IR 05000346/1975020
| ML19319B412 | |
| Person / Time | |
|---|---|
| Site: | Davis Besse  |
| Issue date: | 11/21/1975 |
| From: | Hayes D, Sutton J, Yin I NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML19319B385 | List: |
| References | |
| 50-346-75-20, NUDOCS 8001150984 | |
| Download: ML19319B412 (16) | |
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0-U. S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT
REGION III
Report of Construction Inspection IE Inspection Report No. 050-346/75-20 Licensee:
Toledo Edison Company Edison Plaza 300 Madison
Toledo, Ohio 43652 Davis-Besse Nuclear Power Station License No. CPPR-80 Unit 1 Category:
B Oak Harbor, Ohio
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Type of Licensee:
B&W PWR-871 MWe Type of Inspection:
Routine, Announced Dates of Inspec:
October 29 - 30, 1975
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Principal Inspector:
J. Wy Sutton 3,/
(Date)
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Accompanying Inspector:
I. T Yn I
(Date)
Other' Accompanying Personnel:
W. Dircks Assistant Executive
Director of Operations Headquarters bf'iffu->seleu.~ft~
Reviewed By:
- vD. W. Hayes
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Section Leader
/ (Date)
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O SUMMARY OF FINDINGS
Inspection Summary Inspection of October 29-30, (75-20):
Routine inspection, reviewed licensee's corrective action relative to previously' identified non-compliance and unresolved matters.
Observed Base-line Inservice
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Inspection and reviewed records and data pertaining to the Base-line
Inspection.
Preliminary review of Toledo Edison's Snubber / Hanger installation and inspection program.
Enforcement Action j
A.
Items of Noncompliance
.None Identified.
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Licensee Action on Previously Identified Enforcement Items
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i Previous Notices of Violations:
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Protection of 4KV Circuit Breakers (R0 Inspection Report No. 050-346/74-10)
Reactor Coolant Pump Repairs (IE Inspection Report No. 050-346/75-16)
I Storage of Electric Material (IE Inspection Report No. 050-346/75-13)
The licensee's corrective action, as outline in Toledo Edison
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Company's (TECO) August 29, September 8, and October 9, 1975 responses to the above listed IE inspection reports were deter-mined to have been satisfactorily accomplished and documented.
(Report Details,Section I, Paragraph 1)
Other Significant Findings i
A.
Systems and Components i
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1.
Unresolved Item Base-Line Inspection Procedure - Authorized Inspector (AI) Sign Off
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Written documentation pertaining to the AI's review and x_
verification of the base-line inspection procedures and changes were not included in the Base-line Procedures Manual.
(Report Details,Section I, Paragraph 2A-(3))
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Unresolved Item V
Non Code FilJet Weld Installed on Containment Personnel Lock Expansion Bellows Ring The inspector was informed by TECO QA personnel that an unauthorized fillet weld was installed on the personnel lock i
expansion bellows ring and that three embedment sleeves in containment had not been seal welded as required by manufac-turing specification.
This matter is considered reportable per re'quirements of 10 CFR 50.55(e).
(Report Details,Section I, Paragraph 4 )
B.
Facility Items (Plans and Procedures)
Current Status
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The licensee indicated that, as of October 1975: (1) plant
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overall construction was 92% complete, and (2) design and engineering 98.8% complete.
2.
The special, electical inspection being conducted by the licensee is progressing on schedule.
Findings are being documented and reviewed.
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Managerial Items G')
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The inspector was informed that the stop-work order issued to
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Fischback and Moore (F&M) on June 17, 1975, relative to the installation of terminal boxes, supports, and associated equip-ment was lifted on October 27, 1975.
(Report Details, Paragraph 4)
D.
Noncompliance Identified and Corrected by Licensee None.
E.
Deviations
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None.
F.
Status of Previously Reported Unresolved Items I.
