IR 05000438/1982012
| ML20062H960 | |
| Person / Time | |
|---|---|
| Site: | Bellefonte  |
| Issue date: | 05/21/1982 |
| From: | Quick D, Wilcox J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML20062H902 | List: |
| References | |
| 50-438-82-12, 50-439-82-12, NUDOCS 8208160224 | |
| Download: ML20062H960 (12) | |
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d 4 UNITED STATES P 4 NUCLEAR REGULATORY COMMISSION
$ E REGION 11 o, - 101 MARIETT A ST., N.W., SUITE 3100 s ATLANTA, GEORGIA 3n303
Report Nos. 50-438/82-12 and 50-439/82-12 Licensee: Tennessee Valley Authority 500A Chestnut Street Chattanooga, TN 37401 Facility Name: Bellefonte Docket Nos. 50-438 and 50-439 License Nos. CPPR-122 and CPPR-123 Inspection at Bellef te site near Scottsboro, Alabama Inspectors: - ]
J. Dr Wilcox,'Jf. ', /
2-/ 8 U fate / Signed
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Approved by: , g 2./ 82-D. R. Quick Secttion Chief 7 Division of Bate Signed Project and Reactor Programs SUMMARY Inspection on April 1-30, 1982 Areas Inspected This routine, announced inspection involved 176 inspector-hours on site in the areas of construction surveillance, Quality Control Investigation Report (QCIR)
review, QA audit review, licensee identified items (Unit 1 & 2), housekeeping, Nonconformance Condition Report (NCR) review, welding performance qualification record review, licensee action on previous inspection findings, work release review, Design Information Request, construction test, document, tool, and material control, hyprochlorite injection system, clarification of previous reports and trainin Resul ts Of the 15 areas inspected, no violations or deviations were identified in 14 areas; 1 item of noncompliance was found in 1 area (tool and material control).
8208160224 820809 PDR ADOCK 05000438 C PDR
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- DETAILS E Persons Contacted Licensee Employees
- Dahnke, Project ihnager
- F. Gilbert, Construction Engineer G. Blackburn, General Construction Superintendent
- D. Freeman, Electrical Engineer Supervisor EEU
- T. Brothers, Hanger Engineer Supervisor
- F. Moses, Hechanical Engineer Supervisor H. Johnson, Welding Engineer Supervisor WEU
- D. Smith, Assistant Construction Engineer
- J. T. Walker, Assistant Construction Engineer
- F. Huffman, Assistant Construction Engineer
- J. Barnes, QA Unit Supervisor D. Bridges, Assistant Construction Engineer
- L.11cCollum, Instrument Engineer Supervisor J. Olyniec, Civil Engineer Supervisor
- B. J. Thomas, Assistant Construction Engineer
- W. 9. 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. flann, Engineer Ibnagement Assistant B. Sammons, Administrative Officer Q. Franklin, Assistant Gensral Construction Superintendent
- P. McGraw, EEU Other licensee employees contacted included 8 construction craftsmen, 6 technicians,1 mechanic, 4 security force members, and 12 office personne * Attended exit interview Exit Interview The inspection scope and findings were summarized on May 4,1982 with those persons indicated in paragraph 1 abov . - _ _ _ _ _ _ _ _ - _ _ - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
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2 Licensee Actions on Previous Inspection Findings (0 pen) Unresolved Item (438/80-25-01) " Failure to monitor the tempe-rature of the Teflon seats during valve installation." The orginial unresolved item is as follows:
Valve Disassembly / Reassembly to Support Welding The licensee reinstalled a 3" Teflon seated chemical and volume control system valve in the system by making two nozzle butt welds. This valve is identified as INV-IFCV-340 on TVA Dwg. No. 3BWO419-NV-13 Rev. The two butt welds are identified as #1262 and #1263 on weld map
- WitINV-14, Rev. 3. The vendor engineering data sheet applicable to this valve specifies that the maximum temperature fluctuation be limited to 200 degrees F. The Teflon seat is designed to prevent removal. The system mechanical engineer states that he verbally informed the craft to monitor the temperature of the seat during the welding of the butt weld, no device was being used to monitor this temperature. Also the systems mechanical engineer stated that the temperature never exceeded 160 degrees Follow-up of the unresolved item is as noted:
During the week of April 5,1982, the resident inspector observed the installation of the 2" flow control valve #INB-IFCV-547. This valve contained Teflon seats. During welding the center section of the valve must not exceed 200 degree F. This work was performed on Sequence Control Chart (SCC) No. ONB-M096. It was evident from observing this operation of maintaining the valve seat temperature that much care and i control was required. In addition, this SCC did not have WEU concurrence on it; however, controls of the welding operation tere '
