IR 05000352/1979005
| ML19209B439 | |
| Person / Time | |
|---|---|
| Site: | Limerick  |
| Issue date: | 08/20/1979 |
| From: | Mattia J, Mcgaughy R, Varela A NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML19209B431 | List: |
| References | |
| 50-352-79-05, 50-352-79-5, 50-353-79-05, 50-353-79-5, NUDOCS 7910090717 | |
| Download: ML19209B439 (14) | |
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U.S. NUCLEAR REGULATORY COMMISSTON OFFICE OF INSPECTION AND ENFORCEMENT Region I Report No. 50-352/79-05 & 50-353/79-05 Docket No. 50-352 & 50-353 License No. CPPR-106 & CPPR-107 Priority:
Category: A
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Licensee:
Philadelphia Electric Company 2301 Market Street Philadelphia, Pennsylvania 19101 Facility Name:
Limerick Generating Station, Units 1 & 2 Inspection at:
Limerick, Pennsylvania and Philadelphia, Pennsylvania Inspection conducted: May 7-11, 17, 18-21, 1979 Inspectors:
.k 7 !i h7 N Ma ia, tor Inspector date signed ILL k
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Reactor Inspector
date signed A.Varela,k rhJw.
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L. Gage /Reac{orInspector date fighdd
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W3c}79 P. Koltay, Reactor spector date s'igned Approved by:
N, M I/lth dA/h.
k71 R.'McGaughy, C1M R, rojects dite signed Section RC' & ES Branch Inspection Summary:
Unit 1 Inspection on May 7-11, 17~, 18-21,.1979 (Report No. 50-352/79-05)
Areas Inspected: Routine, unannounced inspection by regional based inspectors of work activities and recordt associated with the fuel pool girder, safety related piping and instrumentation.
The inspectors conducted an inspection of the QA Program, including licensee's functional responsibilities and procedures in the area of design control and audits.
The inspector also performed a plant +.our inspection. The unit 1 inspection involved 92 inspector hours on site by five regional based inspectors.
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Results: Of the five areas inspected, no items of noncompliance were identified in four areas, one apparent item of noncompliance was identified in one area (Infraction - failure to follow prcce-dures when reworking slipped strands of fuel pool girder in that
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the elongation and force'used were not documented - para 7.)
Unit 2 Inspection on May 7-11, 17, 18-21 1979 (Report No. 353/79-05 Areas Inspected: Routine, unannounced incoection by regional based inspectors of work activities and r cds associated with instrumentation. The inspectors also conoucted an inspection of the QA Program, including licensee's functional responsibilities and procedures in the area of design control and audits.
The inspectors also performed a plant tour inspection. The Unit 2 inspection involved 44 inspector hours on site by five regional based inspectors.
Results: No items of noncompliance were identified.
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DETAIL _S_
1.
Persons Contacted Philadelphia Electric Co.
- W. Broome, EIC Station Engineer
- ***D. Clohecy, QA Engineer
- ***J.
Corcoran, Field QA Branch Head
- D. Corey, Head Electrical Field Engineer
- J. Fedick, Construction Engineer
- G. Hutt, QA Branch Head
- ***G. Lauderback, QA Engineer
- R. Lees, QA Fngineer
- T. Loughran, Electrical Project Group Leader
- D. Marascio, QA Engineer
- R. Mulford, Project Manager
- C. Patton, Field Engineer
- L. Pyrih, M.E. Supervising Engineer
- T. Shannon, Mechanical Engineer
- R. Sheibley, Construction Engineer
- J. Walton, Electrical Project Engineer
- H. Walters, QA Manager Bechtel Power Corporation
- R. Brech, Material Storage Er.gineer
- "**J. Blevins, QA Engineer
- ***B. Dragon, QA Engineer
- R. Faust, Subcontracts Engineer
- ***T. Fallon, Assistant Project Field QC Engineer
- ***H. Foster, Project Field QC Engineer
- J. Gwin, Project Superintendent
- D. Michaels, Project Materials Supervisor
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- J. Reinoy, Project Construction Manager J. Reynolds, Materials Supervisor s
- ***A. Weedman, Project Field Engineer VSL Corporation B. Raffensperger, QC Manager J. Skinner, Foreman P. Wilson, Superintendent
- Denotes thos:. present at the exit interview on 5/11/79 at the Limerick site.
