IR 05000397/1983035
| ML20024F481 | |
| Person / Time | |
|---|---|
| Site: | Columbia  |
| Issue date: | 08/16/1983 |
| From: | Dodds R, Toth A, Wagner W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V) |
| To: | |
| Shared Package | |
| ML20024F477 | List: |
| References | |
| 50-397-83-35, NUDOCS 8309090419 | |
| Download: ML20024F481 (7) | |
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t-U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT
REGION V
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Report No. 50-397/83-35 Docket No. 50-397 License No. CPPR-93 Licensee: Washington Public Power Supply System 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: July 1-31,.1983 Inspectors:
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A. D. Toth,'SenioE Resident Inspector Date' Signed W1lb
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gner, Rea ' or Inspector Da'te Signed
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//N3 Approved By:
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R'. T. Ifodds, Chief Dite Signed Reactor Projects Section 1 Summary:
. Inspection on-July 1-31, 1983 (Report No. 50-397/83-35)
Areas Inspected: Routine, unannounced inspection of construction quality reverification activities, allegations and employee concerns, and status of previous inspection findings..The-inspector also assisted with the NRC Construction Assessment Team inspections.of concrete, piping, and supports.
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The inspection involved 68 inspector hours on-site by.the construction resident inspector and 8 inspector hours at Bechtel's San Francisco office by a regional inspector.
Findings:. No items of noncompliance or deviations were identified.
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DETAILS
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Persons' Contacted Washington Public Power' Supply System (WPPSS)
C. Carlisle',(Program Director H. Crisp,, Construction Manager H. Boarder, Quality Assurance Engineer
'L..Floyd,; Quality. Assurance Engineer
~*J._Garvin,-Quality; Engineering Manager.
- R.;Glasscock, Licensing a.id Assurance Director
- R.~ Johnson,, Project Quality Assura'ce' Manager n
R. Knawa, Reverification Program Manager
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P. Powell, Licensing. Engineer'
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R. Ramsgate, Reverification Program Engineer D. Walker, Operations Quality Assurance Manager Burns and' Roe' Engineering Incorporated (BRI)
A. Cygelman, Engineering Hanager G. Englert, Pipe Support Engineer B. Gonthier, Senior Quality Assurance Engineer R. Sanan, Resident Group Supervisor - Civil H. Tuthill, Engineering Quality Assurance Manager f
Bechtel Power Corporation
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'H. Boarder, Quality Assurance Engineer
- D Cosgrove, Quality Assurance Engineer.
T. Fallon, Quality Control Supervisor
- J. Gatewood, Project Quality Assurance Engineer
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- D. Johnson, Manager of Quality M. Leach, Reverification Group Supervisor i
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- Denotes personnel present at the exit management meeting.
l In addition-to the personnel noted above, the inspector interviewed j-various other construction, engineering, operations, and quality control (
personnel from'the licensee and contractor organizations.
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General
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The resident inspector was on-site July 1, 5-8, 18-22 and 25-29, 1983.
He visited Bechtel San Francisco' materials testing laboratories July 15, 1983 to observe layout and sectioning of weld samples from WNP-2 piping.
He was accompanied by a regional office metallurgist (W. Wagner) during U
the Bechtel visit.
Several regional office inspectors and managers visited the site this
. month for routine inspection activities. Their activities are documented
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in other separate inspection reports. These included:
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A radiation safety inspector (G. Yuhas) was on-site July 18-22, 1983, to review environmental and radiation safety matters.
NRC licensing staff members (W. Lovelace, R. Auluck, and A. Schwencer)
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were.onsite July 12-14, 1983, to review fuel load schedule bases
information.
Regional office inspectors were on-site on July 19-22 (D. Haist) and July 25-29, 1983 (W. Wagner) to review licensee actions on matters reported to NRC under 10 CFR 50.55(e).
NRC Headquarters inspection staff (K. Herring) and a regional office inspector (W. Albert) were onsite July 26-28, 1983, to review licensee actions to explore in place concrete.
Security system inspectors (D. Schaefer and C. Schwan) were on-site July 18-22, 1983, to review security programs, hardware and personnel.
