IR 05000438/1982009
| ML20054H015 | |
| Person / Time | |
|---|---|
| Site: | Bellefonte  |
| Issue date: | 04/22/1982 |
| From: | Quick D, Wilcox J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML20054G980 | List: |
| References | |
| 50-438-82-09, 50-438-82-9, 50-439-82-09, 50-439-82-9, NUDOCS 8206220496 | |
| Download: ML20054H015 (10) | |
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So UNITED STATES
NUCLEAR REGULATORY COMMISSION o
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REGION 11
101 MARIETTA ST., N.W., SUITE 3100
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ATLANTA, GEORGIA 30303
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Report Nos. 50-438/82-09 and 50-439/82-09 Licensee: Tennessee Valley Authority 500A Chestnut Street Chattanooga, TN 37401 Facility Name:
Bellefonte Docket Nos. 50-438 and 50-439 License Nos. CPPR-12? and CPPR-123 Inspection at Bellef t site near Scottsboro, Alabama Inspectors:
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kb J. D Wilce,J te S'igned
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_I D 8L Approved by:
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i D. R. Quick, Sect.on hief,___ivision f D'a e Sitned Project and Reactor Program SUMMARY Inspection on March 1-31, 1982 Aren Inspected Thi s routine, announced inspection involved 176 inspector-hours on site in the are<.s of construction surveillance, Quality Control Investigation Report (QCIR)
review, QA audit review, licensee identified items (Unit 1 & 2), housekeeping, t.onconformance Condition Report (NCR) review, welding performance qualification record review, licensee action on previous inspection findings, work release review, Doric acid pump room receiving inspection checklist, welding inspector training program, pipe vibration, mechanical cleaning, storage of rebar.
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Results Of the 15 areas inspected, no violations or deviations were identified in 12 areas; 1 item of noncompliance was found in 1 area (boric acid pump room).
8206220496 820609 PDR ADOCK 05000438
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DETAILS 1.
Persons Contacted Licensee Employees
- W. Dahnke, Project Manager
- F. Gilbert, Construction Engineer
- G. Blackburn, General Construction Superintendent
"D. Freeman, Electrical Engineer Supervisor EEU
- T. Brothers, Hanger Engineer Supervisor
- F. Moses, Mechanical Engineer Supervisor
- H. Johnson, Welding Engineer Supervisor WEU D. Smith, Assistant Construction Engineer
- J. T. Walker, Assistant Construction Engineer
- F. Huf fman, Assistant Construction Engineer
- J. Barnes, QA Unit Supervisor
- D. Bridges, Assistant Construction Engineer
- L. McCollum Instrument Engineer Supervisor J. Olyniec, Civil Engineer Supervisor
- B. J. Thomas, Assistant Construction Engineer W. P. Chapley, IEU
- G. Greer, QA Unit
- K. Lawless, WEU
- E. Rose, QA Unit
- A. Richards, EEU QC Supervisor
- D. Gillies, Hanger Engineering Unit
- K. Frazier, Staff Engineer
- T. F. Newton, STW Supervisor
- P. C. Mann, Engineer Management Assistant
- B. Sammons, Administrative Of ficer Other licensee employees contacted included 12 construction craf tsmen, 8 technicians, 2 mechanics, 4 security force members, and 10 of fice personnel.
- Attended exit intervies 2.
Exit Interview The inspection scope and findings were summarized on March 31, 1982 with those persons indicated in paragraph 1 above.
3.
Licensee Actions on Previous Inspection Findings a.
(Closed) Violation (438/81-31-14) Undersize weids on the ERCW valve handling bridge crane rails.
The resident inspector reviewed the corrective action taken and results achieved and the steps taken to avoid further recurrence stated in a TVA letter dated February 5,1982. The inspector considers the correc-
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tive action and steps taken to be satisfactory; therefore, this item is closed.
4.
Unresolved Items Unresolved items are matters about which more information is required to determine whether they are acceptable or may involve violations or devia-tions. New unresolved items identified during this inspection are discussed in paragraphs 14,15, and 17.
5.
Independent Inspection Effort - Construction Surveillance The inspector spent most of his time in direct surveillance of hardware in the field which includes the following areas:
(Unit 1 Reactor Building) Witnessed portions of erecting steel in annulus area; installing decay heat removal, startup and recirculation, chemical addition and boron recovering, component cooling water, spent fuel cooling, makeup and purification and waste disposal piping; installing steam genera-tor bumpers and snubber plates; installing main steam and feedwater piping whip restraints; installing reactor coolant whip restraint caps; installing exposed conduit and associated supports; installing local instrument panels in the instrument room; installing pressurizer and hardware; pulling and terminating cables; installing pressurizer surge line; tensioning upper steam generator supports; installing reactor coolant drains and vents; flushing core flooding piping.
