IR 05000354/1978014
| ML19261A774 | |
| Person / Time | |
|---|---|
| Site: | Hope Creek  |
| Issue date: | 12/22/1978 |
| From: | Mcgaughy R, Narrow L, Sanders W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML19261A773 | List: |
| References | |
| 50-354-78-14, NUDOCS 7902080155 | |
| Download: ML19261A774 (9) | |
Text
U.S. NUCLEAR REGULATORY COMMISSION 0FFICE OF INSPECTION AND ENFL iEMENT g
Region I Report No.
50-354/78-14 Docket No.
50-354 Category A
License No.
CPPR-120 Priority
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Licensee:
Public Service Electric and Gas Company 80 Park Place Newark, New Jersey 07101 Facility Name:
Hope Creek Generating Station, U: lit 1 Inspection at:
Hancocks Bridge, New Jersey Inspection cond led:
N
.ber 28-30, 1978 Inspectors:
'44 4[
lA/RL/74 L. Narrow, Reactor Inspector date signed Wt(c/k A.
IA/L'/ 7 A W. F. Sanders, Reactor Inspector date signed
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lllLLl7f J.
r, Reactor Inspect date signed
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W.H.Bateman, Reactor 7nspector date ' signed Approved by: hhNM
,2% 1678 R.W.McGaughy(,/gef,ProjectsSection date signt!d Reactor Construction and Engineering Support Branch Inspection Summary:
Inspection on November 28-30, 1978 (Recort No. 50-354/78-14)
Areas Inspected:
Routine, unannounced inspection by regional based inspectors of QC programs for installation of piping and erection of structural steel; weld material control and examination of weld radiographs; the Peabody Testing Services QA program and its implementation and the status of previously reported significant deficiencies.
73e inspection involved 68 inspector-hours on site by 4 NRC regional based inspectors.
Results: No items of noncompliance were identified.
7902080157
.
DETAILS 1.
Persons Contacted Public Service Electric and Gas Company
- A. D. Barnabet, QA Enginee-
- ). I. Contractor, QA Engineer
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- A. E. Giardino, Project QA Engineer
- P. S. Hunter, Lead Engineer
- P. J. Kudless, Senior Construction Engineer
- F. M. Linn, Principal Construction Engineer
- L. A. Murray, QA Coordinator
- A. C. Smith, Project Construction Manager Bechtel Power Corporation W. Cole, QA Engineer L. Fine, Lead Welding Engineer
- R. L. Hanks, Project Field Engineer W. Hindle, Project Field Engineer
- 0. F. Long, Project Superintendent
- J. McCall, Project Engineer
- D. M. Stover, Project Superintendent of Services S. Vezendy, Lead Welding QC Engineer Peabody Testing Services
- R. Erdman, Project Manager
- H. Doty, QA Engineer Pittsburgh-Des Moines Steel Company M. Steiger, QA Manager The inspector also talked with several other employees of the licensee, architect-engineer constructor and subcontractor.
denotes those present at the exit interview
.
2.
Plcnt Tour A tour of the site was made to observe the status of the work and construction activities in progress.
The inspector noted the presence of and interviewed QC personnel inspecting work in progress. Areas observed included: welding in progress on containment suppression chamber, weld material control, radiography facilities and -esults, and structural steel erection.
No items of noncompliance were identified.
3.
Peabody Testing Services (PTS)
The inspector was informed that PTS had been selected to operate the site laboratory and perform the required concrete, soils and rein-forcing steel tests.
PTS had taken over this work on October 27, 1978.
The technicians previously employed on this work had been retained with PTS providing supervisory personnel.
a.
PTS Procedures The inspector examined the QA/QC procedures shown below for conformance to the requirements of the PSAR and Bechtel specification C-191, Revision 4, " Technical Specification
-
for Centract for Materials Testing Services."
(1) Quality Assurance Program for Peabody Testing Services, Revision 8, which had been approved by Bechtel for work to proceed on October 26, 1978.
