IR 05000387/1978017
| ML18031A056 | |
| Person / Time | |
|---|---|
| Site: | Susquehanna  |
| Issue date: | 11/15/1978 |
| From: | Cerne A, Gallo R, Mcgaughy R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML18031A055 | List: |
| References | |
| 50-387-78-17, 50-388-17-16, NUDOCS 7812290238 | |
| Download: ML18031A056 (18) | |
Text
Report No.
Docket No.
U,S.
NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT Region I 50-387/78-17 50-388/78-16 50-387 50-388 CPPR-101 Li Priority Category Licensee:
Penns lvania Power and Li ht Com an orth Nin h S
et Allentown P nns ivan'acility Name:
Sus uehanna Steam 1 ctri Inspection at:
Berwick, Pennsylvania
'on, Units 1 and
Inspection conducted:
September 26 - October. 27, 1978 3n i. p-~-'.
R.
M. Gallo, Resident eactor Inspector A. C. Cerne, Reactor Inspector
/t ld date signed li )5 Vb date signed Approved by:
.
W. McGaughy, Chief, Projects Section, Reactor Construction and Engineering Support Branch date signed rW/Vi'ate signed Ins ection Summar
Ins ection on Se tember 26-October
1978 Combined Re ort Nos.
50-387 78-17 and 50-388 78-16 Unit 1 Areas Ins ected:
Routine inspection by the resident inspector and a
regional based inspector of work activities relative to:
installation and welding of reactor coolant pressure boundary and other piping; installation of reactor vessel internals; storage of reactor vessel and internals; spray pond concrete placements and records; reactor building superstructure; subcontractor gA program and installation activities; and, installation of containment electrical penetrations.
The inspectors also performed plant tours and reviewed licensee action on previously identified items.
The inspection involved 104 inspector-hours by two NRC inspectors.
Results:
No items of noncompliance were identified.
Region I Form 12 QQ+gg9 gQ38 (Rev. April 77)
,. <<4J.8 i'
Ins ection Summar ':
Unit 2 Areas Ins ected:
Routine inspection by the resident inspector and a regional base inspector of work activities relative to:
storage of the reactor vessel and reactor vessel internals; spray pond concrete placements and records; reactor building superstructure; subcontractor gA program and installation activities.
The inspectors also performed plant tours; The inspection involved 29 inspector-hours
.
by two NRC inspectors.
Results:
No items of noncompliance were identifie DETAILS 1.
Persons Contacted h
Penns lvania 'Power and Li ht Com an L.
R.
G.
P.
E.
J.
H.
R.
A.
G.
Ballard, Site QAE Beckley, Site QAE Burvis, Site QAE -
Capotosto, Site QAE Carroll, Site QAE Green, Resident NQA - 1,, 2, 3, 4,
Harris, Project Construction Manager Prego, Site QAE R. Sabol, Manager, Nuclear Quality Assurance - 3 Shamis, Construction Superintendent
- New Generating Plants Bechtel Cor oration Y. Ananda, Civil QAE M.
M.
M.
M.
K. Boone, Lead Welding Engineer -
Collins, Superintendent
- Night Shift L. Daubenheyer, Project Superintendent Services -
A. Drucker, Electrical QAE - 1, 2, 3, 4,
G. Gallandorm, Lead Pipe/Mechanical Engineer
'G. Gelinas, QC Lead Engineer Piping/Mechanical A. Gore, Senior Civil Engineer J.
J.
A.
R.
H.
Kato, Electrical Seismic Engineer Khandar, Mechanical QAE Konjura, Mechanical QAE Lamb, QC Assistant Lead Enaineer - Welding Lilligh, Project QAE
1, 3, 4,
O'ullivan, Assistant Project Field Engineer - 3 S. Schoenenberger, Field Construction Manager - 3 C. Seesholtz, Subcontracts Office Engineer - 2 N., 0. Shah, Subcontracts Engineer G.
A.
K.
Schrader, Project Field QCE - 2, 3,
Spielhagen, Project Field Engineer Stout, Assistant Project Field QCE.- 1, 2,
3'
NISCO T. Kopac, Site Manager M. Sky, QC Supervisor Gives Cor oration J. Conigliaro, QC Supervisor J. Zalys, Project Manager General Electric Com an Nuclear Ener Division NED E. A. Gustafson, Site Manager T.
M. LeVasseur, QC Representative
- 3 R.
