IR 05000400/1982011
| ML20053B376 | |
| Person / Time | |
|---|---|
| Site: | Harris  |
| Issue date: | 05/04/1982 |
| From: | Coley J, Herdt A, Kleinsorg W, Kleinsorge W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML20053B368 | List: |
| References | |
| 50-400-82-11, 50-401-82-11, 50-402-82-02, 50-402-82-2, 50-403-82-01, 50-403-82-1, NUDOCS 8205280349 | |
| Download: ML20053B376 (14) | |
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e UNITED STATES
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NUCLEAR REGULATORY COMMISSION
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I REGION 11 o/-
101 MARIETTA ST., N.W., SUITE 3100 ATLANTA, GEORGIA 30303
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Report Nos. 50-400/82-11, 50-401/82-11, 50-402/82-02 and 50-403/82-01 i
Licensee:
Carolina Power and Light Company 411 Fayetteville Street Raleigh, NC 27602 Facility Name:
Shearcn Harris Docket Nos. 50-400, 50-401, 50-402 and 50-403
License Nos. CPPR-158, CPPR-159, CPPR-160 e.nd CPPR-161 Inspection at Shearon Harris site naar Raleigh, NC
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DatlR Si'gned Approved by:
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A. R. Herdt, Section Chief ategign'd e
i Engineering Inspection Branch Division of Engineering and Technical Programs SUMMARY Inspection on April 13-16, 1982 Areas Inspected
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This routine, unannounced inspection involved 58 inspector-hours on site in the areas of licensee action on previous inspection findings (Units 1-4),
construction progress (Units 1 and 2), safety related piping (Unit 1), safety related <,tructures (Units 1 and 2), reactor vessel installation (Unit 1), safety related components (Unit 1) and inspector followup items (Units 1-4).
i Results Of the seven areas inspected, no violations or deviations were identified.
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b REPORT DETAILS 1.
Persons Contacted Licensee Employees
- R. M. Parsons, Project General Manager
- N. J. Chiangi, Manager, Engineering and Construction QA/QC
- A. M. Lucas, Senior Resident Engineer
- R. Hanford, Resident Engineer, Metallurgy / Welding
- W. J. Szuba, Mechanical, C.I. Supervisor
- E. E. Willett, Resident Engineer, Mechanical
- F. Taylor, QC Supervisor
- G. M. Simpson, Principal Construction Specialist
- C. R. Osman, Principal QA/QC Specialist, NDE Other licensee employees contacted included construction craftsmen, technicians, and of fice personnel.
Other Organizations W. D. Goodman, Project Manager, Daniel Construction Company (DCC)
- Attended exit interview 2.
Exit Interview The inspection scope and findings were summarized on April 16, 1982, with those persons indicated in paragraph 1 above. The inspectors described the areas inspected and discussed in detail the inspection findings listed below. No dissenting comments were received from the licensee.
(0 pen) Ur..
_ lved Item 400,401/82-11-01, Adequacy of Storage Maintenance on NS#S Components paragraph Nos. 8.c and 9.c.
(0 pen) Jnspector Followup Iten 400,401/82-11-02, Procedure ES-169, Revised for Control of Temporary Attachments paragraph 10.a.
3.
Licensee Action on Previous Inspection Findings a.
(Closed) Violation 400,401,402,403/81-13-01:
" Inadequate Measures to Control Preservation of Safety Related Materials and Equipment".
Carolina Power and Light Company (CP&L) letter of response dated September 11, 1981 has been reviewed and determined to be acceptable by Region II. The inspectors held discussions with the Director of QA/QC and examined the corrective actions as stated in the letter of response. The inspectors concluded that CP&L had determined the full extent of the subject violation performed the necessary survey and
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followup actions to correct the present conditions and developed the necessary corrective actions to preclude recurrence of similar circum-
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stances.
The corrective actions identified in the letter of response
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have been implemented.
b.
(Closed) Violation 400,401,402,403/81-13-02:
" Failure of Training Records to Accurately Reflect Training and Experience". CP&L letter of response dated September 11, 1981 has been reviewed and determined to be acceptable by Region II.