Hydraulic Snubbers (Inspection Reports No. 050-346/74-07, No. 050-346/75-01, No 050-346/75-03, No. 050-346/75-07, No. 050-346/75-13, and No. 050-346/75-16)'
This item remains unresolved pending final review tj ITT Grinnell (Grinnell) and TECO.
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Class IE Electrical Cable Trays (Inspection Reports ( _,
No. 050-346/74-02, No. 050-346/74-04, No. 050-346/74-07,
' No. 050-346 / 74-10, No. 050-346/75-03, No. 050-346/75-07, No. 050-346/75-13, and No. 050-346/75-16)
The inspector determined that drawings and procedures still require approval.
No inspection activities have been performed.
This item remains unresolved.
3.
Bagwell Coating, Incorporated (Bagwell) Stop-work Order (Inspection Reports No. 050-346/74-07 and No. 050-346/75-16)
The stop-work order issued in 1974 concerning safety related painting work remains in effect.
This item remains unresolved and will be reviewed during subsequent inspections.
4.
Inappropriate Closure of Nonconformance Reports (NRC's)
IE Inspection Reports No. 050-346/75-03, No. 050-346/75-07,
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No. 050-346/75-13, and No. 050-346/75-16)
This item remains open pending review of the tests conducted on samples of activated charcoal used in the filters.
5.
Incomplete Test Data (IE Inspection Reports No. 050-346/75-03, No.050-346/75-07, No. 050-346/75-13, and No. 050-346/75-16)
/\\' 'f Documentation relative to the results of the minimum elongation tests has not been received at the site.
This item remains
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unresolved.
6.
Audits of the Installation Restraints (IE Inspection Reports No. 050-346/75-03, No. 050-346/75-13, and No. 050-346/75-16)
The item remains unresolved pending review of the corrective action taken by the licensee.
7.
Cable Identifying and Pulling Material Certifications (IE Inspection Reports No. 050-346/75-09 and No. 050-346/75-16)
Cable pulling compound fire propagation test procedures and results have not been reviewed.
This item remains unresolved.
8.
Cable Material Certifications (IE Inspection Reports No.
050-346/75-09 and No. 050-346/75-16)
Certifications are still required which will satisfy the requirements of Specifications No. 7749-E-13, No.
7749-E-15,
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('s and No. 7749-E-17 relative to radiation resistance tests, t
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flame resistance tests, and concentrated borated steam spray
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tests. This item remains ~ unresolved.
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9.
Equipment Secured by "Hilti-Kwik" Devices (IE Inspection Reports No. 050-346/75-10 and No. 050-346/75 })
No action has been taken on this item.
This item remains unresolved.
10.
Motor Operated Valves (IE Inspection Reports No.
050-346/75-15 and No. 050-346/75-16)
This item remains unresolved pending further review.
11.
Valve Design and Manufacturer (IE Inspection Reports No. 050-346/75-15 and No. 050-346/75-16)
This item remains unresolved pending further review.
12.
Reactor Main Coolant Pumps - Repairs (IE Inspection Report No. 050-346/75-16)
a.
Original NDE documentation for the reactor coolant pump casing was not available for the inspector's p.
review for comparison with current base-line NDE (
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documentation.
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b.
Verification is required as to what steps are to be taken to recertify the repaired reactor coolant pumps to B&W's Sgccification 1035, paragraph 6.8, Hydrostatic Test.
These items remain unresolved.
13.
Electrical Penetrations (IE Insocction Report No.
050-346/73-18)
Penetration assembly prototype test results, required by Bechtel Specificaticn No. 7749-E-25, Section 15.4.1, do not have the required Bechtel engineering approvals.
This item remains unresolved.
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TECO Review of Babcock and Wilcox Company (B&W) Vel _an Engineering Company (Velan) Valve Data Package (IE Inspection Report No. 050-346/75-18)
The inspector' reviewed the B&W nonconformance Report (Serial Number 194) issued for the deficiencies found in the Babcock fh and Wilcox Company (B&W) Package for Velan Valves on Purchase k)
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Order No. 022614LS, with change orders 1 through 6.
A list s,j of valves have been generated and distributed to involved
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s contractors.
