IR 05000353/1986010
| ML20206P286 | |
| Person / Time | |
|---|---|
| Site: | Limerick  |
| Issue date: | 08/17/1986 |
| From: | Gallo R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML20206P276 | List: |
| References | |
| 50-353-86-10, NUDOCS 8608270146 | |
| Download: ML20206P286 (14) | |
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U.S. NUCLEAR REGULATORY COMMISSION
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REGION I
Report No. 86-10 I
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Cocket No. 50-353
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License No. CPFR-107 Category A
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Licensee: Philadelphia Electric Company
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2301 Market Street
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Philadelphia, PA 19101
Facility Name:
Limerick Generating Station, Unit 2
Inspection Conducted: May 29 and July 10 - August 3, 1986
Inspector:
R. A. Gramm, Senior Resident Inspector
Approved by:
'2b b!/7/8h
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R. M. Gallo, Chief, Date l
Reactor Projects Section 2A i
Inspection Summary: Report for Inspection Conducted May 29 and July 10 -
l August 3, 1986 (Report No. 50-353/86-10)
Area Inspected: Routine inspection by the resident inspector of work
activities procedures, and records relative to quality assurance activities, l
reactor pressure vessel and internals, piping and pipe supports, structural I
concrete, structural steel, mechanical equipment, and electrical components and cables.
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l The inspector also reviewed licensee action on previously identified items and i
performed plant inspection tours. The inspection involved 73 hours8.449074e-4 days <br />0.0203 hours <br />1.207011e-4 weeks <br />2.77765e-5 months <br /> by the
inspector.
Results: No violations were identified, i
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i 8608270146 860818 PDR ADOCK 05000353 d
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DETAILS j
1.0 Summary
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Work activities that were satisfactorily examined during the inspection include drawing control, concrete drilling, applicant and Architect i
Engineer Quality assurance implementation, installation of reactor
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pressure vessel jet pumps and shroud and associated quality records, j
safety related piping and pipe supports, structural concrete specifica-
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tions and QC procedures, diesel generator building framing steel, and plant mechanical equipment in>tallations.
Seven previously identified
inspection findings were reviewed and six were satisfactorily closed.
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j An open item was identified relative to an inaccurate FSAR description of
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the primary containment diaphragm slab support steel connections. The
lack of requisite washer material for high strength bolts on the centrol j
rod drive restraint beam is an unresolved item pending licensee investi-gation of the component inspection status and design assumptions. A
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i second unresolved item involves the review of the battery rack seismic qualification test report which identified a test configuration that is
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not reflective of the installed racks.
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2.0 Plant Inspection Tours
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The inspector observed work activities in progress, completed work and l
l plant status in several areas during general inspection tours. Work was i
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examined for any obvious defects or noncompliance with regulatory require-
ments or license conditions.
particular note was taken of the presence of J
quality control inspectors and quality control evidence such as inspection records, material identification, nonconforming material identification,
i housekeeping and equipment preservation.
The inspector interviewed craft I
supervision, craft and quality control personnel in the work areas.
Observations are noted below:
The inspector examined the use of proper drawings by craft and QC (
personnel. The following drawings were checked:
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Drawing Field Revision Document Control Current Revision i
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C-1204
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C-938
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C-929
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C-263
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'As documented in section 7b of this report, the out of revision drawing had been independently identified by QC and appropriate corrective
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actions were instituted.
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The rod issue station for Schneider Corporation was examined by the
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inspector. The filler material was properly segregated in the holding
ovens and storage areas. The inspector reviewed the oven temperature
logs and filler material disbursement logs. The inspector had no questions.
The use of drill stop devices for in process concrete boring activities
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was noted by the inspector.
The drill stop prevents the bit from unknowingly cutting structural reinforcing bar.
The inspector addition-ally noted that reinforcing bar scans are routinely performed prior to concrete boring, to reduce the number of rebar cits.
