IR 05000358/1982002
| ML20052C263 | |
| Person / Time | |
|---|---|
| Site: | Zimmer |
| Issue date: | 04/15/1982 |
| From: | Christianson W, Gwynn T, Hunter D, Schapker J, Schapker J, Ward K NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML20052C257 | List: |
| References | |
| 50-358-82-02, 50-358-82-2, IEB-80-21, NUDOCS 8205040548 | |
| Download: ML20052C263 (11) | |
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U.S. NUCLEAR REGULATORY COMMISSION
REGION III
Report No. 50-358/82-02(DPRP)
Docket No. 50-358 License No. CPPR-88 Licensee: Cincinnati Gas and Electric Company 139 East 4th Street Cincinnati, OH 45201 Facility Name:
Wm. H. Zimmer Nuclear Power Station Inspection At:
Wm. H. Zimmer Site, Moscow, OH Inspection Conducted: February 1-5, 8-12, 16-19, 22-26, and March 1-5, 1982
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Inspectors:
V. F. Christianson X
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T. P. Gwynn A
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J. E. Sch (e T
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iYn'ter, Chief
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Approved By:
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Rgactor Projects Section 2B
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InspectionSum)ary
Inspection on isebruary 1-5, 8-12, 16-19, 22-26, and March 1-5, 1982 (Report No. 50 *358/82-02(DPRP))
Areas Inspecteoj,1fied items; Routine resident and regional personnel inspection of previously ider; fuel receipt and storage; observation of special process,and test activities; followup on the Quality Confirmation Program; followsp of the April 8, 1981 Immediate. Action Letter; and plant tours. This inspection involved a total of 148 inspector-hours onsite by
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two NRC resident;and two regional inspectors, including 16 inspector-hours onsite during offshifts.
Results: No itees of noncompliance or deviations were identified.
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SECTION I Prepared by W. F. Christianson T. P. Gwynn Reviewed by D. R. Hunter, Chief Reactor Projects Section 2B 1.
Personnel Contacted Cincinnati Gas & Electric Company
- J. R. Schott, Plant Manager
- H. R. Sager, QA Manager
- D.
J. Schulte, QA Engineering Director F. K. Pfeiffer, QA Engineer F. Lautenslager, Security Supervisor C. Blenstroub, QCP Task VII Coordinator Henry J. Kaiser Company
- D. Howard, Acting Site QA Manager W. Wagner, QA Engineer General Electric Company A. L. Jenkins, Site Operations Manager D. L. Snyder, System Engineer The inspectors also contacted and interviewed other licensee and contractor technical and administration personnel.
- Denotes those attending interviews conducted during the inspection period of February 1 through March 5,1982.
2.
Licensee Action on Previously Identified Items (0 pen) Unresolved Item (358/81-15-10): Electric (Nuclear) Production Department did not have a program for control of design changes and modifications. The licensee had not completed developing corporate directives and lower tier administrative and implementing procedures to control design changes and modifications to plant systems and equipment. With respect to the diesel engine modification, an Engineering Change Request (ECR #634) was approved for_the modifica-tion on December 2, 1981, referencing the applicable documentation.
A procedure (ME CMP 4100, Revision 0, " Diesel Engine Vibration Damper Replacement") for performance of diesel engine vibration damper replace-ment was subsequently prepared and approved on February 27, 1982, specifying quality control inspection (witness) requirements, acceptance criteria, and retest requirements.
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(Closed) Unresolved Item (358/81-22-02): Valve RH IE12F306, the shutdown cooling suction valve, is a manually-operated gate valve located inside containment but no position indication is provided in the control room. The inspector verified that the residual heat removal system operating procedure OP.RH.01, Revision 06, dated January 28, 1982, requires that valve 1E12F306 be locked open prior to system operation.
In addition, a physical locking device (chain)
was available on the valve. To resolve this matter, the licensee has issued a nonconformance report (NRC-QAD-82-1304-E) identifying the deviation from the GE design specification.
(Closed) Unresolved Item (358/81-22-09): Several deviations from the GE Design Specification and the FSAR description, involving valve packing leak detection, require resolution by the licensee. The li-censee has issued nonconformance reports pertaining to valves 1E51F066 (NR-QAD-82-1092E) and 1B21F016 (NRC-QAD-82-1091E) for engineering disposition to resolve this matter. The remaining valves, including the reactor vessel head vent and vent to radwasta valves 1B21F001, F002, F005. and the RCIC steamline drain valve 1E51F076 listed by the inspector are of a packless variety and require no licensee actions.
3.
Fuel Receipt and Storage
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The inspector verified the integrity of security controls in effect for the new fuel storage area, verified proper environmental protec-tion for the new fuel storage area, and spot checked the implementa-tion of licensee commitments under NRC Special Nuclear Materials License SNM-1823.
a.