(Unit 2 Reactor Building) Witnessed portions of installation of the reactor coolant system, large core flooding, decay heat removal, reactor building spray, waste disposal, 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; installing electrical penetrations; installing HVAC ductwork and associated hangers, cable trays and supports, and exposed conduit and supports; instal-ling spray line supports, installing pressurizer surge line.
(Auxiliary Building) Witnessed portionc of installing chemical addition and boron recovery, startup and recirculation, component cooling, feedwater, main steam, auxiliary steam, auxiliary feedwater, make up and purification spent fuel handling and reactor building spray piping; installing spent fuel cooling and decay heat removal hangers, piping and valves; installing pipe supports in Unit 1 and 2 main steam valve room A; pulling and terminating cables, installing pipe supports on roof; installing radiation monitors; erecting fuel storage bridge in spent fuel pool; applying protective coating on Unit 1 ELEV 649, 667 and 686; and working on catwalks and concrete pours.
(General) Witnessed portions of installing fire protectio r..
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6.
Quality Control Investigation Report (QCIR) Review The resident inspector reviewed the description and recommended disposition of the following QCIR's:
QCIR No.
Date Title 17190 3/1/82 Gap on IKE-HPG-0061R0 17194 3/1/82 Jamnuts on OVL-MPHG-0484,51R0
- 17290 2/25/82 Vendor drawings, internal cable diagrams & B&W drawings The QCIR denoted with (*) under the disposition section of paragraphs 6 a..d 8 gives no justification for acceptance.
No violations or deviations were identified.
7.
Nonconforming Condition Report (NCR) Review The resident inspector reviewed the item description, noncompliance descrip-tion, recommended disposition and action required to prevent recurrence for the following NCR's:
NCR No.
Date Title
- 749 2/17/82 Pump Staft for IRC-flPflP-001-A These site NCR's were handled in accordance with Bellefonte's Quality Control Procedure, BNP-QCP-10.4, Rev 8.
The NCR designated by (*) was generated by ENDES.
The NCR designated by (**) did not meet the required reporting time.
No violations or deviations were identified.
8.
Work Release Review The resident inspector reviewed the type of work, description, engineering unit approval, and QA records affected for the following work releases (UR):
UR No.
Date Title 30440 3/1/82 flove Electrical Cables
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30434 3/1/82 Remove valve to inspect for possible purge block 30429 3/1/82 Orill 1" diameter for chemical grout
30428 3/1/82 flotch inlet & Discharge Expansion Joints Bellows Protection Ring 30400 3/1/82 Vacuum Blasting Floor
- 30649 3/4/82 Replace Root Valves The above noted (*) work releases should have been identified to the flechanical Engineering Unit per Table 1 of BilP.QCP 10.26 Rev.12.
These work releases were handled in accordance with Bellefonte's Quality Control Procedure, BilP-QCP-10.6, Rev.12.
No violations or deviations were identified.
9.
Licensee Identified Items (LII)
The resident inspector reviewed the status of the following LII's with site and EflDES personnel.
The following licensee idtitified items have been reported to RII by TVA unless otherwise specified.
a.
(0 pen)LII 438, 439/82-09-01:
Deficiencies identified by IE Bulletin 79-14 inspection (BLN CEB 8202).
b.
(0 pen) LII 438, 439/82-09-02:
Incorrect inspection code on hanger drawings by ITT Grinnell (NCCR 1748)
c.
(0 pen) LII 438, 439/82-09-03:
Incorrect installation of pressure relief and safety valves (BLfl BLP 8210).
d.
(0 pen)LII 438, 439/82-09-04:
Elevation of diesel generator lube oil cooler (BLN HEB 8202).
e.
(0 pen) LII 438, 439/82-09-05:
Dissolvable glue used for purge dams (NCR 1725).
f.
(0 pen)LII 438, 439/82-09-08:
Unacceptable replacement pump shaft (NCR 1749).
10.
Housekeeping The resident inspector reviewed the following housekeeping deficiency reports for deficiencies identified and action taken to correct these deficiencies:
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Deficiency Report No.
