IR 05000397/1978009

Insp Rept 50-397/78-09 on 780822-25.No Noncompliance Noted. Major Areas Inspected:Review of Quality Records,Installation Procedures & Implementation of Fire Protection Program

ML20062A982
Person / Time
Site:	Columbia
Issue date:	09/14/1978
From:	Bishop T, Haynes R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V)
To:
Shared Package
ML17272A175	List: IR 05000397/1978009
References
50-397-78-09, 50-397-78-9, NUDOCS 7810190093
Download: ML20062A982 (10)

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U. S. NUCLEAR REGULATORY COMMISSION y 0FFICE OF INSPECTION AND ENFORCEMENT

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REGION V

Report No. 50-397/78-09 Docket No. 50-397 License N CPPR-93 Safeguards Group

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Licensee: Washington Public Power Supply System

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P. O. Box 968 Richland, Washington 99352 Facility Name: Washington Nuclear Project No. 2 (WNP-2)

Inspection at: WNP-2 Site, Benton County, Washington Inspection Conducted: August 22-25, 1978 Inspectors: -S h 9 3 8 T./ W. Bisho Reactor IMfettor '/Date digned o~tUm ~ dw f 3/78 L./E. Vorderbrueggen, REE4for Inspector Aate/ Signed 0 /ltluAA fM'f78 ac Inspector Da e Signed G/er nde

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, Reactor Inspector c7 abr

'/ Date/ Signed G.Jghns l Approved By: ,

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R. C. Hayne r ChisV, Projects Section, Reactor Construction and Engineering Support Branch Date Signed Sumary:

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Inspection on August 22-25,1978 (Report No. 50-397/78-09)

i Areas Inspected: Routine, unannounced inspectio'n by regional based inspectors j of construction activities including: structural steel QA implementing proce-i dures,. installation activities, and review of quality records; diesel generator installation procedures and installation activities; instrumentation insta11atioa preparations; HVAC installation activities; licensee control of actions required from a GE 10 CFR 21 report; pipe support records falsification and allegation follow-up; fire protection program implementation; follow-up on previous inspec-tion findings; and tour of plant areas. The inspection involved 77 inspector-i hours onsite by four NRC inspector ! Results: No items of noncompliance or deviations were identified in the 13 l j areas inspected.

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l 7 Tr/o y oe 93 IE:V Form 219 (2)

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< DETAILS s, ;

.,~ Persons Contacted

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. )[ Washington Public Power Supply System .

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• D. L. Renberger, Assistant Director, Generation & Technology

• M. E. Witherspoon, Quality Assurance Division Manager

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• A. D. Kohler, WNP-2 Project Manager i

, *J. C. Janus, WNP-2 Construction Manager  !

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• A. M. Sastry, WNP-2 Project Quality Assurance Manager

• J. D. Martin, Startup and Operations Manager .

• A. N. Kugler, Design Supervisor  !

• J. M. Steidle, WNP-2 Senior Quality Assurance Engineer S. L. Washington, WNP-2 Quality Assurance Engineer  :

E. L. Stevens, WNP-2 Quality Assurance Engineer W. G. Conn, WNP-2 Engineering Supervisor O Burns & Roe, In .

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• R. Root. Deputy Project Manager

• G. Harper, Technical Support Manager

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• H. Tuthill, Senior Project Quality Assurance Engineer D. Reader, Lead Quality Assurance Engineer - Mechanical P. Massman, Senior Quality Assurance Engineer - Electrical

'l M. Vire, Senior Field Safety Specialist D. Bonelli, NCR Administrator i j WSH/Boecon/Bovee and Crail/GERI l f ,

j A. Larson, Quality Assurance Manager .

L. Buckner, Quality Control Manager l G. Durkee, Quality Engineer ,

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! Pittsburgh-Des Moines (PDM) l 1 '

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R. McMahan, Quality Assurance Manager i i B. Shea, Quality Assurance Inspector  !

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D. Chase, Quality Assurance Inspector-I .!

