IR 05000438/1982002
| ML20050J592 | |
| Person / Time | |
|---|---|
| Site: | Bellefonte  |
| Issue date: | 03/03/1982 |
| From: | Quick D, Wilcox J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML20050J170 | List: |
| References | |
| 50-438-82-02, 50-438-82-2, 50-439-82-02, 50-439-82-2, NUDOCS 8204140190 | |
| Download: ML20050J592 (9) | |
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o, UNITED STATES
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NUCLEAR REGULATORY COMMISSION
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E REGION 11
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101 MARIETTA ST,, N.W., SUITE 3100 o,
ATLANTA, GEORGIA 30303 Report Nos. 50-438/82-02 and 50-439/82-02 Licensee:
Tennessee Valley Authority 500A Chestnut Street Chattanooga, TN 37401 Facility Name: Bellefonte Docket Nos. 50-438 and 540-439 License Nos. CPPR-122 and CPPR-123
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Inspection at Bel nte site near Scottsboro, Alabama 8 37!8L Inspector:
w J. t. Wilcof,~Jr.
7 yate S4 ned Approved by:
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D. R. Quick /Section Chie7, Division of Oate/ Signed
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Resident and Reactor Project Inspection SulttiARY Inspection on January 1-31, 1982 Areas Inspected This routine, announced inspection involved 104 resident inspector-hours on site in the areas of construction surveillance, quality control investigation report (QCIR) review, licensee action on previous inspection findings, nonconforming condition report (NCR) review, QA audit review, work release review, welding performance qualification record review, licensee identified items, interviews with construction craftsmen, inspector follow-up items, housekeeping, spent fuel coolant pump flush and training.
Resul ts Of the 12 areas inspected, no violations or deviations were identified in 11 areas; one item of noncompliance was found in 1 area, violation - prerequisites for construction flush.
8204140190 820405 PDR ADOCK 05000438 G
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DETAILS 1.
Persons Contacted Licensee Employees
- W. Dahnke, Project flanager
- F. Gilbert, Construction Engineer G. Blackburn, General Construction Superintendent
- L. McCollun, Instrument Engineer Supervisor
- T. Brothers, Hanger Engineer Supervisor
- F. Moses, Mechanical Engineer Supervisor
- J. T. llalker, Assistant Construction Engineer D. Smith, Assistant Construction Engineer
- F. Iluffman, Assistant Construction Engineer
- A. Richards, Electrical QC Supervisor D. Gillies, Hanger Engineering Unit P. licGraw, Electrical Engineering Unit
- J. Barnes, QA Supervisor B. Jarmaos, Administration Officer
- T. McCollum, WEU
- K. Johnston,11EU
- J. Olyniec, Civil Engineer Supervisor H. Johnson, Welding Engineer
- D. Bridges, QCRU
- B. Thomas, Assistant Construction Engineer
- D. Freeman, Electric Engineer
- T. flewton, STil Supervisor
- P. liann, CEO
- K.
Lawless, WEU
- J. Knight, Construction flanagement Office
- J. Love, EllDES Other licensee employees contacted included 8 construction craftsmen, 8 technicians, 4 mechanics, and 12 office personnel.
- Attended exit interview 2.
Exit Interview The inspection scope and findings were summarized on February 4,1982 with those persons indicated in paragraph 1 above.
3.
Licensee Actions on Previous Inspection Findings a.
(Closed) Infraction 438/81-19-02 " Inadequate Rigging Technique".
The resident inspector reviewed the corrective actions, results achieved and the steps taken to avoid further recurrence stated in TVA letter, dated September 11, 1981.
The inspector considers the
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corrective action and steps taken to be satisfactory; therefore, this item is closed.
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(Closed) Violation 438, 439/81-21-01 " Hanger Records not Reflecting
Date of Inspection".
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The resident inspector reviewed the corrective action, results achieved and the steps taken to avoid further recurrence stated in TVA letter, dated October 26, 1981. The inspector considers the corrective action and steps taken to be satisfactory; therefore this item is closed.
