IR 05000361/1978018
| ML13309A611 | |
| Person / Time | |
|---|---|
| Site: | San Onofre  |
| Issue date: | 01/05/1979 |
| From: | Haynes R, Kirsch D, Pate R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V) |
| To: | |
| Shared Package | |
| ML13309A610 | List: |
| References | |
| 50-361-78-18, 50-362-78-14, NUDOCS 7903120499 | |
| Download: ML13309A611 (12) | |
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U. S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT
REGION V
50-361/78-18 Report N /78-14 50-361 CPPR-97 Docket N License N CPPR-98 Safeguards Group Licensee:
Southern California Edison Company P. 0. Box 800 - 2244 Walnut Grove Av Rosemead, California 91770 Facility Name:
San Onofre Units 2 and 3 Inspection At:
Construction Site, San Diego County, California Inspection Conduc ed:
November 27 through December 1, 1978 Inspectors 4-
,AnlJo4 cR.. Pte, Resident eactor Inspector Date Signed D.F. Kirsch, Reactor Inspector Date Signed T. W.Hutson, Reactor Inspector Date Signed R. C. Haynes, Section Chief Approved By:
P e St-7 R. C. Haynes hi-, Projects SectionSigned Reactor Construction and Engineering Support Branch Summary:
Inspection during period of November 27 through December 1, 1978 TReport Nos. 50-361/78-18 and 50-362/78-14)
Areas Inspected: Routine, unannounced inspection by regional based inspectors and the resident inspector of licensee action on previous inspection findings; electrical components and systems work observation and record review; instrumentation components and systems work observation and record review; structural concrete work observation and record review; reactor coolant and safety related piping (including welding); review of quality assurance RV Form 219 (2)
7903120
'94
Summary:
(Continued)
Inspection during period of November 27 through December 1, 1978 (Report Nos. 50-361/78-18 and 50-362/78-14)
implementing procedures, work observation and record review; QA audit review and nonconformance reporting system review. The inspection involved 96 inspector hours by three NRC inspectors and one regionally based superviso Results: No items of noncompliance or deviations were identified in the ten areas inspecte DETAILS 1. Individuals Contacted a. Southern California Edison Company (SCE)
- H. B. Ray, Manager, Quality Assurance
- R. R. Hart, Construction Superintendent
- P. A. Croy, Site QA/QC Supervisor
- L. L. Seyler, Project QA Supervisor
- L. D. Hamlin, Project Manager M. E. Rodin, QA Engineer R. P. Frick, QA Engineer P. R. King, QA Engineer P. Belhumer, Startup QA/QC Supervisor J. J. Pantaleo, QA Engineer b. Bechtel Power Corporation (Bechtel)
- C. A. Blum, Quality Control Manager
- R. H. Cutler, Project Field Engineer
- J. E. Geiger, Project Field QA Supervisor
- J. R. Caldwell, Project QA Supervisor P. Huber, QC Engineer D. Newberry, QC Engineer A. Coate, Lead QC Engineer D. Reddy, QC Engineer J. Kartz, Instrumentation Field Engineer D. Stikeleather, Electrical Construction Field Engineer M. L. Hess, Instrumentation Engineer J. L. Kopicka, Electrical Field Engineer R. M. Reinsch, Welding QC Engineer R. S. Koogle, Lead Field Welding Engineer A. Paulos, Field Welding Engineer R. A. Meggison, Welding QC Engineer E. W. Stanton, Welding QC Engineer D. C. Martin, Lead Field Welding QC Engineer R. J. Stevenson, Assistant Piping Group Leader E. A. Desbiens, Rod Room Supervisor c. Peabody Testing A. W. Morrill, Level III Inspector
- Indicates those attending Exit Interview
-2 2. Construction Status The licensee reported that site construction work is 63% complete as of December 1, 197. Licensee Action on Previous Inspection Findings The inspectors examined those corrective actions taken by the licensee on the previously noted unresolved ite (Open) Unresolved Item (50-361/78-13)
