IR 05000410/1983005
| ML20024A846 | |
| Person / Time | |
|---|---|
| Site: | Nine Mile Point  |
| Issue date: | 06/10/1983 |
| From: | Gramm R, Kister H, Schulz R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML20024A838 | List: |
| References | |
| 50-410-83-05, 50-410-83-5, NUDOCS 8307010036 | |
| Download: ML20024A846 (11) | |
Text
.
.
.
- - - _ _ _ _ _ _ _ _
.
.
U. S. NUCLEAR REGULATORY COMMISSION
REGION I
,
Report No.
83-05 Docket No.
50-410 License No.
CPPR-112 A
--
Priority Category Licensee:
Niagara Mohawk Power Corporation 300 Erie Boulevard West Syracuse, New York 13202 Facility Name:
Nine M.ile Point, Unit 2 Inspection At:
Scriba, New York
-
Inspection Conducted:
April 25 to May 27,1983
'
[o[/ Oft Inspectors:
o
.'D. SEhd11, Senior Resident Inspector
'd fe 0 Ww
[R.'A. Gramiii, Resident Inspector b /c
' datfe date Approved by:
[o ([fo[Q H.'B. Kistr% Chief, Reactor Projects Section 2C
' datie e
'
Inspection Summary:
Inspection on April 25 to May 27,1983 (Report No. 50-410/83-05)
Areas Inspected:
Routine inspection by the senior resident inspector of work activities relative to reactor recirculation piping, primary containment liner plates, procurement program, nonconformances/ corrective action, quality assurance /
quality control personnel, instrumentation tubing supports, safety-related piping, and pipe supports. The inspector was accompanied by the next prospective resident inspector from May 9-13, 1983, and the inspection activities included piping and supports, facility status, and familiarization tours. The inspection involved 131 hours0.00152 days <br />0.0364 hours <br />2.166005e-4 weeks <br />4.98455e-5 months <br />.
Results: Two violations were identified:
Failure to identify nonconforming trends for causal indications and take subsequent corrective action (paragraph 6), and Failure to make welds in accordance with drawing requirements (paragraph 8).
Region I Form 12 (Rev. February 1982)
8307010036 830615 PDR ADOCK 05000410
PDR-
,
.-
- - - _ -
..
-,
- -
-.
-
-
.. -.
-.
.
.
DETAILS
.
1.
Persons Contacted
Niagara Mohawk Power Corporation W. D. Baker, Construction Engineer M. A. Balduzzi, Assistant Q. A. Engineer
-
J. L. Dillon, Q. A. Supervisor L. G. Fenton, Q. A. Engineer J. P. Ptak, Manager of Construction, Site J. Swenszkowski, Lead Mechanical Q. A. Engineer Johnson Controls, Inc.
'
R. Askew, Q. C. Inspector H. Washington, Q. C. Inspector V. Williams, Q. C. Inspection Supervisor
Stone & Webster Engineering Corporation R. Bolick, Senior Q. C. Inspector J. A. Burgess, Q. C. Assistant Superintendent T. Dean, Senior Q. C. Inspector
-
T. J. Dougherty, Q. C. Inspector
'
D. O. Gibscn, Senior Q. C. Engineer R. J. Huggon, Q. C. Engineer
'
G. E. Martin, Purchasing Agent J. C. Thompson, Superintendent of Field Q. C.
Reactor Controls, Inc.
i R. Hall, Q. C. Inspector B. Kienlen, Q. C. Inspector ITT Grinnell Industrial Piping, Inc.
S. Ansbrow, Personnel Administrator R. Banks, Documentation Supervisor M. Henn, Lead Auditor J. Padgett, Q. C. Inspection Supervisor C. Wandell, Senior Q. C. Inspector 2.
Plant Tours The inspectors observed work activities in-progress, completed work and plant status in several areas 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, nonconfoming material identification, housekeeping and
I n-
-- --,.,,
- -- -,,- -----, e
.,-n
...,,-
, -,
,
,- - ---
,,v.
-- --
.
.
equipment preservation.
Craft personnel, supervision, and quality inspection personnel were interviewed as such personnel were available in the work areas.
