IR 05000414/1985043

Insp Rept 50-414/85-43 on 850930-1004.No Violation or Deviation Noted.Major Areas Inspected:Qa Insp of Civil (Concrete Repair & Structural) Work Activities

ML20134A878
Person / Time
Site:	Catawba
Issue date:	10/25/1985
From:	Belisle G, Wright R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
To:
Shared Package
ML20134A871	List: IR 05000414/1985043 ML20134A868
References
50-414-85-43, NUDOCS 8511110085
Download: ML20134A878 (8)

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UNITE 1J 2TATES

[mft ur o NUCLEAR REGULATORY COMMISSION

[ , REGION 11 g j 101 MARIETTA STREET, * ATLANTA, GEORGI A 30323

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Report No.: 50-414/85-43 Licensee: Duke Power Company 422 South Church Street Charlotte, NC 28242 Docket No.: 50-414 '.icense No.: CPPR-117 Facility Name: Catawba 2 Inspection Conducted: September 30 - October 4, 1985 Inspector: hb R. W. Wright' ca

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Approved by: /C r 1 G. A. Belisle, ' Acting Section Chief Ddte S'igned Division of Reactor Safety SUMMARY Scope: This routine, unannounced inspection entailed 37 inspector-hours on site in the areas of quality assurance (QA) inspection of civil (c. crete repair and structural steel) work activitie Results: No violations or deviations were identifie ,

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REPORT DETAILS  !

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I Persons Contacted

Licensee Employees

• T. Bright, Construction Engineering Manager

, S. Caulder, Mechanical Engineering Technician M. Couch, Project Manager B. Harris, Civil Quality Control (QC) Supervisor J. Kinard, Technician, Welding Technical. Support i

• H.' Mason, QA Engineer, Civil

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• McCollum, Acting Plant Manager G. McDowell, QC Inspector

• D. O'Brien, Administrative Methods Supervisor

• F. Schiffley, Licensing Engineer

• K. Schmidt, QA Engineer l T. Summey, QC Inspector

• E. Williams, QA Technician

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Other licensee employees contacted included construction craftsmen,

! engineers,- technicians, QA/QC personnel and office personne NRC Resident Inspectors

, *P. Skinner, Senior Resident Inspector

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"R. Schepens, Resident Inspector

• Attended exit interview

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1 The inspection scope and findings were summarized on October 4,1985, with j those persons indicated in paragraph 1 above. The inspector described the areas inspected and discussed in detail the inspection findings listed

below. No dissenting comments were received from the licensee.

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Unresolved Item: Fillet Weld Leg Size Joint Geometry Configuration (1/16" to 3/16" gap) Not Considered at Final Visual Inspection, .

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Unresolved Item: Missing M-18G Trending Documents, paragraph The licensee did not identify as proprietary any of the materials provided

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to or reviewed by the inspector during this inspection.

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4 Licensee Action on Previous Enforcement Matters

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This subject was not addressed in the inspectio . Unresolved Items *

I Two unresolved items were identified during this inspection and are discussed in paragraphs 5.a. and . QA Inspection of . Civil (Concrete' and Structural Steel) Work Performance (35061B)

The inspector observed concrete repair activities utilizing SiKa Proprietary '

Products and the completed work concerning M-18A, Serial No. 2AB97? R1,

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involving the . addition of support steel .to an existing cable tray support

per variation notice (VN) 4993 "

This inspection was performed to determine whether site work was being i performed in accordance with NRC requirements and SAR (Topical Report)

commitments, that the QA/QC program was functioning in a manner to assure a requirements and commitments were met, and that prompt and effective action j was taken to achieve permanent corrective action on significant discrepan-

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cie The following acceptance criteria were examined to verify these inspection objectives:

} Procedure CP-22, R32 Fabrication of Welded Structrual Steel, 4 Miscellaneous Steel, and Other Steel Construction for Nuclear Structures

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Procedure CP-68, R11 Concrete Repair l J

l Procedure CP-374, R14 Structural Steel Administrative Control, i Fabrication / Erection Guidelines and l Inspection Guidelines

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Procedure CP-830, R3 Use of SiKa Proprietary Materials for j Various Concrete Repair Applications

i Procedure E-3, R21 Field Procurement of Items.and Construc-j tion Services i

Procedure M-2, R27 Inspection of Design Concrete

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• An Unresolved Item is a matter about which' more 1.1 formation is required to

! determine whether it is acceptable or may involve a violation or deviation.

