IR 05000354/1979005
| ML19249E414 | |
| Person / Time | |
|---|---|
| Site: | Hope Creek  |
| Issue date: | 08/08/1979 |
| From: | Bateman W, Mcgaughy R, Narrow L NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML19249E410 | List: |
| References | |
| 50-354-79-05, 50-354-79-5, 50-355-79-05, 50-355-79-5, NUDOCS 7910010329 | |
| Download: ML19249E414 (10) | |
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U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF, INSPECTION AND ENFORCEMENT
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'a Region I 50-354/79-05
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Report No. 50-355/79-05
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50-354
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Docket No. 50-355
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CPPR-120 j
License No. CPPR-121 Priority Category A
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Licensee:
Public Service Electric & Gas Comoany
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80 Park Place
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Newark.'New Jersey 07101
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Facility Name:
Hope Creek Generating Station, Units 1 & 2
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Inspection at:
Hancocks Bridge, New Jersey Inspection conducted: Ju 18-21, 1979
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Inspectors:
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_ fug), Chief, Engineering Su~pport Section ' /@/ 8/7c/e Aijned 0.
/i No. I date signed date signed Approved by:
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R. W. McGaughfM.Hief, Projects Section, date signed RC&ES Branch Inspection Summary:
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Inspection on June 18-21,1979 (Combined Report Nos. 50-354/79-05; 50-355/79-05)
Areas Inspected: Routine, unannounced inspection by regional based inspectors, which commenced on the evening shift, of June 18, 1979, of the QC program for structural welding; pipe welding; receipt and storage of equipment; and the status of outstanding items.
The inspection involved 94 hours0.00109 days <br />0.0261 hours <br />1.554233e-4 weeks <br />3.5767e-5 months <br /> on site by four NRC regional based inspectors.
Results : No items of noncompliance were identified.
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7910 010 3D Region I Form 12
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(Rev. April 77)
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DETAILS 1.
Persons Contacted Public Service Electric and Gas Company Y. Contractor, Site QA Engineer
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- A. E. Giardino, Project QA Engineer
- R. T. Griffith, Senior Staff Engineer, QA R. Inverso, Construction Engineer
- L. Jankowski, Site QA Engineer
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Pochank, Senior Construction Engineer
- A. C. Smith, Project Construction Manager Bechtel Power Corporation (Bechtel)
B. Bain Lead Field Welding Engineer
- R. Barclay, QC Engineer S. Bhat.tacharya, Resident Engineer W. Cole, QA Engineer W. Dorman, Lead Piping Field Engineer
- R. L. Hanks, Project QC Engineer
- W. F. Hindle, Project Field Engineer B. Jones, Night Superintendent C. Kasch, Assistant Project QC Engineer R. McCcy, Lead Maintenance Engineer R. McKinnor), Assistant Prdject Field Engineer
- P. Schuetz, Resident Engineer
- 0. W. Stover, Project Superintendent of Services S. Vezendy, Lead Welding QC Engineer Peabody Testing Services (PTS)
R. Davis, Night Superintendent
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Pittsburgh-Des Moines Steel Company (P-DM)
M. Steiger, QA Manager The inspectors also talked with several other employees of the architect-engineer constructor.
- denotes those present at the exit interview.
2.
Plant Tour (Units 1 and 2)
A tour of the site was made to observe the status of the work and construc-tion activities in progress.
The inspectors examined work items for any 4 n /-
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obvious defects or noncompliances with regulatory requirements or license conditions.
Areas observed included: placement and compaction of backfill, structural welding within containment, placement of rebar for the RPV support structure, fit-up and preparation for welding of the suppression chamber.
3.
Attachment Welds-Hangers to Structural Steel Paragraph A.7.1 of Specification P-408(Q), Design and Documentation for Pipe Supports in Nuclear Service for Pipe 2 1/2 Inches and Larger, Revision 2, states in part:
" Field welds made on beams and girders under load or columns shall be parallel to the longitudinal axes of these members...."