No violations were identified.
3.
Reactor Recirculation Piping The inspector observed work in-process on 12" reactor recirculation piping for recirculation loop B.
Examinations involved the weld end details, fit-ups, purge dam, and root pass gas-tungsten arc welding for weld #12B, joining a discharge closure spool to the discharge header at elevation 279' in the primary containment. The work in-process was done in accordance with General Electric procedures and the ASME Boiler and Pressure Vessel Code.
The following documentation associated with weld #12B and the discharge closure spool was reviewed:
1)
NPP-1 Data Report for the discharge closure spool identified as G012-B-210-2, 2)
Receipt Inspection Report for the closure spool.
3)
General Electric weld end detail drawing 137C5056.
4)
General Electric Procedure 22A6793, Machining and Templating.
'
5)
Procurement document to Industrial Precision Products, Inc. for machining of weld end details.
6)
Training record of machinist.
7)
Machining inspection report - weld shrinkage taken into account in detennining dimensions, as the nominal weld shrinkage is.250" for 8" to 12" spools.
8)
Calibration records traceable to the National Bureau of Standards for dial calipers, gauge blocks, and micrometers used for dimensional checks.
Dimensional checks included land length, land thickness, C dimension, counterbore angle, counterbore length, and prep thickness.
9)
Penetrant test reports of machined surfaces as required by ASME Boiler a:.d Pressure Vessel Code,Section III, NB-5130.
10) Chemical analysis of penetrant materials for halogen and sulfur content to ASTM E-165-75, paragraph 7.1 and ASME Boiler and Pressure Vessel Code,Section V, Paragraph T-63 _ _ ___
.
.
,
11) General Electric Procedure 22A6792, Installation Instruction for GE Piping Systems.
12) Material test reports for consumable insert ring and GTAW weld metal, including Ferrite Schaeffler of 11.0% as required by ASME Boiler and Pressure Vessel Code,Section V, NB-2400.
13) Weld data report - groove weld with insert.
14) Qualifications for Level II inspector, ANSI N45 2.6, SNT-TC-1 A (penetrant).
No violations were identified.
4.
Primary Containment Liner Plates Overlay plates welded to the primary containment liner, both in the suppression pool and drywell, were examined. The plates are designed to be the attachment point for either electrical, structural, piping or monorail supports.
In the suppression pool, the stainless steel wallpaper attached to the (liner or knuckle) was removed by arc gouging and grinding per Engineering Design and Ccordination Report #F00766.
The surrounding stainless steel wallpaper was then seal welded to the liner and the stainless steel overlay plate was attached to the liner by a stud weld in the center and a fillet weld around the entire plate.
The fillet weld and seal weld involve dissimilar materials since the liner is carbon steel, while the wallpaper and overlay plates are stainless steel.
In the drywell, the overlay plate is carbon steel and was attached directly to the carbon steel liner by a center stud weld and an all around fillet weld. The dissimilar welds in the suppression pool were penetrant tested and the welds in the drywell were magnetic particle tested.
Installations were in accordance with the ASME Boiler and Pressure Vessel Code and the applicable drawings.
The following documentation was reviewed:
Drawings 12177-EV-lDY-2 and 12177-EV-1EJ-1.
--
Material certifications for the overlay plates.
(SA-537CL.1 -
--
drywell, SA-240, Type 304 - suppression pool).
Inspection reports for the stud welds.
--
Penetrant test reports for the plug weld removal areas which joined
--
the wallpaper to the suppression pool liner.
Inspection reports for the seal welds.
--
Penetrant test reports for the seal welds.
--
Inspection reports for the overlay plates fillet welds.
--
,
_ _ _ _ _ _ _ _ _ _.__- - ___-___-_________________ _ _
_
_
__
o
.
Penetrant test reports on the overlay plates fillet welds in
--
the suppression pool.
Magnetic particle test reports on the overlay plates fillet welds
--
in the drywell.
Certifications for the E309 and E7018 weld rod.
--
Welder qualifications.
--
--
Welding Technique Sheets.
No violations were identified.
5.
