IR 05000410/1982005

IE Insp Rept 50-410/82-05 on 820510-0603.No Noncompliance Noted.Major Areas Inspected:Pipe Cold Bending,Hvac Ductwork, welding-piping,heat treating-piping,fuel Storage Pool & Structural Steel Welding

ML20054J665
Person / Time
Site:	Nine Mile Point
Issue date:	06/11/1982
From:	Kister H, Schulz R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I)
To:
Shared Package
ML20054J662	List: IR 05000410/1982005 ML20054J661
References
50-410-82-05, 50-410-82-5, NUDOCS 8206290401
Download: ML20054J665 (12)

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U.S. NUCLEAR REGULATORY COMMISSION Region I Report N Docket N A License N CPPR-il2 Priority

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Category Licensee: Niagara Mohawk Power Corporation 300 Erie Boulevard West Syracuse, New York 13202 Facility Name: Nine Mile Point, Unit 2 Inspection at: Scriba, New York Inspection conducted: May 10 to June 3, 1982 Inspector -

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.' D, Schulz, Resident Inspector ' date signed date signed

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date signed Approved by: Aj f,[//h '

H."BTKister',' Chief, Reactor Projects dat( signed Section 1C Inspection Summary:

Inspection on May 10 to June 3,1982 (Inspection Report No. 50-410/82-05)

Areas Inspected: Routine inspection by the resident inspector of work activities relative to pipe cold bending, HVAC ductwork, welding-piping, heat treating-piping, fuel storage pool, and structural steel welding. The inspector also performed plant inspection tours and reviewed licensee action on previously identified items. The inspection involved 74 inspector hour Results: No violations or deviations were identifie DR ADOCK 05000410 PDR Region I Form 12 (Rev. April 77)

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DETAILS 1. Persons Contacted Niagara Mohawk Power Corporation W. D. Baker, Construction E. F. Crispell, Lead Construction Engineer J. L. Dillon, Q. A. Engineer, Site Lead G. J. Doyle, Q. A. Technician P. E. Francisco, Nuclear Licensing Engineer E. Manning, Q. A. Technician C. H. Millian, Compliance and Verification R. A. Norman, Q. A. Supervisor G. Rhode, Vice President, System Project Management R. W. Smith, Jr., Construction Engineer J. Swenszkowski, Q. A. Technician Stone & Webster Engineering Corporation L. W. Brown, Superintendent of Construction R. L. Bunch, Q. A. Engineer D. Chatterton, Q. C. Inspector-Calibration S. W. Crowe, Assistant Superintendent Field Q. T. Dean, Q. C. Inspector J. Giler, Assistant Superintendent of Engineering R. Kelvin, Senior Q. C. Engineer E. A. Magilley, Assistant Superintendent Field Q. G. W. Pierce, Q. A. Site Supervisor A. H. Rovetti, Engineering Supervisor L. E. Shea, Superintendent of Engineering C. W. Spear, Senior Construction Engineer L. D. Theriault, Principal Piping Engineer J. Wilson, Q. C. Inspector Industrial Engineering Works G. Welde, Field Superintendent ITT Grinnell Industrial Piping, In A. C. Carter, Chief Welding Engineer D. R. Giguere, Q. C. Manager D. L. Grodi, Inspection Supervisor G. P. Henry, Engineering Technician J. Mageski, Receiving Supervisor G. McDonough, Senior Office Engineer L. Pela, Technical Supervisor

