IR 05000440/1981005
| ML20008F811 | |
| Person / Time | |
|---|---|
| Site: | Perry  |
| Issue date: | 04/02/1981 |
| From: | Julie Hughes, Warnick R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML20008F810 | List: |
| References | |
| 50-440-81-05, 50-440-81-5, 50-441-81-05, 50-441-81-5, NUDOCS 8105120092 | |
| Download: ML20008F811 (7) | |
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U.S. NUCLEAR REGULATORY COMMISSION OFFICE-0F INSPECTION AND ENFORCEMENT
REGION III
Report Nos. 50-440/81-05; 50-441/81-05 Docket Nos. 50-440; 50-441 License Nos. CPPR-148;'CPPR-149 Licensee:
Cleveland Electric Illuminating Company P. O. Box 5000 Cleveland, OH 44101 Facility Name:
Perry Nuclear Power Plant, Units 1 and 2
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Inspection At:
Perry Site, Perry, OH Inspection Conducted:
February 1-28, 1981 U
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Inspector:
. Hu es l l R Fu)wwA'
Approved by:
R. F. Warnick, Chief 9/2[8/
Reactor Projects Section
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2B Inspection Summary Inspections on February 1-28, 1981 (Report No. 50-440/81-05; 50-441/81-05)
Areas Inspected: Routine inspection by the IE Regional Resident Inspector (RI) of safety related construction activities, including welding of safety related penetration, welding of reactor recirculation piping system, welding of safety related piping and licensee actions relative to the resolution of the Region III Immediate Action Letter of January 28, 1981. This inspection involved 171 inspection hours by one NRC inspector, including 16 hours1.851852e-4 days <br />0.00444 hours <br />2.645503e-5 weeks <br />6.088e-6 months <br /> onsite during of f-shif ts.
Results: No items of noncompliance or deviations were identified.
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DETAILS
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Persons Contacted
- M. Edelman, Manager, Nuclear QA Department
- G. Croscup, Manager, Nuc.7 ear Engineering Department
- W. Kacer, General Supervising Engineer, CQS J. Kline, General Supervising Engineer, Construction B. Bark'ey, General Supervising Engineer, Design P. Martin, General Supervising Engineer, PQS J. Leidich, CQS QA Supervisor K. Combs, CQS Engineering Aide S. Tulk, CQS Lead Electrical Quality Engineer E. Christiansen, Nuclear Electrical Engineer J. Connelly, CQS Lead Civil QE (GAI)
R. E. Re'~fsnyder, CQS, Quality Control Inspector (KEI)
B. E. Tho=pson, CQS, Quality Control Inspector (KEI)
W. C. Wells, Quality Assurance Manager, Metalveld, Inc.
B. K. !iilligan, Vice President, Field Operations, Metalveld, Inc.
W. F. Helies, Procedure Engineer, Metalveld, Inc.
J. B. Vaspoli, Quality Control Inspector, Metalweld, Inc.
The inspector also contacted and interviewed other licensee and contractor personnel during this reporting period.
- Denotes those attending at least one of the exit meetings.
2.
Licensee Action on Previous Inspection Findings The following paragraphs close out items of nonco=pliance as per Appendix A of Inspection Report 440/81-01; 441/81-01.
Noncompliance la, Ib: Specification 64 and Metalveld's procedures do not--
address dry film thickness inspection frequency for unique steel shapes (i.e. pipe, hangers, chaanels, etc.); specify inspection frequency for wet film thickness (WFT) for coating material applied to concrete surfaces.
The Resident Inspector reviewed Engineering Change Notice (ECN) 5903-64-34 dated
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January 29, 1981, adding paragraph 5:05.6 to SP-64.
The ECN delineates the frequency of measurements and criteria for the aforementioned operations. Metal-weld's procedure IP-210, Rev. 1, dated January 29, 1981 titled Inspection Plan for Level I Steel Coating Work was reviewed to assure that the ECN was incor--
porated into the procedure.
Noncompliance Ic: Metalweld's QA and QC procedures are not controlled in accordance with QAP-006, Sec.tlon 3.0.
Review of the individual attachments to the QA/QC procedures; inspection reports / test results for in-process and completed coatings have been updated (February 20, 1981) to conform with QAP-006.
