346/75-03)
The inspector reviewed available information on the seal material and oil used in the hydraulic snubbers intended for use in hvda radiation areas and determined that the licensee is taking necessary corrective action to ensure that the appropriate seal material and oil will be furnished by the vendors including the oppropriate revisions to the original Bechtel's Design Specificction, Part II, No. 7749-M1-90.
This item remains open pending review of documents received on this subject.
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3.
Cable Tray Installation Procedure (Inspection Report No.
050-346/74-07)
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This matter remains open pending the inspector's review of the licensee's procedure that would verify that these items are included as part of the inspection program.
4.
Cable Tray Storage (Inspection Report No. 050-346/74-07)
This item remains open pending the inspector's review of procedures and observation of the storage area.
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5.
Calibration Records - Stress Relieving Instrumentation and Equipment (Inspection Reports No. 050-346/74-07 and No.
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050-346/75-03)
The inspector reviewed Babcock and Wilcox (B&W) calibration control program 9T-101, Revision 4, January 1:, 1975 detailing the system used to periodically inspect gaging and measuring instruments as required by Section III of the ASME Code.
The equipment is marked with a identitying number and labeled to indicate the calibration date and initialed by the inspector.
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This item is considered closed.
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6.
Diesel Generator-Relays (Inspection Reports No. 050-346/74-07
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No. 050-346/74-10 and No. 050-346/75-03)
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The inspector reviewed a letter from the equipment manufacturer, dated March 17, 1975, which identifies the relay contacts monitcred and further that the control circuitry was energized during the testing period.
The tests appear to be complete.
This matter
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is considered closed.
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7.
Reactor Coolant Pump Suction Weldment Linear Indication (Inspection Reports No. 050-346/74-04, No. 050-346/74-07, No. 050-346/75-01 and No. 050-346/75-03)
This item remains open pending completion of the final two welds i
on the Reactor Coolant Pumps.
Welds No. WJ-2 and WJ-2-4 have been
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completed.
Radiographs of the two welds were reviewed by the inspector and were found to be in order.
Further review of the remaining two welds will be conducted during a subsequent inspection.
(Report Details, Section 1, Paragraph 3)
8.
Class 1E Electrical Cable Trays (Inspection Reports No.
I 050-346/74-02, No. 050-346/74-04, No. 050-346/74-07, No.
050-346/74-10, and No. 050-346/75-03)
This m,tter remains open pending followup review.
9.
Review of Bagwell Coating, Inc., QA Manual (Inspection Reports i
No. 050-346/75-07, No. 050-346/75-10, No. 050-346/75-01 and No.
i, 050-346/75-03)
The inspector was informed by the licensee that they have received Bagwell's Revised QA manual for review and approval.
This item remains open pending final review and acceptance by TECO of Bagwell's QA manual.
No quality related work is being performed by Baguell.
10.
Review of Bagwells Close Out of Outstanding Items (Inspection Reports No. 050-346/74-07, No. 050-346/74-10, No. 050-346/75-01 and No. 050-346/75-03)
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The inspector reviewed documentation that indicated the outstandtig TECO Audit items have been resolved satisfactorily.
The matter is considered closed.
(Report Details, Section 1, Paragraph 4)
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Instructions for Handling Piping, Components, etc., Purchased i
by Grinnell (Inspection Reports No. 050-346/74-10, No. 050-346/75-01 j
and No. 050-346/75-03)
The inspector reviewed Grinnells' instruction to use Form QC FF105A, i
Field Planner, in conjunction with procedure No. SS1201, Revision E.
t The documentation appears to be in order.
The item is considered I
closed.
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Incomplete Installed Equipment Reports (Inspection Reports No. 050-346/75-01 and No. 050-346/75-03)
i The inspector reviewed a letter F112-2294 dated March 20, 1975, from the Bechtel Construction Manager to ITT Grinnell approving Grinnell's letter dated March 13, 1973.
The inspector was informed, that copies of a complete set of the installed equipment reports were furnished to Bechtel construction management for verification, signature and were to be returned to ITT Grinnell if found correct.
Some of these reports were reported ).ost by Bechtel and ITT Grinnell furnished replacements.
The inspector noted that in cases of incorrect installations, corrective action is to be taken to set the equipment correctly.
This item remains open pending verification of the use of installation equipment reports.
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13.
List of Safety Related Items This item remains open pending a final review by the inspector of TECO's management review of this matter.