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2. Plant Tours The inspector observed work activities in-progress, completed work and plant status in several areas of the plant during general inspections of the plant. Particular note was taken of the presence of quality control inspectors and quality control evidence such as inspection records, material identification, nonconforming material identification, housekeeping and equipment preservation. The inspector interviewed craft personnel, supervision, and quality inspection personnel as such personnel were available in the work area No violations or deviations were identifie . Licensee Action on Previous Inspection Findings (Closed) VIOLATION, SEVERITY LEVEL V (82-01-02): Lack of a training program for ITT Grinnell engineering personnel regarding whip restraint ITT Grinnell established a training program for engineering personnel associated with whip restraint installations. The program consists of formalized training sessions and written examinations. This training assures that engineering personnel are proficient in their respective activities concerning whip restraints and Specification P301 (Closed) INFRACTION (80-11-01): Failure to follow procedures concerning incorporation of E&DCR's into drawings. The drawings have been revised to reflect current as-built conditions and drawings affected by E&DCR documents have been carefully examine Future surveillances will be done on a quarterly basis by the licensee to assure implementation complianc . Licensee Action on Bulletins and Circulars The inspector examined records and interviewed licensee personnel to verify action taken with respect to IE Circulars. For each Circular shown below, the inspector verified that the identified problem was resolved as indicated below:

(Closed) CIRCULAR 81-09, Containment Effluent Water that Bypasses Radioactivity Monitor. There are no direct flow paths from the containment to the environment except for the component cooling water system that does have an interconnection with the service water system. The component cooling water system isolates automatically on a high containment pressure isolation signa (Closed) CIRCULAR 81-02, Licensed Operators. Use of Unit 1 operators for training.

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l' (Closed) CIRCULAR'80-ll, Emergency Diesel Generator Lube Oil Cooler Failure The diesel generator lube oil cooler tubes used are rolled and not soldered in place but are held by tube holder , - - - .

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(Closed) CIRCULAR 80-15, Loss of Reactor Coolant Pump Cooling and Natural Circulation Cooldown. General Electric has responded to recommended action No's.1, 2, 3 and 5 and indicated that no problem exists. With regard to recommended action No. 4, there are two modes of cooling for each reactor --

recirculation pump: (a) Common reactor building closed loop cooling for both pumps; (b) Safety-related service water for which each division supplies cooling to its respective divisional reactor recirculation pump. The single

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failure analysis and seal failure identified in the Circular are being addressed as Item No. 29 of the TMI Action Pla No violations or deviations were identifie Cold Bending - Pipe 2 The inspector reviewed ITT Grinnell cold bending procedure CB-2-2, dated -

July 9,1980 and found it to be in compliance with the ASME Boiler and Pressure Vessel Code,Section III, with regard to qualification tests for -

bent piping. Qualification records were examined for the following field planners and associated piping: --

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Field Planner Size - Pipe Specification 534m 3/4" S/80 SA-106 GR. B 535m 1/2" S/80 SA-106 GR. B 535m 1" S/80 SA-106 GR. B 535m 1 1/2" S/80 SA-106 GR. B  ;;

535m 2" S/80 SA-106 GR. B

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The qualification records revealed several deficiencies detailed below:

_ Ovality measurements had not been recorded as required by cold bending procedure CB-2- Heat number traceability had not been maintained for the various sizes --

of pipe in field planner 535 The ovality tolerance (7%) was being applied to the thickness dimensio Fortunately, no safety related piping had been bent for production runs, -

only qualification tests had been performed. ITT Grinnell management was __

informed of these deficiencies and assured the inspector that corrective

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action would be taken. Subsequently, ITT Grinnell management requested additional bending qualification tests to be conducted. The inspector examined the pieces bent and the Conrac 255-RH bender. The Conrac machine was able to bend the piping well within the allowable tolerance Documentation of the bends, including ovality and thickness calculations, __

were in accordance with regulatory requirements, procedural requirements, and the ASME Boiler and Pressure Vessel Code Section III. The pipe bends were traceable to material certifications. The following qualification --

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records were found to be satisfactory:

Field Planner Size - Pipe Specification 582m 3/4" S/80 SA-106 GR. B 583m 1/2" S/80 SA-106 GR. B ,