Hardware debris was noted in cable trays that had cables installe Subsequent to the inspection (50-361/78-13), Bechtel issued two interoffice memorandums to the construction field supervision re emphasizing the importance of keeping debris out of the cable tray However, recent surveillances by the licensee resulted in the issuance of two Corrective Action Requests (CAR), CAR F-707 and F-712. Included in these CAR's was a long list of hardware, tools, trash, etc., that had been observed in the cable trays. The disposition and resulting corrective action from these CAR's will be reviewed during a subsequent inspectio The inspectors observed numerous cable trays and noted debris in several trays. A particular item of concern was the presence of what appeared to be oil on the safety related cables contained by tray No. DBBJAZ in the.Unit 2 penetration area, and the licensee agreed to evaluate and resolve the noted condition. This evaluation and resolution of this item will be examined during a future inspectio. Electrical - Components and Systems Observation of.Work and Work Activities (1) Electrical Panels and Breakers The inspector observed the installation of the following nuclear safety related electrical panels for conformance with selected installation drawing and QC procedure requirement (a) Diesel Generator Control Panel (2L160)
(b) NSSS Auxiliary Relay Cabinet (2L-71-3F)
(c) 4KV Switchgear (2AO4) and 6 Enclosed Breakers (d) 480V-Switchgear (2B04)
-3 It was observed in 480V switchgear 2B04 that the actuating motor brush holder interfered with a panel mounting concrete anchor bolt in circuit breaker 280419, and the motor brush holder for breaker 2B0411 had been broken off by the interfering concrete anchor bolt. The licensee had not yet inspected the installation for acceptance and noted that corrective action would be taken. The inspector noted no other discrepant conditions and will reexamine the installation of panel 2B04 during a future inspection (50-361/78-18/01).
(2) Diesel Generator Receipt During the inspection, the licensee received a diesel on site (S/N 77H1-1028). The inspector examined the unit for physical damage and noted that the unit appeared satisfactor The licensee could not conduct the required receipt inspections because the required documentation had not arrived with the unit. The diesel was placed on hold for receipt inspection upon receipt of the necessary documentation. The receipt inspection documentation will be examined during a future inspection (50-361/78-18/02).
(3) 125 VDC Batteries The inspector examined the storage conditions of Unit 2 battery units No. 28008 and 2B010 and noted that the levels in 10 cells of 2B010 were slightly below the low level mark on the cell cases. This appeared to be acceptable since the batteries were not hooked up for load or charging (merely in storage) and that about four inches of electrolyte remained above the cell.plates. The licensee had not accepted the battery or rack installation The licensee's Procedure No. GT-400-19 ("Preventive Maintenance Program for the Station Batteries") was examined for compliance with the FSAR commitment to IEEE STD 450-1972 ("Recommended Practice for Maintenance, Testing, and Replacement of Large Stationery Type Power Plant and Sub station Lead Storage Batteries"). The inspector noted that the procedure did not address a number of IEEE STD 450 requirements which would be mandated following the installation of the battery loading and charging circuit In addition, the records of factory battery acceptance tests were not available. The licensee stated that the battery
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-4 preventive maintenance procedure would be revised as necessary to include IEEE STD 450 requirements and that battery acceptance test records would be requested from the manufacturer or located if they were onsite. These areas will be examined during a future inspectio (50-361/78-18/03).
b. Review of Quality Records The following quality documents were examined for compliance with licensee procedural requirements:
(1) Receiving Inspection Data Reports for 4KV switchgear panels 2AO4, 2A06, 3AO4 and 3AO6 and associated circuit breaker (2) Manufacturer's switchgear test reports for 4KV switchgear panels 2AO4 and 2A0 (3) Certificates of conformance and seismic certification for switchgear panels 2AO4 and 2A0 (4) Construction Installation Data Reports for switchgear panels 2AO4 and 2B0 No items of noncompliance or deviations were note.