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14.
Johnson Controls Company - Installation / Fabrication I/F Planner i
System Inspection Reports No. 050-346/75-01 and No. 050-346/75-03)
The inspector reviewed Bechtel Field change notice No. 2644 and the Johnson QA manual, Sections 2 and 6, relative to the requirement j
that Bechtel approve all Johnson I/F Planners prior to fabrication.
The inspector determined that the revisions were acceptable.
This
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matter is considered closed.
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Johnson Controls Company - Positioning of Seismic Class 1 i
Mounting Supports (Inspection Re, orts No. 050-346/75-01 and No. 050-346/75-03)
The inspector reviewed a letter from the Architect-Engineer (AE)
dated March 17, 1975, which documented the fact that mounting support calculations had been reviewed.
The letter confirmed that the
seismic support shown on drawing J-G16-4, Revision 1, can be utilized in either a horizontal or vertical position.
This matter is considered closed.
16.
Documentation on Paint (Inspection Report No. 050-346/ 75-03)
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The inspector was informed that the zine primer used during the
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fabrication and repair of the ventilation duct was not one of those specified in table 6-10A Chapter 6 of the FSAR.
The licensee has requested Bechtel (AE) to investigate whether the actual paint used was accepable and is awaiting reply.
This item remains open.
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17.
Inappropriate Closure of Nonconformance Reports (NCRs) (Inspection
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l Report No. 050-346/75-03)
NCR 665 dated April 2, 1975, was issued, reopening the closed NCR 399, that had requested the Materials Supervisor to obtain the
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missing documentation.
Audit Finding Report No. 344-4 dated April 16,
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1975, was generated reopening NCR 376 and requesting information on the acceptabilit/ of the radioactive iodine tests on charcoal filters.
This iten. remains open pending receipt of the missing
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documentation.
18.
Incomplete Test Data (Inspection Report No. 050-346/75-03)
The inspector reviewed NCR 665 issued on April 2, 1975, requesting documentation on the results of minimum elongation tests.
The inspector will verify the results of the tests during the next
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inspection.
This item remains open.
19.
Clarification in Technical Specification (Inspection Report No.
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050-346/75 13)
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J The inspector reviewed a letter from Bechtel Corporation, i
Gaithersburg to TECO dated April 10, 1975 stating that Specification l
7749-M-404 Revision 4, Section 8.1.1.A.3 should read:
"The minimum j
tensile strength.
1.25 pound per inch of width." This item
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is closed.
20.
Evaluation of Test Requirements on Filters (Inspection Report No. 050-346/75-03)
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The inspector reviewed a letter to TECO from Bechtel Corporation,
Gaithersburg, dated April 23, 1975, stating that the filters manufactured and delivered in 1973 met the requirements of the specification 7749-M-404, Revision 5.
This item is closed.
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21.
Procedure on the Quantity of Zine Inside the Containment (Inspection Report No. 050-346/75-03)
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The inspector reviewed correspondence relative to this subject between TECO and their AE.
The AE informed TECO that the estimated surface area furnished in the FSAR was conservatively estimated.
No
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written indication was provided as to when this would be reviewed.
The inspector transferred this matter to his Items to be checked
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list and will verify the results of the recalculated valves during a subsequent inspection.
This item is considered closed.
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22.
Audits on the Installed Restraints (Inspection Report No.
050-346/75-03)
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The inspector reviewed the results of several audits performed on the installation of hangers.
Specification deviations-such as j
changing the location of the hangers without prior engineering i
approval, flame cutting of holes in support plates and an in-j appropriate mounting of a hydraulic snubber had been identified and documented.
This item remains open pending proper resolutions of identified deviations.
(Report Details,Section III, Paragraph 2)
23.
Emergency Diesel Generator Storage (Inspection Report No.
050-346/75-03)
The inspector reviewed the " Storage Procedure for Generators of the Emergency Diesel Generators" and determined that the revisions were not acceptable.
This matter remains open and will be reviewed
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during a subsequent inspection.
(Report Details,Section II,
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Paragraph 2)
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Design Changes to Seismic Class I Tubing Protection (Inspection l
Report No. 050-346/75-03)
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The inspector reviewed a letter from the tE dated March 17, 1975, regarding this matter.
Reference was made to Specification 7749-M-329 Paragraph 6.6.4.
The inspector inquired how it was documented that the probability of physical damage from any event was considered.