Procurement Program The procurement program was reviewed to ascertain its conformance with regulatory requirements and cannitments in the Stone & Webster Quality Assurance Program. Procurement documents were checked for technical requirements, QA program requirements,10 CFR 21 provisions, and specific identification of items. Procedures were reviewed and responsibilities were assigned in writing for: a) initiation of procurement documents b) review and approval of procurement documents c) making changes to procurement documents and d) basis for classification of procurement items. An approved vendors list was examined.
Procurement documents for various disciplines were checked, along with the supplied materials documentation verifying that the received items conformed to the procurement documents. The following purchase orders and associated documentation were included in the review:
Procurement Document FP0 No.
Product Type 17721 structural steel 17723 pipe 17739 unistrut 17733 unistrut 17673 unistrut 17516 unistrut 18097 bolts / nuts 18078 aipe 18112 bolts / nuts 17741 pressure gauge 17747 ultrasonic gauge 18175 elbows 17782 plate 17829 penetrant, developer 17837 deadweight tester 17847 weld rod 17920 structural steel 17921 pipe, fittings 17922 fittings 17926 pipe
_ _ _ _ _ _ _ _ _ _ - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ - - _ _ _ _ _ _ _ _ _ _
- _ _ _ _
_ _ _ _ _ _ _ _ _ _ _ - _ _ _ _ _ _ _ _ _
- _ _ - _ _ _
_.
.
.
.
Procurement Document FP0 No.
Product Type 17928 structural steel 18090 bolts 18181 pipe 18209 bolts / nuts 14357 unistrut 11727 plate
,
16332 plate
{
14048 bolts / nuts l
Procurement document FP0-17739 was placed with Unistrut Buffalo, Inc.
on March 25, 1983 for unistrut stainless steel pipe clamps. The order stated that the pipe clamps shall be ASTM A240, type 304, but no documentation certifying to ASTM A240, type 304 was required to be furnished. An Engineering and Design Coordination Report #F00696 deleted the documentation requirement.
Deleting the documentation requirement appears to be contrary to procurement requirements for installed pipe clamps. The clamps had not been received on site as of April 26, 1983.
Pending review by the licensee prior to installation, this issue will remain unresolved (410/83-05-01).
Procurement document FP0-17723 was placed with Hub, Inc. on March 14, 1983 for 20" SA-106 GR. B seamless, ASME Boiler and Pressure Vessel Code, l
Class 1, Section III-NB pipe. The order did not specify the nondestructive l
examination method to be used in accordance with Section III, NB-2551.
i Section III, NB-2551 states that any one of four nondestructive examination i
methods may be used including ultrasonic, radiography, magnetic particle or liquid penetrant, and eddy current.
It is not practical or meaningful to examine certain product types by ultrasonic examination or eddy current.
For example, eddy current examination is generally effective only on tubular products less than 3/16 inch thick. Therefore, stipulating a specific nondestructive examination method would appear to be beneficial in eliminating any possibility of error or defect. The 20" SA-106 GR. B pipe had not been received on site as of April 26, 1983.
Pending review by the licensee prior to installation, this issue will remain open (410/83-05-02).
Overall, the program appeared adequate. No violations were identified.
6.
Nonconfomances/ Corrective Action Stone & Webster nonconformance and disposition reports written from February 1,1983 to April 12, 1983 were reviewed for corrective action and design basis disposition.
No violations were identifie.
.
ITT Grinnell deviation reports written from February 3,1983 to March 1,1983 and from April 9,1983 to April 16, 1983 were also examined for corrective action and design basis disposition.
ITT Grinnell procedure QCI 10.1.5, Category I, Deviation Report Root Cause Analysis, dated September 20, 1982, was included in the review.
Procedure QCI 10.1.5 states in part that the QA Manager or his designee will evaluate deviation reports for nonconfoming trends and will issue a Corrective Action Report when a trend is identified.
ITT Grinnell quality control personnel appeared proficient in identifying nonconfoming conditions but the QA Department was deficient in adhering to procedure QCI 10.1.5 regarding identification of repetitive conditions, issuance of corrective action reports, and trend analysis as detailed below:
1)
Fifteen deviation reports were written from February 11, 1983 to February 24, 1983 which identified undersize or undercut hanger welds under the jurisdiction of the ASME Boiler and Pressure Vessel Code.