The valves were observed to be tagged and all deficiencies have been documented. This matter is considered as resolved.
Management Interview
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A.
The following persons attended the management interview at the conclusion of the inspection.
Toledo Edison Company (TECO)
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L. E. Roe, Vice President, Facilities Development E. C. Novak, General Superintendent, Power Engineering and Construction J. D. Lenardson, Quality Assurance Manager J. Evans, Station Superintendent E. M. Wilcox, Field Quality Assurance Engineer C. T. Daft, Field Quality Assurance Engineer G. W. Eichenaver, Field Quality Assurance Engineer R. E. Blanshang, Construction Superintendent,
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Bechtel Corporation (Bechtal)
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C. L. Houston, Field Construction Manager (
J. B. Olmstead, Project Manager, (Gaithersburg)
P. P. Anas, Project Engineer, (Gaithersburg)
P. R. Britnell, Project Quality Assurance Engineer
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R. W. Jackson, Engineering J. D. Heaton, Project Field Quality Control Engineer ITT Grinnell Company (Grinnell)
D. Gignere, Quality Assurance / Quality Control Manager
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L. A. McGuire, Project Manager B.
Matters discussed and comments, on the part of management personnel,
'were as follows:
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1.
The inspector stated that the current inspe~ction covered:
j (1) a review of the corrective action taken by TECO in response
to IE's previous notices of Violations / Infractions (Report Details,Section I, Paragraph 1).
(2) Review of the Base-line inspection in progress (Report Details, Section 1, Paragraph 2)
and (3) a preliminary review of TECO's Snubber / Hanger installation
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inspection program.
(Report Details,Section II)
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2.
In regard to previously identified unresolved matters, s
the inspector stated all items remain open except for
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one, concerning Velan Valves, which has been resolved.
3.
The inspector stated that as a result of the current inspection two additional unresolved items were identified:
(1) Documentary evidence that the Al had approved the Base-line Inspection procedures as well as changes to the procedures, and (2) the circumstances involved with the installation of a non code weld on the personnel lock expansion bellows ring.
The inspector acknowledged that the licensee had indicated derir,g the inspection that the failure to seal weld the embedment sleeves of the three containment locks as well as the non code weld would be reported to conform to 10 CFR 50.55(e) requirements.
(Report Details,Section I, Paragraphs 2 and 4)
4.
The inspector stated it appeared that the Base-line inspection, with the exception of one item (AI Sign off)
wa's being conducted and documented in an acceptable manner.
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5.
The inspector also stated that a review of Electrical i
rework, required as a result of the special electrical
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inspection, '3oield be er'-4ned during a cubscqucnt inspection.
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The inspector added that it appeared the electrical inspection was proceeding on schedule.
6.
The inspector stated that in the areas of hangers and restraints, he had reviewed the QA procedures, observed hardware conditions, and audited the quality records.
The
results indicated that: (1) QA procedures appears to be satisfactory, (2) some snubber installation deficiencies exist, and (3) quality documents for the hangers and restraints were in order.
(Report Details,Section II)
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REPORT DETAILS Section I
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j Prepared By J. W. Sutton Persons Contacted The following persons, in addition to those listed in the Management Interview Section and in Section II of Report Details of this report, were contacted during the inspection.
Babcock and Wilcox Construccion Company (B&W)
R. E. Nelson, Quality Controi Engineer R. Michalski, NDE Examiner
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M. Weis, NDE Examiner
Babcock and Wilcox Company W. R. Klingler, Project Manager J. W. Marshall, Quality Control Supervisor i
Toledo Edison Company (TECO)
d M. s. Calcamuggio, Power Plant Electrical Engineer J. C. Buck, Field Quality Assurance Engineer F. Johnson, Maintenance Foreman
Bechtel Corporation (Bechtel)
i D. D. Bilowus, Electrical Engineer (Gaithersburg)
Results of Inspection 1.
Previous Enforcement Matters The inspector reviewed corrective action and documentation prepared b; the licensee and/or his agent relative to previously identified items of noncompliance as follows:
a.