This matter has not been satisfactorily resolved and will require further review.
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D.
Deviations
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None E.
Status of Previously Reported Deviations
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J None Management Interview A.
The following persons attended the management interview. at the
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conclusion of the inspection.
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Toledo Edison Company (TECO)
L.'E.
Roe, Vice President, Facilities Development
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E. C. Novak, General Superintendent - Power Engineering and Construction
]j J. D. Lenardson, Quality Assurance Manager j
G. W. Eichenauer, Quality Assurance Field Representative E. A. Wilcox, Field Quality Assurance Specialist i
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C. T. Daft, Quality Assurance Engineer
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J. Greer, Quality Assurance Engineer
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Bechtel Corporation (Bechtel)
C. G. Bald, Manager, Division Projects Operations H. A. Ablondi, Project Quality Assurance Engineer C. L. Huston, Field Construction Manager J. D. Heaton, Project Field Quality Control Engineer B.
Matters discussed and comments, on the part of management personnel, were as follows:
1.
The inspect.:s discussed the apparent lack of provisions for separation redundant system electrical cables identified in and 480-volt switch gear room cabinets.
The the contrt'
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.adged that, in some cases, lack of separation per FSAR cm had been previously identified by the licensee or ru.
u actors.
The inspectors added that their concerns were focused in the following areas:
(a) Additional guidance and instructions are apparently needed by field personnel (including QC) relative to end routing of redundant system cables to assure that separation requirements are maintained.
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(b)
Separation deficiencies in several instances had been identified by the licensee's startup and testing personnel
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after installation was nearly completed, rather than by construction QC personnel.
(c) No documented TECO QA audits, relative to electrical cable installation for proper routing and separation, had been performed.
The licensee stated that this matter would be thoroughly reviewed and appropriate, corrective action initiated.
The Bechtel representative stated that criteria relative to cable separation requirements existed and would be made available for review during the next inspection.
Also, subsequent to the management meeting, the licensee's representative stated that a TECO audit of cable installation for routing and separation was scheduled for the immediate future.
2.
The inspector commented that, during the examination of cable installation in the emergency diesel generator control panel, CS715, one of the cabic bundles did not appear to be properly supported, and its weight was being supported by the terminal lugs.
The licensee stated that they would take the necessary corrective action.
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The inspector stated that nonconformance reports, F&M number
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B-080A and number B-100 had been issued relative to DC Panels j
i DIP, D2P, DIN and D2N but that no tags had been placed on the equipment. The inspector added that this was contrary to the requirements of F&M QA procedure number 6 and 10 CFR Part 50, Appendix B, Criterion V.
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4.
The inspector stated that he had been previously informed that j
an In-Depth Audit by an Independent firm, was to be conducted
relative to the NCR's and P&P packages in QC Storage Vault.
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The licensee stated that steps are being taken as indicated by
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the inspector.
The inspector further stated that the matter would be reviewed during a subsequent inspection.
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5.
The inspector stated that tue corrective action taken by the licensee as indicated in the TECO March 26, 1975 letter to IE:III was found acceptable.
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6.
The inspector stated that eleven of the outstanding open unresolved items would be closed out as a result of the current i
inspection. The licensee indicated that review and documentation l
of the remaining open items would be given a top priority.
7.
The inspector inquired if a TECO Corporate audit would be l-f performed within the next few months.
The licensee stated I
that plans for a corporate audit were being formulated and i
l that one would be performed shortly.
The inspector stated
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that he would review the results of thr. audit when made available.
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REPORT DETAILS SECTION I Prepared By:
J. W. Sutton Persons Contacted The fci. lowing persons, in addition to those listed in the Management Interview Section of this report, were contacted during the inspection.
Toledo Edison Company (TECO Operatians Branch (OB))
W. Green, OB Station Technical Assistant B. R. Beyer, OB, Maintenance Engineer J. E. Orkins, OB, Instrument and Control Engineer K. M. Cantrell, Quality Assurance Engineer J. C. Buck, Quality Assurance Engineer Babcock and Wilcox W. R. Klingler, Project Manager J. W. Marshall, QC Supervisor
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G. Berdyck, Site NDE Technician
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Bagwell Coatings, Inc.
C. Monroe, Site Project Manager Results of Inspection 1.
Licensee Corrective Action, Enforcement Matters The inspector reviewed the licensee's implementation of correct:.e action as stated in the TECO letter to IE:III, dated March 26, 1975.