- Denotes those present at the exit interview on 5/11/79 at the PEC0 Corporate Office.
- Denotes those present at the exit interview on 5/21/79 at the Limerick site.
2.
Licensee Action on Previous Inspection Findings (Closed) Noncompliance (352/78-09-01):
This item was reviewed during inspection 352/79-02 and during this review a discrepancy was found in three drawings which were not in agreement as to when the temporary supports are to be removed after con-crete was placed in the fuel pool girder.
The inspector revie.ed the revised B'echtel drawings C-771 (Revision 8), C-772 (Revision 7) and C-637 (Revision 9) and they are now in agreement as to when the temporary supports are to be removed.
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(Closed) Significant deficiency - 50.55(e) (352/76-12-01): This item was reviewed during inspection 352/78-04 and during this review it was noted that Bechtel had not evaluated several girders (G-37,G-03,G-84,G-86,G-13,G-:
and G-35) for having a partial penetration weld joint where a fu.'l penei. ration weld was re-quired. The inspector reviewed Bechtel's letter, dated July 18, 1978 (Code BLP 17453) which stated they had performed calculations for these girders and found that the partial penetration weld was adequate for design loads.
(Closed) Unresolved Item (50-352/79-01-01) pertaining to mal-functioning heater in electrical equipment.
The inspector re-viewed licensee corrective action which was found acceptable.
This item is resolved.
3.
0A Site Audits (Unit 1 & 2)
The inspector reviewed several audits conducted on the installation of safety related equipment by the Bechtel and PECO QA Organiza-tions to determine compliance with the PSAR and regulatory
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conmitments.
The following audits were reviewed:
a.
PEC0 Audit Report P-98 (Audit date 1/2/79-2/16/79). This
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was cn audit of pipe spool installation.
Audit Report P-96 (Audit date 12/12/78-3/5/79).
This
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was an audit of mainsteam isolation values.
Audit Repoit M-169 (Audit date 3/26/79-4/4/79).
This
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was an audit of HVAC installation.
The inspector noticed that some of the finding (Audit) re-ports issued by PECO were not issued on the date the finding was identified.
PEC0's QA procedure in their Limerick QA Plan (Appendix "S" in Section S-5.1.2) states that the finding report shall be issued at the time the finding is identified.
The inspector questioned whethar this is a realistic commitment and suggested considering use of the ANSI N45.2.12 requirement of 30 days, which is the industry standard. This item is unresolved pending review by an NRC inspector of the revision to the PEC0 procedure.
(352 &
353/79-05-01).
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b.
Bechtel Audits
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Audit report PFA-181 (Audit date 12/12-15/77).
This was an audit of installation of RCIC & MPCI equipment.
Audit report PFA-126 (Audit date 4/28-30/78).
This
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was an audit of installation of electrical rotating equipment.
Audit report PFA-228 (Audit date 2/20-23/79).
his
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was an audit of installation of large pipes.
No items of noncompliance were identified.
4.
Observation of Pipe Welding Activities (Unit 1)
The inspector observed weldirg of safety related piping at various stages of weld completion to determine if the applicable weld procedure and ASME code requirements were adhered to.
The inspector inspected the following weld joints:
a.
Weld Joint:
FSK GBB-112-2/0 F.W. 50 Location: Area 12, elevation 187'
System:
Core Spray Size:
14" diameter, 0.375" wali Weldor:
PM6 (verified qualified to weld in accordance with procedure PIAT-LH/5).
Material:
SA 106 Grade B Weld Procedure Used:
PIAT-LH/5 b.
Weld Joint: GB3-112-02-W006 Location: Area 12, elevation 188'
System:
Cor? Spray Size:
12" diameter, 0.375" wall Weldor:
PM6 Weld Procedure Used:
PIAT-LH/5 c.