The inspectors held discussions with the Director of QA/QC and examined the corrective actions as stated in the letter of response. The inspectors concluded that CP&L had determined the full extent of the subject violation performed the necessary survey
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and followup actions to correct the present conditions and developed l
the necessary corrective actions to preclude recurrence of similar
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circumstances.
The corrective actions identified in the letter of response have been implemented.
c.
(Closed) Violation 400,401,402,403/81-15-02:
" Failure to Follow Pro-cedure for Inspection of Fuel Pool Liner Welding".
CP&L letter of
response dated October 12, 1981 has been reviewed and determined to be acceptable by Region II. The inspectors held discussions with the Director of QA/QC and examined the corrective actions as stated in the letter of response. The inspectors concluded that CP&L had deter-mined the full extent of the subject violation performed the necessary survey and followup actions to correct the present conditions and developed the necessary corrective actions to preclude recurrence of similar circumstances.
The corrective actions identified in the letter of response have been implemented.
d.
(Closed) Violation 400,401,402,403/81-22-02:
" Inadequate Measures to Control Construction Loc.is on Safety Related Ma+erials and Equipment" CP&L letter of response cated January 15, 1982 has been reviewed and determined to be acceptable by Ragion II.
The inspectors held discussions with the Director of QA/QC and examined the corrective actions as stated in the letter of response. The inspectors concluded
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that CP&L had determined the full extent of the subject violation
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performed the necessary survey and followup actions to correct the present conditions and developed the necessary corrective actions to preclude recurrence of similar circumstances. The corrective actions identified in the letter of response have been implemented.
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(Closed) Violation 400/82-01-01:
" Failure to Follow Parameter of
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l Welding Procedure" CP&L letter of response dated March 15, 1982 has been reviewed and determined to be acceptable by Region II.
The inspectors held discussions with the resident QA/QC Engineer and examined the corrective action as stated in the letter of response.
The inspectors concluded that CP&L had determined the full extent of the subject violation performed the necessary survey and followup actions to correct the present conditions and developed the necessary corrective actica to preclude recurrence of similar circumstances. The l
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corrective action identified in the letter of response has been implemented.
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(0 pen) Violation 400/82-01-03:
" Failure to Follow Procedure /Instruc-tion for Visual Examination of Welds and Reporting Discrepancies".
CP&L letter of response dated March 25, 1982 has been reviewed and determined to be acceptable by Region II.
The inspectors held dis-cussions with the resident QA/QC Engineer and examined the corrective actions as stated in the letter of response. As a result of this discussion the inspectors determined that the licensee had not per-formed an adequate survey to show that the missing weld and box-frame design hanger, CC-H-469, was an isolated example. Pending an expanded survey this item remains open.
g.
(Closed) Unresolved Item 400,401,402,403/81-13-03:
"No Guidance for Changes to WDR".
This item concerned the lack of documented guidance addressing approval requirements for ravisions or changes to " Weld Data Reports" The licensee in revision 3 to CQC-19 " Weld Control" provided the necessary guidance. This item is considered closed.
4.
Unresolved Items Unresolved items are matters about which more information is required to determine whether they are acceptable or may involve violations or devia-tions. New unresolved items identified during this inspection are discussed in paragraph 8.c and 9.c.
5.
Independent Inspection Effort (Units 1 and 2)
Construction Progress The inspectors conducted a general inspection of the power block to observe construction progress and construction activities such as welding, nondestructive examination, material handling and control, housekeeping and storage.
6.
Inspector Followup Items a.
(Closed) Inspector Followup item 400,401,402,403/81-13-04: " Definition of Classroom Training". This item concerned the lack of a documented definition of classroom training.
The licensee, in revision 7 to CQA-1, " Personnel Training and Qualification" provided the necessary definition of classroom training. This item is considered closed.
b.
(Closed) Inspector Followup Item 400,401/81-22-06: " Field Monitoring of Welding Areas Appears Ineffective".
This item dealt with the inspecters' concern that welding discrepancies noted by Region II were not being identified by the licensee's field monitoring checklist for welding. The licensee agreed that the checklist appeared to indicate that the inspection surveillance program was not effective. However,
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this was primarily due to the limited scope of the checklist.
