IR 05000412/1980010
| ML19351G009 | |
| Person / Time | |
|---|---|
| Site: | Beaver Valley |
| Issue date: | 12/30/1980 |
| From: | Feil R, Mattia J, Varela A NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML19351G005 | List: |
| References | |
| 50-412-80-10, NUDOCS 8102200772 | |
| Download: ML19351G009 (8) | |
Text
,
.
O U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT Region I Report No. 50-412/80-10 Docket No. 50-412 License No. CPPR-105 Priority
--
Category A
Licensee:
Duouesne Licht Company 435 Sixth Avenue Pittsburgh, Pennsylvania 15219 Facility Name:
Beaver Valley Power Station, Unit 2 Inspection at:
Shippingport, Pennsylvania Inspection condu e
December 2-4, and 9-11, 1980 Inspectors:
'IL M N V
/A[JJ / h R. Feil, deactor Ir(spector ddte signed
~
(!
n) b.
tz /3'c /fr A. Yarela, Reactor Inspector d' ate ' signed L
-
date signed
/'t/jc//c Approved by:
u
'
'
h J. C. Mattia, Acting Chief date' signed
Projects Section, RC&ES Branch i
Inspection Summary:
Inspection on December 2-4, and 9-11, 1980 (Report No. 50-412/80-10)
'
Areas Inspected:
Routine, unannounced inspection by two regional based inspectors of concrete placement records, status of shear wall design deficiency, status and procedural review on movement and repair of neutron shield tanks, review of records on cranewall repair in reactor building and review of outstanding items.
The inspection involved 42 inspector hours on site by two regional based inspectors.
Results:
No items of noncompliance were identified.
l t
i l
8102200 [ b R
Apr 7)
l
.
_
.-
.
_
, _ - -...,
_.
__--
- -
- -..
.
-
.
.
DETAILS 1.
Persons Contacted Duquesne Light Company (DLC)
- Mr. R. Coupland, Director of Quality Control
- Mr. H. N. Crooks, Assistant Director of Quality Control
- Mr. C. R. Davis, QA :ngineer
- Mr. D. W. Denning, Assistant Director of Quality Control
- Mr. W. H. Glidden Sr., QA Engineer
- Mr. F. J. Heck, QA Engineer
- Mr. R. J. Swaderski, Site Construction Manager Mr. H. A. Van Wassen, Project Manager (Telephone Contact)
Mr. A. Azzinaro, Senior Field Engineer
- Mr. W. H. Bohlke, Project Manager
- Mr. W. W. Chaisson, Site Engineer
- Mr. R. J. Faust, Structural Engineer Mr. K. Fellers, Welding Specialist, Construction Mr. N. Mcdonald, Rigging Specialist - Boston
- Mr. A. C. McIntyre, Head, Site Engineering Office (SEO)
Mr. P. Raysircar, Project Engineer - Boston
- Mr. R. H. Tarr, Support Engineer - SEO
- Mr. H. W. Thomas, Assistant Superintendent of Construction
- Mr. J. E. Williams, Resident Manager Dick Corporation Mr. T. Everett, Resident Engineer Mr. A. Cafurdi, QC Engineer
- denotes those present at December 4, 1980 exit interview.
- denotes those present at December 11, 1980 exit interview.
- denotes those present at both December 4 and December 11, 1980 exit interviews.
The inspectors conferred with other licensee and contractor personnel during the course of the inspection.
.
, _
. _ - - -
,_
.
.
2.
Facility Tour The inspectors observed work activities in progress, completed work and plant status in several areas of the fac'lity during the course of the inspection.
Presence of quality control inspectors, quality control records, conformance with procedural requirements and equipment preservation was observed.
The inspectors conferred with craft personnel, supervision and quality inspection personnel as such personnel were available in the work areas.
Specific activities observed by the inspectors in civil / structural work included preparations for concrete placements for the safeguards building walls above elevation 750, the fuel transfer canal and fuel storage area walls, and concrete cure and finish of containment interior slab at eleva-tion 767.
The inspectors observed work activities associated with the shipment of the neutron shield tanks including work on the barge used to transport the neutron shield tan).
Other areas of work observed included the containment dome transition pieces and containment spray piping.
No items of noncompliance were observed.
3.
Status of Construction The licensee informed the inspector that the facility is 41% complete.
The shell of the cooling tower has been completed.
The transition piece of the containment dome is being assembled on site.
Structural work is continuing on the safeguards building, fuel and oecontamination building, reactor containment building and condensate polishing building.
Piping and electrical installation is continuing in reactor containment, main steam and cable vault, safeguards building condensate polishing building and fuel and decontamination building.
Some piping is being installed in the turbine building and some electrical is being installed in the service building.
4.