Johnson Controls

R. Swift, Quality Assurance Engineer l

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• Denotes those present at exit intervie ,

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2. Construction Status

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As of August 1,1978, overall completion of the WNP-2 project was considered by the licensee to be 67%. i 1 . .

s 3. Licensee Action on Previous Inspection Findings  ;

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Licensee response to the following items of noncompliance had

- y . not been received by the NRC as of the current inspection: l

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y (1) (0 pen) Noncompliance (50-397/77-07, 78-03): Modifications  ;

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had been accomplished on pipe supports without the required i approva *

(2) (0 pen) Noncompliance (50-397/77-07, 78-03): Pipe supports ;

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were not installed in accordance with prescribed instruc-tions, procedures, and drawing j s O (3) (0 pen) Noncompliance (50-397/77-07, 78-03): Inspections t

.of pipe supports were not adequately performe (4) (0 pen) Noncompliance (50-397/77-07, 78-03): Nonconforming

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conditions existing in accepted pipe supports were not docu- ,

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mented and processed in accordance with established procedure >

However, interim actions taken by the licensee in the above

! areas were reviewe These included upgrading of the pipe i support installation procedure (to clarify tolerances and ,

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acceptance criteria), additional craft and Quality Control  !

(QC) inspector training, and increased surveillance of activ-  ;

ities. The inspector also examined three pipe supports. Two '

I minor discrepancies (lack of thread upsetting and an incomplete  ;

as-built sketch) were noted for the supports examined. Pipe (D support fabrication, installation, and inspection activities i

will be further examined following receipt of.the licensee's f formal response to the above noncompliance '

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i (0 pen) Noncompliance (50-397/77-07, 78-03): Pipe support j

] quality records were deficient as evidenced by incomplete ,

checklists, missing NDE records and weld filler material with- l drawal forms, and lack of traceability between welds, welders i and QC inspector I

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f The contractor's action regarding the formulation of new and revised procedures and training on these procedures was re-i viewed and found satisfactory during a prior inspection. The N , ". item was left open pending the examination of records which 7 were generated under the new program, and the resolution of the previously identified record discrepancies. Although a ..

large number of records have been generated since the new pro-

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gram was established, only a few have been processed through

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the complete review cycle. Accordingly, this item will remain

, open pending NRC examination of a sufficiently large sample of

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records which have had final revie (0 pen) Unresolved item (50-397/77-07, 78-03): A number of

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weld joint offsets (1/4 inch) were noted in some flanges of

, vertical tee stiffeners inside the containment at the 450-foot elevatio <

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G The licensee's corrective action procedure was in the review

M circuit during the current inspection. This item will be fur-ther examined during a subsequent inspectio '

, (Closed) Unresolved item (50-397/77-04, 77-05 and 77-07):

, Inadequately defined completion status of civil / structural work performed by Bovee and Crail under Contract 206 prior to defaul The licensee's review of the inspection records of the defaulted contractor and his structural steel subcontractor narrowed the area of concern to the structural steel connections at the

, j 444-foot elevation of the Reactor Building. This was the loca-tion of principal work activity at the time the 205 Contract was terminated. The records review disclosed that, of the approximately 250 beam connections at that elevation, there Q were no inspection records for 11 welded and 12 bolted con-nections. The licensee examined the 11 welded connections

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j and found them to be acceptable. Then to establish an appro-

priate degree of confidence as to the acceptability of struc-

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tural steel connections at the 444-foot elevation, the licensee

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randomly selected 45 additional joints for inspection - 20 welded and 25 bolte Included in the 25 bolted connections were 5 of the 12 that had no record of previous inspectio Their inspection of the randomly selected connections found one weld that had a minor discrepancy (surface slag still pre-sent) and one bolted connection that had 2 of 4 bolts not properly torqued. Those two bolts were found to have been c l

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.. backed-off to such an extent that indicated that they had been used by Onother contractor for a temporary support. On the

basis of the inspection findings, the licensee concluded that

, the structural steel installation was acceptable. This matter

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' (Closed) Open item (50-397/78-07): Weld Record Sheet for

'i+ completed Weld No.11 on Drawing LPCS-756-19.21 did not con- .

tain all of the information required to be recorded during

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S ]' the welding proces .s The contractor believed that a supplemental Weld Record Sheet i had been processed, but was unable to locate it. Nonconfom-ance Report No. 215-03629 was issued to document the discrep-

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anc The resolution directed by the licensee was that the weld was to be ground out and redone with a new Weld Record