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(Closed) Violation 43, 439/81-21-02 " Improper Storage of Hanger Records".
l The resident inspector reviewed the corrective actions, results achieved and the steps taken to avoid further recurrence stated in TVA letter, dated October 26, 1981.
The inspector considers the corrective action and steps taken to be satisfactory; therefore, this item is i
closed.
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Unresolved Items
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Unresolved items are matters about which more information is required to determine whether they are acceptable or may involve violations or devid-l tions. New unresolved items identified during this inspection are discussed
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in paragraph 12.
5.
Independent Inspection Effort - Construction Surveillance l
The inspector spent most of his time in direct surveillance of hardware in the field which includes the following areas:
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(Unit 1 Reactor Building) Witnessed portions of erecting structural steel in
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the annulus area; installing decay heat removal, startup and recirculation, chemical addition and boron recovering, component cooling water, spent fuel cooling, core flooding makeup and purification and waste disposal piping; installing steam generator bumpers and snubber plates; installing main steam and feedwater piping whip restraints; installing reactor coolant whip restraint caps; installing exposed conduit and associated suoports; installing local instrument panels in the instrument room; construction of the secondary containment wall; installing pressurizer hardware; assembling and installing the reactor pressure vessel internals; installing spray line and associated supports; pulling and terminating cables; closing and installing pressurizer surge line, and installing decay heat removal sump valve room pipe restraint.
(Unit 2 Reactor Building) Witnessed portions of welding reactor coolant system piping; installing large core flooding, decay heat removal, reactor building spray, auxiliary feedwater, makeup and purification, startup and recirculation, main steam, feedwater, component cooling water, and spent fuel cooling piping; installing steam generator snubber plates and bumpers;
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performing fitup of support, shear bars, miscellaneous hardware for
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i pressurizer; installing electrical penetrations; installing cable trays and associated supports and exposed conduit and associated supports; applying I
protective coating in west 'D' ring; and installing spray line supports; installing pressurizer surge line.
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(Auxiliary Building) Witnessed portions of installing chemical addition and boron recovery, startup and recirculation, component cooling, feedwater, i
main steam, auxiliary steam, makeup and purification, spent fuel handling, auxiliary feedwater, and reactor building spray piping; installing spent fuel cooling, and decay heat removal hangers, piping and valves, installing
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pipe supports in Unit 1 and 2 main steam valve room
'A', installing exposed
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conduit and associated supports, local instrument panels and tubing at
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various locations, pulling and terminating cables, working on concrete i
pours; installing pipe supports on roof; installing radiation monitors; and erection of fuel storage bridge in spent full pool; and applying protective coating on Unit 1 floor elevation 649.
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(General) Witnessed portions of installing the fire protective system.
6.
Quality Control Investigation Report (QCIR) Review
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The inspectors reviewed the description and recommended disposition for the following QCIR's:
QCIR flo.
Date Title
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15600 1/4/82 Limit Torque switch of valve 15572 1/6/82 Hanger IRJ EPHG 0181F R0 i
15831 1/11/82 Anchorage bushing material
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15773 1/7/82 QCIR signed off without All!
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15743 1/7/82 Unauthorized grinding gouge
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These QCIR's were handled in accordance with Bellefonte's Quality Control Procedure, BNP-QCP-10.26, Rev. 4.
No violations or deviations were identified.
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Nonconforming Condition Report (flCR) Review The inspectors reviewed the item description, noncompliance description, recommended disposition and action required to prevent recurrence for the following NCR's:
NCR No.
Date Ti tle 1718 1/18/82 Coring room at concrete lab 1713 1/6/82 Types of nuts used in qualifi-l cation tests l
1719 1/12/82 Semifinished hex nuts
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These llCR's were handled in accordance with Bellefonte's Quality Control Procedure, Blip-QCP-10, Rev. 8.
No violations or deviations were identified.
8.
Work Release Review The inspector reviewed the type of work, description, engineering audit approval, and QA records affected for the following work releases (WR):
WR No.