The licensee's corrective action covers both the nonconforming items as listed in IE Inspection Report No. 050-346/75-01 and the items discussed during a management meeting conc ucted on February 12, 1975 and documented in the IE letter of March 4 1975.
The following information and documentation was reviewed:
a.
Concerning IE Letter of March 4, 1975 (1)
Bechtel Power Corporation letters of April 7 and 17, 1975 indicating the change to be made in '_he site QC organization as of Aptil 28, 1975.
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(2)
'he new Bechtel Quality Control Organization is outlined in s
an organization chart issued with the April 17, 1975 letter.
It appears that positive independence from project management has been established for site QC/ QA activities.
(3) The QA engineer hired by TECO has been assigned to the Operations Group.
The licensee stated that a QA engineer, (Electrical) will be hired as soon as possible for assignment to the Construction group.
(4) A interim list of safety related items (Q-list) was submitted to IE:III.
The list was dated February 5, 1975.
The licensee indicated chat a final revised "Q-List" will be available after May 1, 1975.
(5)
The inspector reviewed TECO's monthly QA letters for January, February and March, 1975.
The letters indicated that increased TECO QA Audits of Site Contractors had been performed and documented.
A log of all QA Audits is being maintanined.
(6) The applicability of the TECO Nuclear Quality Assurance Manual for Davis-Besse Unit No. I was delinented in a revision to the introduction Section of the QA manual, (~^g dated February 10, 1975.
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b.
Concerning Infractions IE Irspection Report and Letter February 19, 1975 (1) Use of Approved Instrumentation Installation / Fabrication Planner (Inspection Teport No. 050-346/75-01)
(a)
Johnson Controls Company (JCC) Procedure No. QAS-615, Revision 0, March 26, 1975.
(b)
JCr letters to site personnel informing them of their responsibilities.
(c)
Bechtel Field Engineering Instruction No. 10 Revison 0, March 25, 1975, titled, " Reviewing and approval of JCC 1/F Planner Packeges."
(2) Failure to Provide and Use Approved Instructions, Procedures and Drawings During Installation and Fabrication of Safety Related Comoonents (Inspection Report No. 050-346/75-01)
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(a) A JCC 1/F Planner FS-4135, Titled " Recirculation Pump Monitoring Air Cooler Compressor Out Flow".
The Planner indicated that all the necessary requirements for a "Q" listed item had been included in the planner.
(b) A weld rod control procedure QAS-614, Revision 0, March 29, 1975, Section 3.4.1.
The procedure contained all the necessary requirements for control of used weld rods.
(3)
Improper Storage of Safety Related Piping Components, (Inspection Report No. 050-346/75-01)
1TT Grinnell has revised the instruction for Field Planner QC FF-105A to include the word " equipment", dated March 18, 1975.
Surveillance of the activity is being maintained.
(4) Procedures for Reporting Total Weight af Zine (Inspection Report No. 050-346/75-01)
A log sheet titled " Zinc Coating Unistrut Footage Chart" is being maintained by JCC.
The log is being maintained properly and is verified by BCM using Procedure G-8.
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(5) Procedures for Documentation and Identification of (s,,/
Equipment Known to be Incorrectly Installed (Inspection Report No. 050-346/75-01)
Documentation relative to joint meetings between TECO-
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Bechtel and the constructors o resolve this matter.
The letters and documents revieweu indicate that QA is being informed of all QA/QC actions and are being brought to the licensee's attention.
(6) Failure to Have Documentary Evidence of Material Conformance to Procurement Requirements Prior to Installation of Components and Structures (Inspection Report No. 050-346/75-01)
Available JCC purchase orders.
The orders now i. process identify'"Q" listed matarials that require a certificate of compliance.
(7) Failure to Establish and Control Use of Inspection Stamps During Construction (Inspection Report No. 050-346/75-01)
Documents relative to orientation and training sessions held by JCC.
JCC Procedure QAS 615 has been revised to indicate the responsibilities and duties of the JCC in-process inspector.
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(8) Failure to Control Tools Used*in Quality Related Activities (Inspection Report No. 050-256/75-01)
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i JCC procedure QC 627-revision 0, dated March 26, 1975, titled
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" Calibration Inspection Procedure".
The procedure indicates
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the steps to be taken to prevent improper use of tools.
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A log for the issuance of tools in being maintained.
