IR 05000358/1973001
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U. S. ATOMIC ENERGY COMMISSION DIRECTORATE OF REGULATORY OPERATIONS
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REGION III
REPORT OF CONSTRUCTION INSPECTION RO Inspectic.. Report No. 050-358/73-01 Licensee:
Cincinnati Gas and Electric Company 139 East 4th Street Cincinnati, Ohio 45201 William H. Zimmer Nuclear Power Station Moscow, Ohio.
License No. CPPR-88 Category: A Type of Licensee:
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Type of Inspection:
Routine, Unannounced Dates of Inspection:
January 18 - 19, 1973 Date of Previous Inspection:
September 7, 1972 (O f*
hv Principal Inspector:
J. W. Suttdn
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)?-/ * CI S (Date)
Accompanying Inspectors:
None Other Accompanying Personnel:
None v
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Reviewed By:
D. W. Hayes, Sen or Project Inspector (Acting)
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Reactor Construction Branch i
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L SUMMARY OF FINDINGS
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Enforcement Action A.
Violations
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No violations were identified.
B.
Safety Matters No safety matters were' identified.
Licensee Action on Previously' Identified Enforcement Matters No previously identified enforcement matters were involved.
Design Changes No new design changes were identified.
i Unusual Occurrences No unusual occurrences were identified.
Other Significant Findings A.
Current Findings
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Construction Status The Earth work construction placement is continuing on a 24-hour schedule as weather permits and is 15% complete.
The setting and welding of the main circulating water suction line piping is in progress and welding is 60% complete.
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l Concrete work on the Reaccor Building (RB) tendon tunnel mud mat
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is conplete and rebar work has started.
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Il The storage warehouse base slab has been completed.
l Batch plant building erection has been completed. Mechanical equip-f.
ment ha.r been installed and piping and electrical work is in progress.
The batch plant is scheduled to start operations by the first of
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February 1973 at which time the initial, Class I concrete pour, is scheduled to be made in the RB tendon tunnel.
Implementation of the Class I QA program for concrete will be initiated with this pour.
Contracts have been awarded for the containment vessel post tensioning system, primary containment liner and the phase one piping.
All Kaiser Engineer, incorporated, personnel have been transferred from the Cincinnati office to the construction site.
A CG&E QA Engineer has been assigned full time to the construction site.
B.
Unresolved Matters 1.
NSS Components, Receiving, and Storage The required individual equipment storage instructions are not available at the storage site for the equipment as it is received.
(Paragraph 1..b)
2.
Clarification of Massive Concrete The intent and application of the Sargent and Lundy (S&L)
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concrete specification No. H-2174, Revision R3, Section b.2.3 is not clear in regard to massive concrete.
(Paragraph 2)
3.
Zimr.er QA Manual, Criterion II, Section 2.6, " Control" A documented procedure was not available to assure that the Quality Assurance and Standards (QA&S) Department has reviewed the necessary QA documents prior-to the issuance of a purchase
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order.
(Paragraph 3)
C.
Status of Previously Reported Unresolved Matters Implementation Instruction for Quality Documentation of GE Manufactured Items (R0 Report No. 050-358/72-03)
A revision to the CG&E QA ma'nual was issued October 12, 1972.
The revision contains all the necessary instructions to properly receive GE manufactured items including reference to the necessary quality documents.
Furthermore, the revision has been l
incorporated into the Kaiser Engineers, Inc., inspection-3-
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instruction sheet that is used during the receiving inspection.
This matter is now considered to have been resolved.
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Management Interview A.
The following persons attended the management interview at the conclusion of the inspection.
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Cincinnati Gas and Electric Company (CG&E)
W. H. Dickhoner, Vice President, Engineering and Electrical l
Production J. D. Flynn, Assistant Manager - Engineering Department
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E. C. Pandorf, Principal Quality Assurance and Standards Engineer
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B.
Matters discussed and comments on the part of management personnel were as follows.
1.
The inspector stated that it appeared S&L concrete specification No. H-2174, Revision R3, Section b.2.3, Chapter 14 (Mass Concrete) was not clear as to the intent and application of
the specification during plant construction.
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The licensee stated that this matter would be discussed during a meeting that has been scheduled with S&L on January 24, 1973.
(Paragraph 2)
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2.
The inspector stated that during a discussion of new contracts that have been issued by CG&E, it appears that in some instances purchase orders have been issued, by the Engineering Department, prior to a complete review of the vendor's QA manual by the QA and S section. Documentatica to indicate that the QA documents had been reviewed were not available in the QA&S office.