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Reverification Program In response to the June 17, 1980 NRC inquiry under 10 CFR 50.54.(f), the Supply System, Bechtel, and site contractors have been engaged in a reverification program which includes review of records and re-inspections of hardware installed prior to July 1980.
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On April 19, 1983, the Supply System accepted the Contract 2808-220 Reverification Report for the instrument and control site contractor, Johnson Control Incorporated (JCI). The NRC resident inspector
subsequently found that the report did not contain sufficient information to conclude that proper materials were installed in correct locations by qualified personnel. Such conclusions would require referral to other studies and documents which were neither summarized nor identified in the
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report.
Interview of Bechtel and JCI personnel revealed existence of such studies and documents.which reportedly may demonstrate a sufficient depth of review and inspection. The Supply System representative stated that supporting information had been reviewed by Bechtel and that the
. reverification report would be upgraded to summarize or reference the
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relevant information.
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The inspector discussed detailed comments with the Supply System and Bechtel reverification program managers, for consideration in the report upgrade activity. The adequacy of the JCI quality assurance program, to assure that prior work was properly performed, is unresolved pending
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review of the planned upgraded reverification report and/or supplemental data relating to depth of reviews /reinspections.
(Unresolved Item
.83-35-01)
4.
Licensee Action On NRC Construction Appraisal Team Findings The NRC Const'uction Appraisal Team (CAT) conducted inspections on-site r
May 16-27 and~ June' 6-22,'1983.
The licensee initiated action plans for immediate correction and/or investigation of items identified by the CAT.
The inspector witnessed some of these activities.
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Welding / Nondestructive Examination - Identification of Linear Type Root. Indications in Piping Welds The CAT had noted four pipe weld radiographs which exhibited linear type indications. These were reviewed and accepted by the Bechtel
.NDE level.III reviewer; the indications were not accepted by the CAT reviewers.
Bechtel cut out three of the welds (RIIR-854-12.16-FW14R1, RFW-438-3-FW1R1, and LPCS-756-5.7-FW17R2) and sent these to the Bechtel materials laboratory for sectioning and etching.in an attempt to confirm absence of rejectable discontinuities. The inspector' identified the pre-cut and post-cut specimens on-site and correlated the specimens with the radiographs in question. He visited the Bechtel San Francisco laboratory on July 15, 1983, and confirmed that the laboratory personnel had identified the areas'in question on the physical samples prior to further cutting and mounting for examination. A regional office NRC inspector / metallurgist also monitored the preparations and witnessed some of the investigative slicing / etching / examination of samples.
The regional inspector witnessed the metallographic examination of the welded joints. This included sectioning of the welded joints at the area of concern as shown on the radiographic film (RT location).
The inspector examined the welds at low and high magnification in both the unetched and etched condition. This examination revealed the radiographic indications to be due to slag, porosity, or surface contour of the welded pipe and appeared to be Code acceptable.
There was no evidence o' incomplete fusion in the welding groove, or cracking of the welded joint.
Bechtel plans to document the results of the examinations for consideration in further action plans relative to the CAT findings.
5.
Licensee Action On Prior NRC Inspection Findings a.
(Closed). Follow-up Item (397/82-18-03) - Lost Weld Records and Weakness in Bechtel Process Control Some records of welding and piping installation inspection (QCIRs)
had been lost.
Bechtel corrective actions included a quality control department survey of 6,647 QCIRs, finding that 5.8 percent were missing. The practice of fastening the documents to the work piece until completion of work, and delays in completion of work, appeared to contribute to the problem. Bechtel procedures have been revised to alter the practice and establish QC records in the custody of QC inspection staff.
Administrative Instructions 16 and 18 have been issued to prescribe actions for future cases of lost records. They require preparation of a new record and performance of final inspections and NDE, performance of document reviews and verifications, and performance of any in-process inspection / surveillance steps possible.
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Additional Bechtel actions included establishment of a construction / engineering / quality control team organization for each plant system, resulting in closer coordination and control over work planning and records.. Quality control management also established a system for tracking status of open/ closed /in process quality control inspection and NDE records.