IE Investigation Report No. 050-346/75-10, TECO Reply Dated September 8, 1975 to the IE Letter Dated August 5, 1975 The inspector reviewed pertinent documentation and made observations of the corrective action that has been taken relative to Item No. 24 in the referenced report (4KV Circuit Breakers observed to be covared with cement like dust).
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(l') TECO maintenance department monthly records of s
inspections performed on the 4KV circuit breakers.
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Procedure E2 Revision 1, is being implemented. All
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i Breakers have been throughly cleaned.
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(2)
Bechtel/QC records of surveillance conducted on the F&M/CE storage and protective covering requirements
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as required by F&M/CE storage proced.ure 7749-E-14-5d.001,
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Revision 3.
(3) Two circuit breakers in each 4KV circuit breaker room i
was racked out and examined by the inspector.
The breakers inspected were found to be in a satisfactory j
condition except for deficiencies previously identified and documented by TECO maintenance inspectors.
This matter is considered resolved.
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b.
IE Inspection Recore No. 050-346/75-16, August 18-20, 1975 TECO Reply Dated October 9, 1975 to IE Letter Dated September 16, 1975 The inspector reviewed action taken by B&W to correct the reported infraction.
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B&W QA inter office memo documentating the stop-work j
action taken on August 20, 1975.
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(2)
B&W Field Construction Procedure deviation Report No. 153-01 and approval of the deviation by Bechtel, dated August 21, 1975.
(3)
Documentation that the authorired inspector had
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reviewed the recordt and had signed off.
1.
(4)
B&W Project Manager Memo to B&W Corporation QA
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Departnent requesting review of B&W QA policy, l
9QA-02, " Authority for stoppine work" to include definite requirements for documentating "Stop
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Work" actions.
This matter is considered resolved.
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IE Inspection Report No. 050-346/75-13, June 24-26, 1975 l
TECO Reply Dated Aucust 28, 1975 to the IE Letter Dated, l
July 25, 1975
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The inspector reviewed TECO and Bechtel QA/QC records that inc.',cated that FLM/CE storage areas are being inspected 9-
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and corrective action is taken when required.
The commitments of the TECO August 28, 1975, letter were found to have been implemented.
This matter is considered closed.
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2.
Base-line Inspection and Authorized Inspector (AI) Sign Off The inspector reviewed records and documentation generated by B&W's construction personnel for the base-line inservice inspection.
The inspector also reviewed the corrective action taken to clarify two areas of concern brought to the attention of B&W during the IE
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inspection of September 22-24, 1975. The action taken by B&W was as
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I follows; The approval date of the B&W QA Manual 9-QA-201, Revision 2, a.
was corrected to show that the QA manual and procedures were approved on June 16, 1975.
b.
The inspector reviewed the B&W purchase orders (PO) for the tra,nsducers in questions.
The PO's indicated that the search i
units were purchased in 1972.
The scarch units records were
corrected to indicate the purchase date.
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Base-line Inspeerion j
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(a) Reactor Vessel The B&W Automatic Reactor Inspection System equipeent had been
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removed from the site. The remaining two areas of the Reactor Vessel were inspected by manual means (The Shell to Head circum-ferencial weld. Mark 171-181 and the Dome weld-Mark 181-6).
Manual UT procedures 101 and 102 were used for the inspection.
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(b)
General Information The Davis-Besse base-line inspection was started in February 1975, and is approximately 65% complete.
The inspection is i
i being conducted to comply with the 1971 Edition of Section XI of the ASME Boiler and Pressure Vessel Code, through the~
1971 winter Addenda.
The table being used is for the general examination of the Reactor Vessel and closure head, Pressurizer, Heat Exchanger (Class A) and Steam Generators, Pressure Boundry, Piping and Pump and Valve Pressure boundries.
I The B&W QA Manual had been approved for use by TECO prior to start of the inspection.
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The records reviewed and observation of work in progress appeared to be in order and in conformance with approved procedures.