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3-Procedure M-18, R13 Inspection of Structural Steel Fabrica-tion and Erection Procedure M-21, R18 Inspection of Field Welding of Structural Steel, Miscellaneous Steel and Other Steel Construction for QA Condition Structures Procedure. 0-1,;R27 Control of Measuring and Test Equipment Procedure P-1, R28 Receiving Inspection Procedure Q-1, R24 Control of Nonconforming Items Procedure R-2, R12 Identification and Resolution of Discrepancies Procedure R-5, R8- NRC Reporting Requirements Procedure QA-121, R8 NRC Reporting Requirements Procedure QA-150, R5 . Trend Analysis Procedure QA-300, R15 Construction Surveillance Procedure CDA-9,-R5 Trend Analysis Construction Drawings CN-1212-01, R4 CN-1212-15, R19 CN-1212-CG, R6 CN-1212-16, R11 CN-1212-07, R6 Specification CN-1109.00-1, RIO' . Concrete for 'QA Condition Structures Specification CNS-1121.00-1, R1 Field Fabrication and Erection of Structural Steel, Miscellaneous Steel, and Other Steel Construction for Nuclear Safety-Related Structures The inspector reviewed the listed criteria utilized for concrete repairs and structural steel fabrication / erection activities to determine,- . if the . latest revisions were employed, if they were in agreement with the .-SAR, if . these documents adequately described critical points and methods of installation,1 and if inspection and test hold points ~ properly reflected design inten . _ . _ _ _ _ _ _ _

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The inspector raised some questions concerning the adequacy of control measures being applied to the in:pection of structural steel fillet welds. Section 3.3 of the AWS Code requires (for production material less than 3-inch thickness) that the leg of the fillet weld be increased by the amount of separation for gap separations 1/16 of an inch or greate Procedure CP-22, Section 150, permits the fitter to have undocumented open gaps up to 3/16 of an inch for similar thickness material, and requires the fillet weld leg to be increased by the amount of gap exceeding 1/16 of an inc However, by procedure M-21, Section 4.1.1.A, inspection of fitup is only performed periodically for welds requiring visual inspectio Additionally, Section 4.1.1.C requires the QC inspector at final visual inspection to assure that the weld is the correct size and completed in accordance with applicable construc-tion procedures. Consequently, since gap separations between 1/16 to 3/16 of an inch are not documented, the QC inspector at final visual inspection cannot assure the fillet weld size is correc Discussions with site welding personnel identified that the Stickman Interpretation dated May 29, 1985 (attached to Construction Surveill-ance C85-44) generally describes the QA program applied to structural steel fillet welds. This interpretation states:

The inspector should verify that the size as specified on the design drawing has been met. It is the craft's responsibility to assure weld size is increased when a gap exists. The inspector is not required to check for thi However, it would be advisable for the inspector to check enough of those cases to develop adequate confidence that construction is meeting this requiremen It appears that the fillet weld program described above may be a deviation from AWS Code requirement However, due to time limita-tions, the inspector was unable to discuss this matter with offsite Design or QA Technical Services personnel to determine if any addi-tional conservatism had been designed into the sizing of the subject fillet welds. This matter will be pursued during future inspections a.id is identified as Unresolved Item 414/85-43-01, Fillet Weld Leg Size Joint Geometry Configuration for (1/16" to 3/16" Gap) Not Considered at Final Visual Inspectio b. Field Inspection The inspector observed abandoned drill hole repairs for auxiliary building floor slabs located at elevations 577 and 591. The craftsmen used SiKaTop 123 which is approved for use in all buildings for either horizontal, vertical, or overhead applications. The surface prepara-tion; priming with the "A" component; proportioning and mixing of components A and B, and the placement, rodding, finishing, and curing of the subject repairs were witnessed and found to be accomplished in accordance with approved procedures. The subject concrete repair

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activities were continuously monitored by QC personnel since 100%

inspection of this activity was required. The inspector observed the craftsmen associated with the subject SiKaTop 123 concrete repairs and determined that their level of knowledge was adequate to provide the required workmanship quality. Records examination verified that the crafts making repairs were qualified mixers of SiKaTop 123 proprietary product The inspector accompanied a structural steel QC inspector during his inspection of a cable tray support which had been modified by VN 4993 This structural inspection verified that the steel members added to the subject cable tray support were of proper dimension, type, material, and configuration per approved drawing Within this area,-no violation or deviation were identifie Quality Control-The . inspector reviewed the following inspection records generated for concrete drill hole repairs and structural steel additions to determine their adequacy, whether deficiencies submitted by QC received proper

