IR 05000413/1979005
| ML19273C025 | |
| Person / Time | |
|---|---|
| Site: | Catawba  |
| Issue date: | 04/13/1979 |
| From: | Gouge M, Herdt A, Mcfarland C NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML18024B535 | List: |
| References | |
| 50-413-79-05, 50-413-79-5, 50-414-79-05, 50-414-79-5, NUDOCS 7906180764 | |
| Download: ML19273C025 (7) | |
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UNITED STATES
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REGION ll c
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Report Nos. 50-413/79-05 and 50-414/79-05 Licensee:
Duke Power Company P. O. Box 33189 Charlotte, North Carolina 28242 Facility Name:
Catawba Nuclear Station, Units 1 and 2 Docket Nos. 50-413 and 50-414 License Nos. CPPR-116 and CPPR-117 Inspection at Catawba Site near Lake Wylie, South Carolina M
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NG-M Inspectors:
Date Signed C. R. McFarland 7, p
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r1-77 Date Signed f*M.J. Gouge k
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Approved by:A. R. Herdt, Section Chief, RC&ES Branch Date Signed SUMMARY Inspection on March 13-16, 1979 Areas Inspected This routine, unannounced inspection involved 58 inspector-hours onsite in the areas of Category I concrete placement, containment structural concrete procedures and records, welding and welder qualifications, control of nonconforming items, storage of plant materials, corporate quality assurance audits, and posting 10 CFR 21 notices.
Results Of the seven areas inspected, no apparent items of noncompliance or devia-tions were identified in five areas; two apparent items of noncompliance were found in two areas (Defici'ency - Welder qualification maintenance paragraph 3.a; Inf raction - Containment Spray Heat Exchanger records
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Storage Requirements paragraph 5.b.).
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DETAILS 1.
Persons Contacted Licensee Employees
- D. G. Beam, Project Manager
- D. L. Freeze, Project Engineer
- W. O. Henry, QA Manager, Construction Division
- J. C. Shropshire, QA Engineer (QAE) Mechanical, Welding
- H. D. Mason, QAE Civil, Electrical P. L. Atkins, QAE Civil R. G. Rouse, QAE Welding
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R. D. Blackwelder, QAE NDE J. M. Curtis, QA Manager, Vendor Division E. C. Wall, General Superintendent R. S. Morrison, Assistant General Superintendent
- L. R. Davison, Senior QC Engineer H. R. Kirkland, QC Inspector Civil G. E. Ross, Supervisor, Technical Welding H. D. Best, Welding Foreman T. H. Weir, Mechanical Engineer, Construction V. H. Shellhorse, Mechanical Engineer, Design J. Mayberry, Document Control Clerk Other licensee employees contacte included various construction craftsmen, technicians, and office personnel.
Other Organizations Hartford Steam Boiler Inspection and Insurance Company J. W. Kosko, Authorized Nuclear Inspector (ANI)
C. F. Toegel, ANI
- Attended exit interview.
2.
Exit Interview The inspection scope and findings were summarized on March 16, 1979 with those persons indicated in Paragraph 1 above. The two noncom-pliances were discussed in detail.
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-2-3.
Licensee Action on Previous Inspection Findings a.
(Closed) Unresolved Item Number 413-414/79-02-01, Welder Qualifi-cation Maintenance Records. The licensee has completed a review of the Welder Qualification History File and examined those where the welder's qualification status was updated using the old revision of form M-19A(see licensee Memo to File dated 3/1/79).
This examination revealed that records do not substantiate welder qualification maintenance for one welder (Stencil A60) from June 25 to August 8, 1978. This record deficiency appears to in noncompliance with Criterion XVII of Appendix B to 10 CFR 50, which states in part, " Sufficient records shall be maintained to The furnish evidence of activities af fecting quality.
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records shall also include closely related data such as qualifica-tions of personnel
" Therefore the category of this item
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is changed from an unresolved item to a noncompliance categorized as deficiency 413-414/79-05-03, Welder Qualification Fbintenance Records.
Prior to this inspection, the licensee had completed corrective actions. The inspector examined the corrective actions taken and concluded that Duke Power Company had determined the full extent of the subject noncompliance, performed the necessary survey and follow-up actions to correct the present conditions and developed the necessary corrective actions to preclude recurrence of similar circumstances. Therefore, no response to this item of noncompliance is necessary, b.
(Closed) Item 50-413/78-08-01 and 50-414/78-07-01 Certification of Ladish Carbon Steel Fittings.
The inspector reviewed DPC correspondence with Ladish Company and Energy Products Group, the manufactures of the fittings for safety related piping, the mill certifications for the Ladish fittings related to the unresolved item, and the DPC design engineering review of the above corre-spondence and the questions related to the mill certifications.
The inspector discussed the subject with the DPC QA manager of the vendor division.