The licensee produced a number of discrepancy reports issued by surveillance inspectors during the past six months but not documented on the field monitoring checklist.
In addition, the licensee has recently established a separate QA surveillance inspection branch which is presently reviewing and revising checklists that appear inadequate.
Actions taken by the licensee appear adequate to identify welding discrepancies and to correct the cause of these discrepancies.
This item is considered closed.
7.
Safety Related Piping (Unit 1)
The inspectors observed welding activities for safety related piping as described below to determine whether applicable code and procedure requirements were being met. The applicable code for safety related piping is the ASME B&PV Code,Section III, Subsections NC and ND,1974 edition with addenda through winter 1976.
The inspectors observed in process welding activities of field welds as described below to determine whether applicable code and procedure requirements were being met.
a.
Welding The below listed welds were examined in process to verity work con-ducted in accordance with traveler, welder identification and location, welding procedures, WPS assignment, welding technique and sequence, materials identity, weld geometry, fit-up; temporary attachments, gas purging, preheat, electrical characteristics, shielding gas, welding equipment condition, it.terpass temperature, interpass cleaning, process control systems, qual-fications of inspection personnel, and weld history records.
Weld Number Size System 1-CX-77-FW-350 2.500" X 0.203" Chill Water Return 1-CX-77-FW-349 2.500" X 0.203" Chill Water Return 1-SW-33-6-SW-1 8.000" X 0.500" Service Water 1-SW-33-6-SW-2 8.000" X 0.500" Service Water 1-SF-111-FW-550 12.000" X 0.328" Spent Fuel b.
Welder Qualifications The inspectors reviewed the CP&L program for qualification of welders and welding 9perators for compliance with QA procedures and ASME Code requirements.
The following welder qualification status records and
" Records of Performance Qualification Test" were reviewed relative to the weld joints listed in paragraph no. 7.a:
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Welder Symbol Application B-7 Safety Related Piping C-98 Safety Related Piping B-61 Safety Related Piping A-60 Safety Related Piping c.
Welder Filler Material Control The inspectors reviewed the CP&L program for control of welding materials to determine whether materials are being purchased, accepted, stored, and handled in accordance with QA procedures and applicable code requirements. The following specific areas were examined:
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Purchasing receiving, storing, distributing, handling procedures, and material identification.
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Welding materials purchasing and receiving records for the following materials were reviewed for conformance with applicable procedures and code requirements:
Heat / Lot No.
Type Size 401P1661 E-7018 3/32" 05108 ER-308 1/8" 464802 ER-30S 3/32" Within the areas examined, no violations or deviations were identified.
8.
Reactor Vessel Installation The inspectors reviewed procedures and quality records to ascertain whether procedures, field activities and records pertaining to the installation of the reactor vessel were consistent with NRC requirements, applicable codes standards and commitments.
a.
Review of Quality Assurance Implementing Procedures The inspectors reviewed the below listed documents to determine whether provisions had been established relative to the reactor vessel, to assure conformance with applicable requirements for crane and rigging testing and vessel lif ting, installation and installation inspection.
No.
Title CP&L-AP-XIII-03, Rev. 11
" Receiving Identification and Inspection" CP&L-WP-7, Rev. 8
"Large Vessel and Equipment Off-Loading Procedure
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No.
Title (Continued)
RI-960-10, Rev. 2 RI-960-11, Rev. 0 RI-960-12, Rev. 2 CP&L-WP-119. Rev. 4
" Reactor Vessel Setting"
" Westinghouse Nuclear Energy Systems Mechanical Service Manual" -
Second Edition dated April 1,1978 Westinghouse "NSSS Component Receiving and Storage Criteria" Volume 1,
" Mechanical Equipment" dated March 1976.
CP&L-TP-04, Rev.17
" Calibration of Controlled Tools" CP&L-TP-28, Rev. 4
" Inspection of Equipment Installation" CP&L-WP-25, Rev. 7
" Field Engineering" CP&L-PGD-002(AP-XIII-07),
" Material Maintenance Requirements Rev. 17 During Storage for SHNPP" CP&L-AP-XIII-07, Rev. 14 In Storage Inspections and Maintenance" b.