Inspection of hanger attachment welding to structural steel showed transverse welding taking place on the beam web of several load bearing beams.
Bechtel field engineering personnel stated that the hanger design drawings show this type of welding as permissible and that the above referenced paragraph from Specification P-408 are intended to specify that the longitudinal weld re-quirement is applicable only to the beam or column flanges.
This item is unresolved pending revision of the specification document to state more specifically the portions of beams or columns which have weld direction constraints.
(354/79-05-01;355/79-05-01)
4.
Resolution of Maintenance Inspection Punchlist Items Paragraph 8.b of Bechtel Quality Control Instruction (QCI) S2.00, Maintenance Inspection, Revision 5, states in part: "Upon resolution of the punchlist line item, the QCE shall signify acceptance of the item by initialing and dating the appropriate block of the punchlist.
The PCQCE shall provide a copy of the punchlist, updated weekly, to the PFE for evaluation and corrective action as required."
As regards the above paragraph, the Project Fiela Engineer (PFE) has no formal requirement to notify the Quality Control Engineer (QCE) when an item on the Maintenance Inspection Punchlist has been resolved.
Because the PFE has the responsibility for accomplishing the work required to clear the punchlist item, it is necessary that he inform the QCE of resolved items so that the QCE may comply with the acceptance signoff requirements.
Additionally, the PFE has no requirement to take timely corrective action to clear items from the punchlist.
This may allcw a maintenance requirement to remain incomplete for an unacceptable period of time.
The two concerns discussed at,ove are unresolved pending the establishment of requirements for the PFE to notify the QCE upon resolution of punchlist items and to take timely corrective action to resolve the punchlist items.
(354/79-05-02;355/79-05-02)
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5.
Safety Related Components - Observation of Work and Work Activities The inspector selected a main steam isolation valve, a safety relief valve, and tne RCIC pump and turbine for observation of work performance as regards storage, protection, and installation.
The identification of the components is as follows:
Safety Relief Valve by Target Rock; S/N-350; G.E. Master Parts List
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No. B21-F013 Main Steam Isolation Valve by Atwood-Morrill; S/N-02-685; G.E. Master
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Parts List No. B21-F028 RCIC Turbine by Terry Turbine; S/N-T37123A
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RCIC Pump by Bingham; S/N-200361
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In particular the warehouse storage environment and protection for the two valves and the in place storage environment and protection for the RCIC pump and turbine were investigated.
Quality Control Inspection Reports (QCIR's)
10-5212-M-200 and 10-P203-M-200 for the installation of the RCIC turbine and pump, respectively, were examined.
No items of noncompliance were identified.
6.
Safety Related Components - Review of Quality Records The inspector reviewed quality related records for the safety relief valve, main steam isolation valve, and RCIC pump and turbine detailed in paragraph 4 above.
The purpose of the review was to ascertain that the records were available and contained the information specified in the PSAR and jobsite technical specifications.
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The particular records reviewed were storage and installation records, non-conformance reports, and material and fabrication certifications and test reports.
The following is a list of the specific documentation reviewed:
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Material certification Package No. 35574
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Material Certification Package No. P558 Nonconformance Report No. 171
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Field Inspection Plan No. QAD-58-2
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PSE&G Receiving Inspection Report No. 94
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Quality Control Inspection Record, Log No. NSSS-164 Applicable Maintenance Action Cards
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No items of noncompliance were identified.
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7.
Structural Welds a.
Drywell
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A visual inspection was made of selected welds in the drywell which had been completed.
The inspector examined welds 8E4, 8AE4 and 6E37 for location, surface finish, finish grinding and surface defects for con-formance to the applicable rt
~rements of the ASME Section III, Sub-section NE.
This area of the _.ywell was examined to determine the conformance to the following P-DM drawings.
Dwg. No. E-37, " Half DW Shell Rollout Showing Penetrations"
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Dwg. ho. 26, " Details of 2nd Course Drywell Shell Plates" Dwg. No. E-50, "Drywell Penetration Erection"
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Dwg. No. E-4, " Lower Drywell and Jet Deflector Erection.