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Sheet properly filled out. This item is close ' '

- Instrumentation and Controls Review of Quality Assurance (QA) Implementation Procedures

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The inspector reviewed the following Johnson Controls document No items of noncompliance or deviations were identifie <

Quality Assurance Procedure, QAS-501-H2, Procurement Document Control Quality Assurance Procedure, QAS-701-H2, Document Control Quality Assurance Procedure, QAS-802-H2, Receiving, Unloading Inspection Quality Assurance Procedure, QAS-902-H2, Traceability i Quality Assurance Procedure, QAS-1401-H2, Handling and l Storage

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! Quality Assurance Procedure, QAS-1402-H2, Preservation of Equipment

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Quality Assurance Procedure, QAS-1601-H2, Control of Nonconformances

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Work Procedure, SP-201-H2, Non-QA/QC Personnel / Training and Indoctrination of QA Requirements 1.,

,- P Work Procedure, SP-1201-H2, Hydrostatic Inspection

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Work Procedure, SP-1202-H2, Pneumatic Testing

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1' n Work Procedure, SP-2005-H2, Installation and Erection QA procedures addressing installation of Class I equipment had not been submitted to the licensee from Johnson Controls (220

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Contract). No Class I work is anticipated until late December 1978 or early January 1979. A licensee representative indicated d that the Test and Startup Group will be handling all of the i testing of components and will assume the maintenance and sur-veillance of the installed equipment after system turnove ;

O The erity of the instrumentation and controis equiment has been received onsite and is being stored by the electrical and

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i mechanical contractor The onsite electrical contractor (Fisch-bach / Lord) will be installing the instrument racks, and pulling and teminating the cables for all of the system o Structural Steel and Supports l Review of 0A Implementing Procedures

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The following procedures relating to Pittsburgh-Des Moines (PDM) structural steel activities were reviewed: >

(1) 34117-EPI, Rev. O, Receiving, storage, requisition ,

l issuance and control of welding material filler metal '

O (2). 34117-Bolt, Rev. O, Procedure for installing and inspecting ASTM A325 and A490 high strength bolts.

l l f (3) WVT-01, Rev. O, Visual inspection procedur '

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1 (4) CP-IA, Rev. O, Calibration procedure, i The procedures appeared complete and adequate, except as ,

noted below:

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E It was observed that PDM's procedures did not address the frequency of calibration of the torque wrenches or the Skidmore-Wilhelm bolt tension indicating device. Also, not

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specified was not how often the torque wrenches would receive

.' a calibration check to verify the job inspecting torque. Li-censee representatives stated that this matter would be invest-igated and appropriate action taken. This item is open and

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will be examined during a subsequent inspectio b. Observation of Work and Work Activities

Structural steel activities performed by PDM, including

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bolting installation and inspection, were observed at the top of the Reactor Building. The inspector observed cali-bration checks of the inspecting torque wrench on the Skidmore-Wilhelm bolt tensioning device and the torque ver-ification of approximately 20 joints. The inspecting torque Q wrench was properly calibrated and all joints were tight and properly torqued. No items of noncompliance or deviations

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were identifie c. Review of Quality Records i

Records associated with material certifications, installation and inspection, receiving and inspection were examined. Non-

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conformance reports and inspector qualifications were reviewe The following items were noted as a result of this revie It was observed that the material certification for A325 bolts consisted of a shipping list with a stamp of conformance. The stamp indicated that the material shipped met the appropriate specification and standards. Concern was expressed by the NRC inspector about the validity of such a stamp, since standard industry practice is that the reliability of such a stamp be

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verified. Cognizant personnel stated that before a supplier can get on PDM's vendor list, a Quality Assurance audit is performed on the supplier. The contractor indicated that a

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copy of the audit would be available for review during the next inspection. This item is ope i An item of concern was noted during review of nonconfonnance

reports, in that a number of NCRs were observed to be outdated (

and others appeared to be improperly controlled. This item

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I is open and will be examined during a future inspectio t

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l Records Falsification Follow-up .

