IR 05000440/1981003
| ML19345G640 | |
| Person / Time | |
|---|---|
| Site: | Perry  |
| Issue date: | 02/24/1981 |
| From: | Danielson D, Landsman R, Schapker J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML19345G637 | List: |
| References | |
| 50-440-81-03, 50-440-81-3, 50-441-81-03, 50-441-81-3, NUDOCS 8104070684 | |
| Download: ML19345G640 (9) | |
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U.S. hTCLEAR RE';ULATORY COMMISSION OFFICE OF INSPEC', ION AND EhTORCEMENT
REGION III
Reports No. 50-440/81-03; 50 441/81-03-Docket Nos. 50-440; 50-441 Licenses No. CPPR-148; CPPR-149 Licensee: The Cleveland Electric Illuminating Company PO Box 5000 Cleveland, OH 44101 FaLility Name: Perry Nuclear Plant, Units 1 and 2 Inspection At:
Perry Site, Perry, OH-Inspection Conducted: J.auary 21-23, 1981 (Schapker only)
January 28-30, 1981 i
jruk /w Inspectors:
J. F. Schapker
.2.9 d #/
f R. B. Landsman 2 2.4-F (
ww Approved By:
D. H. Danielson, Chief-
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Materials and Processes Section Inspection-Summary.
Inspection on January 21-23 and 28-30, 1981 (Report Nos. 50-440/81-031 50-441/81-03)
Areas-Inspectedi Observation of welding and NDE and review of procedur 's,
- . personnel qualifications and weld procedure specifications for safety related-piping; and quality records for ' safety-related concrete; followup of previously identified. items. -The-inspection involved 62 inspector-hours on-site by two h3C-inspectors.
Results:
In the areas inspected, one apparent violation was identified.
-(failure'to follow procedures for' certifying QA/QC personnel - Paragraph 4,
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Section II).
-18104070684
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DETAILS i
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Persons Contacted Principle Licensee Employees
- G. Groscup, Manager, Nuclear Engineering Department
- M. Edelman, Quality Assurance Manager
-*W. J. Kacer, GSE, Construction Quality Section
- R. Vondrasek, Training / Administration General Supervisor
- G.
Leidich, CQE, dupervisor
- J. Kline, GSE Construction
- B. P. Martin, GSE, Program Quality Kaiser Engineering Inc.
- P. Gibson, Construction Quality Control Supervisor Gilbert Associates, Inc.
- T. Arney, Quality Assurance Program Manager Pullman Power Products J. Miller, Quality Assurance / Quality Control Manager Licensee Action-on Previous Inspection Findings (C1'osed) Noncompliance (440/80-20-01; 441/80-18-01) Failure to-take con-crete testing sample at end of pump discharge line.. Reviewed letter from G. R. Leidrich.to T. Hesmond, dated January 9, 1981,~which states that the Econcrete. sample for in process test is to.be taken at the place concrete is being pumped into the form. A field variance will be required to change this. The onlyLother contractor placing concrete at this time is Dick
- Corporation. ~ Also reviewed letter to Dick Corporation,. dated January 15,.
-1981,' indicating the same as' discussed above. This item is closed.
(Closed)' Noncompliance (440/80-20-02; 441/80-18-02) Jailu. to verify concrete temperature after it: sat in pump line for over an hour. Above referenced letters state to perform termperature measurements-when concrete sits in pump lineLfor one hour or more.
If temperature is not within
- specification,' concrete is'to be discarded. This item is closed.
-(Closed)- Noncompliance (440/80-20-03; 441/80-18-03) Failure to verify concrete' properties -after it sat ' in-pump. line for over an hour.
Previously
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referenced-letters state to' check concrete properties, e.g. slump, etc.
when concrete sits in pump line for one' hour or more.
If properties are not'within specificatich, concrete is to be discarded. This'ttem is closed.
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(Closed) Noncompliance (440/80-20-04; 441/80-18-04) Failed to verify concrete truck agitating times and revolutions.
Reviewed letter from G. R. Leidich to T. Hesmond, dated January 28, 1981, requesting them to record on each batch plant ticket, the actual number of revolutions and truck discharge times. The inspector also re*iewed letter to Dick Corporation, dated January 29, 1981, indicating the same. This item is closed.
(Closed) Noncompliance (440/80-20-05; 441/80-18-G5) Failure to meet ANSI N 45.2.6 experience requirements. Reviewed letter from G. R. Leidich to T. Hesmond requesting him to recertify Tom Gage back to Level 11 instead of Level III since he does not meet the experience requirements for a Level III inspector.
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Section I Prepared by J. F. Schapker Reviewed by D. H. Danielson, Chief Materials and Processes Section 1.