Observation of Work and Work Activities The inspectors reviewed the documents indicated in paragraph 8.a and their associated records for the installed reactor vessel to determine whether the requirements of the applicable specifications, work procedures and inspection procedures were met in the areas of:
stored vessel protection and installation techniques, c.
Review of Quality Records The inspectors reviewed pertinent quality related work and inspection (QC) records relative to the reactor vessel to ascertain whether the records are in conformance with established procedures and whether they reflect work accomplishment consistent with applicable requirements in the areas of storage inspection and installation inspection.
With regard to the inspection above the inspectors, on April 16, 1982, noted the following discrepancies relatino to storage and preventative maintenance records for the reactor vessel.
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Most monthly inspections prior to July 1979 were indicated acceptable
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with check marks only.
After 1975 there is, however, one " performed by" signature for each year. At the time of this inspection, it could not be determined whether the " performed by" signatory perforned each monthly inspection.
At the time of this inspection, records of the performance of reactor
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vessel semi-annual warehouse storage inspection could not be retrieved.
At the time of this inspection, records of the performance of reactor
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vessel monthly storage inspection between March 31, 1980 and August 20, 1980 could not be retrieved.
i The above is part of unresolved item 400,401/82-11-01 discussed further in para,raph 9.c.
Within the areas examined, no violations or deviations were identified.
9.
Safety Related Components The inspectors reviewed procedures and quality records to ascertain whether procedures, field activities and records pertaining to the installation of i
safety related components were consistent with NRC requirements, applicable codes, standards, and commitments.
a.
Review of Quality Implementing Procedures The inspectors reviewed the below listed documents relative to the components indicated below to assure conformance with applicable requirements for crane testing and component lif ting, and installation:
Documents No.
Title CP&L-AP-XIII-03, Rev. 11
" Receiving Identification and Inspection" CP&L-WP-7, Rev. 8
"Large Vessel and Equipment Off-Loading Procedure" RI-960-15, Rev. 1 RI-960-16, Rev. O
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RI-960-17, Rev. 3 RI-960-20, Rev. 1 RI-960-21, Rev. O
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Documents No.
Title (Continued)
RI-960-22, Rev. 1 CP&L-WP-120, Rev. 3
" Setting the Steam Generator"
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CP&L-WP-121, Rev.1
" Pressurizer Setting" CP&L-WP-131, Rev.1
" Setting Reactor Coolant Pumps Phase
- 1 Loop A, B, and C" CP&L-WP-105, Rev. 6
" Installation and Inspection of Equipment (Safety Related Seismic Class 1 and NSSS)"
" Westinghouse Nuclear Energy Systems Mechanical Service Manual" -
Second edition dated April 1,1978
" Westinghouse - "NSSS Component Receiving and Storage Criteria",
Volume 1 " Mechanical Equipment" dated March 1976 CP&L-TP-04, Rev.17
" Calibration of Controlled Tools" CP&L-TP-28, Rev. 4
" Inspection of Equipment Installation" CP&L-WP-25, Rev. 7
" Field Engineering" CP&L-PGD-002(AP-XIII-07),
" Material Maintenance Requirements Rev. 17 During Storage for SHNPP" CP&L-AP-XIII-07, Rev. 14
"In Storage Inspections and Maintenance" Components l
Pressurizer
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Steam Generator B Loop Reactor Coolant Pump B Loop l
b.
Observation of Work and Work Activities
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The inspector reviewed the documents indicated in paragraph 9.a and their associated records for the installed safety related components indicated above, to determine whether the requirements of the applic-able specifications, work procedures and inspection procedures were met in the areas of:. storage; handling; protection; and installation.
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Review of Quality Records The inspectors reviewed pertinent quality related work and inspection (QC) records relative to the safety related components indicated above to ascertain whether the records were in conformance with established procedures and whether they reflect work accomplishment consistent with applicable requirements in the areas of storage inspection and installation inspection.
With regard to the inspection above, the inspectors on April 16, 1982,
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noted the following concerns relating to the storage and preventative maintenance recorde for the "B" steam generator and the pressurizer.