The inspector reviewed associated Drilling Excavation checklists.
The inspector had no
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further questions.
No violations were identified.
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3.0 Licensee Action on Previously Identified Items
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a.
(Closed) Violation (77-10-01): Breventive maintenance requirements
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for recirculation loop valves and motors.
The following documents i
were reviewed by the inspector relative to the preventive
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maintenance requirements:
Field Deviation Disposition Request (FDDRS) HHO-065, and
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HHO-011
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GE Specification 22A2724 Section 4.1.2.4 l
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Lunkenheimer Co. procedure SP2224
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PECO Finding Report N-107
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PECO surveillance check report 2G0126 l
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The requirements to stroke the valves while in storage were waived
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until the system is flushed and filled with water.
The use of
1000 V megger tests was approved by GE engineering for the recircu-l 1ation and core spray pumps as permitted by the revised vendor
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storage instructions. The inspector was informed additionally that
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FOOR HHO-106 approved the use of Hoffman inhibitor in lieu of beater
elements to Ilmit condensation buildup in the limitorque motor
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l operators. The installed condition of the recirculation valves was l
l examined and found acceptable by the inspector. The valve internals t
have been temporarily returned to the warehouse. This item is closed
based upon the reconciliation of the site procedures and vendor preventive maintenance requirements and the current acceptable
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storage conditions of the valves.
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b.
(Closed) Violation (78-05-01):
Chipping of containment concrete.
The following documents were reviewed by the inspector:
Construction Procedures CP-C-10. " Excavation Review" and
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CP-D-9, " Control of Design Change Affecting Completed Work" PEC0 Finding Report N-133
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Field Change Requests (FCRs) C-1933F and C-5111F
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Bechtel Field Inspection Report C-1990-C-63-4
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The construction procedures were amended to address concrete chipping within the excavation review which includes quality control I
personnel.
The review process for design changes that impacted previously inspected hardware was amended tc assure necessary reinspection of the changes.
Criteria regarding the sif smic gap clearances was issued and the four deficient locations in the reactor building were rectified by additional chipping that was inspected by quality control. The inspector was informed that Bechtel Quality Control reviewed 320 FCRs and had not found any other cases where inspected hardware had been modified.
This item is closed.
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(Closed) Unresolved Item (79-04-01):
Internal corrosion on the RHR heat exchangers.
The following documents were reviewed:
GE Field Deviation Disposition Request (FDDR) HH2-197
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Inprocess Rework Notice LTM-898
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Nonconformance Report 5513
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GE directed that the heat exchanger nozzles be cleaned and repaired as necessary. The corrosion was removed by grinding and surface liquid penetrant examinations were performed to assure that no cracks were present.
The nozzles were repaired with additional weld material to assure that minimum wall requirements were met.
This item is closed.
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d.
(Closed) Unresolved Item (79-09-02): ASME site survey for Reactor t
Pressure Vessel (RPV) internals installer. The inspector noted that
GE has replaced Reactor Controls Inc. as the internals installer.
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The inspector was informed that an ASME site survey had been
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performed for GE in May 1986.
This item is closed.
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(Closed) Violation (81-04-01):
Preventive maintsnance requirements for the recirculation system valves.
Based upon the review
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documented in Section 3a of this report, this item is closed.
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(Closed) Unresolved item (82-01-01):
Installation of primary
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containment box beams. The inspector reviewed Nonconformance Report
5396.
The licensee performed a field survey to ascertain the t
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attachment points of the box beams located at elevation 286. The
beam locations were found acceptable-as-is by licensee engineering.
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j The final as-built gaps between the box beams and. adjacent ~ piping will be documented and analyzed during the piping as-built program.
This item is closed.