M. Pulsifier, Mechanical Engineer - 3 General Electric Com an
- Installation and Service En ineerin I8SE
'Reactor Interna s
F. Forsythe, Site Manager D. Hess, QC Engineer Dick Cor oration K. Blasko, QC Inspector J. Borst; FQC Manager R. Hudak, QC Inspector Peabod Testin Com an M. Hhalen, NDE Supervisor Notes denotes denotes those present at exit interview, September 29, 1978 those present at exit interview, October 6, 1978
denotes those present at exit interview, October 13, 1978'enotes those present at exit interview, October 20, 1978 denotes those present at exit interview, October 27, 1978
The inspector also interviewed other PPSL employees as well as employees of Bechtel, Dick Corporation, Peabody Testing Company, NISCO, Civics Corporation and General Electric Company.
Plant Tour The inspector observed work activities in-progress, completed work and plant status in several areas of the plant during general in-spection of the plant.
The inspector examined work for any obvious defects or noncompliance with regulatory requirements or license conditions.
Particular note was taken of presence of quality control inspectors and quality control evidence such as inspection records, material identification, nonconforming material 'identification, house-keeping and equipment preservation.
The inspector interviewed craft personnel, supervision and quality inspection personnel as such per-sonnel were available in the work areas.
No items of noncompliance were identified.
Licensee Action on Previous Ins ection Findin s
(Closed)
Unresolved Item (387/78-03-03):
Documentation of quantitative acceptance criteria for preliminary alignment of rotating equipment.
The. licensee has revised Field Procedure FP-M-1 and guality Control Instruction M-2.10 to provide quantitative acceptance criteria for the preliminary alignment of rotating equipment.
gCI M-2.10, Section 3.l.e references FP-M-1 Sections 7.1.7, 7.1.8 and 7.1.16 for preliminary alignment checks.
FP-M-1 provides specific detailed instructions for preliminary alignment.
Documents reviewed by the inspector included:
Field Procedure FP-M-1, Revision 4, dated September 28, 1978
~-
gC Instruction M-2.10, Revision 4, dated July 20, 1978 Reactor Coolant Pressure Boundar and Safet -Related Pi in Weldin The following listed activities were examined and verified that they were being performed in accordance with the ASME Section III and IX codes,-
PSAR Appendix D, the Bechtel guality Assurance Manual Section III, Site Specification M 204, M 207, drawings M-198 and M-199, and G.
E. Specifications 22A462 a.
Weldin
- Unit
Welding of:
.
VNB 821-1-FW D4 SP-DBA-121-1-FW
GBC-101-20-FW
HBB-109-1-FWl-R2 The inspector verified selected detailed drawings, welding procedure, base and filler material as specified, welder qualification, quality control documentation, weld ap-pearance, welding variables such as gas flow and amperage, and nondestructive testing activities as appropriate.
No items of noncompliance were identified.
b.
Nondestructive Testin
- Unit 1 and Common I
Liquid Penetrant Testing of Weld Joint Nos.
VNB 821-2-FW A4-Rl VNB 821-1-FW-D6 Magnetic Particle Testing of Weld Joint Nos.
HRC-17-1-FW3 (Common)
HRC-17-1-FW4 (Common)
Radiographic Testing of Weld Joint No.
HBB-118-2-FW5 The inspector verified, as appropriate, surface preparation, qualification of examiners, and testing technique.
No items of noncompliance were identified.
c.
Weldin Material Control The inspector examined the control of weld filler metal at site rod rooms.
Documentation and site practices regarding weld filler metal were reviewed to verify that purchasing, receiving, identification, storage, testing,.issue and moisture control in-cluding rebaking, where required, were accomplished in accordance with the Bechtel guality Assurance Manual Section III.
The in-spector reviewed documentation relative to four heats of filler metal.
Those heats were:
Heat No.
775567
~Te ER 309'65058 498236 X74318 E 70S-2 E 309-16 E 309-16 No items of noncompliance were identi fied.
5.
Reactor Coolant Pressure Boundar and Safet -Related Pi in a ~
b.
Piping System Activities The inspector examined work activities for the Main Steam System Line D inside containment and the Class II Control Rod drive -insert/withdraw piping.
