IR 05000423/1982003
| ML20058C134 | |
| Person / Time | |
|---|---|
| Site: | Millstone  |
| Issue date: | 07/08/1982 |
| From: | Elsasser T, Mattia J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML20058C125 | List: |
| References | |
| 50-423-82-03, 50-423-82-3, NUDOCS 8207260271 | |
| Download: ML20058C134 (11) | |
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U. S. NUCLEAR REGULATORY COMMISSION Region I Report No.
50-423/82-03 Docket No.
50-423 Category A
License No. CPPR-113 Priority
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Licensee:
Northeast Nuclear Energy Company P. O. Box 270
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Hartford, Connecticut 06101 Facility Name:
Millstone Nuclear Power Station, Unit 3 Inspection at:
Waterford, Connecticut Inspection conducted:
May 17-31 and June 1-21, 1982 Inspectors: e f. N 6h7 W. C. Mattia, Senior Resident Inspector date signed date signed
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7/8/8h
- i Approved by:
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T. Elsas ief, Reactor Projects
' date signed Section DRPI Inspection Sunmary:
Unit 3 Inspection on May 17-31 and June 1-21, 1982 Report No. 50-423/82-03 Areas Inspected:
Routine, onsite regular and backshift inspection by the resident inspector (99 Hrs.) Areas inspected were pipe erection, non-destructive examination of welds, electrical penetration installation, installation of equipment supports, concrete placement, cadwelding, electrical equipment installation, open items and reports to NRC.
Violations: None
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8207260271 820709 PDR ADOCK 05000423 O
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I DETAILS 1.
Persons Contacted Northeast Utilities Service Company (NUSCO)
F. Comstock, FQC Technician D.Diedrick,QAManager(Berlin)
K. Gray, Construction QA Supervisor W. Langdon, Construction Engineer K. Murphy, QA Specialist S. Orefice, Project Engineer (Berlin)
J. Putnam, Senior Construction Engineer T. Sullivan, Resident Engineer - New Site Construction Stone and Webster Corporation (S&W)
F. Bearham, QA Program Administration (Boston)
C. Goodman, Resident Manager (Acting)
P. Hogan, Field QC Inspector J. Kappas, Superintendent of Construction G. Marsh, Senior Engineer, Welding /NDE M. R. Matthews, Assistant Superintendent Field QC P. Nelson, Engineering Assurance Engineer L. Peterson, Field QC Inspector Supervisor G. G. Turner, Superintendent, Field QC W. Voss, Senior Field QC Engineer
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R. Welch, Field QC Inspector R. White, Material Controls & Maintenance Supervisor
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G. Wilson, Field QC Inspector
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Westinghouse Corporation N
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J. Dolan, Site Manager
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E. Harlow, Site Representative
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s C. Peterson, Site Representative
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Richmond Engineering Company (RECO)
G. Hall, QC Inspector
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Note: The inspector also conferred with other licensee and contrsctor
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personnel during the course of inspection.
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2.
Plant Tours The inspector observed work activities in progress, completed work i
and construction status in several areas of the plant. The inspector examined work for any cbvious defects or noncompliance with regulatory requirements or license conditions.
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.
3.
Licensee Action On Previous Inspection Findings
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(Closed) Violation (423/78-05-02): An item of noncompliance was issued for failure to fully implement the QA Program of the field erection tank subcontractor. At the time of the citation, the subcontractor was close to completing his work on-site and was to return to the site to fabricate the refueling and Demin-l eralized Water Storage Tanks. NRC letter, dated March 28, 1979, to the licensee stated that an inspection will be conducted upon the return of the subcontractor to the site.
The resident inspector reviewed the subcontractor's approved field site QA Program Manual and verified the implementation i
of it for the erection of the Demineralized Water Storage Tank, 3FWA-TK1. The following specific areas were inspected:
- Indoctrination of site personnel. Verified that the five
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welders, plus the foreman were indoctrinated in accordance l
with RECO Procedure ES-136, Rev. 2.
- Verified that training programs were established for QC l
Inspector, Foreman and Welders.
- Verified that Field Change Notices issued to date complied
with QA Manual Section 2.8000. Reviewed Field Change Notices (M-1, M-2 & M-3).
- Field purchases in accordance with QA Manual Section 3.1000 requirements are not performed by subcontractor's site people.
All purchasing for field is done by the subcontractor's
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home office in Richmond, Va.
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- Verified that the subcontr actor is complying with the require-ments of Section 5.0000 ciQA Manual for Document Control.
Inspected the logging of drawings and changes, and also control of these documents.
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- Verified that receipt inspection was performed on material received from the home office. Reviewed Honconformance Report RCN-205-5 for site rejected drain pipe that was returned to home office for repairs.