. corrective action where applicable, and if work and work controls were adequate:

CP-830-A SiKa Product Placement Record '

CP-830-C ' Abandoned Drill Hole Repair 0-1 Calibration of Equipmen <

MM150 SiKa Products Release Log M-2H Compression Test Results, SiKaTop 123 CP-374-8, R1 Supplement Signoff Sheet for M-18A, Serial No. 2AB974R1 CP-374-D, R1 Package Document Log Sheet The inspector reviewed applicable QA/QC procedures (paragraph 5.a) to *

determine if the frequency, timing, and acceptance criteria for the civil inspections of drill hole repairs and structural- steel fabrica-

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tion / erection were adequate. :The number of QC inspectors provided for coverage of these activities appeared satisfactory. Discussions were conducted with QC inspectors to determine if their knowledge of inspection activities was adequate and ~to determine whether they felt their. findings and concerns received proper management attentio The inspector concluded that licensee management was attentive and

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responsive to QC inspector identified problems. The structural steel and concrete repair inspectors examined were ve ry knowledgeable of their inspection functions, acceptance criteria, and they were also proficient in the performance of their assigned function Within this area, no violation or deviations were identifie d. Nonconforming Item Reports (NCIs)

The inspector reviewed selected reports on concrete repair and struc-tural steel for fabrication / erection discrepancies that have occurred during various phases of these work activities to verify that:

The action taken corrected the items; The items were considered for reportability to NRC; The instituted effective action prevented recurrence; and The licensee has an adequate program to detect trends in discre-pancie NCIs reviewed included the following: 12215, 13251, 13573, 18200, 18318, 18379, 18384, 18429, 18486, 18790, 18840, 18850, 19109, 19384, 19562, and 1983 The inspector examined monthly trend analysis program records for NCIs, R-2As, and M-18G type discrepancies for the period January 1985 to June 1985. The trend program established by procedure CDA-9, RS, had provided excellent results for stopping adverse trends and getting to the root cause of persistent problems. It was evident that construc-tion management thoroughly supported this program, was aware of the benefits derived from it, and was involved in providing prompt corrective action to adverse trend Trend summary reports, pertinent responses from supervisors of the trended areas, and project manager final site analyses were examined for each of the above mentioned type discrepancies trended. The NCI and R-2A trending records examined were easily retrievable, complete, and found to be indicative of a worthwhile program. Some responses from supervisors of the trended areas and the project managers final site analyses could not be located for the M-18G program for the interim period evaluated. Discussions with the administrative methods supervisor responsible for trend analysis identified that his group had experienced several relocations and personnel changes, lately, due to

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construction activities winding dow He felt that these missing documents existed but could not. produce them prior to the completion of this inspec-io This item was identified as Unresolved Item ,

414/85-43-02, Missing M-18G Trending Documentatio e. Materials and Equipment The inspector examined purchase requisition 833706798S for SiKaTop 123 proprietary materials..used during abandoned drill hole repair A satisfactory SiKa Corporation . Certificate of Conformance accompanied the shipment of these materials which was receipt. inspected (File No. MM150) on . March 13, 198 The SiKa 123 products were assigned Level B storage requirements and . the inspector verified that the subject materials were stored under such conditions. S1Ka 123 cylinder compression test records examined indicated this proprietary product obtained desired compressive strengths. The ' thermometer (M1-6) used during the witnessed concrete repair operations was found to be in ,

current calibration statu ~

Within this area, no violations or deviations were identifie f. Audits and Construction Surveillance The inspector reviewed the following site QA surveillance and Civil Department audit reports performed on concrete repair and structural steel work activities:

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l Departmental Audits: CD-83-11 (CN), CD-84-1 (CN), and CD-84-4 (SP)

Construction Surveillances: C-85-67, C-85-45,-and C-85-44 Within this area, no violations or deviations were ider.tifie g. 10 CFR Part 21 Requirements The inspector reviewed procedures R-5 and QA-121 to determine if they satisfied 10 CFR 21 reporting requirements. Purchase Rerluisition 8337067985 for S1KaTop 123 products was examined and it indicated that .

10 CFR 21' was applicable. The posting of requisite 10 CFR 21 was examined in the Main Office Building and outside Warehouse No. Within this area, no violations or deviations were identified.