involved. This item will remain open until further valves of this type can be observed to ensure that welding operations would not have introduced temperatures greater than 200 degrees F. to the center '
section of the valv ; Unresolved items Unresolved items are matters about which more information is required to determine whether they are acceptable or may involve violations or deviations. New unresolved items identified during this inspection are discussed in paragraphs 13, 15 and 1 . 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, i
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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 supports; installing local instrument panels in the instrument room; installing pressurizer and hardware; pulling and terminating cables; tensioning upper steam generator supports; installing reactor coolant drains and vents; flushing core flooding piping; chipping concrete and installing reactor coolant system hot leg pipe whip restraints; and installing CRDM's on reactor pressure vessel hea (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; and installing spray line support (Auxiliary Building) Witnessed portions 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 Units 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 protection coating on Unit 1 ELEV 649, 667 and 686; and working on catwalks and concrete pour (General) Witnessed portions of installing fire protectio . Quality Control Investigation Report (QCIR) Review The resident inspector reviewed the description and recommended disposition of the following QCIR's:
QCIR N Date Title 18631 4/2/82 Support clamp not making two point contact 18638 4/1/82 DIR E-134 18643 4/1/82 Temperature controller installed in wrong location 18652 4/2/82 Surface indications on ItK9 restraint These QCIR's were handled in accordance with Beliefonte's Quality Control Procedure, BNP-QCP-10.26, Rev. .. a
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No violations or deviations were identifie . Nonconforming Condition Report (NCR) Review The resident inspector reviewed the item description, noncompliance description, recommended disposition and action required to prevent recurrence for the following NCR's:
NCR N Date Title 1795 3/30/82 Connector and support bracket 1796 3/31/82 ECN (304) reactor building spray system 1792 3/25/82 Valves for fire protection These NCR's were handled in accordance with Bellefonte's Quality control Procedure, BNP-QCP-10.4, Rev. No violations or deviations were identifie . Work Release Review The resident inspector reviewed the type of work, description, engineering unit approval, and QA records affected for the following work releases (WR):
WR N Date Title 32221 4/12/82 Change IRT-ECMS-003A to be wired like wiring diagram 32216 4/12/82 Repair rebar 32206 4/12/82 Chip to repair concrete 32183 4/12/82 Weld two plates together 32182 4/9/82 Repull and terminate new cable These work releases were handled in accordance with Bellefonte's Quality Control Procedure, BNP-QCP-10.6, Rev. 1 No violations or deviations were identifie .
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5 Licensee Identified Items (LII)
The resident inspector reviewed the status of the following LII's with site and ENDES personne The following licensee identified items have been ;
reported to RII by TVA unless otherwise specified: (0 pen) LII 438, 439/82-12-01 " Valves not qualified to applicable design requirements" (BLN BLP 8214 and 8215) , (0 pen)LII 438, 439/82-12-02 " Failure to properly review Auxiliary i Feedwater System" (BLN MEB 8203) (0 pen)LII 438, 439/82-12-03 " Stress fractures in support brackets in RPS modules by Barton tieter Co." (NCR 1795) (0 pen) LII 438, 439/83-12-04 " Errors in computer progi n SPSTRESS by CDC" (GEN CEB 8203) :
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~ (0 pen) LII 438, 439/82-12-05 " Electrical penetrations in DHR sump valve !
room" (BLN NEB 8204) (0 pen) LII 438, 439/82-12-06 "QA deficiencies at Nuthern" (81V27, De #5) .
! (0 pen) LII 438, 439/82-12-07 " Lack of Proper environmental qualifi- [
cation of equipment in auxiliary building due to potential failure of Startup and Recirculation System" (BLN NEB 8203)
[ (0 pen)LII 438, 439/82-12-08 " Error in WERC0 program by AAA Technology" i (BLN CEB 8204) (Close) LII 438, 439/81-25-27 "itEU at site not performing periodic maintenance inspections as required by procedure" (BN-M-80-05, MEU).