(2) Administra-recedure (AP) 33.G.1, Revision 1, "Docu-ment Contru
"
(3) Administrative Procedure 33.G.2, Revision 1, " Procurement and Receipt of Controlled Equipment and Materials" (4) Administrative Procedure 33.G.3, Revision 1, " Process Control" (5) Administrative Procedure 33.G.4, Revision 1, " Audits /
Nonconformances/ Corrective Action"
(6) Administrative Procedure 33.G.5, Revision 1, "Qualifi-cation and Certification of Personnel" (7) Test and Inspection Procedure (T&IP) 199.6.1-6756,
" Construction Materials Testing" (8) T&IP 3.33.0.1, Revision 2, "Conformance/ Performance Checks of CMT Equipment" The inspector observed that the PTS organization includes a QA Engineer on site reporting to the QA Manager /QC Manager and that a QA Engineer has been assigned to the site.
Para-graph 2.1.4 cf the Quality Assurance Program outlines the responsibilities of the QA Engineer.
Paragraph 4.3 of T&IP 199.G.1-6756 describes additional duties of the QA Engineer and also identifies him as an Assistant Shift Supervisor and states that he shall act in the capacity of the shift super-visor in his absence.
The inspector was informed that the QA Engineer had not acted in this capacity to date. However, the lack of separation of QA and work performance responsibility is considered to be an unresolved item (78-14-01).
b.
Qualification and Certification of Personnel The inspector examined Bechtel Surveillance Inspection Reports (SR) for the period November 1-24, 1978.
The SR for November 15, 1978, had identified lack of certifications and incomplete quali-fication records as a nonconformance.
The inspector reviewed personnel records for the PTS supervisory personnel. The qualification records for the shift supervisors c.nd the QA Engineer were incomplete and they were not certified to level II as requi,ed by T&IP 199.G.1-6756 except that one shift supervisor was certified to level II for concrete.
This item is unresolved (78-14-02).
c.
Equioment Calibration The inspector discussed the program for equipment calibration with Bechtel and PTS representatives. The equipment records had been turned over to Bechtel by PTL, the previous operator of the laboratory.
Calibration of equipment was in progress
.
and the PTS Project Manager stated that it was intended to re-calibrate all equipment and establish a list / chart for control of equipment and its calibration.
Pending its completion, equipment was being calibrated as its calibration due date approached.
The inspector checked calibration stickers on a random selection of items of equipment and observed that all of the items checked were within their calibration period.
This item is unresolved pending review by an NRC inspector of the completed equipment list and documentation of calibration control (78-14-03).
4.
Reactor Coolant Pressure Boundary and Safety-Related Pioing - Review of Quality Assurance Procedures A selective review of the licensee's quality assurance / control pro-gram procedures was performed to verify that the requirements of the Hope Creek PSAR, Chapter 16; the ASME III Code, Winter 1974 edi-tion, subsection NA-4000; and NRC requirements are being implemented for the reactor coolant and safety-related piping installation.
The following documents were reviewed:
Bechtel Documents 10855-P-202, Field Fabrication and Installation of Piping for Nuclear Service, Revision 2 Field Procurement Manual, FPP-16, Revision 0 Individual Jobsite Instructions, Field Procurement, Revision 3 Quality Control Instruction (QC:) R-1.00 Rece"/ing Inspection, Revision 4 Q.C.I. P-1.00, Piping Completed Line Installation, Revision 0 Q.C.I. P-1.10 Piping Subassembly 'tabrication, Installation, and Rework, Revision 1 Q.C.I. W-1.00 Weloing, Heat Treating, and Nondestructive Examination of Q-Listed and ASME III Items
Q.C.I. T-1.00 Hydrostatic, Pneumatic, and Preoperational In-Service Leak Testing Bechtel Quality Assurance Manual ASME III, Division 1 The review confirmed that procedures have been established to provide for purchasing, receiving, storage, handling, cleaning and installation of reactor coolant and safety-related piping.
No items of noncompliance were identified.
5.
QA/QC Program - Structural Steel Erection and Welding The inspector examined the Bechtel documents listed below to ensure that QA/QC plans, instructions and procedures were established and that they conformed to the quality assurance program as described in Chapter 16 of the Safety Analysis Report:
a.
Nuclear Quality Assurance Manual b.
Specifications (1)
10855-C-126(Q), Revision 3, Erection of Structural Steel for Category 1 Structures (2)
10855-C-127(Q), Revision 0, Nondestructive Examination of Structural Steel (3)
10855-C-130(Q), Revision 3, Structural Field Welding Pro-cedures c.