Date Ti tle 28655 1/22/82 Relocate conduit 28608 1/21/82 flove support ORf-11PHG-0306 52 R1 28604 1/21/82 Chip concrete to lower pipe sleeve MK60 28599 1/20/82 Install (6)h" expansion sheel anchors These work releases were handled in accordance with Bellefonte's Quelity Control Procedure, BNP-QCP-10.6, Rev.12.
No violations or deviations were identified.
9.
Licensee Identified Items (LII)
The inspectors reviewed the status of the following LII's with site and ENDES personnel. The following licensee identified items have been reported to RII by TVA:
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(0 pen) LII 438, 439/82-02-02 - Welds by Johnson flachine Works on the revolving platform (NCR 1638)
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(0 pen) LII 438, 439/82-02-02 - ECN Review and Handling (Audit M 81-13 Def #2-4)
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(0 pen) LII 438, 439/82-02-03 - Generic deficiency in design review (Audit M81-13 Def #5)
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(0 pen) LII 438, 439/82-02-04 - Bonnet studs not properly torqued on decay heat removal (NCR 1686)
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(0 pen) LII 438, 439/82-02-05 - Seismic support lugs on 2" or less SS pipe (NCR 1690)
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(0 pen) LII 438, 439/82-02-06 - Tapes for heat tracing do not meet chemical specifications (NCR 1692)
(0 pen) LII 438, 439/82-02-07 - Attachments of pipe supports in RB to 6" strip plates (BW BLP 8133)
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(0 pen)LII 438, 439/82-02-08 - Chiller unit piping components improperly welded (NCR 1707)
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(0 pen) LII 438, 439/82-02-09 - Temperature of nitrogen supply (BLN BLP 8201)
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(0 pen) 438, 439/82-02-10 - Failure of TransAmerica Diesel to Promptly Correct Deficiencies (Audit 81V-47 Def #1)
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(0 pen) 438, 439/82-02-11 - Resolution of unanticipated vibratory loading concerns (Gen CEB 8201)
(0 pen) 439/82-02-12 - Su 1.
expansion (BLN BLP 8130)pports in fiUPV System not designed for thermal 10. Welding Performance Qualification Record The inspector reviewed the following welding performance qualification records for completeness:
Stamp No.
Welding No.
Test No.
Date FAP0 GT-11-B-1A Rev. 6 GT-6.0.1.2 1/8/82 FAZF Sit-11-B-3 Rev. 6 Sti-4-B-3-H 1/8/82 FBGQ Sit-11-B-3 Rev. 6 Sf t-4-B-3-H 1/8/82 These welding performance qualification records were handled in accordance" with Bellefonte's Quality Control Procedure, BNP-QCP-10-24, Rev. 5.
No violations or deviations were identified.
11. QA Audit Review The inspector reviewed the following Quality Assurance Audit for accuracy and completeness:
Audit No.
Title No. of Deficiencies BN-!1-81-13 Pipe hanger instal
lation and inspection No violation or deviations were identified.
12. Spent Fuel Coolant Pump Flush On January 3,1982, the resident inspector observed portions of construction flush N!1FA (supply for Spent Fuel Coolant Pump 1A-A and common interface piping to Unit 2, Phase II, Auxiliary Building).
During this observation it was noted that the test director was performing this flush without the required QC/ Engineering hold point to the flush procedure being signed. The
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hold points in question included paragraphs 7.0 A1, 2, 3, 4, 5, and 7 to fif1FA flush procedures.
Bellefonte's Construction Test Procedure, BNP-CPT-6.1, Rev. O, states the following in the respective paragraphs:
P.5.1 (5): The startup Testing and Coordination Unit (STCU) shall be responsible for the following:
Verification of completion of cleaning and flushing activities and ensuring all documentation has been accomplished as specified by individual system / subsystem procedures.
P.6.1: (in part): A construction test procedure package will be developed for each system or portion of a system to be cleaned.
This package will contain the instructions for accomplishing the individual system cleaning.
In addition, each package will contain the required documentation and verification of completion of each system cleaning activity.
This is identified as violation 50-438/82-02-12, " Prerequisites for Construction Flush".
