IR 05000440/1980028
| ML19351G179 | |
| Person / Time | |
|---|---|
| Site: | Perry  |
| Issue date: | 01/08/1981 |
| From: | Konklin J, Schapker J, Williams C NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML19351G174 | List: |
| References | |
| 50-440-80-28, 50-441-80-26, NUDOCS 8102230228 | |
| Download: ML19351G179 (8) | |
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U.S. NUCLEAR REGULATORY COTIISSION OFFICE OF INSPECTION AND ENFORCEMENT
REGION III
Reports No. 50-440/80-28; 50-441/80-26 Docket Nos. 50-440; 50-441 Licenses No. CPPR-148; CPPR-149 Licensee: The Cleveland Electric Illuminating Company Post Office Box 5000 Cleveland, OH 44101 Facility Name: Perry Nuclear Fower Plant, Units 1 and 2 laispection At: Perry Site, Perry, Ohio Inspection Conducted: December 16-19, 1980
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Inspectors:
J. E. Konklin (December 16, 7, 19, 1980)
J. Schapker
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(December 1, 17, 18, 1980)
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Approved By:
.' C Will ams Chie
!- h-N Projects Section No. 2 Inspection Summary inspection on December 16-19, 1980 (Reports No. 50-440/80-28; 50-441/80-26)
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Areas Inspected: Structural welding work activities, procedures, and records; ongoing construction act ivities; site contractor audit programs; site contrac-
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tor QC coverage of wort activities. This inspection involved a total of 36 onsite inspector-hours by two NRC inspectors.
Results: No items of noncompliance were identified in the areas inspected.
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DETAILS i
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Persons Contacted i
Principal Licensee Employees i
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+*M. Edelman, Manager, Nuclear QA Department
- G. Groscup, Manager, Nuclear Engineering Department i
+*W. Kacer, CQS General Supervising Engineer
+*P. Martin, PQS General Supervising Engineer l-
+*K. Combs, Senior Engineering Aide
+B. Barkley, General Supervising Engineer, Design Other Personnel
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- C. Hunter, CQE Lead Auditor (GAI)
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J. Connelly, CQS Lead Civil QE (GAI)
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i W. Ware, CQS Civil QE (GAI)
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J. Miller, QA Manager (Pullman)
i T. Payne, QC Manager (NNIC)
B. Romano, Senior Quality Analyst (NNIC)
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C. Hubbuch, CQS Mechanical QA (GAI)
i NRC Personnel
+*J. Hughes, Perry Resident Inspector, RIII The inspectors also contacted and interviewed other licensee and contractor personnel.
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+ Denotes those attending the exit interview on December 18, 1980.
- Denotes those attending the exit interview on December 19, 1980.
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Section I Prepared by J. E. Konklin Reviewed by C. C. Williams, Chief Projects Section No. 2 1.
Ongoing Site Construction Activities The inspector observed ongoing work activities and equipment status in ihe 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.
2.
Site Construction Audit Programs The inspector reviewed the internal audit programs of two site contrac-tors, Pullman Power Products (Pullman), the contractor for installation of safety-related piping, and Newport News Industrial Corporation (NNIC),
a contractor invol red in safety-related structural steel fabrication and installation.
a.
Pullman Audit Program During discussions with the Pullman Site QA Manager, the inspector determined that all audits of Pullman site activities and vendors are performed by the Pullman corporate office. The inspector reviewed the following documents related to the Pullman audit program.
(1) The Pullman Approved Vendor List, issued July 2, 1979, and revired August 5, 1980 and November 11, 1980, which includes the schedule for QA audits of all vendors for safety-related equipment and materials.
Copies of past vendor audits are maintained in the Pullman corporate offices.
(2) Pullman Audit Report No. 7026-1-80,- which reported an audit of Pullman site activities, conducted on March 24-27, 1980, and which generated eleven Audit Action Requests (AAR's).