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Licensee actions taken as a result of the falsification of weld rod

, withdrawal fanns were examined. The actions were identified in WPPSS Letter No. G02-78-155 of June 8,1978. Each action was veri-fied to be satisfactorily implemented. It is concluded that the .

actions identified are sufficient to prevent the recurrence of such

.' . activities under this contract. In addition, the inspector examined

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five nonconformance reports which provide disposition of specific falsified forms and associated welds. Each of the dispositions examined appeared appropriate. The inspector has no further ques-tions at this tim . '10 CFR'21'Reporti' ' Defects in GE's Power Generation Control Complex

^(PGCC)

@ The licensee's program to assure resolution of the defects in General

.' 1 Electric's PGCC, as identified by GE in their 10 CFR 21.21 Report t (NRCNo.78-063-000), were reviewed. The licensee has applied a hold

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tag to the PGCC and issued Inspection Report No. E-531 to document a'ction being taken. GE's correct 1ve action plans are not anticipated before March 30, 1979. This item is open and will be examined dur-

/ ing a subsequent inspection after the corrective action plans are

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availabl / ' Control Room and Cable Spreading Room Ventilation Systems Activities involving installation of Control Room and Cable Spreading Room ventilation systems were observed. The systems were undergoing modifications to correct a problem of excessive inleakage. Much of the work to be done was still in the design stage. Cleanliness of the ducting appeared satisfactory with no loose material or insula-Q- tion in the ducting. No items of noncompliance or deviations were i

identified.

' ! Diesel Generators

.i The procedures, nonconfonnance reports, material receiving reports,

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and inspection reports relating to the diesel generators were re-l viewe It was noted that only the HPCS diesel generator has been

{ delivered to the sit No items of noncompliance or deviations were

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.} i p 10. Allegation - Pipe Support Stress Calculations i

. An a11eger contacted the NRC Region V office on August 24, 1978,  !

N'l- indicating he had been made aware of certain irregularities in  ;

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the area of pipe support stress calculations at WNP-2. Specific {

, allegations were: (1) stress calculations were being performed  ;

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i tained; and (3) certain personnel; welds(2)forcalculation pipe supports records were were not main-designed too i small to meet code requirements. All allegations referred to non-

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, reactor coolant system (non-safety related), USAS B31.1 pipe sup- i port Each allegation was investigated and none were substanticte f

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The. alleger apparently was not aware of the full scope of the pro- l

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gram for designing and modifying pipe supports. Additional calcula-  !

tions were made verifying that the loads for the small welds were i within USAS B31.1 requirements. The alleger was subsequently noti-1 fied (by telephone) of the results of the NRC investigation and was  :

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1 Fire Protection / Prevention During Construction  ;

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The licensee's procedures for fire protection / prevention were [

reviewed during a previous inspection and determined to be satis-  ;

factory. The control and implementation of the procedures were examined during the current inspection. This included verifica- l

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tion of availability and operability of a random sample of fire  ;

suppression equipment and compliance with procedures for three

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activities utilizing ignition sources. During observations of

. the electrical contractor (Fischbach/ Lord) welding activities,

, it appeared that fire watch coverage was not fully consistent with procedures. Licensee representatives indicated that this situation would be investigated and appropriate action taken. The inspector

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has no further questions on this matter at this tim l

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h 1 Plant Tour l

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The inspectors walked through various areas of the plant to observe  !

I activities in progress to note status and condition of "nonconform-  ;

i ar.ce" tags affixed to equipment, and to examine the general state l of cleanliness and housekeeping. Improvement was noted in the .

. storage of gas cylinders, although general housekeeping still  !

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1 Unresolved Items

Unresolved items are matters about which more information is

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required in order to ascertain whether they are acceptable items,

o ' items of noncompliance, or deviations. Unresolved items remain-i

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ing from this inspection are discussed in Paragraph ; .

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1 Exit Interview

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At the conclusion of the inspection, a meeting was held with licensee and Burns & Roe representatives denoted in Paragraph The activities covered during the inspection 1.id observations and

, findings of the inspectors were discussed. The inspectors noted the improvement which had been made in the area of pipe support procedures, but also noted that attention to detail must continue to be stressed to craftsmen and inspectors (as evidenced by the Q two minor discrepancies noted on the three supports inspected).

Licensee representatives indicated that they are conducting, and will continue, their own 100% inspection of pipe supports until a satisfactory level of confidence had been astablished in the contracto .

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