Pipe Hanger Welds: HBB-104-H4/7 Location:
(RHR Room) Area 15, elevation 182'
System:
RHR Weldor:
PN-0 (verified qualified to weld in accordance with procedure Pl-A-LH/3)
Inspection Report:
QCIR #M-51-HBB-104-5-8
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Pipe Hanger Welds: HBB-101-H1 Location: Area 15, elevation 178'-191'
System:
RCIC W'1 dor:
PY-2 (verified aualified co weld in accordance with procedure Pl-A-LH/3)
Weld Procedure Used:
PI-A-LH/3 Inspection Report:
QCIR #M49-EBB-14-16-1 e.
Weld Joint: ECR-M-2969F Weld #4 Location:
Pipe tunnel System:
RHR service water Size:
20 inch diameter. 0.375" wall Weldor:
PH2 (verified qualified to weld in accordance with procedure P1-A-LH/3)
Weld Precedure Used:
PI-A-LH/2 No items of noncompliance were identified.
5.
Plant Tour (Units 1 & 2)
The inspectors toured the Units 1 and 2 containmeat, reactor
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enclosures and diesel generator building observing work in-progress, in-p hce storage practices, area cleanliness, and completed work.
He discussed the technical aspects of the work in-progress witn the construction craftsmen, supervisors and quality coatrol personnel. The following item was identified during this plant tour:
The inspector questioned the fillet weld size for the main steam hangers APE-IMS-HHDI, -HHBI & -HHAf inside containment.
When reviewing the drawing C-292 revision 8 for the fillet size (3/8") with licensee we noticed that the drawing had two views (Section & Elevation) calling for 3/8" fillet weld on all sides of shim plate. The fillet welds for toe above three hangers had not been inspected by Bechtel QC, but were completed and the side fillet weld called for in the drawing section view was not accomplished. A discussion was held with Bechtel engineering and
's.ey stated that the drawing was in error since the weld indi-cated by the elevation view of the drawing was adequate to meet the design loads.
During this inspection period Bechtel issued a field change request (FCR) C-5666F to eliminate the side fillet weld called out in detail 4 of the C-292 drawing.
The FCR was approved by Bechtel project engineering.
The NRC inspector had no further questions on this item at this time.
No items of noncompliance were identified.
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6.
Record Review - Stage 1 Fuel Pool Girder Post Tensioning (Unit 1)
Pertinent work and QC documentation were reviewed on construction observed during previous inspection.
Stage number 1 post tension-ing records for the north and south fuel pool girders were evaluated against criteria established in the following documents.
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Limerick Generating Station Units 1 and 2 PSAR, Appendix D.
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Bechtel Specification 8031-C-57, Furnishing and Installing Fuel Pool Girders Post Tensioning System.
VSL QA Program for the Post Tensioning System, date of latest
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revision, January 5,1979.
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VSL Construction QA Records for Installation, Stressing and Grouting, date of latest revision, January 5,1979.
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VSL Nonconforming Reports and Supplier Deviation Disposition Requests, SDDRs Numbers L-4 and L-8 of January 16, 1979, L-11 and L-12 of January 22, 1979 through Revision 3 of January 29, 1979, (SDDRs are approved by Bechtel project engineering and reouire PECO concur.nce).
The inspector reviewed documents relative to the following:
Cuncrete Prepiacement Records - Bechtel and VSL sign-off a.
approving confonnance of VSL furnished sheathing, bearing plates and other sub contractor - furnishec materials which require field installation prior to girder concrete placement.
b.
Tendon Installation QC Visual Inspection Records - north and south tendons L-1 through L-14, visual inspection check list and tendon installation reports.
Anchor Head Assembly Installation and Tendon Stressing - QC c.
vcrification requirements identified in check list for each tendon, and individual tendon stressing reports for north and south L-1 through L-14 tendons.
d.
Identification on Tendon Stressing Reports of Strand Slippage and Required Rework - reports of slipped strands in six north and five south girder tendons.
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Tendon Lift-Off QC Check List and Report f.
QC Inspection for Slippage at Stressing End and Dead End Anchorages and Monitor for Slippage - records prior to grouting, g.
QC Documentation on Tendon Grout Injection - reports on all stage 1 vertical and longitudinal tendon, check list and grout injection.
h.
VSL Nonconformance Reports and Supplier Deviation Disposition Requests - NCR's and SDDR's on tendons for strand slippage found to be outside of acceptance limits were reviewed for proper Engineering disposition and licensee ap.,'roval.