583m 1" S/80 SA-106 GR. B 583m 1 1/2" S/80 SA-106 GR. B 583m 2" S/80 SA-106 GR. B -

584m 3/4" XXS SA-106 GR. B Due to prompt corrective action, this issue is resolve The inspector reviewed Stone & Webster Specification NMP2-P301C, Field Fabrication and Erection of Piping, Revision 2, dated May 21,1981 for cold bending and discovered a reduction in wall thickness allowance of 20%. ASME Boiler and Pressure Vessel Code,Section II, Part A, Ferrous Materials, states in SA-106 and SA-530 in part, "The minimum wall thickness of any point shall not be more than 12.5 percent under the nominal wall thickness specified." The 12.5 percent applies to furnished material onl The inspector requested the principal piping engineer for Stone & Webster to validate the basis of the 20% wall reduction allowance. After investigating the issue, the principal piping engineer told the inspector that the 20% wall reduction allowance was only for the qualification tests and that the 12.5 percent minimum wall reduction applied to all field pipe bends. Since qualification tests establish the capability of the bending process and the minimum wall is not verified for each field bend, the principal piping engineer's answer did not appear correct. The inspector requested the licensee to investigate the 20% wall reduction allowance and furnish actual design calculations to the resident inspector verifying the 20% figur One week later, Stone & Webster engineering responded to the licensee stating that the 20% figure was derived from practical application on other Stone &

Webster jobs and that at Millstone a 12% figure was first used but found to be impractical, due to 14% - 16% thinning in stainless bending, and the thinning requirement was raised to 20%. The inspector questioned whether this answer implied the 20% figure was reached because the bender was incapable of meeting the 12% design criteria. At that point in time,'the inspector requested a formal meeting with the licensee and re-stated the request for actual design calculations for the Nine Mile Point, Unit 2 site, as required by ASME Section III, ND-4223.1, ND-3641, and ND-3642, based on design system parameters for the site. In addition, the licensee requested Stone & Webster to clarify whether the 20% wall reduction allowance applied to nominal wall or 20% below the 12h% ASME reduction allowanc Subsequently, design calculations were presented to the resident inspector verifying the 20% wall reduction allowance based on design system parameters for the Nine Mile Point, Unit 2 site. The 12h% figure was not to be applied

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to field pipe bends. Stone & Webster issued an Engineering and Design Change Coordination Report explaining that the 20% figure applied to 20% below actual wall measurements. The licensee stated that future responses to the resident inspector from Stone & Webster engineering personnel would only be presented after thorough research to assure information. The inspector considers this issue resolve No violations or deviations were identifie . HVAC Ductwork The heating-ventilation and air conditioning ductwork inspection program was reviewed to ascertain that the licensee is implementing a program that is in conformance with Specification P413L, Ventilation and Air Conditioning System Ductwork, dated June 30, 1981, Revision 1. The following procedures and inspection plans were reviewed:

-- QAD-11.5 Ductwork Inspections, dated August 31, 197 QAD-7.ll, Sampling Inspection, dated September 4,198 Inspection P1an.N20P413LFA001, Ventilation and Air Conditioning System Ductwork, Revision C, dated April 15, 198 Inspection Plan N2QIPSUFB001, In-Process Surveillance of Construction Activities, Revision A, dated February 12, 198 The inspector discovered the following discrepancies in the ductwork inspection program: Handling and storage inspections required to be done weekly by inspection plan N2QCIPSUFB001 were being done monthly, Cleanliness inspections were required to be done weekly _ by inspection plan N20CIPSUFB001 but were required to be done prior to ductwork testing by inspection plan N20P413LFA001. The inspector and the Stone & Webster Field Quality Control inspector were unable to determine if cleanliness inspections needed to be done prior toiductwork installation Installation inspections required to be done weekly by inspection plan N2QCIPSUFB001, were being done randomly, but not on a weekly basi Location and orientation inspections required to be done weekly by inspection plan N2QCIPSUFB001 were being done randomly, but not on a weekly basi There appeared to be misunderstandings between Stone & Webster management

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personnel, who were determining inspection requirements thru inspection plans, and Stone & Webster field quality control inspection personnel, who were actually doing the ductwork inspection . .