The inspector verified that the activities examined were in accordance with the ASME Code Section III, PSAR Appendix D, FSAR Sections 5.4.9 and 4.6.1, the Bechtel guality Assurance Manual Section 'III, GE Specification 22A 4628, FDDR KRI-081, Bechtel Specifi-cation M-164, M-204, M-207 and drawings VNB B21-1, M-164-69(1)-2, M-164-127(l)-2, M-164-127(2)-2, and the NISCO Field gA Manual.
The inspector observed the handling, installation, protection, initial alignment, and'identification.
The inspector reviewed associated QC inspection records, verified material certifi-cations, and reviewed gC Engineering certification records.
The inspector examined two partially completed piping runs and verified that they were installed in accordance with approved drawings and specifications.
Piping runs examined were:
(1)
The reactor drain line from the reactor vessel to pipe spool DCA-103-1-29 The inspector verified conformance to FSAR Section 5.4.8 and drawings SP-DBA-121-1, DCA-103-1 and M-144.
During review of material certifications for selected pipe spools in the reactor drain line, the inspector reviewed documentation for spool piece DCA-103-1-28.
The spool piece certification, heat number 462127,-
SA-312 material, states that it is stainless steel annealed pipe= type 304 L.
However, Bechtel Specification M-207, para-graph 6.1.l.d states that the material is to be quenched in water.=
The inspector requested confirmation that the vendor, Sandvik, Inc., included quenching in their annealing pro-cedure.-
This item is unresolved pending determination of the method of annealing by the vendor (387/78-17-01).
(2)
The RHR pump "A" discharge line to the RHR heat ex-changer The inspector verified conformance with FSAR Section 5.4.7-and drawings GBB-104-1, GBB-104-2,. GBB-105-1 and M-151.
No items of noncompliance were identified.
6.
Reactor Vessel Installation Units 1 and
The inspector examined protection of the installed reactor vessels and stored closure heads for compliance with site procedures and PSAR Appendix D commitments.
The inspector reviewed the procedural requirements for vessel protection and verified that required in-spections and preventive maintenance were being completed.
The in-spector observed that openings were covered as required, work plat-forms inside the Unit 1 vessel were nonflammable and that Unit
vessel access was controlled.
Documentation reviewed by the inspector included:
Field Inspection Procedure G-5, Revision
Project Special Provisions Notice SF/PSP G-5.1, Revision
Equipment Maintenance Requirement and Record Form for Units 1 and 2 Reactor Vessels and for Reactor Vessel Closure Heads No items=of noncompliance were identified.
7.
Reactor Vessel Internals a.
Protection of Stored Vessel Internals - Units
and
The inspector examined protection of the stored reactor vessel
- internals for compliance with site procedures and PSAR Appendix D commitments.
The-inspector reviewed the procedural require-ments for internals protection and verified that required in-spections were being completed.
The inspector observed in-plant storage of the Unit
Steam Dryer and the shroud head and separato Documentation reviewed by the inspector included:
Field Inspection Procedure G-5, Revision
Project Special Provisions Notice SF/PSP G-5.1, Revis.ion.3 Equipment'Maintenance Requirements and Record (EMRR)
Form for Units 1 and 2 Steam Dryer and the Shroud Head and Separator The inspector noted that the EMMRs for the Unit 2 internal components had been revised to reflect their movement to in-plant storage.
NCR 2969 regarding the storage of the internals had received a disposition, but corrective actions had not been completed.
Previously identified item 388/
78-13-01 remains open pending verification of corrective actions.
b.
Installation of Internals - Unit
The inspector observed. welding of the vessel shroud to shroud support.
The inspector verified that welding and shroud align-ment measurements were being accomplished in accordance with procedures and specifications listed below.
The inspector reviewed welder qualifications, filler metal certifications, and daily alignment readings.
The inspector reviewed the following documents relative to this work:
FSAR Section 3.2 GE Drawing 197F633, Revision
GE Specification 22A 4273, Revision
GE FDI 30/68754 GE I&SE Joint Process Control Sheet No.
135-11 GE I8SE Shroud Installation Traveler 13T-1 Material Certification for Held Filler'etal - Lot No.
7M1B MIX 6
Record of welder qualifications for shroud weld in ac-cordance with ISE-WQ-41, Revision
Weld procedure ISE-DWP-4001, Revision
No items of noncompliance were identified.
8.
Containment Penetrations The inspector observed the installation of containment electrical penetration
W 106A and reviewed pertinent documents to verify that they were technically adequate, current and approved.