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Weekly inspections prior to July 1979 were indicated acceptable with check marks only. After 1976, for the pressurizer and all records for the
"B" steam generator have one " performed by" signa-ture for each year. At the time of this inspection, it could not be determined whether the " performed by" signatory performed each weekly inspection.
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The " Equipment In Storage Maintenance Sheet" (EISMS) for the "B" steam generator and the pressurizer do not reflect the require-ments of Westinghouse "NSSS Component Receiving and Storage Criteria" (NCRSC) in the following areas:
(1) Moisture Content of Purge NCRSC
"Less than -20 F dew point" EISMS
" Remove Excess Moisture"; and (2) Oxygen Content of Purge NCRSC
"Less than 500 PPM" (0.05's), EISMS
"Less than 5's.
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The EISMS requires that only unacceptable (greater than 5"4 0 )
oxygen analysis be recorded.
Therefore, it could not be deter 2 mined whether all the semi-annual oxygen analyses for the pres-surizer and all oxygen analyses before April 18, 1981 for "B" steam generator were acceptable or were not accomplished.
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At the time of this inspection, the records of the performance of maintenance inspections on the
"B" steam generators between May 4,1980 and January 2,1982 could not be retrieved.
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From the records provided at the time of this inspection, it could not be determined when the tube side and shell side purges were terminated for the "B" steam generator.
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The inspectors discussed the above concerns as well as those described in paragraph S.c with the licensee. The licensee indicated that they would evaluate the degree of degradation, if any,-to the steam genera-tors, pressurizers, and reactor vessels.
The inspectors stated that tne safety significance of the above would be determined upon the completion of the licensee's evaluation.
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identified as unresolved item 400,401/82-11-01:
" Adequacy of Storage Maintenance on NSSS Components".
Within the areas examined, no violations or deviations were identified.
10.
Safety Related Structures (Units 1 and 2)
This inspection was performed to review the 'icensee's practices and quality assurance records related to the installation of the mainsteam and feedwater restraint for Unit 1.
The mainsteam and feedwater restraints were fabricated in accordance with the 1971 edition of the ASME B&PV Code,Section III, with summer 1973 addenda, and ANSI B31.1, 1971 edition with summer 1973 addenda.
The inspection also included a review of Richmond Engineering Company's (RECO) work practices, quality records and imple-menting procedures for the manufacture of sa fe ty related boric acid tanks for Units 1 and 2.
The applicable code for the boric aci_d tanks is the 1977 edition of the ASME B&PV Code Section III Subsection NO with no addenda.
a.
Review of RECO Quality Assurance Implementing Precedures (Units 1 & 2)
RECO procedures were reviewed to determine whether NRC requirements and SAR commitments had been met.
Procedures which identify inspection hold points; provisions to assure that welding procedures and welding personnel are properly qualified in accordance 'with applicable
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requirements; provisions to assure that NDE techniques conform to applicable codes and have been qualified; provisions for cleaning Class 2 and 3 components;. provisions to insure that pneumatic,
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atmospheric and vacuum box - testing conform to requirements.
The following procedures were reviewed:
(1) REC 0 Visual Inspection Procedure ES-134, Revision 5
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(2) RECO Procedure for Repair of Weld Metal Defects ES-123N (3) RECO Procedure for Cleaning Class 2 and 3 Components ES-104NC-312, Revision 2 (4) RECO Radiographic Examination Procedure ES-106N, Revision 13 l
(5) RECO Liquid Penetrant Examination Procedure for Nuclear Items, ES-102-111, Revision 2 (6) RECO Pneumatic Testing Procedures ES-145, Revision 4
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(7) RECO Atmospheric Test Procedure ES-160NC, Revision 1 (8) RECO Procedure for Vacuum Box Testing ES-107-111, Revision 2 (9) RECO Inspect, ion Procedu';e ES'169 c
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. During review of Procedure ES-169, paragraph 3.0, the inspector noted that the QC inspector was.responsibYe for-marking the location of temporary attachment. Velds s priorito their being removed, blended and tested, if applicablet Subsequent inspection of the boric acid tanks revealed that fitters;were removing temporary attachments and blending the areas before the inspectors were able to trhrk the temporary attachments.