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(0 pen) Unresolved Item (83-06-01):
Potential carbon contamination
l of stainless steel piping. The inspector reviewed the following
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PECO Finding Report N-362
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Nonconformance Report 8373 f
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GE Letters LS-6450 and LS-6546
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PECO Surveillance Report 2P-474
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The licensee had reinspected the recirculation piping spool pieces l'
with carbon steel wire rope. The licensee engineering had evaluated l
and had documented two instances of rigging the stainless piping
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the observed conditions to be acceptable. The licensee parformed i
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training sessions to reinstruct the craft regarding proper handling
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of the spool pieces. The licensee QA personr.el performed a recent
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j surveillance of the recirculation piping installation and found the i
proper handling techniques in use. Pending licensee clarification
i of !.he nonconforming spool piece numbers relative.to the soool piece
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originally identified by the NRC inspector, this item remains open.
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4.0 ggalityAssurance
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a.
The inspector reviewed the PECO Quality Assurance Plan for Design
J and Construction phase regarding Quality Finding Reports (QFR).
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QFR serves as a multipurpose document tu report nonconforming
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conditions or other situations that require corrective action. The
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conditions are identified by PECO surveillances or audits.
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The current open findings in the electrical, mechanical, civil, and general areas for Unit 2 were reviewed by the inspector. The inspector noted conformance of the issued findings and control of
' responses in accordance with Appendix S of the QA plan.
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The inspector reviewed the following Bechtel QA docurrents:
Quality Assurance Department Manual Rev. 36
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QA Master Audit Plan
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QA Management Audit 86-10 Bechtel Audit PFA 731 (21-4-6) CRD Hydraulic System
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To assure implementation of various QA program elements, the inspector discussed the program requirements with the Project Quality Assurance Engineer.
The inspector then reviewed the QA documents discussed below.
The inspector reviewed a recent QA audit that had been performed by independent QA personnel. The management audit has assessed quality programs and hardware design conformance.
A recent site audit, associated audit checklist and the auditor data collection sheets were reviewed by the inspector. The audit appeared comprehensive in nature in that essential hardware and software elements of the audited activity were examined.
A current QA activity report that provided a surr, mary of Bechtel QA activities which included a delinquent open items report was reviewed by the inspector.
The inspector reviewed the Nonconformance Report (NCR) trend log and discussed how the monthly trend analysis is performed with a Quality Engineer.
The inspector noted that the QA Department Manual (CADM) required that design documents such as Field Change Requests (FORs) be included in the trending effort but noted that the Bechtel QA staff no longer trended those items.
The inspector was presented recent correspondence that approved the elimination of the design document
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treed efforts and was informed that the QADM would be revised accordingly.
Open Management Corrective Action Report (MCAR) 37 regarding Limitorque operator gear ratios was reviewed by the inspector.
Bechtel had determined the problem to be reportable under 10CFR50.55(e).
The inspector reviewed PECO Significant Deficiency Report (SDR) file 176 that documented Region I notification of the problem and the subsequent applicant corrective actions.
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The inspector reviewed the following docu:nents regarding the
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delineation of safety related components:
FSAR Section 3.1 and 3.2
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FSAR Table 3.2-1
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Project Q-List
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Quality Assuraace Diagrams (QADS)
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M-11 Rev 21 Emergency Service Water
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M-20 Rev 20 Fuel and.011 Storage ind Transfer
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M-76 Rev 14 Reactor Enclosure RefJeling Area HVAC
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j All the documents consistently defined the extent of the system safety related boundaries.
No violations were identified.
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5.0 Reactor Pressure Vessel and Internals Installation a.
In process work activities on the Reactor Pressure Vessel (RPV)
internals were observed by the inspector.
The shroud fitup, alignmsnt, and welding processes were observed.
The inspector examined the jet pump installation including the rams-head and diffuser assemblies.
The inspector had no questions, b.