The inspector verified that the installation activities were being conducted in accordance with commitments in the PSAR Appendix D; FSAR Sections 3.1.2.5 and 3.8.1; Bechtel Specification E-135; West-inghouse Installation Instruction PEN-TR-76-19, revised July 7, 1978; and, QCI 6.6, Revision 5.
The inspector verified the following relative to the above:
Method of assembly is consistent with design requirements
'Measures to protect installed components Installation including bolting and leak testing QC inspection activities Installed penetration identi.fication The inspector also reviewed the following documents relative to the above:
QCIRs E-135-1 W 106A E-135-1 W 106A-1 E-135-1 W 106A-2 E-135-1 W 106A-4 E-135-R-33929-2 Drawing E-62 Westinghouse Test Data Reports E-135-37-2
The inspector noted that an unresolved item, 387/78-03-06, regarding the qualification of penetrations, remains open pending further review by the NRC.
No items of noncompliance were identified.
9.
Reactor Buildin Su erstructure a.
Review of Subcontractor ualit Assurance Manual The inspector reviewed the Gives Corporation gA Manual and referenced documents to determine if adequate gA plans and procedures have been established to assure that safety-related activities are controlled and accomplished in accordance with
CFR 50, Appendix B and commitments in the PSAR Appendix O.
The inspector verified that the following activities were in-cluded:
Organizational structure including gA personnel Audits guality requirements including test reports, procurement methods and identification of components guality inspection Control of material Control of special processes Corrective action Oocument control Control of measuring and test equipment guality records Oocuments reviewed by'he inspector included:
Cives Field guality Assurance Manual, Revision A
Gives Fabrication Quality Assurance Manual, issued September 1,
1977 Gives Supplementary QA Procedures SUS-l, Revision B
SUS-2,,Revision B
SUS-3, Revision
SUS-4, Revision A
SUS=5,,Revision B
SUS-6,.Revision B
SUS-7, Revision A
Bechtel Specification C-66, Revision
No items of noncompliance were identified.
Observation of Work Activities (1)
The inspector witnessed the in-process erection of structural steel above the refueling floor elevation 818'.
He checked the condition of various bolted joints for fit-up damage, over sized holes, and minimum edge distance requirements.
He also interviewed the Gives QC Supervisor and a Bechtel QC inspector relative to the plumbing, torquing, reaming, welding, and coating of the pieces being installed.
Records of material conformance and receipt inspection, bolting inspection, and inspection personnel qualifications were reviewed on a sample basis.
The above items were evaluated against criteria established in the following documents:
AISC "Specifications for Structural Joints Using ASTM A325 or A490 Bolts," 1976 Edition ANSI 'N45.2 and N45.2.6 Bechtel Specification. 8856-C-66, Revision
Gives.Steel Company Field Quality Assurance Manual, Revision A
Cives Corporation guality Assurance Program Supple-ments:
SUS-3, Revision D'US-5, Revision B; and, SUS-7, Revision A
The following documents were included in the review:
Gives Steel Company Receiving Report for Structural Steel Mark Nos.
B1015, A1021, A261-5, A261-6 and A1071 Gives Steel Company "Statement of Conformance for Structural Steel,"
dated June 2, 1978 Modulus Corporation letter to Gives Steel Company, dated July 28, 1978; providing certification of all high strength bolts to ASTM A490 magnetic particle inspectio'n criteria Gives Steel Company Welding Inspection Form, dated October 23, 1978 Gives Steel Company Bolting Inspection Forms, dated October 10, 12 and 23, 1978 Record of Certification of qualification as a Level-II Civil Inspector for the Gives Steel Company gC Supervisor
.No items of noncompliance were identified; however, one item remains unresolved as discussed below.
(2)-
The inspector noted structural steel bracket (Mark No.
A1071)
had been field welded onto column B1015 to replace a shop welded bracket located approximately one foot too low.
He reviewed Gives Steel Company Nonconformance and Disposition Report (NSDR) No.
3 and the Welding Procedure Specification for Field Fillet Weld-l, and checked the qualification of Gives Steel Company welders to weld using the above procedure and had no questions.
However, his review of the Gives Steel Company Receiving Report for piece A1071 and subsequent interview with the Gives gC Supervisor indicated that no mill certification, test results, or statement of conformance for that piece was available on-site.
A Gives Steel Company NSDR No.
was immediately issued and dispositioned to attach a red (hold) tag to piece A1071 until proper documentation arrives on site.
