IR 05000358/1974002
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U. S. ATOMIC ENERGY COMMISSION
' DIRECTORATE OF REGULATORY OPERATIONS
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REGION III
Report of Construction Inspection
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RO Inspection Report lNo. 050-358/74-02
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Licensee: Cincinnati Gas and Electric Company 139 East 4th Street Cincinnati, Ohio 45201
William H. Zimmer Nuclear License No. CPPR-88
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Power Station Category:
A Moscow, Ohio
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Type of Licensee: BWR (GE) 807 Mwe Type of Inspection: Routine, Announced Dates of Inspection: May 15-17, 1974 Dates of Previous Inspection February 7-8, 1974
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Principal Inspector:/ J."5utton d -/V-2 Y
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i Accompanying Inspector: None Other Accompanying Personnel: None
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D. W Hayes
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Reviewed B):
Senior Reactor Inspector
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MEN 287-111 PDR
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SUMHARY OF FINDINGS Enforcement Action A.
Violations One of the activities at the W. H. Zimmer site appears to be in violation of AEC regulations and in nonconformance with the Sargent & Lundy Engineers Purchase Specification, as identified below, and is considered to be of Category II severity.
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10 CFR Part 50, Appendix B, Criterion V, States, in part, that: " Activities affecting quality shall be prescribed by documented in'structions, procedures, or drawings.
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instructions.
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The Sargent & Lundy Engineers (S&L) Purchase Specification H-2174.R for the Containment Building Liner, Paragraph 5-IG.7.7. states that: "All
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shop radiographs with appropriate reports shall be submitted to the Consulting Engineers for review and comments preliminary to release for shipment."
Contrary to the above, the containment equipment hatch was delivered to the site and installed in the containment liner by the Chicago Bridge and Iron Company prior to review by S & L personnel.
(Paragraph 1, Report l
Details)
B.
Safety Patters: No safety catters were identified.
Licensee Action on Previcusly Ide_n_tified Enforcement Matters l
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Reacter Pressure Vessel Cleaning and Storage (R0 Inspection Report No.
U50-358/74-01)
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The corrective action, for the above item, outlined in the Cincinnati Gas and Electric Company (CG&E) letter of April 8, 1974, in response to the RO:III letter and report dated March 14, 1974, was found to have been satisfactorily l
accomplished and documented. This matter is considered to have been resolved.
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Design Changes No new design changes were identified.
Unusual Occurrences: No unusual occurrences were identified.
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Other Significant Findings
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A.
Current Findings 1.
Status of Design - Percent Completed General Electric Company (GE)
-97%
l Sargent and Lundy Engineers (S&L)
-80%
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Status of Construction
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a.
Class I concrete placement work is continuing in the Reactor, Auxiliary and Turbine buildings. Two concrete lifts for the Reactor Pedestal have been completed, b.
Installation of the primary containment liner has progressed to
the final ring. Work on this ring and the containment cover is
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under way.
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c.
Concrete pours for the primary containment shell has started, two pours have been completed to the third ring at the 501'
elevation. Written approval to pour concrete to the 520' level has been submitted to KEI.
d.
Class 1 piping work is scheduled to commence during July 1974.
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Overall plant construction, percent complete May 1974, 15%.
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3.
Personnel Changes Cincinnati Cas and Electric Company (CG&E)
CG&E has announced the following Personnel changes; Mr. W. H. Dickhoner, Vice President, Engineering and Electrical Production has been appointed Executive Vice President.
Mr. E. A. Borgmann has been appointed, Manager General Engineering Department, replacing Mr. A. E. Rothenberg who has been designated as a consultant to the company.
Kaiser Engineers, Incorporated (KEI)
Five QC inspectors have been added to the site QC force. As the work load increases, additional QC inspectors are to be added. All site QA positions have been filled.
4.
Contracts Contracts have been awarded for the following; Structural Steel (Bristol Steel and Iron Works) and the fuel Pool Liner (Chicago
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B. ' Unresolved Matters
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No unresolved matters were identified.
[C.
Status of Previously Reported Unresolved Matters 1.
Clarification'of Receiving Procedures (KEI)'(R0 Inspection Report No. 050-358/74-01)
KEI has revised the material receiving and warehousing operations procedure.