The resident inspector reviewed the corrective action stated in TVA ~
letter dated July 31, 198 The inspector considers the corrective action and steps taken to be satisfactory; therefore, this item is t close , (Close) LII 438, 439/81-29-02 " Deficient cables manufactured by [
Rockbestors Co. or Raychem Corp." The resident inspector reviewed the '
corrective action stated in TVA letter dated December 29, 198 The inspector considers the corrective action and steps taken to be ;
satisfactory; therefore, this item is close (CDR 50-438/81-62, CDR '
50-439/81-60) (Close) LII 438, 439/81-20-03 "Use of the unapproved masonary bits" (NCR 1396). The resident inspector reviewed the corrective action stated in TVA letter dated December 29, 198 The inspector considers -
the corrective action and steps taken to be satisfactory; therefore, f
this item is close (CDR 50-438/81-22, CDR 50-439/81-24). i f
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10. Housekeeping The resident inspector reviewed the following housekeeping deficiency reports for deficiencies identified and action taken to correct these
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deficiencies:
Deficiency Report N Date 707 4/16/82 i 708 4/20/82 i 709 4/20/82 710 4/21/82 These housekeeping inspections were handled in accordance with Bellefonte's Quality Control Procedure BNP-QCP-10.27, Rev. 4 and Rev. No violations or deviations were identifie i
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11. Quality Audit Review
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The resident inspector reviewed the following Quality Assurance Audits for ;
accuracy and completeness: ;
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Audit N Title No. of Deficiencies BN-G-82-02 Preparation of Quality Control 0 Procedures ;
i BN-G-82-03 Stop Work Authority / Allegation 4 t
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Reporting / Employee Concerns ;
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l BN-G-82-04 Control of Temporary Installation 2
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BN-E-82-03 Computer Data Control 0 v BN-W-82-03 Fitup and Cleanliness / Arc 0 i
Strike Removal No violations or deviations were identifie <
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12. Welding Performance Qualification Record The resident inspector reviewed the following welding performance qualifi- .
cation records for completenes i Stamp N Welding Procedure N Test N Date FCOD Sil11-B-3 Rev 6 SM-4-B-3H 4/6/82 FC0F GT-18-0-1 Rev 5 GT-7-0-1-L(a) 4/6/82 FC0J GT-18-0-1 Rev 5 GT-7-0-1-L(a) 4/6/82 [
FC0I GT-18-0-1 Rev 5 GT-7-0-1-L(a) 4/6/82
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FAIJ S!1-11-B-3 Rev 5 SM-4-B-3-H 4/6/82 These welding performance qualification records were handled in accordance with Bellefonte's Quality Control Procedure, BNP-QCP-10.24, Rev. No violations or deviations were identifie '
1 Design Information Request The resident inspector reviewed Design Information Request (DIR No. 0-38).
The description of information requested is as follows: sel f-drilling i expansion concrete anchors are to be procured as safety-related, quality level III and certified to quality level II by testing in confonnance with TVA Construction Specification G-3 The Engineering Design Disposition is as follows: purchase and qualification of self-drilling expansion anchors as described above satisfies ENDES requirements. It is requested that TVA obtain Civil Engineering Branch (CEB-ENDES) concurrence with the above DI .-
This is identified as Unresolved Item 50-438, 439/82-12-09 " Design Infor-mation Requested."
1 Construction Test Document The resident inspector reviewed the Construction Test Document for cleanliness of system identifie This verification of clealiness test is .
j provided to include Unit 1 Reactor Building Spray System Sodium Hydroxide (
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Tank. This procedure was handled in accordance with Bellefonte's [
Construction Test Procedure BNP-CPT-6.1 Rev. ANSI N45.2.1 - 1973 e Paragraph 3.1.2 states in part: ;
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3.1.2 Class B-A high level of cleanliness applicable to reactor coolant systems, components, and other items, such as the reactor coolant purifi-cation system, which have similar cleanliness requirement r i
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Piping and components in systems which are designed as requiring Class B cleanliness shall meet the following requirements: The surface shall appear " metal clean" when examined without mag-nification under a lighting level (background plus supplementary lighting) of at least 1GJ foot candles. Scattered areas of rust are permissible provided the aggregate area of rust does not exceed 2 square inches in any one square foot are liote: Localized rusting may indicate pitting of the surface and should be evaluated (metallurgically). Thin temper films resulting from welding or post-weld heat treatment are acceptabl . The surface shall be free of purticulate contaminants such as sand, metal chips, weld slag, et . The surface shall be free of organic films and contaminants such as oils, paint, and preservatives as detennined by a visual examination or an organic solvent-dampened white cloth or an equivalent alternate metho . When a visual inspection is not possible and the surfaces are accessible, a dry white-cloth wipe, followed by a solvent-dampened white cloth wipe, may be used to evaluate the cleanliness of the surfac If either cloth exhibits indications of contamination, the system shall either be recleaned or the specific contaminant shall be detennined and evaluated as to its potential . deleterious effec This will be followed up by the resident inspector to ensure these require-ments are met. This is identified as Inspector-Followup Item 50-438/82-12-13 " Sodium Hydroxide Storage Tank Cleanliness."