The following QA procedures and records related to the internals i
work were reviewed:
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GE specification 22A2693 Rev. 5, " Reactor and Assembly
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Installation"
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GE Installation Instruction 22A4111 Rev. 1, " General
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Instructions for Reactor Assembly"
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l GE traveler package 2-106-T
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GE Nuclear Quality Assurance Manual PIA-AE-11 Rev. 4
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Bechtel QC Instruction SM-1.01, " Reactor Pressure Vessel
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Internals Installation Subcontract Surveillance" J
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GE drawing 197R62 Rev.19, " Reactor Assembly"
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GE Fleid Deviation Disposition Reports HH2-8155 and HH2-8126
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l Joint Process Control Sheet 2-108J-1 at 285 degrees
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GE Nonconformance Reports 2-5, 2-6, 2-7 and 2-8
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GE procedure PQ-I-005 Rev. O " Audits of Traveler Package"
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i The GE traveler packages were reviewed for ANI involvement, proper nondestructiva examinations, QC holdpoint adherence, nonconforming condition resolution, QC surveillance conduct and material traceabil-ity forms. The GE QC supervisor will provide a note in all traveler packages to define the hold point symbols.
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The QC records for the vessel support, alignment, and bolting l
installations were reviewed by the inspector that were contained in Reactor Controls Incorporated Phase 1 Quality Control Data Package.
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The inspector reviewed: Quality Control Data Sheets, receipt inspection reports, weld material certifications, liquid penetrant certifications, welder qualification records, instrument calibration records, weld maps and nonconformance reports. The inspector had no questions.
No violations were identified.
6.0 Piping and Pipe Supports a.
In process welding and installation activity on safety related piping were observed by the inspector.
The inspector reviewed the associated work packages which contain inspection records, filler material withdrawal forms, and piping isometrics. Activities on the following pipes were observed:
Isometric Weld System HBB-244-1 FW1 HPCI HBB-208-1 Rd-3 HPCI VRR-2RD-2A A7 Recirculation DLA-207-1 FW1 Feedwater DLA-212-2 FW3 RHR HBB-245-1 FW2 RCIC b.
The inspector reviewed the following documents regardi.g the Main Steam Safety and Relief Valve (MSRV) quencher supports:
Drawing C-263 Rev 4, " Primary Containment Quencher Support Base
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Plates"
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Work Package CO263-MS-QB2B
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Field Change Requests CS-88, CS-25, CS-21, CS-39, C8468F,
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CS-262, CS-98, CS-133 and CS-200 Nonconformance Report 10959
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Inspection Report C-263-MS-QB1B-20-1
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The inspector observed installation activities on the base stand
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anchor bolt tensioning. The inspector interviewed the field engineer and QC inspector. The use of calibrated tensioning equipment was noted. The inspector had no further questions.
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The inspector reviewed the following documents that provide design details for the Main Steam Relief Valve (MSRV) pipe bracing:
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C-270 Rev 11, "MSRV Discharge Pipe and Downcomer Bracing" C-271 Rev 13, "MSRV Discharge Pipe and Downcomer Bracing
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Supports and Details" C-272 Rev 8, "MSRV Discharge Pipe and Cowncomer Bracing
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Details" Sheet 1 and 2 l
C-257 Rev 4, " Pipe Supports Sections and Details"
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Chicago Bridge and Iron Drawing 355 Rev. 3 The inspector exarained installation details of_ the installed ring collars and bracing. Member size, configuration and weld sizes were-checked for downcomers 34, 35, 39, 40, and 41. The inspector questioned Bechtel QC regarding temporary attachment welds for several lugs on the downcomer piping. The inspecto.r was informed that qualified welders had made the welds and that 'a final magnetic particle examination would be performed on the lug welds in accordance with FCR CS-163.
The inspector had no further questions.
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No violations were identified.
7.0 Structural Concrete
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a.