The items noted as "not clear" in the initial finding are now " clear" and the values noted in the fitting material certifications and the mill certification are now accepted as within the tolerances specified.
The values reported are the chemical and mechanical properties of representa-tive materials supplied and used for the DPC Catawba project.
The DPC QA Vendor Division provides surveillance of the Ladish Company work per DPC QA procedure QA-601 Vendor Evaluation. DPC QA-601 requires evaluation and documentation of audit and surveil-lance work related to the materials certification work.
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Unresolved Items Unresolved items were not identified during this inspection.
5.
Independent Inspection System For Control of Nonconforming Items (Units 1 and 2)
a.
The Region II inspector examined the system for contret of noncon-forming items. DPC Procedure Q-1, R12, Nonconformin Items, is o
the applicable procedure for identification, control and disposi-tion of nonconforming items. The inspector reviewed nonconforming item (NCI) reports 759 through 5004 that were in a pending status.
The NCI reports had been correctly documented in accordance with DPC Procedure Q-1.
It was observed that numerous NCI reports had been in a pending status for a lengthy period of time. The following NCI reports were generated when it was identified that a licensee employee had superceded documents in his possession:
NCI Serial Number Date Originated 3940 9/22/78 3946 9/25/78 4029 10/6/78 4506 12/15/78 4664 1/16/79 The above NCI reports were open on March 15, 1979. The specified corrective action provided for each employee to verify that no work was performed with superceded documents. This corrective action becomes increasingly difficult to verify the longer the interval before corrective action is taken and the NCI report closed. NCI report 3938 was generated on September 22, 1978 when it was discovered that welding personnel were bypassing QC hold points.
The specified corrective action included instructing welders on the importance of QC hold points. This corrective action had not been implemented as of March 15, 1979.
The licensee is amare of the large number of NCI reports pending action, some of which could be closed by a thorough review of outstanding NCI reports.
Site management has recently modified the NCI reporting system to start an automated dats printout of all outstanding NCI reports that sorts reports pending action to the individual responsible for corrective action.
Additionally, site management is conducting a comprehensive review of all open NCI reports in an effort to reduce the number of open NCI reports to those which clearly warrant a pending status. Region II will monitor the ef fectiveness of the licensees current actions to 2353 062
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t-4-improve the site noncomforming item system. This area is identi-fied as Inspector Followup Item 413-414/79-05-01, Nonconforming Item System.
No items of noncompliance or deviations were identified in the above area inspected.
b.
Storage of Permanent Plant Materials (Units 1 and 2)
An inspection was conducted of site warehouses and yards used to store permanent plant materials requiring Level B, C,
and D storage as defined in ANSI N45.2.2.
The following documents contain guidance on receiving, storing and performing preventive maintenance on items to be installed in the nuclear plant:
(1) ANSI N45.2.2-1972, Packaging, Shipping, Receiving, Storage and Handling of Items for Nuclear Power Plants (2) DPC Procedure P-1, Material and Equipment Receiving Inspection (3) DPC Procedure P-3, Storage Inspection Areas inspected included control of storage environment where applicable, accessibility of stored items, arrangement of items, housekeeping practices, identification and segregation of noncon-forming materials and access control to the warehouse areas.
Warehouses and field yard storage areas observed were neat and orderly and nonconforming items were tagged and segregated.
The licensee was storing four N-stamped containment spray beat exchangers manufactured by Yuba Corporation.
It was determined on receiving inspection that the temporary valving used to apply a nitrogen blanket had been damaged on three of the four contain-ment spray heat exchangers. This was documented on nonconforming item reports 4481 and 4482 originated on December 12, 1973. The disposition of this nonconformance was made by DPC engineering staff and stated "If the heat exchangers will be in storage greater than 3 months, the nitrogen blanket should be reapplied."
On March 15, 1979 the Region II inspector recorded the following values of shell and tube side nitrogen blanket pressure on the four containment spray heat exchangers:
Heat Exchanger belkNitrogen Tube Nitrogen Serial Number Biariket Pressure Blanket Pressure if 0 psig 2 psig dl'
74-N-008-2A 0 psig 0 psig 74-N-008-2B 74-N-009-2A II O psig 0 psig 74-N-009-2B i
4 psig 8.5 psig 2353 063
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s-5-The manufacturer's general instructions for storage of these heat exchangers are given in CNM 1201.06-79.
Section 3.1.1 of this manual states, "If nitrogen pressure has fallen below 5 psig pressure should be restored to approximately 10 psig." DPC Con-struction Procedure P-3, Section 4.2 gives requirements for the incorporation of special storage and maintenance requirements on Fo rm P-3A Equipment Special Storage and Maintenance Inspection Form.