Pending review of this documentation by the licensee, this" item is unresolved (387/78-17-02).
c ~
Concrete Excavation for Structural Steel Erection The inspector noted that, dur ing the erection of str uctural steel piece A1021 at the U and 22 lines, a portion of the con-crete of a stairway wall from elevation 818'o 828'ad to be chipped away.
The inspector examined Bechtel Field Change Request (FCR) C-2355, which authorized this excavation,, and gCIR C-1.20-171-W-06-101 with attached Core Drilling Excavation Checksheets, used= by gC to inspect the work.
These documents and the excavation work were checked for compliance with Bechtel Specification 8856-C-8, Revision 8.
Since the excavation was somewhat deeper than that authorized by the FCR and since a portion of one vertical rebar had been exposed, the inspector questioned the, lack of any paperwork documenting the need for further corrective action.
Discussion with the'responsible Bechtel gC engineer revealed that such cor-rectiye action would be initiated prior to closing the post-placement inspection plan (gCIR C-l.40-171-W-06) for the concrete in question.
Subsequently Bechte]'n-Process Rework Notice No.
2708 was issued to note. the required repair to the excavated concrete.
d.
The inspector has no further questions on this matter.
Reactor.Buildin Crane Rail During review of Specification C-66, the inspector noted that Paragraph 17.4.8 exempts certain structural items from the requirements of Criterion VIII, Identification and Control of Materials, Parts. and Components.
, The items exempted are shown on detail drawings.
The. inspector noted that Bechtel Drawing No. C-326, Revision 6, exempted the reactor building crane rails, crane rail joint bar and crane rail clamps.
The inspector was informed that these materials, therefore, would not be traceable by heat number or other means.
During this inspection, Field Change Request C-2408 was issued to modify Drawing C-326 to state that the aforementioned items "shall be furnished as non-g items."
The inspector stated that the justification was not clear for the evaluation of these items as non-safety related.
This item is unresolved pending further evaluation by the licensee and review by the NRC (387/78-17-03; 388/78-16-01).
10.
,S r Pond Concrete Placements and Records-The inspector observed a portion of a Spray Pond backfill concrete placement (BF-Bl-3) and witnessed one set of quality concrete tests for air content,-slump, unit weight, and the formation of compressive test cylinders.
He interviewed responsible QC inspection personnel and examined a sample of concrete batch plant delivery tickets, the Dick. Corporation Concrete Placing Release No. BF-Bl-3 and Dick Corporation-QCIRs BF-B1-3-A, B and C.
Subsequently, the inspector interviewed QC Dick Corporation Field QC Manager and reviewed QC records relative to various spray pond concrete place-ment activities,, receiving inspections and material certification and the qualifications of QC inspection personnel.
The. above areas were evaluated against criteria established in the following documents:
ASTM A185-73, C138-74, C143-71, C172-71 and C231-73 ANSI N45.2.6 Bechtel Specification 8856-C-36, Revision 2'ick Corporation Quality Assurance Program Manual, Revision
Dick Corporation Quality Control Procedures FQC 1.2, Revision 1; FQC 10.1,. Revision 1; and, FQC 10. 2, Revision
Dick Corporation Construction Work Procedure CWP 10.2, Revision
The following documents were included in the review:
Bechtel Field Change Request C-2432 Bechtel-Drawings C-65, Revision 4; C-66, Revision 5; and C-67, Sheet 1, Revision 6; and, Sheet 2, Revision
Dick Corporation Quality Control Inspection Reports for the following concrete placements:
S-29-A E-67, E-99, MSB-41A SB-43A B-70 B-21 SB-15 SB-16 SB-18
Dick Corporation Receiving Reports for the following material, as listed:
Rebar - R16, R21, R27 Welded Wire Fabric - R2, R4, R7, R8, R17, R19 Waterstop - E10, Ell, E12 Expansion Joint Filler - E13, E13A Record of Qualification as a Level. I QC Inspector for Dick Corporation Employee; No items of noncompliance were identified.
11.
Unresolved Items Unresolved items are matters about which more information is required in order to ascertain whether they are acceptable items, or items of noncompliance.
Unresolved items identified during the inspection are discussed in Paragraphs 5 and 9.b and 9.d.
12.
Exit Interview.
~
~
~
~
~
~
~
~
~
~
~
At periodic intervals during the course of this inspection, meetings were held with facility management (dates and attendees are denoted in Detail 1) to discuss inspection scope and findings.