The trend analysis perfomed, however, did not identify the repetitive condition. The fifteen deviation reports identified ninety-five deficient welds and were designated by the following numbers and corresponding dates:
- 3816 - 2/11/83, #3817 - 2/11/83, #3818 - 2/11/83, #3819 - 2/11/83,
- 3826 - 2/12/83, #3827 - 2/1/83, #3859 - 2/22/83, #3860 - 2/22/83,
- 3861 - 2/22/83, #3862 - 2/23/83, #3863 - 2/23/83, #3874 - 2/24/83,
- 3875 - 2/24/83, #3876 - 2/24/83, #3877 - 2/24/83 2)
Trend analysis was done from October 1982 through February 1983 but Corrective Action Reports were not issued by the QA Manager or his designee identifying numerous repetitive nonconfomances. The Quality Assurance Department's failure to issue a single Corrective Action Report for repetitive nonconformances appeared to be the result of insufficient resources.
3)
Deviation reports were not analyzed for nonconfoming trends by the QA Manager or his designee for the months of March or April 1983.
Again, this analysis apparently was not done due to an inadequate number of personnel assigned to the QA function.
Failure to identify trends for causal indications and take subsequent corrective action to preclude repetition is a violation of 10 CFR 50, Appendix B, Criterion XVI (410/83-05-03).
7.
Quality Assurance / Quality Control Personnel The purpose of this inspection was to detemine if ITT Grinnell has an adequate number of qualified quality discipline personnel to assure that all piping safety-related activities are being correctly performed.
Personnel records for those individuals hired within the last two months,
l
. _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ - _ _ _ _ _ _ _ _ _ _ _ _ _
___
.
.
who are perfonning inspection activities, were examined for qualific'ation compliance to Regulatory Guide 1.58 and ANSI N45 2.6, 1978.
Interviews and record reviews resulted in the following observations:
1)
Personnel hired within the last two months met the education and experience requirements of ANSI N45 2.6, 1978.
2)
Although ITT Grinnell has lost nine people within the last two months, fourteen additional people have been hired and overall the Quality Control Department has been upgraded.
3)
The Quality Assurance Department appears to be understaffed taking into consideration the responsibilities and duties required by the Quality Assurance Program.
The licensee has been requested to address ITT Grinnell's personnel situation in the Quality Assurance discipline as it relates to optimum surveillance of safety-related functions.
Pending licensee review, this issue will remain open (410/83-05-04).
No violations were identified.
8.
Instrumentation Tubing Supports The inspector examined five instrumentation tubing supports installed in the north auxiliary bay. The supports were identified on the following Stone & Webster drawings:
12177-BZ-410-ME-1 12177-BZ-410-MG-1 12177-BZ-410-EA-1 12177-BZ-410-JJ-1 12177-BZ-410-FR-1 The planner packages for the supports were reviewed and instructions to the craftsmen were considered adequate taking into account such factors as requisitioning material from storage, transferring heat numbers for material traceability, requesting weld filler metal, preparing surface to be welded, and the welding operation. The supports were stamped with the welders identification number and the identification number of the stand. Welder's qualifications and the welding procedure qualification were in accordance with ASME B&PV Code,Section III and Section IX.
Materials were traceable to certified material test reports and the test reports met the specification requirements. Quality control inspection hold points included verification of base metal identification, weld rod identifications, visual acceptance of weld, and final installation acceptance. The qualifications for supports 410-EA-1 and 410-JJ-l were reviewed and found to be acceptable.
_ _ _ _ _ _ _ _ _.
_______
.
. _.. -
-.
-
.._. -
- -
!
.
.
,
.
,.
- The installations for 410-EA-1, 410-JJ-1, and 410-FR-1 were in
.
accordance with the drawings, including the welding details. The welds included flare bevel welds and fillet welds.