Noncompliance Id:
Base line reading on bare steel substrate has not been established and applied to dry film thickness measurements as required by SP-64.
The Resident Inspector reviewed ECN 6054-64-35 dated February 20, 1981, which delineates base steel measurements and acceptance criteria. Review of Metalveld's Inspection Plan IP210, Rev. 2 and QCP-027 dated February 20, 1981, incorporates the ECN require =ents.
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n Noncompliance 1e: Metalweld personnel did not' properly identify and con-trol damaged Carbo Zine II containers, and therefore was nonconforming in accordance with the requirements of QAP-015.
Nonconformance Report (NR).
was issued by Metalweld on January 26, 1981 against the damaged ~ containers.
During review of procedure QCP-005, Rev. 9, the contractor determined that the procedure was inadequate to cover receipt inspection of coating.
materials. - QCP-005 was revised to clarify the receipt inspection of all coating materials and how to document nonconforming items.
Noncompliance if:
Calibration of field thermometers was performed at one point within their. intended range of use, not three points as required by QAP-012.1, Section 4.3.
The RI reviewed calibration data for surface -
thermometers (10).
Calibration was done by U.S. ' Testing Co. using National-Bureau Standards thermometer TH719/4-24-80, which was calibrated to NBS-213.12/215441.
Calibration was performed using five points versus three points, between the ranges of 410 F. and 1630 F.
Noncompliance Ig, lh:
One Metalweld QC inspector did not meet specific project requirements or qualification / certification required by QAP-002.4.1, Sections 5.2 and 5.1.3. The RI reviewed records of indoctrination, train-ing and certification of all QC inspectors. Review. indicated that Section 5.2 was satisfied and the one individual.who did not meet the site criteria for minimum on-the-job training was reverted back to a trainee working under the direction of a Level I or Level II inspector.
Noncompliance ~.a:
Microtest magnetic dry film thickness gage No. - 273 was available for use in field inspec tion activities, having been previously damaged and not removed from service or tagged to control:its use.
The RI reviewed indoctrination and training records to verify that QC in-spectors have been instructed on the use, calibration, recalibration and expiration of calibration for each piece of inspection equipment in'ac-cordance with QAP-012.1.
The inspector observed that Metalweld has identified a holding area for out of calibration or damaged equipment.
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The damaged mikrotest gage found by the Region III inspector was removed from the site.
l Noncompliance 2b: The calibration of standard thermometers No. 819 and l
829 had expired and the calibration sticker affixed to each incorrectly I
specified the re-calibration date.
The RI reviewed (10) calibration data
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records for thermometers used by Metalweld and found them to be currently.
calibrated. Metalweld's calibration procedure QAP-012.1, Calibration of Inspection Instruments has not been revised at this time. However, all instruments (thermometers) have been re-calibrated by U.S. Testing Co.
in accordance with NBS.
In the interim prior to the revised procedure, j
the RI observed that the contractor has devised a visual monitoring system i
to insure that equipment will not be used after the calibration date has expired.
The inspector found this to be adequate.
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Noncompliance 3: Based on interviews conducted with responsible Metalweld QC inspectors, it was concluded that those inspectors had not achieved the necessary level of competency to perform their assigned responsibility as Level I and Level II inspectors.
The RI reviewed Metalweld's indoctrination and ' training records to verify that QC inspectors had received hands on training and to qualify individuals by QC procedure to perform their
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specific functions.
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3.
Functional or Program Areas Inspected g
One or more plant areas were toured several times during this reporting -
period to observe general construction practices.
One tour was made on back shift.
No items of noncempliance or deviations were identified.
4.
Immediate Action Letter of January 28, 1981 Background - During an inspection by Region III inspectors at the Perry site ~
j on January 21-23, 1981, Inspection Report No. 81-01, the inspectors identified numerous problems pertaining to the nuclear coatings contractor, Metalweld, Inc.
a.
The following corrective actions required by the,Immediate Action Letter (1AL) have been taken:
(1) Augment and revise CEI and Metalweld procedures and checklists to assure proper coatings application.
(2) Conduct comprehensive indo6trination and training of Metalweld site quality control personnel.