1.
Bechtel and PECO Audit Reports on Post Tensioning Activities -
BC audit number PFA-222 (25-14-1) of November 2 to December 12, 1978 and response to findings, and PECO audit reports C-135, 136 and 137 over period November 10, 1978 to March 7, 1979 were reviewed for coverage, findings and close-out/ resolution of negative findings.
Except as identified in following paragraph, as regards documentation of the rework force applied and elongation obtained to unseat and replace wedges of slipped strands, no items of noncompliance were identified in above record review.
7.
Lack of Documentation in Post Tensioning Rework (Unit 1)
As identified ir, inspection report 79-01, Paragraph 5.d a rework procedure was approved in SDDR L-1?. for correction of excess strand slippage during longitudinal tendon stressing.
Steps 1 and 2 of the
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procedure, for recovery of slippage, require installation of a calibrated mono-strand ram with an initial pressure of 500 psi to seat wedges in the mono-strand ram.
Step 3 states:
" Stress the strand to the required dead-end anchor force.
A higher gaqe reading may be required to unseat and replate wedges.
Record elongation and force.
If nccessary continue to elongate strar.d and, if possible, remove wedges and replace with new wedges."
The inspector's review of QC records identified that strands which required mono-strand ram rework lacked documentation to record elongation and force.
The inspector identified in the records that nine of 28 stage 1 longitedinal tendons in the north and south fuel pool girders had approximately 20 strands that required mono-strand 1117 022 JMY
ram rework - (One other 1endon had 3 slipped strands that were abandoned, and a second tendon had one strand slip within minimum of h" and did not require mono-strand ram connection).
The licensee was informed that this is an infraction, applicable to Docket 50-352 (352/79-05-02).
8.
Design Control (Units 1 & 2)
The inspector verified that the. licensee has developed functional responsibilities and procedures for design control.
He examined the following documents:
Philadelphia Electric Company (PECO) Quality Assurance Procedures
"LSG QAP, Vol. I, Design, Construction & Pre-operational Phase",
dated 3/23/79:
Chapter 3.0, " Design Control," Rev. 3
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Appendix B, " Electrical Engineering Design Review Procedure,"
Rev. 4 Appendix C," Mechanical Engineering Division, Construction
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Division, & Research & Testing Division Design Review," Rev. 3 The inspector selected mechanical items and electrical items from the following list of safety-related equipment:
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" Project Q List, Job 8031, Limerick Generating Station" He reviewed the documentation for the Emergency Service Water Pumps and RHR Service Water Pumps, produced by Byron-Jackson; item numbers 741-S-1503/6 and 741-S-1507/10, including:
Specification 8031-M-12, Rev. 2
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Byron-Jackson (Los Angeles) Quality Manual Procedure No. 13,
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Design Control," Rev. 8 He reviewed the documentation for the Power Generation Control Complex (PGCC), produced by General Electric (San Jose), including:
G.E. "BWR Quality Assurance Program Description," NED0-11209-04A,
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dated March 1978, section 3.10, " Design Verification" G.E. "BWR Quality Assurance Manual," NEDE-20586, dated 1/15/79,
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section 2.3, " Design Control" 1117 023 L13BA g
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G. E. Instruction 70-23, "~' dependent Design Reviews,"
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dated 5/31/78
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G. E. Licensing Topical Report, NED0-10466, " Power Generation
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and Control Complex Design Criteria and Safety Analysis,"
Rev. 1.
He reviewed the following PECO audit reports which included the G.E.
design control function:
Audit Report No. 116, dated 2/24/76.
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Audit Report No. 201, dated 11/28/78 He also reviewed the PEC0 - G.E. correspondence files for 1975, 1976, 1977, 1978, and 1979, which provided evidence of continuing PEC0 engineering review of the PGCC design.
Among the more significant items were:
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PEC0 letter no. PLG-160E (4/11/78)
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PECO letter no. PLG-146E (2/23/77)
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PEC0 letter no. DLG-141E (10/7/77)
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PEC0 letter no. PLG-62E (12/16/75)
He also reviewed PEC0 audits which included design-control activities of their own electrical and mechanical engineering departments, and of their architect-engineer, including:
Audit Report No. AR 164, dated 6/29/77
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Audit Report No. AR 161, dated 6/14/77 Audit Report No. AR 190, dated 11/6/78
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No items of noncompliance were identified 9.