Specific Work Plan / Procedures (1) SWP/P-19, Field Welding Activities (2)
SWP/P-C-lll, Revision 1, Erection of Structural Steel and Miscellaneous Metal d.
Construction Quality Control Manual - Section III Quality Ccatrol Instructions (1) QCI-10855/W-1.00, Revision 4, Welding, Heat Treating and Nondestructive Examination of Q-List and ASME Section III Items
(2) QCI-10855/C-2.10, Revision 3, Structural Steel Erection No items of noncompliance were identified.
6.
QC Records - Structural Steel Welding The inspector examined the Quality Control Inspection Records (QCIRs)
listed below to verify conformance to the established program reviewed in item 5 above:
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QCIR No. C-126-C-ll53-6, Auxiliary Building
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QCIR No. C-126-C-0801-6, Reactor Building Room 4106 QCIR No. C-126-C-0801-23, Reactor Building Room 4118
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The inspector used the welder identification code stamped adjacent to several Q-listed structural steel welds to retrieve the appropriate QCIRs. The QCIRs were revicted for completeness and accuracy.
No items of noncompliance were identified.
7.
Procurement of Safety-Related Materials The inspector discussed problems identified at other sites with procurement of materials from Modern Suppliers and Manufacturers, Inc.
No materials had been purchased to date from this vendor and the inspector observed that this vendor was not listed on the Qualification Bidders List for specification E-037(Q) attached to Bechtel letter dated January 4,1978.
The inspector had no further questions concerning this matter.
8.
Welding in Progress A visual inspection was made of the welding in progress to join certain subassemblies of the primary containment drywell and torus suppres-sion chamber. The inspector observed the welding performed on two circumferential weld seams #180 and kl79 and the welding on a jet assembly D inart into the drywell.
Particular note was made of the welding poe:tions, slag removal, cleanliness, preheat, weld metal disposition, electrode handling, disposition of unused electrodes, welder identity and preparation of fusion lines and undercuts prior to nondestructive examination.
No items of noncompliance were identifie.
Weld Material Control For primary containment welding, the following areas of weld material control were observed by the inspector to ensure conformance with the requirements of the contractor QA program and walding specification WS-3:
a.
Storage of materials - identifice. ion, segregation and cleanliness b.
Temperature control and calibratic a of holding ovens c.
Issue records - approval, amount withdrawn, identity of persons making withdrawal, dates, a ! identification of weld location d.
Handling and disposition of unused and returned material No items of noncompliance were identified.
10.
Radiography An inspection was made of the radiography facilities and equipment for film loading, developing, density measuring and viewing.
In addition twenty-one (21). films were randomly selected from weld seam #16, on subassembly sa5 to examine for radiographic quality and conformance to procedure P.D.M. CRT-03/0.
Specific attention was given to the following attributes:
a.
Identification of material type and size b.
Type, size and strength of source c.
Size of penetrameter d.
Film quality, artifacts, waw.': narks and blemishes e.
Required density range f.
Station markers and film identification No items of noncompliance were identifie.
Review of Nonroutine Events Reported by the Licensee The licensee had reported, as a significant deficiency in accordance with 10 CFR 50.55(e), that BIF Industry butterfly valves were sub-ject to a possible operating defect.
It was possible for the shaft key and operator spline adapter to vibrate loose rendering the valve inoperable.
The inspector examined Nonconformance Report (NCR) No. 372, Manage-ment Corrective Action Report (MCAR) No. 9, and the letter dated October 18, 1978, from BIF Industries to Bechtel which described the problem, the corrective action recommended by the vendor, the engineering disposition and the corrective action which had been verified by Bechtel Supplier Quality Representative (SQR).
The inspector had no f-ir questions.
12.
Unresolved Items Unresolved items are matters about which more information is required in order to ascertain whether they are acceptable items, or items of noncompliance. Unresolved items identified during the inspection are discussed in Paragraph 3.
13.
Exit Interview The inspector met with licensee representatives (denoted in paragraph 1)
at the conclusion of the inspection on November 30, 1978.
The inspector surmiarized the scope and findings of the inspection.