JCC's i
letter to March 7, 1975 indicated the esponsibility for controlling AMP crimpings tools.
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I (9)
Failure to Control the Handling, Storage, and Preservation
of Quality Related Materials and Components (Inspection Report I
No. 050-346/75-01)
JCC letter dated March 20, 1975, to all site Craf tsmen and In-Process Inspectors.
The letter requires those persons involved in site construction to cap or tape all instrument
connection parts and tubing and pipe ends when not being
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worked on.
The JCC Specification M329 revised March 26, 1975
was reviewed for site storage instructions.
Outdoor storage i
was found acceptable.
(10) Failure to Issue a Stop Work Order Relative to the Installation of Safety Related Instr 2 mentation Components Found to be
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Improperly Controlled (Inspection Report No. 050-346/75-01)
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Documentation including letters, summaries of meetings, and QA/QC instructions.
The documentation indicated that TECO-Bechtel QA/QC/BCM personnel have been communicating on problems found during audits and that inspections are being conducted and documented, i
2.
Johnson Controls Company Vendor Inspections
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l During the inspectors review of JCC implementation of their QA program relative to the reported infractions of the previous inspection, the inspector inquired of the QA manager if he had conducted any
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vendor inspections to ascertain if his vendor's had an approved QA
program to be used in conjunction with JCC work.
The QA Manager
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replied that inspections of this nature had not been conducted and
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that he was not aware that they would be required under his QA I
program. The inspector indicated that if a certification system for materials is used the contractor should ascertain if his sub
contractor has a reliable QA/QC program for those c.cas of the program he is certifying.
In the case where the subcontractor is doing
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fabrication work such as welding, JCC should be aware if the sub-contractors personnel and materials will comply with the applicable i
requirements of 10 CFR, Part 50, Appendix B.
This matter will be i
further reviewed during a subsequent inspection.
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3.
Reactor Coolant Pumps Section Weldnent Linear Indication (Inspection Reports No. 050-346/74-07, No. 050-346/74-10, No. 050-346/75-01, and No. 050-346/75-03)
The inspector reviewed documentation that has been generated for the repair of pump welds WJ-2-1 and WJ-2-4.
The records indicated that repair procedure H27-01-9-13 '4 with hold and sign off points had been completely filled out and signed as required.
Third Party inspection was used during the repair.
The qualification records of the welders and NDE personnel were reviewed and found to be in order.
The inspector also reviewed the final radiographic film for both welds.
The film was found to be in order and signed off by B&W Bechtel, TECO and HSB personnel as required by the repair procedure. Welds No. WJ-2-2 and WJ-2-3 are currently in the process of being repaired.
The final documentation for the above welds will be reviewed during a subsequent inspection.
4.
Bagwell's Closecut of Outstanding TECO Audit Items (Inspection Report No. 050-346/74-07, No. 050-346/74-10, No. 050-346/75-01 and No.
050-346/75-03)
The inspector reviewed a Bagwell letter to TECO dated January 14, 1975.
The letter replied to the outstanding items as reported in the TECO Audit Report of May 21, 1974.
The Bagwell letter indicated:
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a.
A fire resistant file has been purchased and QC documentation has been transferred to it.
b.
Unledgible forms in the Bagwell QA manual have been replaced.
c.
Vendom audits of the two "Q" listed paint suppliers has been performed and documented.
Final disposition of these findings is in process.
d.
An internal audit by Bagwell Corporate QA manager was conducted on June 13, 1974.
The audit had been reviewed by TECO/Bechtel QA Personnel.
TECO QA personnel conducted an audit of Bagwell on January 17, 1975, to verify the corrective action as indicated in the Bagwell letter of January 14, 1975.
The action taken by TECO and Bagwell appears to be in order.
5.
Instrumentation Inspection Meeting The IE Ccr.struction inspectors held a brief meeting with TECO's Operations personnel to infom them of the types of inspections that would be conducted by the construction inspectors during instrumentation installation. This action was taken due to possible overlapping of
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inspection activities by IE operation and construction inspectors.
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The meeting presented TECO with a better understanding of the interface
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bet. men these two IE branches during this phase of plant inspection.
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REPORT DETAILS SECTION II Prepared By:
F. J. Jablonski Persons Contacted The following persons, in addition to those listed in the Management Interview Section of this report, were contacted during the inspection.