The following documents regarding concrete placement activities were reviewed by the inspector:
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FSAR Table 3.8-12 FSAR Se'ctions 1.8 and 3.8.6
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Job Rule 8031-J!(-C-3, " Concrete Construction" Specifications C-36, " Forming, Placing, Finishing, and Curing
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of Concrete" C-114, " Purchase of Offsite Supplied Concrete" C-115, " Civil and Structural Design Criteria"
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Bechtel Quality Control Instructions C-1.20, "Preplacement Inspection of Concrete"
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C-1.30, " Concrete Placement Inspection"
C-1.40, " Post Placement Inspection of Ccncrete" i
The inspector found consistant licensee commitments and procedural
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requirements regarding concrete construction and inspection i
activities.
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b.
The inspector observed Bechtel QC performing a pre placement inspec-
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tien of embedded items in the Diesel Generator building. The inspector reviewed drawings C-680 Rev 9 and C-1204 Rev 10 that were used by the QC inspector. After the inspection was performed, the t
'NRC inspector and the QC inspector independently identified that
drawing C-680 Rev 10 should have been used to perform the inspection.
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placement inspection, removed the superseded drawings from the files,
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and performed additional training to reiterate document control
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requiremerts. The inspector had no further questions.
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Construction activities associated with the Diesel Generator
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building wall construction were observed by the inspector.
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inspector examined rebar location, cleanliness inside the forms, and the use of tie wire to secure the rebar and embeds.
The inspector noted craft supervision, QC personnel, and field engineers properly monitoring the field activities.
The inspector had no further questions.
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d.
The inspector observed concrete pour RW-PR-52 at elevation 283 in the Reactor Building. The inspector noted that QC had taken the appropriate slump and cylindrical test samples. Associated work i
package C-159-SL-29-56 and QC Inspection Report C0159-SL-2956-5-1 were reviewed. The inspector interviewed the in process QC Inspector
that was covering the pour operation.
e Pour numbers DW-HK-49 and DW-HK-45 were observed by the inspector.
The pours were for the diesel generator building walls. The inspector noted use of proper equipment to limit the free fall of the concrete.
In process quality control records were reviewed relative to mix ingredients, concrete slump, concrete temperature,
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entrained air content, limit for mixer rotation and water addition.
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A cloggea pipe led to formation of a cold joint due to excessive I
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time lag between pours. The inspector was informed that the surface will be prepared for a subsequent pour attempt.
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No violations were identified.
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8.0 Structural Steel a.
The inspector examined a structural steel framing connection at the southwest corner of the diesel generator building. The connection
configuration was reviewed with respect to the following documents:
Bechtel drawings C-667, C-666 and C-687
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Bethlehem drawings Bechtel File Number 8031-C41C-13-5,
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8031-C41C-9-7 and 8031-C-41C-26-5
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Work Packages C0667-SS-0244B and C0666-SS-217 The connection was determined to be in accordance with the design drawings.
b.
The inspector examined a structural steel beam member located immediately below the primary containment diaphragm floor.
In accordance with drawing C-297 the beam had been cut free from connections to the reactor pedestal and support columns. The inspector reviewed FSAR figure 3.8-42 that depicted a permanent five bolt A490 connection of the beam to the support column. This item is open pending licensee reconciliation of the FSAR connection details consistent with the as-built plant.
(86-10-01)
c.
The inspector examined the CRD lateral restraint beam installation beneath the reactor pressure vessel.
The inspector noted the presence of long slotted holes with A325 bolts without plate washers and the absence of hardened washers for the splice plate A325 bolts.
The observed conditions are contrary to the AISC criteria for A325 joints. Tha inspector reviewed FSAR section 3.8.4.6.2.3 which documents that fabrication of structural steel shall conform with AISC. The licensee was asked to ascertain the inspection status of the restraint beam, the design requirement for the restraint beam, and to provide the installation drawings. Pending the completfor; of the described actions to ascertain the current status of the installation, this item is unresolved.
(86-10-02)
9.0 Mechanical Equipment a.
The inspector toured the Reactor Building and verified the location and configuration of major mechanical equipment in relationship to FSAR information.
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FSAR Figure Elevation Equipment 1.2-3 177 Core Spray pumps, HPCI turbine, RCIC turbine, RHR pumps, RHR heat exchangers and various unit coolers.