In addition, for proof of cleanliness flush, General Construction Spec-ification G-39, Rev. 4, paragraph 8.5.3.1 and 8.5.3.2, allows for the use of a sample line cartridge filter and specifies that the sample apparatuses used to check for particulates shall draw samples from the sides or bottom of the process pipe.
From samples taken from the pumps protective strainer (#4 seive) upstream of spent fuel coolant pumps 1A-A and the sample line cartridge filter, the cartridge filter is not giving a representative sample of the system. TVA is requested to evaluate the particulates obtained on the pump protective strainer and justify in writing the use of a sample line cartridge.
This is identified as Unresolved Item 438/81-02-13 " Sample Line Cartridge."
Also during this flush it was noted that a large piece of what appeared as purge paper was obtained from inside the system.
The resident inspector obtained some of these particulate pieces of the glued purge paper to soak them in water in excess of 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> and other pieces of the glued purge paper was boiled in water for approximately 1 hour1.157407e-5 days <br />2.777778e-4 hours <br />1.653439e-6 weeks <br />3.805e-7 months <br />, fleither the soaked or boiled glued purge paper changed in consistancy. TVA is requested to evaluate the purge paper taken from this flush and evaluate it to determine if it is meeting its intended function and sutxait their results in writing.
This is identified as Unresolved Item 50-438/82-02-14 " Purge Paper".
13. Tra ining The resident inspector attended the retraining session on Instrument Tube Installation conducted on January 11, 1982.
The reference document to this training session was Bellefonte's Quality Control Procedure Bf4P.QCP 4.3, Rev. 3.
This session's performance was improved in comparison to the session originally conducted on December 28, 198.
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In addition, a review was made of the craft training certification program printout, dated January 7,1982.
It was noted that no craft personnel had been trained on numerous Bellefonte Quality Control Procedures (QCP)
specified in Attachment C of BNP.QCP-10.30, Rev. 2.
The following is a list of QCP's on which the craft at Bellefonte have been trained.
QCP 3.1 Embedded conduit and Grounding Systems 3.9 Electrical and Instrumentation Panels, Boards and Equipment 3.10 Circuit Breakers 15 KV and below 3.11 Switch Ajustment (Limit and Torque Types)
3.12 110 tor Rotation and Performance 3.19 Lighting 3.22 Permanent Identification of Electrical and Instrumentation Devies 3.26 Electrical Local Contrel/ Test Panels 3.27 Indefinite Status Control During Troubleshooting, Inspection, and Test Activities 3.29 Electrical Heat Trace 10.16 Bending of Partially Embedded Reinforcing Steel 5.1 Backfill thterial Placement 4.3 Instrument Tubing Installation This is a continuation of Inspector Follow-up Item 438, 439/81-33-07 " Craft Training".
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Housekeeping The resident inspector reviewed the following housekeeping deficiency reports for deficiencies identified and action taken to correct these deficiencies:
Deficiency Report No.
Date 666 1/8/82 668 1/11/82 669 1/12/82 670 1/18/82 671 1/19/82 672 1/20/82 673 1/21/82 The deficiencies noted in housekeeping inspection #668 and 669 were not correct in the required amount of time as specified in BNP-QCP 10.27 R4.
This was primarily due to the adverse weather conditions at that time.
The remaining housekeeping inspections were handled in accordance with Bellefonte's Quality Control Procedure BNP-QCP-10.27, Rev. 4.
No violations or deviations were identified in this are,
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15.
Interview with Construction Craf tmen The resident inspector interviewed six construction craf tmen on site during the week of December 14, 1981 and January 20, 1982.
Craftmen interviewed included boilermakers, iron workers, electricians, and steamfitters.
The craf tmen interviewed had been working at the Bellefonte site from 4 to 6 years and all work on safety-related items. The length of each interview was approximately 15 minutes. The intent of the interviews was to determine if the individual had any outstanding concerns about the quality of construction at Bellefonte. The results of these interviews will be maintained by the NRC and followed up as necessary.
16.
Inspector Followup Items (Correction on report 438,439/81-31)
In report 438, 439/81-31 the following Inspector Follow-up Item was identified 438, 439/81-31-11 " Acceptable vibration levels on pumps when performing construction test".
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