Contrary to DPC Procedure P-3, no Form P-3A had been initiated for the four containment spray heat exchangers stored on site and the licensee had no mechanism to check nitrogen blanket pressure on these heat exchangers through a periodic storage inspection program. Lack of a storage inspection require-ment resulted in a greater than three month interval without a
nitrogen blanket on the containment spray heat exchangers. The licensee placed a nitrogen blanket on the af fected containment spray heat exchangers on March 15, 1979 and initiated Form P-3A for the four containment spray heat exchangers on March 16, 1979.
Failure to identify and implement special storage requirements for the four containment spray heat exchangers is contrary to Criterion XIII of Appendix B to 10 CFR 50 and is identified as infraction 413-414/79-05-02, Containment Spray Heat Exchanger Storage Requirements.
Spent Fuel Building Concrete Pour (Unit 1)
c.
The Region II inspector observed portions of Category I concrete placement 2915 conducted in the roof area (M-56) of Unit 1 Spent Fuel Building. The following documents specify requirements for Category I concrete and were reviewed prior to the placement:
(1) Drawing series CN-1229, R2, Spent 7uel Pool (2) DPC Procedure M-2, R14, Inspection of Design Concrete (3) Spec CNS-1109.00-1, Specification of Concrete for Category I Structures (4) ACI Standard 318-1971 Cleanliness of the formwork and spacing of the reinforcing steel were inspected prior to the placement. The Region II inspector observed delivery of the concrete to the pour location, conveying, in process testing, placement and consolidation of the Category I concrete.
In process testing was conducted with clean and cali-brated instruments in accordance with applicable procedures.
Form M-2D, Record of.uncrete Placed, was reviewed for conformance to DPC Procedure M-2.
Quality Control (QC) personnel closely 2353 064
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s-6-monitored the concrete placement. Placement and consolidation of the Category I concrete was conducted in accordance with applicable procedures.
The concrete laboratory maintained by the Civil QC group was inspected for general cleanliness and calibration of measuring and test apparatus. The concrete laboratory was clean and all test equipment was in calibration.
No items of noncompliance or deviations were identified in the above areas inspected.
d.
Welding of Main Coolant Loop Piping (Unit 1)
The Region II inspector observed in process welding of 31 inch OD main coolant loop piping located in the Unit 1 Containment Building.
The following procedures provide requirements in the area of nuclear safety related pipe welding:
(1) DPC Procedure M-4, R2, Visual Inspection and NDE of Welds (2) DPC Procedure I-1, R7, Qualification of Welders and Welding Operators (3) DPC Procedure H-3, RIO, Identification and Control of Welding Material The inspector observed in process welding on the following welds:
Weld Number Location CN-1NC-22-5 Intermediate Leg, Loop B CN-INC-23-4 Intermediate Leg, Loop D CN-lNC-23-6 Intermediate Leg, Loop D Areas inspected included cleanliness, preheat and purge requirements, use of proper filler material, welding technique, and qualification of welders to the proper weld procedure. Welding QC personnel had conducted the required inspections prior to commencement of welding and were observing in process welding on a periodic basis. Welding on the 31 inch main coolant piping was conducted in accordance with applicable procedures and documented correctly on form M-4A, Weld Process Control Sheet.
No items of noncompliance or deviations were identified in the above area inspected.
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-7-Corporate QA Audit (Units 1 and 2)
e.
The inspector reviewed documentation of the corrective actions taken to resolve the questions and findings of the corporate level II audit C-78-1 conducted January 16-25, 1978. The inspector had attended the exit meeting of the audit as reported in Rll reports 50-413/78-1 and 50-414/78-1. Revisions to construction procedures and to construction QA procedures have been made and implemented.
The Audit Division memo dated November 15, 1978 documents that Audit C-78-1 is closed and that the revisions to the procedures satisfy the audit discrepancies.
No items of noncompliance or deviations were identified.
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Containment Structural Concrete Procedures and Records (Unit 1)
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The Region 11 inspectors reviewed the procedures and records related the Category I concrete pour 2873 conducted in the dome area of to Unit 1 Containment Building. DPC Procedure M-2, Inspection of Design Concrete, provides requirements in the area of concrete inspection and records. The following records of pour 2873 were reviewed:
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Form M-2A, Prepour Site Inspection b.
Form M-2D, Record of Concrete Placed Form M-2Q, Finishing and Curing Inspection Log c.
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Form 79-051, Concrete Surf ace Temperature Log No items of noncompliance or deviations were identified in the above area inspected.
7.
10 CFR Part 21 Inspection (Units 1 and 2)
The site facilities were inspected to determine if the posting require-ments specified in 10 CFR 21.6 had been implemented. The licensee had posted notices prepared per 10 CFR 21.6(b) in three conspicuous locations in the construction area. The posting requirements of 10 CFR 21.6 had been implemented at Catawba Nuclear Plant.
No items of noncompliance or deviations were identified.
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