- Reviewed the nondestructive examination qualifications of the on-site QC Inspector.
- Reviewed the welder qualifications for five welders employed by the subcontractor.
- Inspected control of construction processes to verify implemen-tation of Section 8.0000 of QA Manual. Reviewed work travelers, storage and control of welding materials, welder records, and inspected welding activities and fit-up of tank stainless steel sheets.
- Verified that Field QC Inspector was perfonning the monthly storage inspections as required by Section 12.0000 of the QA Manual.
The inspector also reviewed S&W Field QC activities for this sub-contractor. The specific items inspected are as follows:
- Reviewed all S&W Inspection Reports issued to date (Nos. S2040018, 52040040, S2040033, S2040039, S2040038, S2040037, S2040036, S2040032, S2040030, S2040029, 52040028 and S2040042). During this review, the inspector noted that S&W had only verified that one subcontractor welder was qualified (S2040018). The S&W Specification #023 for this contract states that Field QC shall verify that the welders are qualified. The specification is
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not specific as to quantity of welders QC should verify. There are currently six welders on site, and S&W stated that it is up to the inspector's judgement as to how many he should verify.
The inspector infonned S&W that the industry is currently experiencing problems in this area, and verification of qualifications should be of all welders.
S&W perfonned this inspection (No.S2040042) and found all welders properly qualified.
No violations were identified, b.
(Closed) Unresolved Item (423/82-04-02):
During welding of electrical penetrations, the inspector noted that a sooty material is deposited adjacent to the edge of the weld beads made by the Gas Tungsten Arc Welding Process in Type 304 stainless steel to carbon steel joint, using Icconel Filler Metal. The concern was that this sooty deposit might haYe an
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adverse effect on weld quality which would not be detected, since Volumetric Inspection is not a requirement. A demon-stration weld was produced as on the production welds. The same weld procedure requirements were followed. When com-pleted, the weld was radiographed and found free of reject-able defects. The inspector had no further questions for this item.
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(Closed) 50.55(e) Item (423/80-00-05): Northeast Nuclear Energy Company was notified by Westinghouse Electric Corpor-ation that a main feedline rupture with an assumed failure in the Steam Generator Blowdown System could lead to reduced cooling to the Steam Generator. To preclude this from happening, the Millstone Unit No. 3 design has been modified to include cavitating venturies. The inspector reviewed S&W design documents to verify that cavitating venturies are included in the documents. The specific documents reviewed are as follows:
S&W Drawings EP-17N, P & Q S&W Specification #674 d.
(Closed) Unresolved Item (423/81-02-13):
During a review of a draft copy of NUSCO QA Procedure NQA-2.01 for Trend Analysis of Category I related problems, it was noted t. hat the draft procedure did not require the trending of Millstone 3 con-struction findings. Revision 0 of Procedure has been issued and it requires the trending of Millstone 3 findings.
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(Closed) Unresolved Item (423/81-02-10): An unapproved draft of the QA Construction Supervisor's position description was reviewed and found to be outdated and did not fully describe his primary duties. An approved position description was issued on February 1, 1982, delineating his primary duties, accountability, authority, and the minimum requirements for the position.
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(Closed) UnresolvedItem(423/81-02-25):
NUSCO QA Procedure NQA-1.18, Revision 0 did not adequately define the stop work authority for the QA Construction Supervisor. Revision 1 of Procedure NQA-1.18 was issued and it adequately addressed the stop work authority of the QA Supervisor.
In addition, the
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QA Supervisor's position description also describes his stop work authority.
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(Closed) Unresolved Item (423/81-02-09): The NUSCO QA Procedure
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NQA-1.01, Revision 0, did not describe the QA Construction groups'
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functions in the operating plants.
It implied that it's duties were only for Millstone III. Revision 1 of the procedure was issued detailing the various functions of the QA Construction i
Group.
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(Closed) Unresolved Item (423/81-05-08): Lack of NUSCO QA Construction Groups activities in the erection of Reactor Cool-ant Piping. A review of audits, surveillance and in-process verification reports conducted by the NUSCO QA organization indicates that additional staffing has improved their coverage of critical construction activities. The following reports were reviewed by the inspector:
Audit #A-40614 In-process Verification #V-16 Surveillance Reports C-1645. C-1833 & C-1870 1.
(0 pen) Unresolved Item (423/81-11-03): A review of a NUSCO QA Construction Auditor's Qualification for nondestructive examination " Witness Level II" noted discrepancies in the qualification records. The inspector reviewed the records for this QA Auditor and noted that the certification for
" Witness Level II" for visual, liquid penetration and magnetic particle examinations was in accordance with NUSCO QA Pro-cedure NQA-2.109. The clarification of this procedure for
" Witness Level" as required for Millstone III construction activities has not been accomplished. This item is still
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considered unresolved.