Observation of Welding and NDE of Safety-Related Piping The inspector observed welding in progress for (Room 01 of ele-a.
vation 599) the girth weld identified as Field weld #05 on Iso.
drawing #1P45-2 Emergency Service Water System. Weld procedure specification (WPS) ITI
.sion 1/09/79 was applicable, E-7018 electrodes heat nup'
A95229 was utilized. Field weld 02 and 03 of ISO. drawing 1-E12-4, Residual Heat Removal system, was observed
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for fit up and weld to completion (Room 06 of elevation 574').
WPS ITI revision 1-09-79 was applicable. Filler materials:
E70S-2 heat number 3 4370B131 (K insert), E-70S-6 heat number F5757 (bare wire), E7018 heat numbers 412K6511 and N95229 (3/32" and 1/8" low hydrogen covered electrodes) was utilized. The inspector verified preheat and interpass temperature and essential welding variables. Filler material test reports were reviewed for compliance to applicable material specifications, welder qualifi-cations to referenced WPS's, and WPS's procedure qualification
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records (PQR) were reviewed for applicability in accordance with ASME Section IX requirements.
The inspector also observed welding in progress in Pullman Power Products (PPP) shop on site. Tield welds identified #2 and 28 on isometric drawing D-301-706, Fuel Pool Cooling and Clean-up System piping, in process to WPS-24. Pipe material specified is stainless steel SA-312 type 304 with E308L-16 and ER308L filler material. The longitudinal seperation of the two referenced girth welds ranged from approximately 3/8" to 1/2", 'due to dimensional inadequacy of the pipe as ordered. A field change was implemented which added pipe material in dimensions referenced above and an additional weld to attach the same. The inspector questioned the welding engineering basis for this type of a fix, as it is generally not considered good engineering-practice for a weldments
.to be_ fabricated in such close proximity due to welding stresses
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and heat' input. The inspectorfalso noted the probability of the stainless steel material-between the two welds in the heat
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affected zone (HAZ) being sensitized due to the heat input from the' process of the two welds, thereby increasing the possibility of intergranular' stress corrosion cracking. The inspector ~
informed the licensee'that this matter would be considered an unresolved. item. Th'e licensee agreed to ascertain acceptability of these welds.
(440/81-03-01).
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The inspector observed liquid penetrant examination (PT) to
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Residual Heat Removal system piping field welds numbers 15, 16, 17,18 19, 21, 22 and 23 identifiad on Isometric drawing number 1-E12-510, revision 3.
PT proceuare IX PT-lW75 revision 2/12/79 was applicable.
Penetrant materials were verified for compati-bility; sulfur and halogen content.
Examination personnel qualifications were reviewed and found to be in compliance with SNT-TC-1A recommended practice, The inspector reviewed the following radiographs performed by c.
Pullman Power Products:
(1) Reactor Lore Isolation Cooling System field weld #40 per isometric drawing 1-E51-2.
(2) Residual Heat Removal System field weld #01 and #10 per isometric drawings 1-E12-44 and 1-E12-17 respectively.
(3) Containment Spray Syst+;n field weld #03 per isometric drawing 1-E15-2.
(4) High Pressure Core Spray System field weld #02 identified an isometric drawing E-22-4.
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The referenced radiographs were reviewed for compliance to applicable ASME code Section III and Section V, 1974 Edition and Addenda through W75, and PPP radiograph procedure IX-RT-5 revision 8/29/79. No items of' noncompliance or deviations were identified.
2.
Review of Procedures, Personnel Qualifications, and Weld Procedure Specifications The inspector reviewed the following PPP procedures:
a.
Identification Revision Title IX-PT-1-W75 2/12/79 Liquid Penetrant Examination Winter 1975 Addenda PQR-PT-1 9/06/78 NDE Procedures Qualification Record Liquid Penetrant IX-MT-1-W75 4/01/80 Magnetic Particle Examination Procedure, Dry Powder Continous Method IX-RT-5 8/29/79 Radiograph Inspection of Weldments L
PQR-RT-5 3/12/79 Procedure Qualification Record (RT)
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11-2 1/14/80 Levels I and II Nondestructive
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Examination Personnel Control
& Administration of Training,
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Examination, Qualification &
Certification.
4-IV-5-4W 7/12/79 Purchasing Specification for Mild Steel Gas Tungsten Arc Welding Wire l
IV-500W 11/19/79 Purchasing Specifications for Mild Steel Covered Arc-Welding Electrode-b.
PPP Welder qualfications reviewed:
l Identification WPS Test #
TR Itl-III-1-KI-12 PQT-0518
,JR IT1-III-1-KI-12 PQT-0275 TR-ITIA-III-1-KI-12 PQT-0646
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JR ITIA-III-1-KI-12 PQT-0649
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PPP welder nondestructive examination personnel qualifications
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reviewed:
I Identification Discipline
J.'McPherson.