The inspector also examined work and quality records for weld nos. 6E37, 8E4 and SAE4' showing that visual and dimensional inspections were performed.
The weld history records were complete and reflected adequate weld quality.
No items of noncompliance were identified.
b.
Beam Seats The inspector examined the location and installation of Beam Seats for Beams No. 73-B1, 74-B1, 74-B2, 74-B4 and 75-B1 for conformance to the following Bechtel drawings:
No. C-1359-0, Rev. 9 (Q) " Auxiliary Building Structural Steel -
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Sections and Details"
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FSK-CB-3219, Rev. 0 " Beam Seat Locations for Center Radwaste Room 3219 - El.87-0 and E1.102-0"
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FSK-CB-3208, Rev. 0 " Beam Seat Locations for Center Radwaste Room 3208 - E1.87-0 and El.102-0" The inspector performed a visual examination of the welds for attachment of the above beam seats.
Their size, shape and surface finish were examined for conformance to the structural welding code AWS Dl.l.
Supplemental welding reports to PQCI C-2.10 were examined to determine that visual and dimensional inspections had been performed, that the records were complete and reflected adequate weld quality.
No items of noncompliance were identified.
However, the inspector observed that paragraph 3.4 of QCI C-2.10 establishes a requirement that the completed welds be inspected for contour and surface appearance, the inspection attributes are not clearly defined.
This item is unresolved.
(354/79-05-04;355/79-05-03)
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8.
Reactor Coolant Pressure Boundary and Safety-Related Piping - Review of Quality Assurance Procedures The inspector reviewed selected quality assurance and quality control pro-cedures.
This review was performed to determine whether the procedures meet the requirements of Chapter 16 of the facility PSAR,Section III of the ASME Code, 1974 Winter Addenda subsection NA-4000 and NRC requirements.
Specific procedures selected are associated with the installation of reactor coolant and other safety-related piping, and included:
Bechtel Construction Quality Control Manual
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Administrative Quality Control Instruction, Rev. 4
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Project Quality Control Instructions
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Technical Quality Control Instructions
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Field Procurement Manual
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Quality Control Instruction (QCI)
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QCIR-1.00, Receiving Inspection b.
QCIP-1.00, Piping Completed Line Installation c.
QCIP-1.10, Piping Subassembly Fabrication, Installation and Rework d.
QCIW-1.00, Welding, Heat Treating and No-tt'uctive Examination of Q-Listed and ASME III Items Based on this review and discussions with cognizant personnel the inspector determined that adequate procedures have been established to control activ-ities such as; purchasing, receiving, storage, handling, installation of safety-related piping.
No items of noncompliance were identified.
9.
Safety Related Pipe Welding
_0bservation of Work (Unit 1)
The inspector examined the following nuclear class #1 weld joints to verify that work, as completed, was in accordance with the Bechtel welding pro-cedure, ASME Section III and Section IX and regulatory requirements.
Finished weld 1P-BC-005-FW7
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Root portion 1P-BC-001-FW1 Additionally, the inspector reviewed welder and procedure qualification records associated with these welds.
Weld history and quality control records
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were also audited for verification of compliance with specified quality functions.
Based on this review, and discussions with quality control personnel, the inspector determined that quality related activities were conducted in accordance with appropriate instructions / procedures.
No items of noncompliance were identified. _
10.
Qualification of Inspection (QA/QC) Personnel The inspector audited qualification records of two quality assurance and three quality control personnel.
The records in the personnel folders were.
up to date, approved and signed by their supervisors.
No items of noncompliance were identified.
11.
Steel Structures and Supports Welding Material Control The inspector audited Pittsburgh-Des Moines (PDM) welding control to assure compliance with the requirements of the contractor QA program and welding specification WS-3.
The following items were observed.
a.
Storage of materials - identification, segregation and cleanliness.
b.
Temperature control and calibration or holding ovens.
c.