(c)
Examination Techniques and Procedures The inspector reviewed the B&W Innervice Inspection Procedurcs, Revision 3, dated January 20, 1975 and Revision 4 dated July 25, 1975.
The procedures were approved and signed by TECO and B&W personnel.
The inspector asked if the AI had also reviewed and verified the procedures and any changes to the procedures.
The licensee stated that the AI had reviewed the procedures i
but this review had not been formally documented.
The inspector was shown a copy of notes taken during a preinspection =ecting held during February 1975, with TECO B&W and the AI.
The licensee indicated that he would discuss the subject of a formal sign off of procedures and changes to procedures with the AI as soon as possible.
The inspector stated this matter
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vould be unresolved pending further review.
(d)
Qualification of Nondestructive Examination Personnel
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The inspector reviewed the test vendors' personnel qualification
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records relative to conformance to requirements of SNT-TC-1A and j
its supplements and appendices, as applicable for the examination technique and =ethods used.
The records reviewed indicated that the written tests, and employment and czperience history racceds
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for the inspecting personnel, were in order and being properly
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maintained.
(e)
Basic Calibration Status of Instruments The electronic equipment and search transducers calibration records were reviewed and found to be in order and in confor-mance with test procedures and code requirements.
Instruments checked included:
Transducer - Aerotect,.225 Serial numbers 219, 4101, and 1101.
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Electronic Unit - Bronson 301, Serial Number 73874 (f) Material Certifications The material certifications for the UT couplant and UT calibration reference materials were examined and found to be in order.
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_Couplant - Hamiller - Batch 668
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UT Reference Block Serial Number 1420 (g) Test Records
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The inspector reviewed base-line rough draft records.
The records were found to be in order and properly reviewed and signed.-
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Data acq.uisition is taken and recorded manually.
(h)
Quality Assurance Activities TECO QA personnel had reviewed the QA program of the test vendor prior to start of the inspection program.
(IE Report No. 050-346/75-18). The license has not performed an audit of the on going inspection but indicated that an audit was planned prior to completion.
B&W QA/QC personnel have performed audits of the inspection activities and QC surveillance reports dated July 17, August 20, September 18, and October 10, 1975 were reviewed by the inspector.
(1)
Observation of Work Th'e inspector observed the B&W examiners inspecting the Pressurizer Circumferenial Seam Weld (Mark 5).
The examiners vere using B&W procedures No.101 and No.102.
The instruments C)
had been properly calibrated and docu:cated cn ban calibration sheet BLI, form No. 11.
4.
Non-Code Fillet Weld - Personnel Lock Expansion Bellows Ring During the inapection, the licensee informed the inspector that a non-code weld had been installed on an expansion bellows ring of the containment personnel lock.
The inspector was shown Bechtel Nonconformance Report No. 8-194, prepared in regard to this matter.
The weld was installed as a result of a misinterpertating of the field drawing by the welder.
He deposited a full seal weld on the embedment sleeve.instead of the bellows ring.
The embedment
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sleeve is classified as-a Bechtel Q item and also as a ASME code component where as the bellows ring is not.
Welding performed on the sleeve must be accomplished by a ASME code qualified welder and the welder who made the weld was not.
The sleeve weld is to be removed and replaced by u properly qualified welder.
In addition to the above occurrence, the inspector was also informed, that CB&I, during a further review of their Field
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Drawing No. 36, Revision 1, discovered that due to a misinterpertation of a weld symbol on the manufacturing drawing (at the manufacturing
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plant) that seal welds on the eebedment sleeves of the containment
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equipment hatch and emergency lock had not been made.
This matter is being reported by the licensee as required by 10 CFR 50.55(e).
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cent sleeves in question.