(CACHI No. G-3) to reflect KEI's intent to prepare an
inspection plan for all essential'or ASME items purchased by either KEI or CG&E. This matter is considered to be resolved.
2.
Chicago Bridge and Iron Company (CB&I) Weld Rod Issuance Control (R0 Inspection Reports No. 050-358/73-07 and No. 050-358/74-01)-
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CB&I has issued a supplement to their " Nuclear QA manual for ASME Class 1, 2, 3 and MC products." The supplement, designated Issue 4,
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establishes additional controls. with regard to storing, drawing and returning of welding materials for shop and site use. The welding-l materials controls, as indicated in the supplement, are considered
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adequate. This matter is considered closed.
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3.
' Audit Followup (R0 Inspection Reports No. 050-358/73-07 and No. 050-358/74-01)
The inspector reviewed a CG&E instruction, issued on May 10, 1974, that revised the CG&E audit logs (site-vendor) to document the action taken, to review and correct any deficiencies that were found during l
audits. This change is to be incorporated into the audit procedure
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in the r. ext revision to the CG&E QA canual. This iten is considered as resolved.
4.
Hoisting Equipment (R0 Inspection No. 050-358/74-01)
The inspector reviewed two KEI letters to the Besl Transfer Company, dated April 30 and May 3, 1974, that indicated, the 3500 Manitovac yard crane and the R & M 15 ton warehouse overhead Bridge Crane, had been inspected and approved for capacity lifts of 26 and 13.5 tons respectfully. The inspection was conducted in accordance with the KEI QACMI, MS.
This matter is considered closed.
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' Management Interview
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The following persons attended the management interview at the conclusion I
of the inspection.
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Cincinnati Cas & ' Electric Company (CG&E) -
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W. H. Dickhoner, Executive Vice President
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E. A. Borgman, Manager - General Engineering Department E. C. Pandorf, Principal Quality Assurance and Standards Engineer W. W. Schwiers, Site Quality Assurance Engineer - Quality Assurance and Standards Section J. H. Hoffman, Quality Assurance Civil Engineer, Quality Assurance and Standards Section
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Kaiser Engineers, Incorporated (KEI)
W. J. Freldrich, Quality Assurance Manager - Site B.
Matters discussed and comments, on the part of Management personnel were as follows:
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1.
The inspector stated, that, during a review of construction records
for the containment liner, it was noted that a nonconformance report (NCR) had been issued on the containment equipment batch. The NCR indicated that a radiographic film for a shop seam weld had been questioned by the consulting Engineers (S&L). Additional review of the S&L Specification indicated that it appeared the consulting engineers had not reviewed the CB&I Shop film, preliminary to release of the hatch for shipment. The inspector added that this was an-apparent violation of 10 CFR Part 50, Appendix B, Criterion V, requirements as well as the S&L specification and would be brought
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to the attention of corporate management in our report of the results of the inspection. The licensee stated that this ites would be discussed with CB&I.
(Paragraph 1, Report Details)
2.
The inspector stated that all the unresolved items from the previous
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inspection had been satisfactorily resolved.
3.
The inspector stated that site QA audits were being conducted but were not being formally documented. The licensee stated that the matter will be reviewed and that necessary steps would be taken to resolve the item.
4.
The inspector stated that the general classification of Type 1 equipment and components should be clarified to indicate those items requiring full QA documentation and handling. The licensee stated that the matter would be reviewed.
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_ REPORT DETAILS
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l Persons Contacted The following persons, in addition to individuals listed under the Management Interview Section of this report, were contacted during the inspection.
Kaiser Engineers, Incorporated (KEI)_
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M. G. Franchuk, Quality Assurance Engineer - Mechanical C. H. Makowsky, Supervisor - Site Document Center
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C. A. Smith - Quality Assurance Engineer - Civil.
Chicago Bridge & Iron Company (CB&I)
W. F. Eiser, Project Quality Assurance Supervisor W. R. Wagner, Area Quality Assurance Supervisor
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H. C. Nutting Company A. Brucato, Laboratory Chief.
Results of Inspection 1.
Containment Liner, CB&I (R0 Inspection Report No. 050-358/74-01)
Site construction documentation prepared by CB&I for the containment building liner was reviewed for compliance to the CB&I QA manual.