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(Closed) Unresolved Item (423/81-14-01):
Inspector noted that a pipe spool piece had a large gouge and requested that it be evaluated. An inspection (Report #X1000641) was per-fomed by S&W Field QC, and it was determined that the mini-mum wall thickness was not exceeded.
It was also the contractor's conclusion that the depth of the gouge was not an
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unacceptable stress riser. The NRC inspector also requested that the resident ASME Code Inspector review this gouge on the pipe for ASME Code acceptability. His inspection also found it to be acceptable.
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(Closed) Violation (423/81-14-05):
Failure to take prompt corrective action on various deficiencies associated with
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i items in storage. The inspector reviewed the following inspection and nonconfomance reports (N&D) to verify that i
the required corrective action was performed:
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1 Inspection Report No.
Date Action Completed X1000416 5/20/82 X0000077 4/20/82 X1000158 5/21/82 X1000079 12/8/81 X7050133 This was superceded by N&D #6708 and the corrective action was completed on 3/9/82.
The inspector also verified that corrective action items have been added to the agenda for the weekly construction meeting between Stone & Webster and NNECO to ensure that the required action is timely. The inspector reviewed several of the weekly construction meeting reports since the violation,to detemine that corrective action on reported items was timely.
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(Closed)
50.55(e) Item (423/81-00-03): On October 19, 1981, the licensee infomed the NRC of a Significant Deficiency in the cable tray sections manufactured by T. J. Cope.
It was determined, by the licensee, that the vendor drawing did not
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reflect some current fabrication practices and did not contain sufficient information to facilitate proper weld inspection.
A stop work was issued for Millstone III, and a 100% inspection was performed on all tee sectionson site. Of the 102 tees inspected, a total of 35 was rejected. To preclude any possible recurrence, the S&W Procurement Specification E-979 was revised (issued on May 17,1982) to require that all welds on all tee sections be 100% inspected; also the vendor's fabrication draw-ings, 37-06FT-24, 77-06FT-24, 37-06FT-36 & 47-06FT-12, were revised to incorporate welding dimensions.
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(Closed) Unresolved Item (423/82-06-03): The Reactor Pressure Vessel interior and stud holes had not been inspected since it was installed inside containment. The inspector observed the inspection perfomed by Westinghouse site representatives and S&W in accordence with Westinghouse Instructions WMP-0131. Minor construction debris (dirt & wood) was found and this was removed.
A reinspection by S&W, Inspection Report No. X2000317, after cleanup, found it to be acceptable.
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(Closed) Unresolved Item (423/82-06-02): Timely corrective action for discrepancies found by S&W materials group weekly surveillance of equipment stored in-place. The inspector re-viewed the following weekly surveillance reports and noted that timely corrective action was taken:
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9 Week Surveillance Report No.
5/7/82 82-5-1 5/14/82 82-5-2 5/21/82 82-5-3 5/28/82 82-5-4 6/4/82 82-6-1 6/11/82 82-6-2 o.
(Closed) Unresolved Item (423/82-04-01):
Fonnal procedures for installing surface mounted plates using drilled-in expansion type concrete anchors and Richmond inserts were not available. S&W has issued two Field Construction Pro-cedures Nos. 299 & 309 for this work activity.
4.
Cadwelding of Reinforcing Steel The inspector inspected the construction activities associated with Cadwelding of reinforcing steel for Main Steam Valve Building as shown on S&W Drawing EC-31C, Revision 7.
The inspector verified that the Cadwelding (Joints T27090, T27091 & T27092) requirements of Procedure CMP 6.1-3.78 were adhered to by the qualified Cad-weldor.
No violations were identified.
5.
Installation of Electrical Penetrations The inspector observed the installation of electrical containment penetration No. 1B-3 to verify that the installation is in accord-ance with vendor's installation manual IPS-158 dated 4/10/78.
Prior to the actual installation, a modification to the penetration was required by the vendor's procedure No. 1BS-374, dated 10/3/78.
The inspector observed both of these activities.
No violations were identified.
6.
Installation of Reactor Coolant Pump Supports The inspector observed the installation of two of the three
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Reactor Coolant Pump Supports to verify that the requirements of installation procedure FCP-311 were adhered to. One of the thre*;ded supports, upper clevis connection, gauled (thread pick-up)juringinstallation. The removal using impact wrench was also observed by the inspector. The damaged threads (both mating
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parts) were also inspected. S&W issued a nonconformance report for the damaged threads. Two of three supports were successfully installed during this reporting period.