Documentation Reviewed (1)
SE. SAD.03, " Interim Access Control New Fuel Storage Area",
Revision 6, dated June 25, 1980 (2) Refueling Floor Access List (3)
EC. SAD.07, " Cleanliness Control", Revision 0, dated August 3, 1979 (4) Station Security Contingency Plan b.
Findings (1) Members of the guard force interviewed were alert and know-ledgeable of procedures and requirements.
(2) The licensee was in compliance with special nuclear materials license requirements checked.
No items of noncompliance or deviations were noted.
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4.
Observation of Special Test Activities The inspector observed partial performance of SU.SP.23, " Initial Recirculation Pump Operation". This inspection included verification of a sample of test prerequisites, verification that the latest revision of the test procedure was available.and in use, that sufficient personnel were available for conduct of the test, that all test participants were briefed prior to test performance, that essential plant systems were in operation as required by procedure, and that the system operating procedure was checked out to the extent practicable during test performance.
a.
Findings (1) The training records of two test participants (the test director and CG&E staff engineer) were reviewed to verify that the qualification requirements of the Final Safety Analysis Report for preoperational test personnel were met.
Both individuals had received the required training and their qualification was documented in accordance with procedure SU.ACP.07, " Qualifications of Preop Phase Personnel."
(2) CG&E management maintained apprcpriate overview of test activities. Technical support was available through rep-resentatives of the station technical staff, the generation construction department, and the pump vendor representative.
(3) Communications were established between the control room and remote test locations. There was coordination between the other test locations. The actions of the rest director were appropriate, timely, and in accordance with procedural controls.
No items of noncompliance or deviations were noted.
5.
Followup on the Quality Confirmation Program - Review of Voided Nonconformance Reports The inspectors reviewed an additional 51 essential H. J. Kaiser nonconformance reports (NRs) which had been " voided" rather than
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" superseded". The review consistud of determining that the exact problem described on the original (voided) NR had been copied on the superseding NR.
The review was performed after each voided NR and superseding document had been submitted to and approved by the NR review committee per procedure 15-QA-04, Revision 0, " Review and Processing of Voided Nonconformance Reports".
This review included the following nonconformance reports:
E-1422 E-1784 E-5004 E-1448 E-1862 E-2057 E-1485 E-1862, R1 E-5015 E-1574 E-1966 E-5073
E-1591 E-1973 E-5076 E-1591, R1 E-1984 E-2578 i
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E-1607 E-2010
- E-2578, R1 E-1610 E-2601 E-5105 E-1610, R1 E-2671 E-1078 E-1637 E-2711 E-5129 E-1641 E-2787 E-5149 E-1641, R1 E-2790 E-6006 E-1641, R2 E-2875 E-6027 E-1641, R3 E-2880 E-784 E-1707 E-2912 E-6080 E-1708 E-2955 E-6084 E-1769 E-2966 E-6085 The inspectors identified two discrepancies with NR E-1591 which addressed traceability of material for pipe attachments in ASME code-class systems, as follows:
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(a) On the original NR the pipe attachment number RT-RH-99 was changed to RT-RH-98.
This change was not reflected in subsequent revisions of the NR (revision 1 and 2).
(b) The final disposition which closed NR E-1591 Revision 2, did not address.the applicability of the NR to systems other than the reactor water cleanup system, although the condition description stated "This condition is also evident in other systems."
These items are considered to be open and will be followed up in a
future inspection.
(358/82-02-01)
No items of noncompliance or deviations were noted.
'6.
Plant Tours The inspectors conducted frequent plant tours throughout this inspec-tion period. During a tour on February 11, 1982, the inspector ob-
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served that the reactor building floor drains were overflowing onto the floor on the 496' elevation of the reactor building. The inspector informed the control room operators who immediately corrected the problem. No essential equipment was affected.
No items of noncompliance or deviations were noted.
7.
Management Exit Meeting f
Due to the frequent interviews with licensee representatives throughout the inspection the routine exit meeting was not conducted concerning_
t this report section.
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SECTION II Prepared by K. D. Ward Reviewed by D. H. Danielson, Chief Materials Processes Section-1.
Persons Contacted Cincinnati Gas and Electric Company (CG&E)
- D. Sch 21te, QA Engineering Director
- J. Vannier, NDE Level III Kaiser Engineers, Inc. (KEI)
- D. Howard, Director, QA
- W. Hedzik, Site QA Manager
.The inspector also contacted and interviewed other licensee and contractor technical and administrative employees.
- Denotes those attending the exit interview on February 25, 1982.
2.