Instrumentation - Components and Systems a. Observation of Work and Work Activities The following instrumentation components and systems were examined for compliance with licensee installation drawings and procedures:
(1) Pressure instrumentation installation (including the detectors, mounting and selected tubing) for gas decay tanks No. 3 and (2) Instrument plate mounting, detector mounting and associated tubing for twelve Unit 2 safety injection tank level and pressure instrument (3) Instrument plate mounting, detector mounting and associated tubing for three reactor coolant pump auxiliary pressure transmitter No items of noncompliance or deviations were identifie b. Review of Quality Records The following quality records were examined and appeared to adequately reflect the status'of instrument installation as required by the licensee procedures:
(1) Construction Inspection Data Reports for concrete anchors and final instrument installation, pressure test records, pressure gauge calibration, and water chemical content certifications for the installation of gas decay tanks No. 3 and 4 pressure instrument (2) Supplementary Inspection Data Reports for mounting plate assembly and installation associated with fifteen level and pressure instrument No items of noncompliance or deviations were identifie. Structural Concrete The inspectors examined the following items for compliance with installation drawings, procedures and ASTM standard requirements, as appropriate, for Unit 2 MSIV wall placements 23-919-A and 920- a. Preplacement Construction Inspection Data Reports b. Reinforcing steel placement and cover c. Formwork installation and placement cleanliness d. Consolidation equipment readiness and use e. Portions of concrete placement activities f. Batch plant operations including mix selection, materials proportioning, mixing, and trip ticket generation for two truck loads g. Testing laboratory activities including sampling of fresh concrete, slump testing, air content testing, molding of concrete compressive test cylinders and temperature measurement No items of noncompliance or deviations were identifie *
-6 7. Reactor Coolant Pressure Boundary Piping (RCPB)
a. Observation of Work and Work Activities The inspector observed the following activities relating to RCPB piping in Unit (1) Fitup of S3-1201-ML-055 Weld B (2) Handling and fitup of S3-1201-ML-003 Weld C (3) Grinding and blending on the outer diameter of welds S3-1201-ML-008 Weld A and S3-1201-ML-007 Weld A (4) Storage and cleanliness of 30 inch reactor coolant piping inside containment The handling and fitup of pipe for welds S3-1201-ML-005 Weld B and S3-1201-ML-003 Weld C were conducted in accordance with WPP/QCI 400, Revision 8, "Field Fabrication and Erection of Nuclear Piping to ASME Section III.."
The grinding and blending on the outer diameter of the reactor coolant system welds in (3) above was performed using the proper tools as required by WPP/WCI 206, Revision 3, "Control of Grinding Wheels, Discs, Wire Brushes and Files."
All piping stored in containment had the ends covered to prevent the entry of foreign debri No items of noncompliance or deviations were note b. Review of Quality Records The quality records associated with Unit 3 reactor coolant system pipe spools 503-01 (north hot leg), 503-03 (south hot leg) and 505-01 (northeast cold leg to reactor vessel) were reviewe These records included certification of equipment (in accordance with the purchase order); certificates of compliance (in accordance with ASME Section III, 1971 Edition through the Summer 72 Addenda); code data reports for fabricated nuclear piping subassemblies; and material certifications (chemical, physical and heat treatment records). The record packages included numerous other Certificates of Compliance attesting to the quality and standards used during operations such as welding, welder qualifications in accordance with Section IX of the ASME Code and ND No items of noncompliance or deviations were identifie II
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-7 8. Reactor Coolant Pressure Boundary Piping Welding a. Observations of Work and Work Activities The welding activities associated with the Unit 3 weld joints listed below were observed by the inspecto Weld Size Activity S3-1201-ML-005 Weld B 30" Fitup, root and machine cover passes S3-1201-ML-003 Weld C 30" Fitup S3-1201-ML-009 Weld B 30" Backwelding using machine on inner diameter S3-1201-ML-008 Weld A 30" Backwelding using machine on inner diameter and final liquid penetrant test S3-1201-ML-007 Weld A 30" Final liquid penetrant test on inner and outer diameter S3-1204-ML-045 Sht 2 Weld BA 8" Fitup and tack CEDM upper housing/motor Completed tacks and seal welds using shroud seal welds machine S023-901-19 Welds 8 and 13 All activities were conducted in accordance with the applicable procedures. The preheat was maintained as required and checked periodically by welding quality control inspectors. The welding was monitored periodically by quality control inspectors and required hold points were enforced. Automatic gas tungsten arc welding