IR 05000440/1980026
| ML19343B536 | |
| Person / Time | |
|---|---|
| Site: | Perry  |
| Issue date: | 11/18/1980 |
| From: | Erb C, Konklin J, Williams C NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML19343B534 | List: |
| References | |
| 50-440-80-26, 50-441-80-24, NUDOCS 8012240172 | |
| Download: ML19343B536 (7) | |
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U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT
REGION III
Report Nos. 50-440/80-26; 50-441/80-24 Docket Nos. 50-440; 50-441 License Nos. CPPR-148; CPPR-149
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Licensee: The Cleveland Electric Illuminating Company Post Office Box 5000 Cleveland, OH 44101
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Facility Name:
Perry Nuclear Power Plant, Units 1 and 2 Inspection At:
Perry Site, Perry, OH Inspection Conducted:
November 3-5l,4 %
1980 t*z i MIf/fd.
Inspectors:
J. E. Konklin Erb 7ptr / f' /9 fc Approved By:
C. C. Willi s Ch
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Projects Section 2
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?nspection Summary Inspection on November 3-5, 1980 (Report No. 50-440/80-26 and 50-441/80-24)
Areas Inspected: CEI/GAI/GE design control interfaces; licensee and contractor control of craftsmen qualifications; trend analyses and audits of contractors' performance; safety related structures procedures, work activities, and quality records; reactor coolant pressure boundary piping - work activities and quality records.
This inspection involved a total of 40 on-site inspector hours by two NRC inspectors.
Results: No items of noncompliance were identified in the areas inspected.
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DETAILS
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Persons Contacted Principal Licensee Emplovees
- M. Edelman, Manager, Nuclear QA Department
- W. Kacer, General Supervising Engineer, CQS
- P. Martin, General Supervising Engineer, PQS
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- B. Barkley, General Supervising Engineer, Design
- G. Leidich, CQS QE Supervisor
- B. Walrath, PQS QE Supervisor
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- M. Combs, CQS Engineering Aide Other Personnel
- T. Arney, Program Manager (GAI)
- K. Pech, Assistant Program Manager (GAI)
- P. Gibson, CQS QC Supervisor (KEI)
R. Williams, CQS Lead Mechanical QE (GAI)
D. Hess, Site QA Manager (GE I & SE)
P. Hudson, General Superintendent (Schneider)
P. Hunter, CQE Lead Construction Auditor (GAI)
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J. Anulies, Site QA Manager (PBI)
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C. Burnett, Records Quality Manager (PBI)
J. Staffiera, QA Manager (NNIC)
D. Buchanan, Area Supervisor (PPP)
NRC Personnel J. Hughes, Perry Resident Inspector (November 3 only)
- Denotes those present at the exit meeting on November 5, 1980.
The inspectors also contracted other Licensee and contractor employees, including craftsmen and members of the quality, technical, and engineering staffs.
Licensee Action on Previous Inspection Findings I
(0 pen) Unresolved Item (440/80-13-01; 441/80-12-01). Questions regarding review of changes initiated by General Electric. During the previous inspection, the inspector expressed concern regarding the CEI/GAI/GE interfaces related to review of changes initiated by General Electric for the NSSS installation work. During this inspection, the inspector found that redefinition of the interfaces is still incomplete.
Section I of this report contains a more detailed discussion of this area.
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Section I i
Prepared by J. E. Konklin j
Reviewed by C. C. Williams, Chief Projects Section 2 A.
Ongoing Site Construction Activities The inspector observed ongoing work activities and equipment status in the Units 1 and 2 containment buildings, the Units 1 and 2 auxiliary buildings, the intermediate building, the control complex, and the fuel handling building.
No items of noncompliance were identified.
B.
CEI/GAI/GE Design Control Interfaces Previous RIII Inspection Report (50-440/80-13; 50-441/80-12) discussed l
the inspector's review of site design control activities, and noted specific concerns regarding the review of design changes initiated by General Electric (GE) in the NSSS area. The concerns were as follows:
1.
FDIs and FDDRs initiated by GE are reviewed by GAI only for interface considerations.
2.
On the FDIs and FDDRs reviewed, there were no CEI or GAI QA reviews noted, and the CEI procedures did not require such reviews.
In addition, a CEI audit of GE had found that GE was not performing QA reviews on FDDRs.
During this inspection, the inspector reviewed the applicable revised CEI interface procedures and draft copies of the revised GE procedures for control of FDIs and FDDRs, and discussed with i
licensee personnel the steps which are being taken to assure adequate review of design changes initiated by GE.
i The inspector noted that the revised CEI interface procedures and the draft GE procedures now include appropriate requirements for review of design changes to assure compliance with QA requirements. However, since the revised GE procedures have not yet been implemented, and since CEI and GE have not yet reached agreement regarding QA reviews of FDIs and FDDRs which
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have been issued and which did not receive a QA review, the
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inspector informed the licensee that the previous unresolved item will be left open pending completion of those actions.
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C.
Qualifications of Contactors' Craftsmen The inspector discussed with the licensee the qualifications of craftsmen who work on safety related systems, components, and structures at the Perry site. The inspector and the licensee's lead mechanical quality engineer then met with the QA Manager for GE I&SE and the General Superintendent for Schneider, the labor broker for GE at the site.
The discussions elicited the following information regarding the training and qualifications of craftsmen:
1.
The union Locals set their own qualification requirements for the various disciplines. A typical example would be a requirement for a craftsman to have five years of experience as an apprentice or on a permit in order to obtain a union card in a specific discipline.
2.
When qualified craftsmen in a specific discipline are not available in the local, the union may obtain craftsmen from another local (known as travellers), or may issue a " permit" (also known as a " white ticket") to a craftsman from another discipline only for a specific job (i.e., an ironworker to do pipefitting).