Equipment Hatch Assembly No. 260A was included in one of the areas l
reviewed. During the review of nonconformance reports for this assembly it was noted that a shop radiographic report for shop seam
"C" had been rejected by the Consulting Engineers, (S&L). The CB&I shop release and site receiving records were found to be in order with no indication of a rejectable weld.
The assembly was installed in the containment liner and had passed all NDE tests - Final release papers were completed by CB&I and KEI QA personnel. Further review of the matter indicated that S&L specification H2174R, Paragraph 5-lG 7.7 stated that "All shop radiographs with appropriate reports shall be submitted to the Consulting Engineers for review and comments preliminary to release for shipment." The inspector stated that it appeared that this procedure had not been followed by CB&I. The receiving date of the assembly was 4-22-74. A review of the following site construction records for the liner was made with no discrepancies being identified:
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As' built drawing - 260A - Dry Well Shell (180* '- 270') #1-3 --
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CBI Drawing'#260 - Rev. 3 c. ' As built drawing #18. - Rev.1
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d.. ' identification Weld procedure --4101,- Rev.' 0 and 1101, Rev.
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Weld joint _ identification and fit up records including welder -
- finished joint - NDE, and QA sign' off of ' completed weld.
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Channel Test Records f.
Welders qualifications
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Welding procedures
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N311 test reports
i. NDE personnel qualifications j. NDE procedures - RTP - (72-4336-9B) and RTP (72-4336-15L)
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Radiographic film #219 and #134 1.
Receiving Recards m.
Material specifications n.
Site QA/QC audits o.
Personnel lock cs:c:bly - certification.
2.
Reactor Pressure Vessel Cleaning and Storage (R0 Inspection Report No. 050-358/74-01)
The inspector reviewed the corrective action as outlined in the CG&E letter of April 8,1974. The revised KEI QACHI-MI R-3 dated 2-25-74, reflected the water quality requirements as required by General Electric-Company (GE) Specification 22A-2517.
In addition, a certified report of the chemical analysis of water obtained from the deep well and used during the wash down of the Reactor Pressure Vessel was reviewed and found to meet the potable water requirements of the GE specification.
The inspector also reviewed the revised QACMI No. M-1, R3 that'
indicated that the QACMI included procedures for the " Reactor Pressure Vessel'and Internals." The revision was found in order.
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Concrete Testing Laboratory Equipment Certification
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The' certification for.:the Laboratory testing equipment was reviewed
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by the inspector. The' certifications were found to be current..It
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- was noted that protective covers for the weighing scales were'not r
available. The matter was. discussed with the Laboratory Chief'and.
he informed the inspector that this matter would be discussed further F
with the Nutting management.
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4. ' Stored Mat'erials/ Components Maintenance Records l
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A review of the maintenance records for Construction site and-Besi-L )h warehouse' areas.was made by the inspector..The. maintenance schedule for inspection and. servicing of equipment being carried out according
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to the storage procedures.-
'The inspector examined the' interior. surfaces of*the Reactor Pressure T
Vessel. The internal surfaces of the. Vessel' were found to be clean and
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free of mositure.
Storage and instructions for the Vessel was found
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to be-Properly. implemented.
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Nonconforming Reports (NCR's)
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The KEI nonconformance Summary report, dated May 17, 1974, was reviewed by the inspector. Nonconforming items are being resolved in a pronpt manner. Special attention is being given to essential items. These matters will continue to receive attention during subsequent inspections..
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'A its The following audit reports were reviewed by the inspector. The audits
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were conducted by designated QA personnel subsequent to the present RO Inspection. A log of all audits performed is being maintained by the CG&E and KEI QA Departments. The following audits were performed:
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CG&E (1) CB&I Birminghac-Vendor Audit (2) W. Powell Company Vendor Audit (3) Bristol Steel Company Vendor Audit (4) CB&I Kankanee Vendor Audit
(5) KEI - Site Inspection b.' KEI'(site)
't Fourteen site related audits plus four KEI corporate management audits
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were reviewed by the inspector. The site audits are being conducted-according to a master audit plan. Nonconforming items are being recorded and followup is being documented. The inspector plans to continue reviewing audit activities during subsequent inspections.
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