1.2-5 201 Reactor building cooling water pumps and
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heat exchangers 1.2-7 217 Drywell equipment and floor drain sumps 1.2-9 253 Recirculation pumps, multifunction HCU supports 1.2-11 283 Fuel pool cooling heat exchangers, fuel pool service water booster pumps, standby liquid control tank, regenerative heat
exchangers, and hydrogen recombiner.
1.2-13 313 Reactor building HVAC fans and duct.
b.
Installation activity on the outboard Main Steam Isolation Valves (MSIVs) was observed by the inspector.
The inspector examined the MSIV field welds.and temporary riggir,g support. Associated work package APE-2MS-LB was reviewed by the inspector.
No discrepancies were identified.
The placement of the first Hydraulic Control Unit (HCU) was observed c.
by the inspector.
The craft took necessary precautions to avoid damage during the HCU rigging process. The inspector noted the presence of mechanical and civil craft supervisors and engineers.
The absence of protective covers for coaxial cable connectors was
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noted. The licensee informed the inspector that the in place storage requirements would include the cable covers. No other discrepancies were identified.
d.
The inspector observed the torquing of core spray pump 2BP206 anchor bolts. The use of a calibrated torque wrench was noted.
The inspector reviewed Torque Data Sheet M1-E21-C001-K2.2 and interviewed the craftsmen.
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No violations were identified.
10.0 Electrical Components and Cables The installation of cable tray in accordance with work package a.
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R2-0006 was observed by the inspector.
The following documents were reviewed relative to tray support type NS-174:
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I FCR ES-35
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Bechtel drawing E-1406-2 Sheet 3.6-174
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Specifications 1406-1 t
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Welding Specification E-48 l
The inspector had no further questions as the work was proceeding in
accordance with the applicable criteria.
b.
The following documents were reviewed by the inspector that relate to the equipment mounting and seismic qualification tests for the battery chargers and battery racks:
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FSAR section 3.10
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IEEE 344, " Recommended Practices for Seismic Qualification of Class IE Equipment for Nuclear Power Generation Stations" (
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PECO Equipment Qualification Package D-17 " Batteries and Battery Racks"
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C & D Batteries Division drawings M-7114, M-7113, M-7115, M-8052 and NBC-1371.
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Bechtel Quality Control Inspection Report C-64-QB-28
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Bechtel drawings C-632, C-615, C-603, C-426 and M-126
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Wyle Report 43450-1, " Seismic Simulation Test Program on a Battery Rack and Batteries" The battery charger anchor bolts were examined by the inspector and found consistent with applicable design document. The battery rack seismic qualification report was reviewed and the following concerns
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were identified:
The test report did not account for any cable mass on the
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battery posts wheie either 2 or 3 750 MCM cables are used in the field.
The C&D arrangement drawing depicts #2 AWG inter-tier
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connection wire where #3/0 was noted in the b'ttery a
installation.
Pending licensee review of the concerns, this item is unresolved.
(86-10-03)
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c.
Wiring modifications and cable terminations in the control room were observed by the inspector. The inspector reviewed work package ECR-200607-005 and GE connection diagram 204B7659 relative to a socket replacement. The termination of cable 28QE3A09A-244 was observed and the in process QC inspector was interviewed. The associated termination ticket was reviewed.
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No violations were identified.
11.0 Unresolved Items
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Unresolved items are matters about which more information is required to ascertain if it is acceptable, a violation, or a deviation. Unresolved Items are discussed in paragraph 8C and 108.
12.0 Exit Meeting
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The NRC resident inspector discussed the issues and findings in this report with members of the licensee's staff on a weekly basis, and at an exit meeting held on July 28, 1986.
Based on the Region I review of this report and discussions held with licensee representatives on August 1, 1986, it was determined that this report does not 'contain information subject to 10CFR2.790 restrictions.
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