Bechtel Corporation (Bechtell L. D. Jensen, Instrument Engineer J. R. Knoke, Electrical Field Engineer W. C. Lowery, Electrical Quality Assurance Engineer J. W. Toal, Lead Electrical Field Engineer Fischbach & Moore, Incorporated (F&M)
D. M. Moeller, Quality Control Manager Results of Inspection 1.
Observations of Electrical Work The inspector made the following observations at D. C. Panels a.
DlP, D2P, DIN and D2N:
(1) The incoming feeder cables did not appear to have sufficient channel separation.
It was determined that this problem was documented on F&M nonconformance report (NCR) No. B-080A but that no tags identifying this problem had been placed.
(2) At panels DIN and D2N the feeder circuit breakers had been removed.
It was determined that this problem was identified on F&M NCR B-100 but like (1) above, no identifying tags had been placed.
The inspector stated that failure to place these tags was contrary to the requirements of F&M QA procedure No. 6, paragraph 5.3, and criterion V of 10 CFR 50, Appendix B and would be brought to the attention of TECO management.
b.
The inspector observed that cable separation criteria at 480V buses BIE and BlF had apparently not *,een maintained.
This problem was not identified by the licensee.
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c.
The ins retor made the following observations at panel C5715 located in the Main Control Room:
(1) The installed safety related cables did not appear to be j
supported properly.
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(2) Cables 1CAC1033A and 2 CAD 1033A were cross channel connected.
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This matter was identified on Startup Field Report (SFR)
No. E85. The resolution as recorded on reply No. E85 did not appear to correct the channel separatien problem.
It was not apparent that further corrective action was pending.
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(3) The green and orange channel separation criterion as specified in Section 8.3.1.2.25 of the FSAR was not met and there were no apparent provisions for metallic barriers to be installed.
It was later determined that this same problem had been identified and documented in Audit Findings Report (AFR) No. 232E, of April 17, 1975.
d.
The inspectors observed that several interconnecting cables, color
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coded green and including numbers 12RPSM04A, 3D, SB, 1G, 1A, and 12RPSM05A were routed between cabinets C5762E (Green) and C5755E (Orange).
The cables had not been terminated but the
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cable tabs (and drawings) show the cables as terminating in l
adjacent cabinets C5762F (Green) and C5755F (Orange).
The licensee's representative told the inspector that the "To and I
From" designation shown on the cable tabs was not considered as part of the cable terminating process.
The cables are installed
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j in the raceways as shown on the drawings and then field end
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routed to termination points.
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The criteria could not be established for installing or inspecting interconnecting cables for proper end routing to maintain required separations.
In response to further questioning the I
licensee.'s representative stated that this problem had been
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previously recognized and referred to Bechtel engineering in Gaithersburg for resolution.
Letters or other documents in j
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this regard could not be located but are to be made available for review during a subsequent inspection.
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2.
Emergency Diesel Generator Storage I
Procedure SP-7749-E14-5L.001, emergency diesel generator storage has been approved with comments by the licensee and released for interim use.
Section 5, contains several comments which are to be incorporated into the final procedure.
However, procedural actions, if taken could place the generator in a deficient condition.
Procedures must insure that any action which disturbs the original condition l
of the generator must be verified to have been replaced or reconnected.
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The generator configuration must also be verified prior to an insulation test.
Results of tests performed were recorded in Periodic Equipment Log No. M-29, dated March 31, 1975.
Indications are that coil T2-T5 of generator GK-5 apparently was not connected to coils T1 .
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and T3-T6.
Section 5.2.3 of the storage procedure assumes that all i
l coils are connected and that an insulation test made at terminal T1 will result in a conclusive generator test.
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Dispositioning of Electrical Nonconformance Reports The inspector reviewed NCRS B-080, B-080A, B-093, an_ B-100.
a.
B-080 relaued to the identical problem as discussed in item 1.a above.
This NCR was dispositioned to accept "as is" even though electricai separation criterion had not been followed.
This problem was again identified during the licensee's audit of Interim Release Package 2A-2.
As a result, NCR B-080A has been issued and is still unresolved.
b.
NCR B-093 relates that certain specified seismic supports for wireway installations were not in accordance with the details of standard E-302A.
The recommended disposition was "use as is".
" Urgent disposition is needed to facilitate SFAS cable Pulling".
The final disposition is forthecming.
c.