Instrument tubing supports 410-ME-1 and 410-MG-1 required 3/16" flare bevel welds, 3" long on 9" centers, near side and far side, symmetrical about the center line of a 12" long embedment plate. This welding requirement, connecting tube steel to an embedment plate, was stipulated i
on drawings 12177-BZ-410-ME-1 and 12177-BZ-410-MG-1. The inspector discovered, while examining the 3/16" flare bevel welds, that they were i
not in compliance with the drawings. The flare bevel welds for tubing support 410-ME-1 consisted of a 3" long weld located in the center of i
the plate and 2" long welds at each end of the plate, on 5" centers.
The welds had been accepted by quality control on April 29, 1983. The flare bevel welds for tubing support 410-MG-1 consisted of a 3" long weld located in the center of the plate and 1 3/4" long welds at each end of the plate, on 5" centers. The welds had been accepted by quality control on May 2, 1983. This condition is a violation of 10 CFR 50,
Appendix B, Criterion V since the welds were not in accordance with the drawings with regard to length and centers. (410/83-05-05)
i j
9.
Safety-Related Piping l
The following attributes were spot-checked during the installation of piping components:
Weld preparation
--
Alignment
--
Root pass
--
l Final visual
--
f Material identification - spool pieces and welding materials
--
The inspector noted the presence or availability of Q. C. welding inspectors
'
and checked their inspection verification of hold point items on the weld data sheets.
.
,
Specifically, the inspector examined the following weld joints and
,
i associated spool pieces for drawing and specification conformance:
ASME Piping
,
System _
Isometric Weld No.
Class _
Spec.
Residual Heat Removal 66-19 010
901 I
Residual Heat Removal 66-10 007
601 High Pressure Core Spray 25-4 012
153 l
__-_m,-
9---w-w-sw---------em-n.,
v-
- -
g.
p-p
.
g,-s9,
+-=,y..,c..,,_,_,,,m9
__c%_
g,.,j,,,,,,7
.m,,+-mew +
we'-=-W-wwye-=e---r7--'rw--T'--'?NN
~e*w eryvy
-
.
...
_
_
,
,
.
ASME Piping System Isometric Weld No.
Class Spec.
Residual Heat Removal 66-7 00lR1
301 High Pressure Core Spray 25-13 006
911 High Pressure Core Spray 25-5 002
153 Residual Heat Removal 66-24 007
311 Reactor Bldg. Floor Drains 31-5F 006
153 Residual Heat Removal 66-51 002
901 Service Water 21-132 011
151 Residual Heat Removal 66-25 004R1
311 Residual Heat Removal 66-31 012
901 No violations were identified.
10. Pipe Supports Several main steam safety and relief valve vents and drains pipe supports located in the primary containment and service water pipe supports located in the secondary containment, south auxiliary bay, and service water tunnel were examined for the following attributes:
Welding
--
'
Configuration
--
Offset and tolerance gaps
--
Traceability of pressure boundary components
--
The installations were found to be in accordance with the drawings and associated engineering and design change coordination reports with the following exceptions, which will remain unresolved pending licensee review:
1)
ITT Grinnell quality control inspectors have been accepting tolerance gaps between pipe and supports prior to the pipe being permanently set. A procedure has not been established stipulating that these tolerance gaps will be re-examined after permanent pipe setting.
.
This method does not appear to assure that tolerance gaps will remain-(
correct after final acceptance with Q. C.
(410/83-05-06)
2)
Variable spring support-12177-BZ-19GP-1 did not appear to be set correctly en the structural steel, resulting in only 5" of weld metal deposit instead of a possible 8" of deposit along the base of the
<
support. This installation requires clarification by the design i
engineer (410/83-05-07).
No violations were identified.
i I
w-
- - - -
-c
-,,
.--,.e-
,
-n,-,
n-
- - - -
r v,
.
.
11. Unresolved Items
<
Unresolved items are matters about which more information is required in order to ascertain whether they are acceptable items, violations or deviations. Unresolved items disclosed during the inspection are discussed in paragraphs 5, 7, and 10.
!
12. Management Meetings i
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 findings and concerns.
.
i
)
i I
,
k i
t
-
-
n,
- -
,
--
,,
.-n
. -
,
-