Licensee Action On Previously Inspected Findings (0 pen) Noncompliance (358/81-21-01): Discrepancies in radiographs of two welds. One weld was cut out and replaced and the other weld is to be repaired.
(Closed) Unresolved item (358/80-20-01): No specific time for a QC inspector to be in the weld test shop. The inspector reviewed HJK procedure, Welding Performance Qualification Testing, WCP-2, Revision 0, paragraph 4.1.11.
The procedure included the following note:
" Representatives of HJK Weld Engineering and Quality Assurance will be present in the test shop at all times when weld tests are being performed."
3.
Licensee Action on IE Bulletins (Closed) IE Bulletin 80-21.
The inspector reviewed the the following documents which indicate that none of the safety related valves furnished to Zimmer by General Electric were manufactured by the Malcolm Foundry Company:
IE Bulletin 80-21, " Valve Yokes Supplied by Malcolm Foundry, Inc.,"
dated November 6, 1980.
CG&E letter to NRC dated December 29, 1980, and July 1, 1981 interim response to IE Bulletin 80-21.
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CG&E, letter to NRC dated August 3, 1981 final, response to IE Bulletin 80-21.
4.
Examination of Immediate Action Letter Items During the week of February 23-25, 1982, the inspector reviewed the following items concerning the April 8, 1981, Immediate Action Letter.
a.
Radiographs (Pullman)
A review of Pullman shop radiographs is being continued by NES.
The review is approximately 85% complete and radiography is to start in the near future.
b.
NDE Personnel Certification The NDE personnel certifications of the following NES personnel reviewing the Pullman radiographs were reviewed.
Name RT-Level M. Mercer II R. Zieber III S. Provost II c.
Procedures The following procedures were reviewed.
CG&E, " Review and Re-Radiography of Pullman Power Products Pipe Welds", 19-QA-01, Revision 2.
CG&E, " Indoctrination and Training of QA/QC Personnel",
02-QA-01, Revision 5.
HJK, " Preparation, Approval and Distribution of QA Procedures",
A-1.
d.
Training Records The following NDE training records were reviewed.
CG&E HJK Name Name R. Murphy M. DiPuccio-J. Cbermeyer D. Helton D. Podlin B. Ashenfelder F. Rivera J. Craig No items of noncompliance or deviations were identified.
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5.
Review of Radiographs The inspector reviewed the following GE-supplied shop weld radiographs performed by the General Electric Company and Associated Piping and Engineering Corporation.
a.
General Electric Company, Nuclear Energy Division Item Name Piece No.
Weld No.
Date RT Dry Tube 6612406 11-12 12/7/77 Dry Tube 6612407 11-12 12/7/77 Dry Tube 6612408 11-12 12/7/77 Dry Tube 6612409 11-12 12/7/77 Dry Tube 6612410 11-12 12/7/77 Dry Tube 6612411 11-12 12/7/77 Dry Tube 6612412 11-12 12/7/77 Extension TOB34-002 2-3 5/24/77 Safe End TQM43-002 1-2 6/8/77 b.
Associated Piping and Engineering Corporation Recir. Loop Item Piece No.
Weld Date RT Piping 761E379P9-1 W-A 6/1/72 Piping 761E379P9-1 W-B 5/30/72 Piping ELL 22 T
3/22/72 Piping ELL 22 B
3/22/72 Piping 0081-4 L3 4/25/72 Piping 761F379P5 W-C 4/26/72 Piping 761F379P5 W-D 4/26/72 Piping ELL 36 T
3/8/72 Piping ELL 36 B
3/8/72 Piping ELL 28 T
3/20/82 Piping ELL 28 B
3/20/82 No items of noncompliance or deviations were identified.
6.
Exit Interview The inspector met with the licensee representatives (denoted in. paragraph 1 of this report section) on February 25, 1982, and summarized the scope and findings of the inspection activities, The licensee acknowledged-the inspector's findings.
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SFCTION III Prepared by J. E. Schapker Reviewed by D. H. Danielson, Chief Materials and Processes Section 1.
Persons Contacted Cincinnati Gas and Electric Company (CG&E)
- D.
Schulte, QA Engineering Director
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Vannier, NDE Level III D. Kramer, Acting Director, QC Division J. Jones, QC Inspector
J. Reinhardt, QC Inspector Kaiser Engineers, Inc. (KEI)
- D.
Howard, Director, QA
- W. Hedzik, Site QA Manager B. Varchol, QA Administrator Manager The inspector also contacted and interviewed additional licensee and contractor technical administrative en;ployees.
- Denotes those attending the exit interview.
2.
Observations of Welding Activities:
The inspector observed nondestructive examination and welding activities in progress in the ongoing construction program.
Inspections were being performed by Nuclear Energy Services (NES) and Kaiser inspectors with overview by CG&E inspectors.