Licensee Action on Previous Inspection Items l
(Closed) Construction Deficiency Report (80-00-04):
Breakdown in QC Program resulting in issue of type 309 weld rod in welding of :.afety injection l
system instead of type 308 as specified.
On August 1, 1980 the licensee reported, as a significant deficiency in accordance with 10 CFR 50.53(e), that a "Stop Work" order had been issued to Schneider, Incorporated as a result of inadequate weld rod control.
On August 29, 1980 the licensee informed NRC-Region I that they were prepared l
to lift the "Stop Work" order and discussed the corrective measures which I
had been taken to assure adequate weld rod control.
The corrective measures
'
include organizational changes to improve the subcontractor's control of i
welding activities, a revised procedure for weld material control with l
increased requirements for verification by supervision, an expanded training
.
_
_
_ _ _ _ _
w-,.
_, - -
p.
- -
-
--
V
-
_.
_
-
.--
._
program and establishment of an additional QC group for surveillance of weld material control.
In addition a verification program was made by DLC on Schneider, Inc. documentation relating to the use of E-309-16 (1/8 inch diameter) stainless steel welding electrodes.
The verification of documentation was performed by the verification team especially established to check the control and records of welding electrode for Schneider, Inc.
This documentation consisted of S&W Material Receiving Report Site Quality Control Release Forms, Sold Material Reports, Issue Slips and other records and logs.
As a result of their audit, the verifi-cation team found that the Schneider, Inc. investigation was adequate and is readily verifiable and that corrective and preventative action has been taken to preclude recurrence of this type incident and that there is reason-able assurance that this is an isolated incident caused by lack of attention to detail resulting in human error.
The inspector had no further questions concerning this item.
5.
Containment Building Concrete Record Review The inspector reviewed containment crane wall concrete placement records.
He observed documentary evidence of quality control inspections and testing and verified that the QC records conform to established procedures.
The records reflect that the work accomplished is consistent with these estab-lished requirements:
Beaver Valley Power Station, Unit 2 PSAR Appendix B and Sections 15
--
and 17.
Specifications No. 904, Placing and Delivering Concrete and Reinforcing
--
Steel; No. 940, Mixing and Delivery of Concrete; No. 903, Concrete Testing Services.
Beaver Valley Site QC Inspection Procedure IP-6.2.3, Preplacement,
--
Placement and Past Placement of Concrete.
Records of these crane wall placements were contained in the inspector's review:
Pour No.
Inspection Report No.
Date of Placement 171 S-2707 7-24-80 174 S-2725 8-8-80 175 S-2732 8-19-80 178 S-2780 9-23-80 179 S-2768 9-12-80 180 S-2733 9-2-80
..
_
_
_
__
._.._ _,_ _ _ _.
.
,
These concrete records were reviewed for documentary evidence of the follow-ing:
Preplacement preparation and pour card sign-off for forms, rebar,
--
electrical and mechanical embedments.
Concrete acceptance testing at truck delivery, sampling and testing at
--
pump discharge and placement inspection.
Special inspection recuirements for use of starter grout in congested
--
areas.
Batch plant records and truck delivery tickets.
--
Concrete ingredients - testing and qualification.
--
Concrete curing, temperature and moisture control and cylinder test
--
for form removal.
Compressive strength concrete cylinder test and grout cube test, 7 and
--
28 day results.
Calibration of test instruments and qualification of inspection personnel.
--
Construction deficiency report /N&D #1159/ missing rebar:
evaluation,
--
disposition, corrective action and approval of repair.
No items of noncompliance were identified.
6.
Review of Nonroutine Events Reported by the Licensee a.
On December 7, 1979 the licensee had reported as a significant deficiency, in accordance with 10 CFR 50.55(e), that linear indications had been identified in the skirt to base flange weld of the neutron shield tank.
This information was confirmed by letter from the licensee dated January 4, 1980 and was also reported to IE Region IV by the l
vendor in accordance with 10 CFR 21.
An initial inspection of the i
licensee's efforts to determine the extent of the defective areas was j
made during Inspection 50-412/79-09.
On July 17, 1980 the licensee reported as a significant deficiency in accordance with 10 CFR 50.55(e) that linear indications were found by magnetic particle examination of a weld connecting a gib gusset to the reactor vessel support structure (neutron shield tank) (NST) top plate.
An inspection of the repair activities being performed at the site was made and reported in Inspection Report No. 50-412/80-06.
l l
.
-
,
w y--
-
,.--
,
9 -
y --
-
p.,
.
Additional magnetic particle inspection and exploratory ultrasonic inspection, beyond the NDE identified in the previous interim report, has provided further evidence that the deficiencies in the gib and gib gussett welds are extensive and that major rework is required.