(3) Pullman Audit Report No. 7026-2-80, which reported an audit of Pullman site activities, conducted on September 22-25, 1980, and which generated twelve AAR's.
The two audits of Pullman site activities noted above compared the site organization's performance to the requirements of the ASME Code,Section III, and 10 CFR 50, Appendix B.
The RIII inspector reviewed the 23 AAR's generated by the two audits to determine whether the recommended corrective action for each
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finding was appropriate, and whether the completed corrective action for each finding was adequate and was accomplished in a timely manner.
During subsequent discussions with the licensee, the inspector expressed concern regarding the fact that copies of the Pullman audits of vendors, including the audits of CEI as a material supplier to Pullman, were not available on-site.
The licensee stated that an upcoming audit of Pullman by CEI, scheduled for February 1981, will address this concern. This is designated as an unresolved item (440/80-28-01; 441/80-26-01) pending review during a future inspection.
b.
NNIC Audit Program The inspector discussed the NNIC internal audit program with licensee and NNIC personnel. The NNIC site Audit Group performs the internal NNIC audits related to specific areas of work activities and documentation. The inspector also reviewed the following NNIC audit documentation:
(1) The NNIC Internal Audit Schedule for 1980, transmitted by memo dated January 2, 1980, from the NNIC Audit Coordinator to the NNIC QA Manager.
(2) Audit No. NNI-P-20-80, dated October 8, 1980, titled
" Examination or Test Status."
(3) Audit No. NNI-P-21-80, dated November 5,1980, titled
" Organization."
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(4) Audit No. NNI-P-17-80, dated August 27, 1980, titled
" Nonconforming Material or Items."
(5) Audit No. NNI-P-13-80, dated July 28, 1980, titled
" Corrective Action."
Based on the above discussion and document review, the inspector expressed two concerns regarding the NNIC internal audit program:
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(1) The NNIC internal audit schedules are not dated or signed, and.are not being treated as quality documentation per Section 18 of the NNIC QA Manual.
(2) The NNIC internal audit reports do not indicate that copies
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are furnished to the' licensee, and discussions with the CQS lead auditor and the CQS quality engineer assigned to NNIC indicated that those individuals had not received copies of the NNIC internal audit reports.
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During the exit interview on December 19, 1980, the inspector notified the licensee that the two concerns regarding the NNIC internal audit program will be designated as unresolved item (440/80-28-02; 441/80-26-02), for review during a future inspection.
3.
Site Contractor QC Coverage of Work Activities The RIII inspector reviewed the QA organizations of Pullman and NNIC to determine whether the number of QC inspectors provided for coverage of work activities is adequate.
a.
Pullman QC Inspection During review of the Pullman QA organization, the inspector determined that the QC staff consists of one QC supervisor and ten QC inspectors. The QC inspectors are assigned as follows:
one inspector is assigned full time to the emergency service water pumphouse, one inspector is assigned full time to the Unit I dome fabrication activities, three inspectors are dedi-cated to component supports, one inspector is assigned to the turbine building, one inspector is assigned to reactor building No. 1, two inspectors are assigned to the intermediate building and auxiliary building No. 1, and one inspector is responsible for the test shop and fabrication shop. The QC supervisor also performs inspections as required to cover for inspector absences.
With regard to work delays caused by craftsmen waiting for QC inspections, the craft foremen prepare time sheets on a daily basis which show delays attributed to QA activities. However, the inspector found that the QA delay tices indicated on the craft time sheets include not only the time spent waiting for QC inspections to start, but also the time spent in performance of the inspections, as well as the corresponding times associated with inspections by the Authorized Nuclear Inspector (ANI). No evidence was found of inspection hold points which had been can-celled or passed because of the unavailability of a QC inspector.
b.
NNIC QC Inspection During review of the NNIC QA organization, the inspector determined that NNIC presently has 55 QC inspectors onsite, including third-shift radiographers. Of the 55 QC inspectors, 39 are provided by National Inspection Consultants (NIC), a subcontractor to NNIC.