15. Tool and itaterial Control l During the past several months numerous proof of cleanliness flushes have
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been perfonaed on safety-related systems. During these flushing operations
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it is obvious that from the tools and material obtained froin inside these l safety-related systems that cleanliness was not being maintained during construction activities. The following is a list of some systems or portions of systems which have been flushed and tools / materials have been i found in these systems:
Systems /(Portions) fla t'l/ Tool s (a) Spent Fuel Cooling Grey duct tape, plastic bags, rags, grinding disc, cigarette butts, plastic fork, concrete and gravel, paint and woo ,
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l (b) Reactor Building Spray Rags, Grey duct tape, grinding rods with
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emory cloth attache , e .
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(c) Component Cooling Valve wheel cheater, polishing whee (d) Decay Heat Removal Grey duct tape, wood, rebar, protection cap, buffing wheel,16' rubber hose, grinding wheel, sandwich bag and soft drink ca (e) Core Flood Grey duct tap Bellefonte Quality Control Procedure BNP-QCP-6.16 Rev. 0 " Cleanliness Control During Piping System Installation" states:
Paragraph 6.1 - Prior to installation the crafts shall clean all piping material for those systems specified for cleaning per Construction Specification N4M-89 Paragraph 6.2 - After cleaning, the crafts shall maintain cleanliness control of systems by ensuring that all openings on piping materials are sealed or capped at all times when work is not in progres BNP-QCP-7.9 Rev. 8 "Fitup and Cleanliness" states:
Paragraph 6.3.1(b) - The responsible craft foreman has assured that the piping interior is clean in accordance with the criteria of Field Construction Procedure (FCP) 6.1.2 and indicates such by signing the back of the fitup car The WEU representative will verify the foreman's signature of responsibility before making the fitup inspectio This is identified as violation 438/82-12-11 " Tool and flaterial Control".
TVA is to determine when the valve wheel cheater was being used in a safety-related system. This is identified as UNR item 438/82-12-12 " Valve Wheel Cheater".
16. Hyprochlorite Injection System The resident inspector reviewed the following documents / drawings which pertain to the Hyprochlorite Injection System:
Ref: (A) TVA drawing #3GWO653-KE-01 Rev. 8, " Essential Raw Cooling Water Design Criteria Diagram".
(B) TVA drawing #70WO827-YA-04 Rev. 3, " Flow Diagram Hypro-chlorite System".
(C) TVA drawing #7KWO506-KE-01 Rev. 8, "itechanical Intake Pumping Station Piping and Equipment".
(D) TVA drawing #7KWO508-KE-04 Rev. O, " Mechanical Intake Pumping Station Piping and Equipment".
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(E) Design Information Request DIR. No. E-119, " Safety Classi-fication of Heat Trace".
Based on the above review TVA should address the following:
(A) Reference (a) specifies the design condition for the ERCW '
system adjacent to the hyprochlorite system to be 175 PSIG and 95 F. Reference (c) specifies the design condition for the biocide piping (hyprochlorite system) to be 50 PSIG and 130 Valves VPAC-600-A and VPAC-598-B separate the ECRW system from the hyprochlotte system; however, these valves are in the normally open configuration with no check valve With this configuration there is a differin; design condition between the ERCW and the hyprochlorite system (B) Reference (a) and the FSAR Fig. 9.2.1-1 specify that there is heat trace on the hyprochlorite system; however, ref. (d) and other site drawings do not specify heat trac (C) Reference (c) specifies that IPS heat tracing specifications are being downgraded and will no longer meet class IE safety-related requirement TVA should evaluate the above questions. This is identified as Unresolved Item 438, 439/82-1210 "Hyprochlorite Injection System."
17. Training The resident inspector observed a film presentation entitled "The i
Supervisors Role in Quality Control" during the week of April 26, 196 To date approximately 350 TVA Bellefonte personnel have seen this fil . Clarification of Previous Reports Report 438, 439/82-06: In paragraph 13 change the Violation number from 50-438/81-06-10 ,
to 50-438/82-06-1 In paragraph 9 change the LII number from 438, 439/81-25-08 to 438,439/81-25-2 . Report 438, 439/82-02: In paragraph 9a change the LII number from 438, 439/82-02-02 to '
438, 439/82-02-01 " Welds by Johnson flachine Works on the Revolving Platform." < In paragarph 12 change the UNR number from 438/81-02-13 to 438/82-02-1 ,
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3. Report 438, 439/82-05: In paragraph 3a change _ the UNR number from 438, 439/81-25-30 to 438,439/81-25-3 . Report 438, 439/82-09: In paragraph 9(e) change title of LII 438, 439/82-09-05'to
" Insoluble Glue Used for Purge Dams".
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