3.
In addition to the training programs provided by the unions for apprentices, GE provides on-site training or qualification for certain disciplines with regard to requirements which are unique or especially stringent for nuclear safety-related work.
Examples include weld qualifications by welders, physicals and equipment related training for riggers, training for boilermakers and pipefitters in grinding requirements, grouting classes for mi11 wrights, and training courses for electricians working on safety related activities.
The inspector had no further questions at this time, but informed the licensee that future inspections will include a more detailed review of the training provided for craftsmen by site contractors (50-440/80-26-01; 50-441/80-24-01).
D.
Auditing and Trending of Contractor Activities
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The inspector reviewed licensee documentation related to auditing and trending of contractor activities to determine whether an effective system has been established and is being utilized to identify weaknesses in contractors' QA programs, and whether there is evidence of meaningful followup in areas where contractor deficiencies are found.
Included j
in the review were the following:
1.
CQS Procedure 2-1602, Revision 2, dated October 6, 1980, titled " Trend Analysis"
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CQE Audit Status Chart, and the CQS Projected Monthly
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Audit Schedule for November 1980 l
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3.
CQS trend analysis report file, covering analyses of i
various site contractors during the period from February 7, l
1979 to March 24, 1980
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4.
CQE Monthly Performance Analysis Report for September 1980, f
dated October 8, 1980, which includes a summary of the audit reports for audits during September 1980.
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5.
CQS Audit Reports Nos. 436 to 440, for the month of September 1980.
Based on discussions with the licensee, and review of the applicable
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audit and trend analysis documentation, the inspector concluded that j
an effective system is in place for identifying and following up on
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weaknesses in the QA programs of site contractors.
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i No items of noncompliance were identified.
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Section II Prepared by C. M. Erb Reviewed by D. H. Danielson, Chief l
Engineering Support Section 2 1.
Structural Steel Installation Between Containment Wall and Dry Well - Unit 2 The installation and torqueing of bolts with nuts was observed in this area. QA procedures and records were examined in the office of PBI Industries, who have this contract.
A Skidmore equipment #690 was checked and found to have been calibrated on October 22, 1980, with recalibration scheduled at 1 year intervals.
Another Skidmore was out for calibration on the day of our inspection.
The Skidmores are used for calibration of impact wrenches twice a day. The bolts are purchased to ASTM A-325 and are tightened as outlined in the ASTM A-325 specificatien for a particular size.
Welding in structural applications is performed to AWS D1.1-72 with 1973 and 1974 Addenda. Presently nine welders are qualified and qualification tests are through Herron Test Company. Velding procedure " Erection -3" is used with material being SA-36 to SA-36 with electrode 7018. Aminimumpreheatof70Fisusedbelow3/4",
150 F at 3/4" to 1-1/2" thickness and 225 F at 1-1/2" to 2-1/2" thickness.
Nonconformances are written and one involved a pipe condition in the web-flange intersection of a heavy structural beam which was removed and repaired by welding.
Magnetic particle inspection of welds is utilized, with the amount depending on whether the weld is full or partial penetration.
Ultrasonic inspection by a subcontractor is used on full penetration welds, which usually involve a backing bar. Audits are made by PBI twice a yr ar and by the licensee once a month.
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I No items of noncompliance or deviations were identified.
2.
Observation Work On Containment Dome - Unit 1 i
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There are six 8" circular headers mounted in the dome at 3 different levels which will be equipped with spray nozzles to soak down the containment in the event of a radioactive release.
These headers are fed by two 12" vertical' pipes. The inspector noticed that two problems were apparent: (1) the radii of the headers were not held closely enough, resulting in serious mismatches where the circumferential butt welds must be made, (2) many of the nozzles pointed directly-6-
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into or very close to the square vertical pipe supports from the done roof. The licensee stated that corrective action for Pullman Products to use had been prepared. The inspector suggested that the pulling / heating operation to correct the mismatch for welding be performed on a trial piece on the ground before attempting production, since minimum temperature and actual deforming loads need to be known before attempting the operation 40 feet or so in the air.
No items of noncompliance or deviations were identified.
3.
Observation of Work in Unit I Fitup for welding in a main recirculation L ne was inspected.
a.
The purge dans were in place and the consumable insert was cut out in 3 areas to facilitate the observation of the insert during the fusing pass. This weld was No. B33-1-B3 and was in a 21" x 1.29" wall stainless pipe to valve. Weld procedure was GVP 1000 and radiography was to be performed on the root and finished
weld.
A Dimetrics automatic welder is being qualified to make welds in the main recirculation piping.
b.
Quencher to floor plate welds were examined in the suppression pool area. These quenchers were built by CBIN and each has four quenching arms.
Welding procedure No. 8.1.4.1A is used to weld P-8 to P-8 materials and 316L-16 electrode is the filler material.
These welds are Class 3 NPT and are built to the requirements of ASME Section III, 1974 Edition thru Winter 1975 Addenda.
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The root is inspected by penetrant test and every second layer, including the ground final layer, is also inspected.
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c.
Storage of door assemblies for the inlet nozzles has been made
in the annular space between the vessel and shield wall at the sole plate area of the reactor pressure vessel. These door assemblies have gears and shafts for activation and storage in this area appeared questionable. The Licensee agreed to review this practice and take appropriete action. This is an unresolved item (440/80-26-02).
I Unresolved Items
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Unresolved items are matters about which more informatic; is required in order to determine whether they are acceptable items, items of noncompliance, or deviations. An unresolved item disclosed during this inspection is discussed in Section II, Paragraph 3.c.
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Exit Interview The inspectors met with licensee representatives (denoted under Persons Contacted) at the conclusion of the inspection on November 5, 1980. The inspectors summarized the purpose and findings of the inspection.
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