Issue records - approval, amount withdrawn, identity of welders making withdrawal, dates, and identification of welds.
d.
Weld rod material certifications - required tests are performed on each lot of covered electrodes - the inspector reviewed the certi-fication for the following material - Lot 021-08095, Heat 411C2141 Chemtron Corp. 7018, covered electrodes - Lot 26821, Heat 422C4871, McKay 7018, covered electrodes.
Control of electrodes for limiting moisture pickup is obtained by e.
limiting the out of oven time to four hturs.
After the four hours any unused electrodes are destroyed.
-The inspectors reviewed Bechtel Power Corporation Welding Standard WFMC-1 Revision 6, Amendment 1 and 2 for weld rod control.
This procedure allows E 7018 covered electroder to be kept out of heated ovens for 12 hours1.388889e-4 days <br />0.00333 hours <br />1.984127e-5 weeks <br />4.566e-6 months <br />.
Electrodes out of the holding oven more than 12 hours1.388889e-4 days <br />0.00333 hours <br />1.984127e-5 weeks <br />4.566e-6 months <br /> shall be discarded or reconditioned per the manufacturer's instructions.
Electrodes out of the holding ovens less than 12 hours1.388889e-4 days <br />0.00333 hours <br />1.984127e-5 weeks <br />4.566e-6 months <br /> shallbeplacedinaholdingovenforaminimugofeighthoursprior to re-issue.
The holding oven shall be at 250 F minim =..
This welding standard requires that electrodes must be issued in containers.
How-ever this standard does not require that electrodes be kept in con-1 * $.
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tainers after issuance.
The inspector observed the welders removing the electrodes from the containers for convenience purposes while welding in remote locations.
The inspector also observed a rdemorandum from Bechtel Power which stated that loose electrodes, i.e., electrodes out of con-tainers would exceed'the.6% motsture allowances of the AWS code after exposure of four hours.
This item is unresolved pending further review by the NRC.
(354/79-05-05;355/79-05-04)
No items of noncompliance were identified.
12.
Steel Structures Welding - Observation of Work (Unit 1)
The inspector examined weld joint 15675-cal-5HA4 Downcomer section, to verify that work, as completed, was in accordance with the Bechtel Design Specifi-cation 10855-C-152 Rev. 14.
Specifically, the following items were inspected:
a.
Welding procedure, weiders and weld joint geometry were specified.
b.
Welding electrodes are correct and controlled.
c.
Parts to be welded are assemblied and held in place.
These assemblics were being tack welded after fit up at the time the inspector cbserved the activity.
The inspector noted that the fit up tolerances of the weld gap were being exceeded.
The inspector discussed ibis with PDM QC inspectors and it was determined that QC had not perforn.2d these accept-ance inspections on this item.
This item is unresolved pending an inspection by the RRC inspector after. PDM, QC inspection and correctlye actions taken if warranted.
The inspector noted that PDM has approved procedures to correct fit *.? deficiencies such as these.
(354/79-05-03)
13.
Steel Structures and Supports - Observation of Work (Unit 2)
An inspection was conducted of six containment subassembly welds welded by PDM on site.
The six welds audited were.
29E6 Assy. G 15E6 Assy. K 27E6 Assy. G 11E6 Assy. J 23E6 Assy. M 25E6 Assy. M The following areas were specifically reviewed.
a.
Work is conducted by use of a process checklist.
b.
Welds identification is traceable.
c.
Weld procedure is specified and followed.
Weld procedures 68-5 Rev. F and 68-4 Rev. E were applicable.
These procedures were reviewed to 3 L O '] }/9 e i -
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assure compliance with ASME Section IX for essential and nonessential variables.
d.
NDE was accomplished in accordance with ASME requirements.
These welds were subjected to visual and radiographic examinations.
The inspectors also audited PDM film storage facility for storage of exposed radio-graphic film.
The storage had temperature and humidity controls and the facility appeared very adequate.
e.