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A s_s REPORT DETAILS
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Section II Prepared By:
I. T. Yin Persons Contacted Toledo Edison Company (TECO)
C. T. Daft, Field Quality Assurance Engineer Bechtel Power Corporation (BPC) - Gaithersburg R. W. Jackson, Mechnical Engine'er
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ITT-Grinnell Corporation (Grinnell)
P. Stanish, Project Supervisor D. R. Giguere, Quality Control Manager H. L. McGurdy, Quality Control Engineer
F. N. Zinkevich, Manager of Standards
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Results of Inspection 1.
Review of QA Ieplementing Procedures The pipe support installation and inspection procedure has been a.
written by Grinnell, but has not been approved by BPC.
The inpsector reviewed the preliminary procedure and stated that the following should be included:
(1)
Reference documents (2) Air bleeding procedures (3) Pressure test for tightness of fittings and seals (4). Handling of the stop pins after hydro tests
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b.
Field Constr QC-FF-101-5T_y7 tion Receiving Examination Procedure
_ dated April 16, 1974, and attached i
Form FF.01A, Revision 1, dated September 15, 1972,
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A part of Grinnel QA Manual of the Grinnell and Subsidiaries Field
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Construction for TECO Davis-Besse Power Station Q-Listed Items Non-
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Nuclear Code (design Per B31.1.0, not AMSE-III).
This document is contained in QC Programs and Procedures (QCP&P) approved by both j
BPC and TECO on August 11, 1975.
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O were reviewed by the inspector and considered satisfactory.
Review areas included:
(1) Marking and identification, (2) cleanliness, and (3) surface protection, closure, and
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packaging.
c.
Field Construction Examination, Handling, and Storage Procedure QC-FF-1047t /, dated December 12, 1973, and
attached check forms were reviewed by the inspector and considered satisfactory.
Review areas included:
(1) segregation of. items, (2) storage identification, (3) storage condition / protection, and (4) storage and insurance record.
d.
QC surveillance of storage areas of protection against phy.dcal damage during iss'uance to field and installation was documented in Grinnell's Research and Development Instruction-Field-Toledo RDIF-T-20, dated January 24, 1975.
The inspector considered the procedure satisfactory.
For those hydraulic snubbers that require seal replacement i
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and that have already been shipped to the site, a procedure was prepared by Grinnell but it has not been approved by BPC.
The Procedure (Replacement of Seals in Miller Cylinders ik"
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through 6", Drawings AH-1423 and AH-1423A) was reviewed by the inspector, and the work requirements appear to be
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adequately covered.
2.
Observation of Hanger and Restraint Installations The inspector was informed by BPC and TECO representatives that
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all hangers or hydraulic snubbers installed to date are not considered to be officially QC checked and accepted.
When approved installation and inspection procedures become effective, installed hardware will be rechecked for the areas that have not been covered in the present procedure, Standard Specification for the Setting of Pre-Engineered Spring Hangers, ITT-G No. P-F-9984-1, dated August 27, 1975.
Approximately 15 spring hangers and an equal number of hydraulic snubbers were inspected for general installation performance.
l All hangers appeared to be in good condirion.
Some deficiencies
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were observed on the hydraulic snubbers as follows:
Fluid leaks at some valves and fittings.
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Different fluid colors in the unit.
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One snubber installed upside down.
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Ibid.
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i t
The inspector indicated that IE will conduct a detailed, installation inspection during a future inspection after the hangers and snubbers have been checked and accepted by the licensee.
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3.
Review of Quality Records Five hydraulic snubbers and two variable spring hangers were randomly selected for'the quality record checks.
The mark numbers are as follows:
-
a.
,
(1)
40-HCC-45-H7 (2)
35-HCB-6-H5
.
(3)
,
(4)
33B-CCB-1-H2O (5)
Hangers (1,)
-
(2)
34-CCB-5-H26 The audit e=phasized retrievability and completeness of documentation (J
\\
of the following:
I a.
Design and fabrication details b.
Unit identifications Deviation and nonconformance recording and status c.
d.
Material certifications e.
Field receiving inspections f.
Storage and issuance records The site hanger and snubber quality records were considered to be adequate and in good order.
The qualifying records are kept in the vendor's fabrica 'on shop and were not available for review.
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