Discussions with the NNIC QC Manager and the RIII Resident Inspector, and review of the NNIC Daily Work Delay Totals Log, indicated that NNIC presently has sufficient QC coverage for the site work activities. No evidence was found of QC inspec-tion hold points which had been cancelled or passed because of inadequate QC coverage.
No items of noncompliance were identified in the areas inspected.
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Section II Prepared by J. F. Schapker Reviewed by D. H. Danielson, Chief Engineering Support Section 2 1.
Observation of Safety-Related Structures Work Activities The inspector observed welding of biological shield structures a.
in area identified as Bay 8 and welds identified 2-1911, 2-1910, and 2-1744.
Welding personnel qualifications, weld procedure specifications (WPS), and weld rod control were verified to applicable Newport News Industries (NNI) procedure requirements and determined acceptable.
Calibration of weld rod ovens was verified to NNI applicable procedure requirements.
Storage and issuance of welding filler materials were in accordance to NNI procedure requirements, which comply with ASME Section II SFA 5.1.
Calibration of welding machines is accomplished on a monthly basis, where voltage and amperage output is verified to appli-cable standards.
Visual examination of welding in progress by the inspector was determined to be in compliance with applicable standards.
b.
Ultrasonic examination (UT) performed on welds identified 2-109 and 2-110 on the drywall located at 22* 50' was witnessed by the inspector. NNI ultrasonic procedure identified as 948-N-N005 was applicable.
UT machine serial No. 801046 displayed the current calibration sticker, transducer serial No. J-22621, 2.25 megahertz
.5" x 1.0" with 70 lucite wedge was utilized. The inspector
verified calibration set up and examination to referenced pro-cedure requirements, reviewed calibration records of UT machine for resolution, screen height and amplitude control linearity.
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c.
The inspector witnessed visual examination of welds identified
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408 item 2 on plate' identified 77-NNI-194 and weld 405 item 2 on plate 76-NNI-381 located on containment wall. Examinations per-formed by two National Inspection Consultants (NIC) inspectors certified level II for. visual examinations of welds.
(NIC is a subcontractor for NNI.) In addition, magnetic particle examination (MT) of weld 405 item 2 plate number 76-NNI-381 was witnessed by the inspector. Calibration of equipment was properly indicated, applicable. procedure requirements were adhered to.
Verification of inspectors qualifications to SNT-TC-1A level II requirements was accomplished.
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2.
Review of Procedures, Personnel Qualifications, and Documentation of
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Weld Histories a.
The inspector reviewed the following NNI procedures:
Identification Title 946-001, Rev. G General Welding Procedure 948-N-N005, Rev. G Ultrasonic Examination 701-F-WOO 4, Rev. A Welding Filler Metal Handling and Control 465-NC-W001, Rev. A Welder Qualification b.
NDE personnel qualifications reviewed:
Identification Company Discipline J. Ryan NNI UT Level II R. Hinnebusch NIC MT and VT Level II J. Szumski NIC MT Level II c.
Welder qualification reviewed:
Identification Company 892 NNI 903 NNI 033 NNI 433 NNI 650 NNI The above welder's qualifications were current to applicable weld procedures.
d.
Weld histories reviewed:
Weld I.D.
Location 2-1735 Bay 8 biological shield 2-109 22* 50' drywall 2-110 20 51'
No items of noncompliance or deviations were identified.
Unresolved Items Unresolved items are matters about which more information is required in order to determine whether they.are acceptable items, items of noncompliance, or deviations. Unresolved items disclosed during this inspection are dis-cussed in Section I, Paragraphs 2.a and 2.b.
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Exit Interview The inspectors met with licensee representatives (denoted under Per:ans Contacted) on December 18 and 19, 1980. The inspectors summarized the purpose and findings of the inspection.
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