Welding in progress was observed to conform with the applicable weld procedure specification (WPS). Nondestructive examination (magnetic particle) was performed in accordance with the procedure (NES-MT-80A3887, Revision 2) by Level II magnetic particle inspectors.
The following welding and NDE activities were observed while in progress:
a.
Weld MK P-138 to MK 222A; KE1 form Number A10197; Dwg.- S466, Revision P; Weld procedure 3.1.51, Revision 4; Weld material E7018 heat Number 412N-5381; and fit-up and magnetic particle examination (MT)
of the root and every 1/4" to final weld pass. The MT was performed by a NES Level II MT inspector in accordance with procedure 80A3887, Revision 2.
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Weld main Steam Line IMS078B12 to Lug D at 489' level, 7' azimuth within the containment vessel; applicable drawing was PSK 1MS-23A; and weld procedure specifications SPPM 3.1.28, Revision 1, and SPPM 3.1.12, Revision 5.
The inspector observed magnetic particle examinetion (MT) of the final weld. The examination was performed by a NES Level II inspector assisted by a Level.I inspector. The applicable procedure was NES-80A3887, Revision 2, MT machine Number 3622 with calibration sticker indicating due date of September 8, 1982, was utilized.
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c.
The inspector performed in process weld surveillance inspection for fit-up, tacking, weld procedure specification (WPS), welder qualification card, identification of material being welded and welding material withdraw card containing the appropriate infor-mation, and observation of welding in progress to conform with the referenced WPS welding variables such as: preheat and inter-pass temperature; welding rod size and welding position; electrical characteristics; welding progression; interpass cleaning; and the welder's ability to make a visually appearing sound weld. The hanger being welded was Number 1MS465SR and was being welded to the pedestal band using procedure WPS 3.1.81, Revision 5.
The hanger located in the suppression pool elevation 490' 1", azimuth 354*.
No items of noncompliance or deviations were identified.
3.
The following weld forms (KEI-1s) were reviewed for adequacy of information, adherance to procedure requirements, and completion of the required NDE in accordance with the approved procedures:
a.
KEI-1 form 25435, weld number K72, radwaste floor sump drain, ASME Code Class II (NC), 2.5 inch diameter pipe: The applicable isometric drawing was PSK-FR-1 and the weld procedures used was WPS 3.1.7, Revision 3.
The weld material specified was E70S-2, 1/8", and heat number 77402.
b.
KEI-1 form A8466; weld Number MS-K-827; Main Steam 2.5 inch diameter pipe to elbow. The applicable isometric drawing was PSK-MS-14 and the procedure used was WPS 3.1.7, Revision 2.
Weld material specified was E70S-2, 1/8", heat Number 77402 with insert heat Number 6059491.
c.
KEI-1 fcrm A8013; weld Number K88 radwaste floor sump drain; Code Class II; 2.5 inch diameter pipe. The applicable isometric drawing was PSK-RE-1 and the procedure utilized was WPS 3.1.7, Revision 2.
The weld material specified was 1/8" E70S-2, and heat number 77402 with insert heat Number 6059491.
d.
KEI-1 form A11265 and A11266; welds Numbers F1 and F6 and F7 and F8; hanger Number 11H091; electrical conduit support, Class 1 essential.
The weld was a 1/4" plate to 1/2" plate; drawing E-189-10, detail 2; procedure WPS 3.1.51, Revision 4.
The weld material was E7018, 3/32", and heat Number 412P5132.
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The review provided by the licensee of tne KEI-1 forms A11265 and A11266 appears to be in violation of Kaiser's procedure WIP-7, Revision 0, Welding Control, paragraphs 6.1.1 and 6.1.2.
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forms were not made out nor reviewed by a construction welding
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engineer, but were prepared and signed by former clerical personnel with training provided by welding engineers.
This item was dis-cussed in the exit interview with cognizant contractor and licensee representatives who agreed to pursue this matter within their organizations to determine that the capabilities of the personnel now issuing and signing KEI-1 forms are adequate to meet the intent of the procedural and regulatory requirements regarding necessary skills required to ensure control of special processes. This item
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is considered unresolved pending review of the licensee's actions
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and further evaluation of personnel qualifications by the inspector
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(358/82-02-02).
I No items of noncompliance or deviations were identified.
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Unresolved Items Unresolved items are matters about which more information is required in order to ascertain whether they are acceptable items, items of non-
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compliance, or deviations. One unresolved item disclosed during this inspection are discussed in Paragraph 3.d of thisSection III of the report.
5.
Exit Interview The inspector met with the licensee representatives (denoted in paragraph 1 of this report section) on February 25, 1982, and summarized the scope and findings of the inspector activities. The licensee acknowledged the inspectors findings.
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