Additional process control improvement management attention is described in NRC Inspection Reports 50-397/82-23, 82-24, and 82-29 relative to NRC inspector follow-up item 82-23-01.
A Supply System correction action report CAR-1029 describes typical actions in response to the Supply System quality assurance monitoring of the Bechtel process control issue. Routine additions and revisions to work and inspection procedures show evidence of efforts to improve definition of inspection criteria and implementation of specification requirements.
Bechtel has included quality problem oriented questions in exit interviews of terminated quality and engineering personnel, and appears to have taken action on items which suggest weakness in assurance of work quality and process control.
Nonconformance reports have been analyzed for quality trends and corrective actions taken. An experienced quality assurance individual is currently assigned to this activity.
Not withstanding, recent NRC inspection findings regarding specific parts of the quality assurance program, the follow-up issue of general process control is closed.
B.
(Open) Follow-up Item (397/80-08-21) - Pipe Wall Thinning There appeared to be insufficient management attention to significant deficiencies regarding pipe wall thinning.
Corrective actions have been taken but incomplete information was available for the inspector to ascertain resolution of all the issues:
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(1) Weld preparation counterboring - This matter relates to Report 90 filed by WPPSS under 10 CFR 50.55(e), and which was
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addressed in Inspection Report 50-397/82-28. An unresolved point is the demonstration that Bechtel quality control j
procedures provide inspection commensurate with that which I
would have been provided by the contractor program that WPPSS l
described to NRC.
(2) Corrosion allowance - This has been addressed by the architect-engineer, confirming adequacy of the reduced corrosion allowance for a 40-year design life based upon l
reconsideration of expected steam flow velocities. An unresolved point is the Engineer's decision to not seek review
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l of.this basis by the NSSS supplier (GE) that had provided
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original suggested corrosion allowances for the steam system.
(The Engineer declared design prerogative for the part of the
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steam system in question, which is external to the containment l
building isolation valves.)
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i (3) Pitting - This matter relates to Report 118 filed by WPPSS under 10 CFR 50.55(e), the final report having been submitted j
December 1981. The principal issues appear to have been
addressed. Unresolved points include:
(a) Credibility of vendor (AP&E) ultrasonic tests was in question due to surface pitting. Field grinding was performed and field ultrasonic testing then confirmed sufficient wall thickness in those locations. The vendor departure from surface preparation procedures did not appear to be addressed for other locations on the pipe.
(b) Vendor ultrasonic test results for pipe bends appear to not have been located or resolved.
(4) Excessive grinding of small bore pipe in preparation for socket welding. This matter relates to Report 80 filed by WPPSS under 10 CFR 50.55(e).
It is part of an issue discussed under NRC item 397/79-16-05, which was addressed in the June 1983 NRC Inspection Report 50-397/83-27.
(The matter was identified as requiring further information in that report, and is closed relative to item 397/80-08-21.)
-(5) Other specific matters mentioned relative to this item appear to have been addressed by the licensee with regard to specific NRC observations of piping overgrinding, except:
(a) Records were unavailable relative to the gauge noted on
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spool LPCS-4472-1.
(b) No evidence was available to confirm absence of minimum wall encroachment in areas of grinding identified on surface examination NDE reports.
(Bechtel reviewers suggest that visual checks of surface depression depth had been done..This may be confirmed by the licensee or the NRC inspector.)
Bechtel quality assurance staff defined action plans to complete resolution of the above items, and those noted for item 397/79-16-05 in last month's report.
This item remains unresolved pending completion of the licensee *s actions
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noted above.
6.
Unresolved Items Unresolved items are matters about which more information is required in order to, ascertain whether they are acceptable items, items of noncompliance, or deviations.
An unresolved item disclosed during this inspection is discussed in Paragraph 3 of this report.
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7.
Management Meeting i
1The inspector met with a licensee quality assurance representative approximately weekly to discuss the status of inspection findings and other inspector activities relating to this project. On July 29, the inspector met with a representative of the WPPSS Program Director and other representatives of the Supply System and the prime contractors to summarize inspection findings. Persons contacted who attended this meeting are so noted (*) in paragraph 1 of this report.
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