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l The inspector also had concerns regarding inspection plan N2QCIPSUFB001, In-Process Surveillance of Construction Activities. This inspection plan had frequency codes for sampling designated as " weekly", " monthly" or

"as required". These designations appeared extremely general and the inspector finds these terms undefinable with regard to numeric samplin Since any inspection less than 100% is a sample by definition, these terms

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appear to be contradictory to Quality Assurance Directive 7.11, Sampling Inspection, Revision A, which states in part that when no specific sampling plan is identified, the size of the sample will be determined by an approved statistical sampling plan. The inspector has requested the licensee to review the ductwork inspection program discrepancies and the general sampling method frequency codes for clarification and corrective action, if require These issues will be examined in a future inspection period. (410/82-05-01)

l The inspector examined installations of safety related ducts, storage of ductwork, weld rod storage ovens, and marking of fire dampers including manufacturers name, model, serial number, and design conditions. Ductwork storage in the control room building appeared to need additional attention to preclude damage. One of the rod ovens did not have a rod oven thermometer attached but the oven was within acceptable temperature parameters and Stone & Webster took immediate action to attach a thermometer to the oven.

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The following ductwork inspection records were examined:

-- Expansion type anchor inspection reports

-- Welding inspection reports

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Installation inspection reports

-- Location and orientation inspection reports

-- Weld rod oven inspection reports No violations or deviations were identifie . Welding - Piping Actual welding conditions and conduct, the sequence of operations, and the use and documentation of welding materials were spot-checked. The inspector noted the preserce or availability of Q. C. welding inspectors and checked their inspection verification of hold point items on the weld data sheet The welders symbol was noted to be marked adjacent to each weld on the applicable spool piece. Welding was evaluated in accordance with ASME Boiler and Pressure Vessel Code,Section IX and alignment was evaluated in accordance with ASME Boiler and Pressure Vessel Code,Section II Specifically, the inspector observed end preparation, pre-weld cleanliness, pre-heat control, alignment, root pass, and final visual on the following systems:

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-- 4" Service Water Piping - Control Room Building

-- 18" Service Water Piping - Secondary Containment

-- 6" Reactor Core Isolating Cooling Piping - Secondary Containment

-- 18" Residual Heat Removal Piping - Secondary Containment

-- _16" High Pressure Core Spray Piping - Secondary Containment

-- 24" Residual Heat Removal Piping - Suppression Pool

-- 12h" Main Steam Safety and Relief Valve Vents and Drains Piping -

Suppression Pool

-- 3" Chilled Water Piping - Control Room Building

-- 2 " Service Water Piping - Secondary Containment

-- 12" Service Water Piping - Secondary Containment The inspector reviewed welding material certifications as detailed below:

Type Size Heat N Lot N E7018 3/32" 60902 026B610 E7018 3/32" 432N1741 2F130W01 E7018 1/8" 402J5671 2J905T02 E7018 1/8" A83665 026B206 E7018 3/32" 432C1391 026B81 E7018 3/32" 09M288 5621NlAC E7018 3/32" 431X1681 A704P1AC E7018 1/8" 08M639 C70lNIAD E7018 5/32" L00610 026B303 E70S-2 1/8" 055230 05G15 E309-16 1/8" 21716 3287126 The certifications were in accordance with the ASME Boiler and Pressure

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Vessel Code, Section 2, Part C and Section 3.