In addition,' areas that were marked were not marked in a suitable manner that prevented the marking frora being removed when the
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l attachment was removed. Maintaining controi of areas where temporarv attachments have been welded is imperative 09 Class 1 and 2 components where liquid penetrant inspection is reouired af ter the removal of a temporary attachment.
The boric acid taaks fabricated by RECO are Class 3 tanks and do not require r,enetrant inspection. RECO procedure
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ES-169, however, is applicable for inspection af Class 1, 2, and 3 components.
The QC inspector agraed to have procedure ES-169 revised to require the fitter to mark temporary attachadnt locations prior to welding. In addition, the procedure will requir'e the QC inspector to insure that attachments have been marked in a suitable manner so that
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subsequent grinding will not remove the markings.
This item was identified as inspector followup item 400,401/82-11-02:
" Procedure ES-169 Revised for Control of Temporary Attachments".
Within the areas examined, no violatiorys or deviations were observed.
b, Observation of Work and Work Activities The inspectors evaluated the licensee's work performance on structures and supports by direct observation of work in progress. The structures selected for-this inspection wer:e the Lioric acid tanks for Units 1 and 2 and the' supports examined were'the gainsteam feedwater restraints for Unit 1.
The. inspectors observed the in progress work to determine whether aslicable requirements, as well as work and inspection procedures, were being For had been) pet in the following areas:
r (1) Receipt inspec+ an u.d storagy,
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Installatir e-
'n (3) Use of spcf f.5 erials and components (4) Testing ane NDE
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Inspection and inspection records (6) Utilization of qualified NDE and irsdection (QC) personnel
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(7) Calibration and use of proper tesu equipment
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In addition to the work procedures reviewed in paragraph a., above
,in progress werk and work activities sere dw verified by the inspectors to be in conformance with the foiicvn,hg drawings:
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(1) RECO Job No. RCN 313 Dwg. D-81-9515, Revision 2, Boric Acid Tank Unit 1 (2) RECO Job No. RCN 314, Dwg. D-81-9574, Revision 2, Boric Acid Tank Unit 2 (3) Dwg./UF-1 Upper Frame - MS&FW, Restraint Structure Weldment (4)
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12F-1 Lower Frame - MS&FW Restraint Structure (5) Dw ? 2-AF-1 A-Frame Support MS&FW Restraint Structure c.
Review o-Quality Records (Units 1 and 2)
REC 0's quality records for the erection of the boric acid tanks (Tank Nos. RCN 313 and RCN 314) and CP&L's records for the er ection of the mainsteam and feedwater restraint structures were revie< ed to determine whether these records reflected work accomplished cons'; tent with NRC requirements and SAR commitments.
(1) Material records, including material certification records, vendor manufacturing and inspection certifications, radiographs and receipt inspection reports were reviewed. The inspector examined installation /crection records to determine if records reflected compliance with construction / erection specifications.
Inspection records were examined for completeness, legibility and retrievability.
Inspection personnel qualification records were examined to determine if they were current and reflected adequate qualifications for activities performed.
(2) RECO and CP&L nonconformance reports were reviewed to determine if the reports reflected current status, were legible and complete, reviewed by QC personnel, readily retrievable, and adequately described the nonconformance and status of the corrective action.
(3)
In addition, the following radiographs were reviewed:
(a) Job No. RCN 313 Boric Acid Tank Unit 1 Weld 7 Longitudinal 2 Spot 1 Weld 6 Girth 1 Spot 2 Weld 12 Longitudinal 1 Spot 3 Weld 6 Girth 1 Spot 4 Weld 6 Girth 1 Spot 5
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(b) Job No. RCN 314 Boric Acid Tank Unit 2 Weld 6 Girth 1 Spot 3 Weld 10 Longitudinal '
Spot 1 Weld 8 Longitudinal 2 Spot 2 Weld 6 Girth 1 Spot 5 Weld 6 Girth 1 Spot 4 Within the areas examined, no violations cr deviations were identified.
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