The appearance of the welds were observed to determine code compliance such as surface finish, reinforcement, etc.
No items of noncompliance were identified.
14.
Steel Structure and Supports Record Review The inspector reviewed Bechtel Specification No. 10855-C-152(Q) Rev. 7 for certain nondestructive examination requirements for lamellar tearing of the drywell and to. us.
The inspector also reviewed the examination results of both shop and field examinations.
This specification requires that all pressure boundary plate in the area of external supports of the drywell and torus which contain tee-welds in excess of certain sizes must be examined 100% using ultrasonics prior to welding and repeat inspected using ultrasonic after welding and stress relieving.
The percent coverage is specified in paragraph 13.7.3 of the Bechtel Welding standard.
The inspector reviewed the ultrasonic reports for pieces marked 15A9 and 15A2.
The examinations performed after welding indicated a significant change in the ultrasonic signals.
PDM had rejected the inspected areas due to lamellar tearing of the metal and repairs were required.
No items of noncompliance were identified.
15.
Limitorque Operators on Valves Supplied by Anchor Darling The inspectors investigated a reported possible generic deficiency in Limitorque operators on valves supplied by Anchor Darling which do not meet the procurement document requirements.
Specifically, certain valve operators ordered for use inside containment,are t equired to have Type "R" in~sulation but the valves received on site had Type "B" insulation whicfr is not suitable for use inside containment.
The licensee had performed u audit of the affected valves at the Hope Creek site which showed that the valves to be used inside containment do not have type "H" insulation.
The inspector had no further questions regarding tMs item.
16.
Rejectable Defects in Waste Gas Tanks Fabricated by Industrial Piping Supply Company (IPSCO)
Waste gas decay tanks fabricated by IPSCO reportedly could contain rejectable weld defects.
The inspectors questioned the licensee as to the possible use of IPSC0 fabricated tanks on this project.
The licensee stated that no tanks
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by IPSCO are used on the project and that IPSCO is not on their Qualified Bidders list.
The inspector had no further questions regarding this item.
17.
Power Operated Relief Valve Deficiency _
Power operated reli(f valves manufactured by Control Components, Inc. report-edly contain a potential component deficiency.
The inspector questioned the licensee as to the possible use of power operated relief valves manufactured by Control Components on this project.
The licensee stated that nc. power operated relief valves by Control Components are used on the project.
The inspector had no further questions regarding this item.
18.
Licensee Action on Previous Inspection Findings (Closed) Unresolved item (79-01-01): Direct tension indicator gap require-ments.
The inspector discussed the effects of complete gap closure with the licensee's representatives, reviewed a letter dated May 12, 1979 from Cooper-Turner, Inc., the bolt manufacturer and examined a Bethlehem Steel Pamphlet entitled "High-Strength Bolting for Structural Joints," for A-325 bolts, all of this information supported the manufacturer's instructions that the gap is provided to prevent bolt breakage and that breakage will occur due to the torsionaT load and prior to over tensioning.
(Closed) Unresolved item (79-02-01): Storage of primary containment plates.
Paragraph 8.2 of P-DM Procedure P-1 has been revised (Rev. H, April 17, 1979) to require inspection of storage and removal of water within 10 days.
The inspector examined a P-DM log which verified removal of water.
(Closed) Unresolved item (79-03-02): Weld surface cleanliness.
Engineering Corrective Action Request (ECAR) No. F-65 requires removal of existing tack welds, re prep of edges, cleaning and re-tack welding and also revises P-D:4
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welding specification WS-3 to require cleaning for a minimum of one inch on each side of the weld seam.
19.
Unresolved Items Unresolved items are matters about which more information is required in order to ascertain whether they are acceptable items, or items of noncompli-ance.
Unresolved items identified during the inspection are discussed in paragraphs 3, 4, 7, 11 and 12.
20.
Exit Interview The inspector met with licensee representatives (denoted in paragraph 1)
at the conclusion of the inspection on June 21, 1979.
The inspector summarized tne scope and findings of the inspection.
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