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The inspector observed that the Main Steam Piping- that is to be welded to the primary containment penetrations is correctly positioned and within a short period of time welding will commenc No violations or deviations were identifie . Heat Treating - Piping The inspector reviewed ITT Grinnell Heat Treating Procedure, HT-K-311-7, dated October 16, 1980 for compliance with ANSI B31.1 and Project Specification NMP2-P3010, Field Fabrication and Erection of Piping,

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. 9 Revision 2, dated May 21, 1981. Preheating and post heat treating -

instructions were specified as required. Various main steam and feedwater field planners were reviewed and appropriate preheat and post heat treating parameters were correctly designated, taking into consideration carbon content of materials and casting product types. The inspector did note that wall thicknesses are not specified in field planners. The inspector commented that wall thicknesses are important in determining heating and i

cooling rates and their specification in field planners would be helpful j in determining heat treating rate Project Specification NMP2-P30lc states in part in Section 5, under Special Requirements, that Stone & Webster Class 4 Main Steam, Auxiliary Steam, and Turbine Generator Gland Seal and Exhaust Steam Systems noted as Category I (safety-related) on the piping arrangement drawings, shall be supplied to I the Quality Assurance Program - Category I. Certain portions of these systems may require additional nondestructive examinations and heat treatment inspections. The inspector reviewed the piping arrangement drawings and noted the Category I assignment on the Main Steam and Auxiliary Steam drawings, but was unable to determine the applicability of the Category I designation on the Turbine Generator Gland Seal and Exhaust Steam drawings. Also, drawing EP-36C-5, used by quality control and engineering was extremely difficult to read. The inspector asked the Stone & Webster principal piping engineer for clarification and after reviewing the drawing, the piping engineer was also unable to determine the applicability of the Category I designation on drawing EP-36C-5. Subsequently, Niagara Mohawk was able to identify the Category I designation from the drawing as it applied to the specific component part This information was communicated to ITT Grinnell by the inspector and their in process isometric 37-9, Revision 5, which had not picked up the Category I designation, was then correctly noted. The inspector considers this item resolved, but Stone & Webster drawing clarity appears to need additional attentio No violations or deviations were identifie . Fuel Storage Pool The objective of this part of the inspection was to determine that the fabrication of the fuel storage poo! liner was in accordance with Specification NMP2-P283V, Revision 1, dated September 2,1981. The following drawings were checked for material specifications, layout, and welding details:

-- 12177-EV-3A-3, Fuel Storage Pool Liner General Arrangement

-- 12177-EV-3B-3, Fuel Storage Pool Liner West Wall

-- 12177-EV-3C-2, Fuel Storage Pool Liner East Wall

-- 12177-EV-3D-3, Fuel Storage Pool Liner South Wall

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12177-EV-3E-3, Fuel Storage Pool Liner North Wall

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-- 12177-EV-3G-2, Fuel Storage Pool Liner Floor Plates

-- 12177-EV-3T-2, Fuel Storage Pool Liner Wall and Floor Details Material certifications for the following parts were reviewed and found to be in compliance with Specification NMP2-P283V requirements:

-- Liner Plates - ASTM A240 Type 304 - solution annealed and water quenched

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Stiffeners - ASTM A36 (outside walls)

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Nelson Studs - ASTM A108 GR.1016

-- Tell Tale Drain - " pipe - ASTM A312TP304 - solution annealed and water quenched