The licensee stated that this matter would be resolved by the
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issuance of a revision to the CG&E QA manual.
(Paragraph 3)
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3.
The inspector stated that NSS equipment has been received at the storage warehouse without proper instruction for required storage criteria for each individual item.
The licensee stated that a meeting has been scheduled with the NSS supplier and
that these matters vould be discussed.
(Paragraph 1.b)
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4.
The inspector stated that equipment that is required to be l
protected with inert gas should be given a priority in maintaining the required pressure at a]1 times.
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~~Tlni licensee stated that this matter would be discussed with_ _.. - -[
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the contractor.
(Paragraph 1.h)
5.
The inspector discussed AEC personnel access requirements for the construction site.
The licensee stated that instructions would be issued to the site security division indicating the procedures to be followed to admit AEC personnel to the site.
6.
The inspector explained the AEC policy in regard to disclosure of information... stating that inspection reports will be made available to licensees for review to identify proprietary information, and, following appropriate deletion of such information, reports and associated correspondence will be placed in Public Document Rooms.
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REPORT DETAILS
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Persons Contacted
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- The.following persons, in addition to' individuals listed under the~
planagement Interview section of this report, were contacted during the inspection:
Cincinnati Gas and Electric' Company (CG&E)'
W. W. Schwiers,' Quality Assurance and Standards Engineer J. F. Weissenberg, Quality Assurance and Standards Engineer R. P. Ehas, Quality Assurance and Standards Engineer R. L. Wood,' Quality Assurance and Standards Engineer
- J. - H. Hoffman, Quality Assurance and Standards Engineer
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Kaiser Engineers, Incorporated (KEI).
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D. R. McSparrin, Project Manager (Site)
J. H. Jackson,. Quality Assurance. Manager-(Site)
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C. A. Smith, Quality Assurance Engineer - Civil-Structural-r V. C. Griffin, Quality Assurance Engineer - Receiving Inspector Supplier W.'A. Ferree, Warehouseman
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t Results of Inspection c
1.
NSS Components. Receiving, and Storage a.
Warehouse The leased, offsite warehouse, was inspected to determine if the building had been heated as discussed during the previous i
RO inspection (R0 Report No. 050-358/72-03). The licensee i
representative informed the inspector that KII had difficulties in obtaining a permit from the City of Cincinnati to install the large oil tanks to be used in the building heating system.
Consequently, the building has not been heated as previously
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Emergency electric heat, genera.ted by portable
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electric heaters, has been provided for that equipment requiring storage in a heated area as indicated in the GE storage
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specification No. 22A3126.
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A The area in which the equipment'is~ stored is being monitored.,
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by neans of an instrument recording temperature and humidity.
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The heating and controls provided during the interim period was.found to be acceptable. A contract has been awarded for the installation of the heating system and work is scheduled to be completed within two weeks.
b.
Receiving and Storage
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The NSS equipment and piping that was observed stored during the inspection was found to be " hold" tagged due to the lack i;
of receipt maintenance, storage or quality documentation.
It appeared that ever 90% of the stored items were hold tagged.
The inspector stated that some of the dates on the tags indicated that the items were received as early as August 1972, and it appeared that the time required to receive the necessary documents was excessive.
The inspector was informed that in many instances the equipment would be received without the necessary storage information (internal heating - equipment rotation, etc.) and would subsequently be " hold tagged" until the required documents were received. Under these conditions it is possible that equipment could be received
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and improperly stored (lack of internal heat, etc.) for an i i undetermined period until the storage instructions are provided.
The licensee stated that prompt receipt of necessary storage
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instructions would be discussed with the NSS supplier, f
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The inspector observed that one of the two RER heat exchangers
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that had been received on January 5, 1973, had lost its nitrogen pressure.
This matter had been properly documented by the KEI QA receiving f
inspector but the vessel has not been repressurized.
The inspector was informed that the vessel would be repressurized
by one of the contractors personnel when there was a full day's work available at the warehouse.
This matter was *
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discussed with the licensee and the inspector was informed that the matter would be resolved with the contractor.
This matter will receive follow-up attention.during a subsequent inspection.
2.
Massive Concrete i
During review of the S&L concrete specification H-2174, Revision R3,
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Section b.2.3 the inspector stated, that in some areas, restrictions to code requirements have been climinated without replacement or
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~ explanation.
A clarific_ation of the term massive concrete and
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critical size is not indicated in the specification.
i The licensee stated that these matters would be discussed during a scheduled neeting with S&L.
This matter will receive follow-up attention during subsequent inspections.
3.