A non-destructive examination program was initiated to inspect the entire RVSS, to establish the integrity of all of the welds on this support structure.
Based on the reinspection the licensee determined that all the gibs and all the gussets will have to be removed and replaced and the linear indications found in the top plate will have to be repaired.
The licensee original,1y had planned to have the NST repaired on site but because of the extent of the defects and the repair required a contract was given to Babcock and Wilcox (B&W) to have the vessel repaired at the B&W Mt Vernon, Indiar.a facility.
The vessel was to be moved from the 'O' storage area and transported by barge to B&W.
The inspector reviewed the following procedures relating to the move-ment of the neutron shield tank from its storage location in the 'Q'
laydown area to the barge for shipment to the Babcock and Wilcox Company facility at Mt Vernon, Indiana for repair.
FCP 710.3, Upending the Neutron Shield Tank, 11-20-80.
--
FCP 710.4, Neutron Shield Tank - Storage to Barge,12-4-80.
--
FCP 702, Rigging Guideline, 11-9-77.
--
In addition the inspector reviewed the completed Inspection Report ME-AA-0040, Transport and Loading of NST to Barge.
The report documents l
the verification of attributes applicable to the transport of the NST l
to the barge.
Other nonconformance and disposition (N&D) reports and
inspection reports relating to the cleaning and NDE of the NST were also reviewed.
During this review of procedures and records, the
i inspector observed that there might be a potential problem regarding
'
control of drawings when used in FCPs.
Three drawings were used as attachments to FCP 710.4.
Two of these drawings were Newport News Industrial Corporation (NNIC), manufacturer of the NST and one drawing by S&WEC.
One of NNI drawings, Shipping Arrangement, Neutron Shield Tank-NNIC Drawing No. 288865 had been revised by S&WEC to reflect existing arrangements.
This effort results in an as-built drawing by NNIC and the same drawing, albeit revised, being used as an attachment to an FCP.
This could result in a potential control problem for as-l built drawings which are subsequently used in FCPs.
The licensee has committed to revising the document control procedure to provide a mechanism for the control of drawings when used in FCPs.
The item is unresolved pending verification of revision to document control pro-cedure (80-10-01).
.
y
---w-
-p p
-
-e gi g-w
e-F T
""'
T
- * '
"-
.
.
b.
The inspector discussed with licensee and S&W the status of investi-gation of structures for horizontal load carrying capability.
This was found necessary when seismic calculations by S&W were found incom-plete at another site.
Notification by S&W identified that a similar problem could exist at Beaver Valley No. 2 where the same design deficiency was found.
Licensee responded that investigation of the auxiliary building shear wall design found it to be complete and capable of transmitting the vertical force couple through the structure to the mat.
However, the investigation of six other safety related structures, not including the containment building, remained to be done.
S&W Problem Report No. PR-S-20 gives an estimated completion date for these of December, 1981.
Following the inspector's concern of a potential significant deficiency in design of the six buildings, which are presently in various stages of construction, licensee reported this to the regional office by telephone under 10 CFR 50.55e as a potential significant deficiency.
The inspector had no further questions concerning this item.
c.
The inspector discussed with licensee and also with Dick Corporation personnel the incomplete status of corrective action construction of the lower pump cubicles (LPC).
Licensee submitted a final report under 10 CFR 50.55e for this
--
item on September 22, 1978, and IE Report No. 79-14 stated that corrective design and proposed construction remedial actions were considered adequate to resolve the design deficiency of reliance on the reactor containment cofferdum for support.
The licensee was informed that work schedules and priority items under the reduction of craft personel and change in fuel loading date had caused work stoppage on the LPC.
'
The inspector had no further questions on his inquiry of this incom-plete work.
However, he requested via telephone on December 16, 1980 he be informed of work on the LPC prior to its resumption.
7.
Unresolved Items Unresolved items are matters about which more infornation is required in order to ascertain whether they are acceptable items, items of r.oncompliance or deviations.
Unresolved items discussed during the inspection are detailed in Paragraph 6.
.
---
-ww wq---
c-
-,,-
w
, =,
iy-w
..
. _ -_
_
.
-
-..
i 8.
Exit Interview The inspectors ret with licensee's representatives (denoted in Paragraph 1)
at the conclusion of the inspection on December 4 and 11, 1980.
The inspectors summarized find,ngs of the inspection.
The licensee acknowledged the inspectors' coments.
,
i
-
-*.-:.-
g
..g
,_., -, -,
p.
- 9,e y
,-s
,,,.,
-.-y--,
->,,-9
.-.ey. _,
.-,y aa,.,g.-@
- e*ytwarwwv"'
W=- * ' '
'-r7 r=='* r1m e.
-y
- --7 9--f-t
- r=****W