- h" coupling - ASTM A182 Type 304 - solution annealed and water quenched

- h" plug - ASTM A182 Type 304 - solution annealed and water quenched

-- Welding Wire - ER 309 and ER 308 including delta ferrite conten An inspection was made of the fuel storage pool liner located in place at elevation 315' . Horizontal and vertical plate seam welds were examined, as were structural support weld Stone & Webster field quality control personnel were documenting inspections verifying that welders were qualified to perform the specific weld detail they were completing. Quality Control welding inspection reports were reviewed for plate liner welds, stiffener welds, and tell tale drain weld A Stone & Webster Senior Field Quality Control Inspector was interviewed with regard to the fuel pool liner-component parts, welding, nondestructive examination, and leak tests. The Stone & Webster inspector was cognizant of procedural requirements and knowledgeable in Specification P283V and the applicable ASME Code Welder's qualifications were examined and found to be in compliance with ASME Boiler and Pressure Vessel Code,Section IX,1974. All welders who are employed at the Nine Mile Point, Unit 2 site have to pass welding tests, as transfer of qualifications from other projects has not been allowe . Welding tests are witnessed by quality control personnel certified in accordance with SNT-TC-1A. Welder qualification records indicated that welders who fail qualification tests can take a retest the same day without making "two" consecutive test welds.~for each position as required by QW-318.1, ASME Boiler and Pressure Vessel Code,Section IX, under the classification of Immediate Retest. The retest, even though the same day, is not considered imediate and therefore, does not fall under the requirements of QW-318.1, and only "one" test weld is done. The inspector requested the licensee to

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.. , 11 address whether this practice meets the intent of ASME B&PV Code,Section IX, QW-318. Subsequently, the licensee instituted a change whereby either two test welds will be done for retests or training adequacy will be verified by quality control. The inspector considers this issue resolve Welds on the water side of the liner must be examined by a liquid penetrant test in accordance with ASME Section V, Article 6. The inspector randomly selected welds on the water side and reviewed the documentation verifying acceptable penetrant testing in accordance with ASME Section V, Article 6, including traceability of penetrant materials used. Additionally, the inspector verified that penetrant testing on the skimmer tanks was in accordance with ASME Section V, Article Lastly, the inspector examined leak test procedure QAD-9.72, Pressure Differential, Bubble Testing for compliance with ASME Boiler and Pressure Vessel Code, Section 5, Article 10 and zone leak test reports for the liner welds. The leak testing is done by zones as the fuel pool liner is divided into four zones. The leak test performed and the associated documentation reviewed was the first test done, while the liners were preassembled on the ground. There are two remaining leak tests to be done, one before placement of wall concrete and the other after placement of wall concrete. Leak testing was accomplished in accordance with Specification P283V and Code requirements. The pressure gauges used were calibrated prior to the tes No violations or deviations were identifie . Structural Steel Welding The inspector witnessed fit-up and welding on various structural steel components. Q. A. inspection of fit-up and final weld criteria were noted and construction controls over the welding sequence, care of the base metals, and knowledge of the proper quality criteria were eviden The following structural steel joints were examined:

Components Location Joint Type Beams A6864 to A6710 Reactor-Primary Full penetration with-backing Elevation 278'6" bar. Prequalified joint-TCU4d Beams A6864 to A6714 Reactor-Primary Full penetration with backing Elevation 278'6" bar. Prequalified joint-TCU4d Beams A6847 to A6712 Reactor-Primary Full penetration with backing Elevation 288' bar. Prequalified joint-TCU4d Beams G6923 to A6222 Reactor-Primary 3/4" Fillet weld one side Elevation 278'

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Components Location Joint Type l Beams B6862 to A6714 Reactor-Primary Full penetration with backing Elevation 278' bar. Prequalified joint-TCU4d Beams A6658 to B6951 Reactor-Primary Full penetration with backing Elevation 278' bar. Prequalified joint-TCU4d Top Plate G6796 to Reactor-Primary 3/4" Fillet weld three sides Beam B6814 Elevation 288'

Top Plate G6796 to Reactor-Primary 7/8" Fillet weld two sides Beam D6796 Elevation 288'

Top Plate G6796 to Reactor-Primary 3/4" Fillet weld three sides Beam E6807 Elevation 288'

All of the structural welding was evaluated with regard to AWS Dl.1-77, approved drawings, and welding detail sheet No violations or deviations were identified, 11. Management Meetings At periodic intervals during the course of this inspection, meetings were held with senior plant management to discuss the scope and findings of this inspection. The licensee acknowledged the inspectors concern _ _ _ _ - _ _ _ _ _ _ _ . _ _ _ ___