Date
- 688 3/1/82
- 689 3/8/82 The above noted (*) housekeeping deficiency report was signed by the Con-struction Superintendent (disposition complete) after the required 4 day due date as required by BNP-QCP-1A27R1.
The above noted (**) housekeeping deficiency report had two attached deficiencies dated 2/22/82 with the cover page dated 3/8/82.
This exceeds the two day requirement date as required by BNP-QCP-10.27R4.
Unit 1 valve Room 'A' was noted to be below housekeeping cleanliness requirement, however, this was immediately corrected, excepted as noted above.
These housekeeping inspections were handled in accordance with Bellefonte's Quality Control Procedure BNP-QCP-10.27, Rev. 4.
No violations or deviations were identified.
11.
Quality Audit Review the resident inspector reviewed the following Quality Assurance Audit for accuracy and completeness:
Audit No.
Date No. of Deficiencies BN-E-82-02 3/3/82
BN-M-82-02 3/11/82
BN-C-81-07 3/25/82
BN-W-82-01 3/26/82
BN-W-82-02 3/30/82
No violations or deviations were identified.
12. Welding Performance Qualification Record The resident inspector reviewed the following welding performance qualifi-caton records for completeness.
Stamp No.
Welding Procedure No.
Test No.
Date FBNX Sfi-18-B-1, Rev. 5 Sit-5-B-3-H 3/5/82 FBRB GT-11-0-1A GT-6-01-L 5/4/82 FBWJ GT-11-0-1A GT-6-0-1-L 3/5/82
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FBYT GT-11-0-1A GT-6-0-1-L 3/5/82 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.
13.
Storage of Rebar During the week of liarch 22, 1982, the resident inspector made a surveil-lance of the rebar yard to ensure that the rebar was being properly stored.
Rebar storage is inspected per Bellefonte Quality Control Procedure BNP-QCP-10.27 Rev. 4.
The inspector verified that the rebar was being properly stored.
This closes Inspector Follow-up Item 438,439/81-29-08
" Storage of Rebar".
14. tiechanical Cleaning During the week of 11 arch 1,1982, the resident inspector noted that between construction flushes the site had mechanically cleaned an interior surface of the decay heat removal system without detailed controlled instructions and no quality control inspection.
The area was mechanically cleaned to remove attached purge paper from the inside of the piping.
The area cleaned was adjacent to temperature element IND-ITE-0DI!1-A adjacent to valve IND-VDBB-257-A.
The section of piping was cleaned by mechanically grinding / polishing.
General Construction Specification No. G-39, para-graph 5.1, states in part:
"All cleaning process shall be controlled to ensure effective cleaning."
Paragraph 5.2.1 states:
" Grinding and polishing shall be performed with a wheel or cloth that will ensure a cleanly cut surface.
During grinding, the material or component part shall be oriented in a manner that particles will fall away from it.
A vacuum hose may be employed near the work to remove fine airborne particles.
Completed materials or components shall be cleaned, as required, to remove particles created by the grinding and polishing operation."
10 CFR 50 Appendix B, Criteria V states:
" Instructions, procedures, and drawings activities affecting quality shall be prescribed by documented instructions, procedures, or drawings of a type appropriate to the circumstances and shall be accomplished in accordance with these instructions, procedures, or drawings.
Instruc-tions, procedures or drawings shall include appropriate quantitative or qualitative acceptance criteria for determining that important activities have been satisfactorily accomplished."
The above mechanically cleaning operation is identified as Unresolved Item 438/82-09-09 " Mechanical Cleaning".
Action is needed by the site to determine adequacy of procedures / inspections in similar condition _
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15.
Pipe Vibration During the week of flarch 22, 1982, the resident inspector identified sections of piping adjacent to the Unit 1 decay heat removal heat exchanger that was vibrating during a construction flush.
The piping in this area was vibrating with a displacement of 25 mills and a velocity of 1 inch per second.
At present, the site (ie construction) has no criteria for acceptance of allowable piping vibration during the construction phase.
AflSI tt 45.2.B. Paragraph 4.6 states in part:
Temporary use of equipment or facilities to which this standard applies that are to become part of the completed project may be desira ble.
Authorization for such usage shall be as provided for in the contract or by written approval from the responsible organization.
Such temporary use shall not subject the equipment or systems to conditions for which they were not designed.
The only acceptance criteria at Bellefonte for piping vibration is outlined in flechanical Design Standard DS-t12.16.1 Section 5.0 (Preoperational Test Program).