RT,'PT & MT-Level II R. Kowalcyzk PT.& MT Level II
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D.- Denlinger PT-Level'II J. Copel PT
. Level II
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PPP weld' procedure specifications reviewed:
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Identification Date I
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12/10/76
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~IT8-III-1-BR-2-12/15/76 ITIA-III-1-KI-12 7/14/77 jf 4No items of noncompliance or deviations were identified.
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Section II
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Prepared by R. B. Landsman Reviewed by C. C. Williams, Chief Plant Systems Section Review of Onsite QC Inspector Qualifications As a follow up inspection to IE Report Nos. 50-440/80-20 and 441/80-18, 440/81-01 and 441/81-01 and the history of noncompliances in this area dating back to October 1979, Report No. 440/79-10 and 441/79-10, the
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inspector reviewed the' qualifications of the remaining Civil QC inspectors on site.
CEI Corporate QA Program, Section 0200 requires that examination and test personnel...shall qualify to and be certified to the requirements of the Regulatory Guide 1.58 and ANSI N45.2.6.
The following is a summary of the QC personnel on site at the time, except fc-r National Engineering
- which was reviewed during the inspectors last inspection and United States Testing which,was reviewed by a previous inspection (See Report No. 79-10):
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National Mobile Concr_ete Corporation a.
Certified Level I on November 6, 1980; had an associate degree in Electrical Construction technology with one month experience; he does not meet the ANSI requirements for Level I.
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Certified Level II on March 27,:1978; had an associate degree in Civil Technology with'14 months experience; at the time of certification he did'not meet the intent _of ANSI requirements; he:is now qualified for Level II.
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Great Lakes Corporation Company a.
Certified Level-II on April 11, 1978; had an. associate degr_ee in Civil Technology with 22 months experience; at the time of
. certification-he did not meet the intent of ANSI requirements; he is_now qualified for Level II.
b.
. Certified Level II on June 21, 1978 had an associate degree in Civil Technology with nine months experience; at the time of
= certification he did not meet the intent of ANSI requirements; he-.is now' qualified for Level II.
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. Certified Level'I on April _.30, 1980; hau'no high school ~ degree or experience; at the time of cert ification he_ did not meet the -
intent.of' ANSI requirements;-he is now qualified.for Level I.
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Certified Level 11 on September 8, 1978; had a BA degree in accounting with four months experience; at the time of certi-fication he did not meet the intent of ANSI requirements; he is now qualified for Level II.
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L. K. Comstock Certified Level II on May 7, 1979; had a high school degree with three years experience on a nuclear site; at the time of certifi-cation he met ANSI requirements.
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Dick Corporation a.
Certified Level III on February 18, 1980; had a high school degree with six and one half years experience with four of that on a nuclear site; at the time of certification he met the intent of ANSI requirements.
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Certified Level III on July 20, 1979; had a high school degree with 18 years experience with one and one half on a nuclear site; at the' time of certification,.he did not meet the intent of ANSI requirements; he is now qualified for Level III.
These records revealed that:
(1) The documented experience and education factors did not meet the levels specified in ANSI N45.2.6-1973 with regard to' type and' duration, and, (2) Proficiency testing appeared to be the main basis for certifying individuals.
.This excessive substitution of the proficiency testing for prior experi-ence'at the time of certification does not meet the intent of Regulatory
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Guide 1.58 and ANSI N45.2.6-1973 and as such is in noncompliance with 10 CFR 50,' Appendix B, Criterion V,.as discussed in Appendix A (440-81-03-02; 441/81-03-01).' Additionally,.this' item is repetitive since similar items of noncompliance were. identified in previous Inspection Reports.
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LThe NRC has no: concern about the quality of work performed by these
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individuals since' previous )0N: inspections _of concrete pours occurring
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-following.their' certification have not raised serious questions regarding the quality ofithe concrete _ placement. With respect to the_ individual who
- still does not' meet ANSI requirements, the inspector requested that-the -
l licensee l review his qualifications before' allowing him to inspect any work activitici. ; Subsequently, CEIrinformed the RIII offices on February.26, 1981, by telephone that his certification.has been reduced to a Limited-
. Level-1.
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Unresolved items
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Unresolved items are matters about which more information is required in order to ascertain whether they are acceptable items or items of noncom-pliance or deviations. Unresolved items disclosed during this inspection are discussed in Section I, Paragraph 1.a.
Exit Interview The inspector met with site staff representatives (denated under Persons Contacted) at the conclusion of the inspection an Janua y 30, 1981.
The inspectors summarized the purpose and findings of the inspection. The licensee acknowledged the findings reported herein and agreed to perform a complete audit of all onsite QC inspector qualifications.
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