The problem identified in NCR B-100, item 1.a.(2) above, was discovered relative to start up system 02 IR-0257, dated February 13, 1975.
The inspector informed cognizant TECO management that basic construction problems such as cable separation, barrier installation and insulation test failures should not be identified during the
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start up phase but rather during the construction phase.
The
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inspector further stated that " urgency" should never satisfactory reason further stated that " urgency" should never be a satisfactory reason for accepting "use as is" as a disposition to a nonconformance item.
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%J REPORT DETAILS SECTION III Prepared By:
K. R. Naidu Reviewed By:
J. LeDoux Persons Contacted
The following persons, in addition to individuals listed under the Management Interview Section of this report, were contacted during this inspection.
Babcock and Wilcox (B&W)
W. R. Klingler, Project Manager J. W. Marshall, Quality Control Supervisor ITT Grinnell Corporation (Grinnell)
D. Giguere, Quality Control Manager
)
Results of Inspection y
1.
Protection of Installed Safety Related Items During the previous inspection the inspector observed and brought to the licensee's attention that areas of the auxiliary building and emergency diesel generator rooms were not being adequately maintained.
The following items were noted:
a.
Rain water was accumulating on the floor of the auxiliary building in the proximity of safety related equipment.
b.
Wash water was being sprayed into an emergency diesel generator control cubicle during routine housekeeping operations.
The licensee failed to take any action which would have verified that the equipment had not deteriorated, or to instruct personnel regarding area coordination and, the protectica and preservation of safety related items after installation.
However, the licensee indicated that this matter would be reviewed and instructions prepared.
This matter will require further review.
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2.
Audit On Installed Restraints The inspector reviewed the results of audits - AFR 181 dated March 11, 1975, AFR 182M dated March 12, 1975 and AFR 183M dated March 12, 1975 relative to installation of restraints and hangers.
The deficiencies identified were items such as noncompliance of specifications and welding procedures.
The inspector will review this item during a subsequent inspection.
3.
Licensee's Audit On Lum Irsay As a result of deficiencies identified in the activities of the above contractor during a previous inspection, the licensee conducted an audit of the contractor.
The inspector reviewed the audit findings and determined that a deficiency in weld rod control was rectified with a written procedure.
The licensee identified a lack of procedure to segregate inspected incoming material and requested Lum Irsay to develop and implement a procedure on this subject by May 2, 1975.
The inspector will verify the implementation of this procedure during a subsequent inspection.
4.
Pipe Spool Record Review (Grinnell)
The inspector reviewed the records of the pipe spool on the turbine s
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side of the main steam isolation valve identified by EBD-1-17 where N'
all the welding and inspection activities were completed and established that the applicable codes and QC work performance procedures were satisfactorily met.
The record review included the following.
a.
Pipe Fabrication (1)
Receipt inspection of the plate A155KC from which the pipe was fabricated.
(2) Receipt incpection of the SFA 5.17 filler weld rod.
(3)
Certification on the SA516A pipe.
b.
Spool Fabrication Grinnell (1)
Receipt inspection of the pipe at Grinnell, Kernersville.
(2)
Shop traveller D 645 on piece identified as PC3A-EBD-1-17 which indicated that certified Weld Rod was used for tack, root pass and filler and material.
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Records Upgraded The inspector noticed that certain dates of the records had been changed.
The Grinnell QC manager indicated that the A/E instructed them to do so because this spool piece was placed on the "Safet'f Related Items" list after the fabrication.
The inspector requested the licensee to verify whether the fabrication had to meet any additional criteria to be qualified as a Safety related item.
The licensee stated that he will follow this matter with the A/E.
The inspector will review the results during a subsequent inspection.
5.
Incore Instrumentation Welding (B&W)
The incore instrumentation tubing was being welded during the inspection.
The inspector revieued the following selected weld records for two welds which had been completed and found them to be in order.
a.
Field Procedure No. 81.
b.
Drawing M297 and 298.
c.
Tack weld insert appeared to satisfy procedure WIN 221-2 (Inconnel).
A t
d.
Tack weld and alignment were to have been performed per (N procedure 9T-191.
e.
Weld joints appeared to satisfy procedure WIN 221-2.
f.
Radiograph test appeared to have performed per 9T-RT-200.
g.
Dye Penetrant Tests appeared to satisfy procedure 9T-PT-200.
h.
Procedure WIN 219-1 was used for welding tube to tube (ss).
(3 c)
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