The inspector verified that the licensee has developed functional responsibilities and procedures for audits.
He examined the following documents:
PEC0 Major Activities Schedules, for the months of October,
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November, and December,1978; and for January, February, March and April,1979 (Nos. 81 through 87, respectively).
These schedules indicate the audits pecformed and the audits to be performed.
PECO Exhibit XXXIII, " Instructions for Use of the (audit)
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Finding Report.
Fonn QAF-8".
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PECO Audit Reports Nos. 116, 201, AR 161, AR 164, and AR 190 (discussed in paragraph 2).
PECO Audit Report No. 200 (for the diesel - generator
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supplied by Colt Industries), dated 11/8/78.
No items of noncompliance were identified.
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.0, Review of QA Procedures for Instrumentat':on Components / Systems.
The ir.spector reviewed current quality assurance procedures and instructions pertaining to the identification, installations, storage, termination, surveillance, and inspection of activities involving Instrument Components and Systems for compliance wf cr the QA program de;;ribed in Appendix D of the facility SAR.
Documents examined include:
a.
Administrative Procedure No. 8031-A-7 revision 3, dated January 3, 1979.
b.
Electrical Procedure Nos. 8031-E-3 revision 5, dated August 31, 1978, 8031-E-9 revision 0, dated April 28, 1979 and 8031-E-10 revision 0, dated August 1,1979.
General Procedure Nos. 8031-G-3 revision 24, dated May 16, c.
1979, 8031-G-32 revision 1, dated May 15, 1979 and 8031-G-7 revision 17, dated March 21, 1979.
d.
Job Rule Nos. JR-G-ll revision 8, dated February 12, 1979; JR-G-26 revision 4, dated September 12, 1978; JR-G-7 revision 17, dated March 21, 1979 and JR-G-31 revision 1, dated June 26, 1978.
No items of noncompliance were identified.
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11.
Instrument Components / Systems - Observation of Work Activities The inspector performed an inspection of instrument components /
systems stored at the licensee's off site warehouse (Adwin Facility) to determine whether the Quality Assurance Program and its implementation are being accomplished in accordance with NRC requirements and SAR commitments described in Appendix D.
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o During this inspei.i. ion, the inspector observed a number of valves throughout the facility without protective end caps.
Many of the ered caps lay along side the valve or in the immediate vicinity.
There was no apparent reason for the end cap removal other than the aluminized tape used to hold the end cap in place appeared to have poor adhesive qualities resulting in slippage of the end cap of its own weight.
Others were removed for inspection but not replaced. Licensee representative could not establish the length of time valves remained uncovered.
The inspector noted that the metal end caps usually shipped with the comnonents are removed and replaced with one of several types of end caps in use at this facility.
The inspector observed valves capped with sheet cork, impregnated paper, plastic, plywood, metal and aluminized tape.
Since the primacy purpose of the end cap is to protect the com-ponents weld preparation surface against physical damTge in addition to protection of internal surfaces against dirt, dust and condens-'icn, the inspector requested the licensee represen-tatives accompanying the inspector to provide the criteria or basis for removal and replacement of end caps.
The licensee representative stated this information was not readily available at the offsite storage facility and that storage requirements / instructions come from the site via computerized Maintenance Record Caris for each component.
Upon completion of the surveillance requirements listed on the Main-tenance Record Card the card is then signed and returned to the site minus the pink copy which remains at the off site storage facility.
The pink copy is filed by scheduled inspection completion date and not by component identification number.
Discussions with the licensee wt the site and a review of component documentation assured the inspector that the items noted above were non-Q listed.
The inspector had no further questions.
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Unresolved Items Unresolved items are matters about which more information is required in order to ascertain whether they are acceptable items, items of noncompliance, or deviations.
One unresolved item disclosed during this inspection is discussed in paragraph 3.
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13.
Exit Interview The inspector met with the licensee representatives (denoted in Paragraph 1) at the conclusion of tha inspection on May 11 and 21,1979. The inspector summarized the purpose and the scope of the inspection and the findings.
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J.R 6 188'
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