No violations were identified.
7.
Concrete Placement The inspector observed portions of a concrete placement No. C-3948.
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The inspector verified that for the portions he observed, the l
requirements of S&W Specification C-999 and Quality Standard Q5-10.13 were adhered to. The following are the specific items inspected:
- Verified that the preplacement inspection by QC has been performed.
- That the inspection personnel were located in close proximity to the truck discharge and final placement location.
- The quality requirements (slump, air content & temperature) of concrete being placed was verified by testing and that they met the design mix requirements.
- Consolidation of concrete in the forms was adequate.
- The form work was adequate and the rebar cover was as required.
- S&W concrete pour card wac properly filled out.
No violations were identified.
8.
Geological Fault Found In The Discharge Tunnel Excavation The inspector observed the fault found during the excavation of the discharge tunnel.
Discussions were held with S&W geotechnical people and the cognizant NRC geotechnologist in headquarters per-taining to this faulting. The inspector also observed some of the mapping, excavations and examinations performed by the S&W geologist.
9.
Welding Material Control The inspector inspected the two welding material issuing rooms #1 and #2 to verify that they are complying with the critical require-ments of Construction Procedure CMP-6.4, dated April 27, 1982, for controlling welding materials.
No violations were identified.
10. Cleaning and Adjusting of Circuit Breaker The inspector observed the cleaning, adjustment and lubrication of 4.16/6.9KV AC Circuit Breaker Serial #256A 7900-030. The work was
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under the technical direction of vendor serviceman and licensee production department. The Circuit Breaker was partially dis-assembled and cleaned. The main contacts, termination disconnects, arcing contacts and rollers were lubricated. The arcing " wipe contacts" were also adjusted.
No violations were identified.
11. Piping Weld Activities The following weld joints in various stages of completion were inspected for compliance with ASME Section III Code, S&W Specifica-tion 968, and the various S&W Weld Technique sheets:
Weld Joint Identification Weld Technique Location CI-FWA-9; Field Weld Nos 31 & 44 W21K, Rev. 1 ESF Building CI-CLP-E; Field Weld Nos. 56, 58 & 61 W86K, Rev 1 AUX Building CI-BM1-1: Field Weld Nos. 237, 238, 239, 240, 247-250 W13J, Rev. 1 Containment CI-CHS-27; Field Weld No. 3 W12F, Rev. 3 AUX Building 3FWS-020-26-2; Field Weld No. 9 W21K, Rev 1 Containment CI-FWS-24A; Field Weld No. 6 Repair-Observed
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liquid penetrant examination of excavated area, CI-MSS-503; Field Weld No. 18 W11B, Rev 1 Containment 3CHS-92-2; Field Weld Nos 32 & 33 W12G, Rev. 1 AUX Building
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CI-CHS-18; Field Weld No. 4 W12G, Rey, 1 3FWS-020-18-2; Field Weld No. 20 W20B, Rey, 1 Containment
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CI-RCS-LP1; Field Weld Nos, 7 & 8 W138, Rev. 3 CI-RCS-LP3; Field Weld No. 7(repair)
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CI-CHS-661A; Field Weld #16 W21K, Rey,1 No violations were identified, 12. Welding of Cable Tray Supports The inspector inspected welding activities associated with the installation of electrical cable tray seismic supports in the Aux-iliary Building. These supports were located at elevation 63'-6" and 4' west of F-8 line, The welding was in accordance with S&W Weld Technique Sheet W70G, Rey, 4, No violations were identified,
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13.
Integral At'
hments to ASME III, Code Piping It was brought to the inspector's attention that a significant defi-ciency existed concerning the lack of material certification for integral attachments supplied by ITT Grinnell Corporation. The ASME III Code, 1971 Edition through Summer 1973 Adenda requires material certification to be supplied by the material manufacturer. The inspector reviewed S&W Engineering & Design Coordination Report
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(E&DCR) F-J-7549 which described the prcblem.
ITT Grinnell had sub-mitted a certificate of conformance as defined in ANSI N45.2.10-19T3; however, a material certification was not submitted as required.
The inspector requested that the licensee produce some objective evidence that this item was evaluated for reportability in accordance withthe10CFR50.55(e)reportingcriteria. A S&W Problem Report, No. MT-21 dated 3/19/82, determined that this item was not reportable because the technical adequacy of the material supplied under the ITT Grinnell approved ASME QA program was not in question. The licensee stated that ITT Grinnell has informed them that material certifications can be supplied with the required traceability. The traceability will be thru paper work since the integral attachments are not stamped with Heat or Code Nos. The inspector informed the licensee that this will be followed by the inspector during subse-quent inspections.
(423/82-03-01)
14.
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.
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