Further investigation was performed by the resident inspector because of this condition. A telephone conversation was initiated between the llRC resident, D. Terrill (TVA), J. Kincaid (TVA) and R. ficColl (TVA)
concerning this condition.
During the telephone conversation it was agreed that EfIDES would to be notified, by TVA construction, whenever piping was identified to be vibrating at a mode which could be visually noted.
Further action is required by TVA to detennine if acceptable piping vibration limits need to be identified to construction during certain construction phases (ie flushing).
This is identified as Unresolved Item 438/82-09-10
" Pipe Vibration".
16.
Boric Acid Pump Room During the period between September 28 - October 2,1981, the resident inspector identified to the flechanical Unit Supervisor and the Assistant Construction Engineer of flechanical/ Welding, several questionable areas in Unit 1 Boric Acid Pump Room.
There were indications that numerous welds had been re-melted to assist in alignment of pipe.
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The site generated QCIR #13,352 on October 2,1981 to address this area and to cut out nine OflB welds and visually inspect these welds after they had been cut out.
The results of welding engineering unit QC is as follows:
(welds noted are ones cut out)
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Weld flo.
Visual Examination Results OtiB-54B Weld OK OflB-54H Suck-back two places OilB-56 Weld OK l
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ONB-63 Weld OK ONB-39 Sugared plus suck-back ONB-91 Suck-back ONB-107 Sugared ONB-163 Lack of fusion plus suck-back ONB-231 This weld OK but weld No. ONB 229 was rejected on visual as a result of cutting weld No. ONB-231 On Itarch 9,1982 a welder infonned the resident inspector that he had re-melted three welds in the Boric Acid Pump Room on the week-end of September 19, 1981.
The three welds were identified as ONB-54HS1, ONB-126T1 and ONB-163FSI.
The site generated QCIR 17774 on 11 arch 10,1982 identified this condition and required the welds ONB-126T1 and 0NB-163FS1 to be cut out.
It should be noted that weld 0NB-54HS1 has already been cut out per the previous QCIR 13,352.
In addition, the welder infonned the resident inspector that the craft had used 2X4's to attempt to cold bend the pipe in the Boric Acid Pump Room to bring it within the specified alignment on the pipe drawings. Bellefonte's Quality Control Procedure BNP-QCP-10.13 Rev. 5 requires that all welding shall be perfonned using qualified detail weld procedures; however, this was not done in the above situation.
This is identified as violation 438, 439/82-09-06 " Boric Acid Pump Room".
This action closes Unresolved Item 50-438/81-29-10 " Boric Acid Pump Room".
17.
Receiving Inspection Checklist The resident inspector reviewed the contents of the receiving inspection checklist (Attachment A) of the following checklist:
209 No.
Date Description 80-7033 9/9/80 Self drilling, snapoff type concrete anchors
- 80-6859 9/2/80 Self drilling, snarff type concrete anchors
- 82-383 (Task 41)
10/23/81 Component cooling pump shaft The receiving inspection checklist (RIC) denoted by (*) had CitTR's received marked (SAT); however, no C!!TR's were present.
Also reviewed was TVA memo identifications #BLN 81082527 (dated August 24,1981) and BLN 811016008 l
(dated October 6,1981) which state:
"all expansion anchor shells and i
wedge bolts are exempt from requirements of Certificates of Compliance (C0C)
i and Certified ltaterial Test Reports (CitTR) required by General Construction l
Specification G-53".
The RIC denoted by (*) did not have either C0C's or CllTR attached.
The receiving inspection checklist denoted by (**) had manufacturer's documentation marked (UNSAT) and no Certification of j
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Compliance was received with the shaft. However, the shaft was released and installed into pump IKC-tiPHP-001A without a QCIR being generated to note this condition.
This is identified as unresolved. item 438, 439/82-09-07 " Receiving
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Inspection Checklist".
Action is needed by the site to determine the location of the replacement shaft C0C's, i
18. Welding Inspector Training Program The resident inspector attended a session, conducted by Bellefonte's Welding-Engineering Unit, of welding inspector training on March 26, 1982. The j
training consisted of three problems dealing with the following:
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3" Fit-up Code Butt Welds
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Fit-up 2" Socket Weld 3.
Weld defects / wide weaves
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This session was conducted in accordance with Bellefonte's Standard Opera-
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ting Procedure WEU-SOP-715 R2 in an outstanding manner.
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No violations or deviations were identified.
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