machines were used on the cover passes and backwelds on the 30 inch diameter pipe and the single pass seal welds on the CEDM. The welders used proper filler metal and were qualified for the processes and positions employed. The Welding In-Process Control Sheets-(Forms WR-5) and Filler Metal Withdrawal Sheets (Forms WR-6) were properly maintained and completed. All inspection hold points were adhered to and signed off before welding proceede The welding filler metal issue operations at rod..rooms 3 and 4 were observed. The Filler Metal Issue Logs for the day shift on November 29, 1978 were reviewed and found satisfactory. The holding ovens and portable heaters had been calibrated and checked to ensure the proper temperature was maintained. During the tour of rod room 4, the inspector noted that two cans of E7018 electrode, heat number 421C9521, had been damaged in that the seal was broken exposing the electrodes to humidity and
possible moisture absorption. The two cans had apparently been damaged during handling while being placed in storage in the rod room. The inspector discussed with the licensee the need for careful handling of low hydrogen electrodes to prevent damage. The licensee stated that this area would be looked into furthe No items of noncompliance or deviations were identifie b. Review of Quality Records The quality records relating to the welds listed below in the reactor coolant pressure boundary piping of Unit 3 were reviewe S3-1201-ML-008 Weld A S3-1201-ML-007 Weld A S3-1201-ML-001 Welds A and B S3-1201-ML-002 Welds A and B S3-1201-ML-007 Weld B S3-1204-ML-045 Sht 1 Weld C These records included Welding In-Process Control Sheets (WR-5);
Filler Metal Withdrawals (WR-6); Nondestructive Test Reports; welder qualifications for twelve welders; welding procedure specifications and qualifications for the procedures used; qualifications of four NDE personnel (one level III, two Level II and one level I); post weld heat treat records; and the material certifications for two batches of liquid penetrant material Liquid penetrant test report PBT-PT-594 did not list the batch numbers used on the NDE report. The inspector verified that only one batch of cleaner, penetrant and developer was presently being used in the kits. The batch numbers were then properly completed by Peabody. All other records reviewed appeared to accurately reflect the status of the work and document the quality related activities performe No items of noncompliance or deviations.were identifie. Safety Related Piping Welding a. Observation of Work and Work Activities The welding activities associated with the Unit 3 weld joints listed below were observe System/Weld Activity Safety Injection S3-1204-ML-055 Weld C Repair 1 Preparation for welding after grind out S3-1204-ML-021 Sht 3 Weld CB Fitup, purge, tack and root pass S3-1204-ML-035 Weld B Fitup and tack S3-1204-ML-038 Weld BF Fitup and tack In addition to the above, the inspector visually observed the surface of completed weld S3-1204-ML-038 Weld DB. The surface of the weld appeared satisfactory for nondestructive testing per ASME Section III and was free of surface defects. The activities observed met the requirements of the applicable welding standards and procedure No items of noncompliance or deviations were identifie b. Review of Quality Records The inspector reviewed the quality records for welds S3-1203-ML 275 Sht 1 Welds C and D and S3-1203-ML-281 Sht 1 Welds C and D in the component cooling system. These records included:
(1) In-Process Control Sheets (WR-5)
(2) Filler Metal Withdrawals (WR-6)
(3)
Nondestructive Test Reports (4) Welder Qualifications (5) Welding Procedure Qualification Records The records reviewed showed that the work had been properly documented and conducted by qualified personnel using qualified procedure No items of noncompliance or deviations were identifie.
QA Audits The inspector examined five licensee QA audits, five Bechtel QA audits and five licensee surveillance reports in the areas of electrical, instrumentation and welding of safety related pipin These audits/reports were examined for scope, depth and resolution of any adverse findings. Eight adverse findings had been identified and the corrective actions appeared to be adequate and in accordance with the licensee's corrective action syste.
Nonconformance Reports The Bechtel nonconformance reporting system was inspected by examining six nonconformance reports for compliance with the Bechtel non conformance reporting and resolution procedures. The problems appeared to have been adequately described and resolved as required by procedures.,
1 Exit Interview The inspectors met with licensee representatives (denoted in Paragraph 1) at the conclusion of the inspection on December 1, 1978 and summarized the inspection purpose, scope and findings. Licensee representatives noted that corrective actions regarding cable tray debris are in the implementation process and that the effects of oil on the cables contained in tray DBBJAZ would be evaluated and resolved (see Paragraph 3).
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