Zimmer QA Manual Section 2.6 Control During a review of new contracts that have been awarded by CG&E, the inspector requested to review documentation that would indicate that required QA documents of the vendor had been reviewed prior to issuance of a purchase order.
The licensee informed the inspector
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tha; reviews had been made of vendor QA documents but that this ini. rmation was not documented.
The QA&S engineers have a personal con act and verbally discuss their findings with the Engineering Del etment cognizant engineer who is responsible for approval prior to he issuance of a purchase order.
The CG&E QA manual, Section 2.6,
"Cs :rol," does not require written documentation of the QA&S review.
Thc lack of documentation by QA&S had been noted and reported at the
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il coroletion of a management QA audit that was conducted on Nm anber
.j 21, 1972.
The licensee stated that a form will be developed i
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The fc.- will provide for documentation, to indicate to the cognizant neer that QASS has completed the required reviews.
et-The form is tc te incorporated into the CG&E QA manual.
This matter will receive f t __ iow-up attention during subsequent inspections.
f LC Activities'
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CpiE QA Activitier CG&E has assigned a resident QA Engineer to the site.
He will be responsible for continuously auditing KEI procedures for receiving equipment, accepting construction material, operation jj of tlus site document center and performance of construction
'1 QA activities.
II The inspector was informed that CG&E had applied for an Owner's
'i Certificate of Authorization as required by the ASME Boiler i
and Pressure Vessel Code,Section III, and C0&E was notified
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that they would be surveyed on February 5-6-7, 1973.
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b.
KEI Activities
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(1)
QA Personnel The following QA personnel presently comprise the site QA organization.
2 - QA Engineers - Civil-Structure 1 - QA Engineer - Welding NDT 1 - QA Engineer - Supplier-Roceiving Additional personnel will be added as the need arises.
The manpower schedule was reviewed and presently appears adequate for work in progress.
The inspector was informed that KEI will be resurveyed for "N" stamp authorization by the survey committee on February 12-13-14, 1973.
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A revised QA manual effective January 15, 1973, is to be issued and will incorporate additional ASME requirements and will be used to obtain the "N" stamp for piping construction.
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(2), Construction Logs I
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The use and maintenance of construction logs was discussed
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He was informed that the logs would be subject to AEC review.
New contractors coming onsite are to be informed of this requirement.
The licensee also stated that REI would be informed by letter of this requirement.
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(3) Deviation Notices i
i The KEI QA Department has issued 54 DDR's as of January 5, l
,1973, 20 are presently considered as open.
is prepared by KEI QA Department and indicates theA weekly report i
disposition of, and outstanding, DDR's remaining.
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5.
Construction Contracts a.
CG&E Contracts The following contracts have been awarded:
(1) Post Tensioning System - The Inland Ryerson Construction Products Company
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(2) Pricary Containment Liner - The Chicago Bridge and Iron Ccapany (3)
Phase II Piping - The Southwest Fabricating Company b.
KEI Contracts
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The following contracts have been awarded:
(1) Reinforcing Bars - The Inland Ryerson Construction Products Company 6.
QA Audits a.
CG&E Audits The CC&E QA audit reports, of four vendors, were reviewed and
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found to have been conducted according to procedures as required by the CG&E QA manual.
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A managecent audit of QA&S conducted on November 21, 1972, covered all phases of QA activity.
The report was found to
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be comprehensive and thorough as shown by the comments made
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regarding the lack of documentation after a review of purchase I
documents by the QA&S.
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b.
KEI Audits i
Eleven site audits performed by site QA personnel covered:
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configuration control, procedure records, equipment identifi-l
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cation and handling, procurement document center, control of nonconformance, inspection planning and inspection.
Records of all the audits were available for review and copies had
.bcen sent to CG&E for their review. The audits reviewed were found to be comprehensive and thorough.
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Design and Engineering
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The inspector was informed that S&L has presently completed 55% of the total plant design and engineering work.
8.
Thin Wall Valves Progress CGLE was inforned by CE that all required valves will have documentation to verify that measurements have been taken to determine that the valve wall thicknesses meet design requirements.
All CG&E contracts for Class I valves contain a wall measurement requirement as part of the specification.
This matter will be reviewed during subsequent inspections.
9.
Reactor Pressure Vessel The reactor pressure vessel is presently scheduled to be delivered to the site on October 1, 1973.
The inspector was informed that the vessel will be stored outside and that vessel storage and handling procedures are presently being prepared.
The effects of the 10 CFR 50.55(a) ruling for upgrading code require-ments on a component is under discussion by GE and S&L but no decision has been made. These items will receive follow-up attention during the next inspection.
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