(3) Assure that qualifications and certifications of all Metalweld site quality control inspectors meet the requirenents of Reg.
Guide 1.58/ ANSI N45.2.6-1973.
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(4) Review, update, and revise the measuring and test equipment system used by Metalweld, to include appropriate requirements for recall methods, accuracy and calibration.
(5) Prior to restarting safety-related coatings activities, verify that existing coating naterials and applications meet the speci-fied requirements and control all identified nonconformances in-accordance with your approved QA Program.
(6) Following receipt of the confirmation, and concurrent with restart of the coatings activities, implement a 100% QC overview of Metalweld activities until confidence in Metalweld's performance is achieved.
b.
The following correct ve action was taken by the licensee:
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(1) On January 23, 1981, the licensee issu(d a Stop Work Notification (SWN) No. 81-01 and Corrective Action Raquest (CAR) No. 0504.
(2)
The Resident Inspection observed and reiiewed the licensee corrective
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action to resolve the 1AL and determined the following:
(a)
The nuclear coatings co-tractor has revised their Individual-attachments, checklists and inspection records to comply with QAP-006 to assure the use of the correct revision and date specified for the individual procedure.
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(b)
Review of CAR procedure QAP-016, Rev. 5 dated January 29, 2 Cul, clarify how a CAR -is to be used for identifying, documenting and verifying implementation for significant conditions ad-verse to quality.
Ir.doctrination and tri4ining
' lessons were given to QC inspectors pertaining to the working mechanisma of the procedure.
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(c )
Receipt inspection procedure QCP-OhJ does not re-quire opening of boxes to check coating containers for damage. The RI reviewed QCP-023, Rev.~10 dated January 25, 1981 which stated in part "When the
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coating containers are shipped inside boxes, each box shall be opened and each container inspected _
for evidence of damage and proper identification".
(d)
Reviewed Inspection Plan, IP-210, Rev. I and Rev. 2 dated January 29 and February 20, 1981 respectively which incorporated the inspection requirements for measuring base steel readings after surface prepar-ation; frequency of dry film thickness (DFT); fre-quency for taking surface profile measurements on steel substrate after surface preparation and frequency of wet film thickness (WFT) reading on coatings applied to concrete.
Inspection Plan IP-210 appears to adequately address all concerned areas.
(e)
Review of Metalweld's indoctrination and training of their on-site QC-inspectors indicated that a comprehensive program was completed for the follow-
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ing procedures for Unit #1 containment dome and a continuing training program is in process for other work procedures that have not been issued and ap-proved:
IP-210, QCP-008, QCP-007, QCP-011, QCP-015, QCP-025, WI-210, WP-133, WP-134 and WP-142.
The I
inspector determined.that the training program is adequate and will continue to monitor the con-tractors training program.
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(f)
Review of Metalweld's quality control inspectors to assure that qualifications and certifications meet the requirements of Reg. Guide 1.58/ ANSI N45.2.6-1973 was completed during this reporting period. Personnel records appear to be satisfactory and complete.
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The RI reviewed (10) calibration data records for thermometers used by Metalweld and found them to be currently calibrated. Metalweld's calibration pro-cedure QAP-012.1, Calibration Inspections Instruments is currently being revised and should be approved by the licensee by the middle of March. However, all thermometers have been re-calibrated by U.S. Testing Co.
in accordance with NBS.
In the interim prior to the
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release of the revised procedure, the inspector ob-served that the contractor has devised a visual monitoring system to insure that instruments will not be used after their calibration date has expired.
The inspector found Ulis to be adequate in 'the in-terim.
c.
Prior to NRC Region III concurrence on the results of the corrective actions set forth in the IAL, the RI observed and reviewed daily surveillance inspection reports conducted by the licensee's, Construction Quality Control Section (CQC) on previous existing coating materials and applications to insure that tjecified-re-quirements were met.
The inspector determined that all readings (average 3) were in the specified limits aof the contractor's specification. The areas included the interior of Reactor Pres-sure vessel Unit #1 pedestal, above and below the platform; blast shop structural steel and hangers.
d.
RI reviewed all documentation pertaining to the NRC's IAL and li-censee's SWN No. 81-01 and CAR No. 0504 and determined that cor-rective action taken by the licensee and nuclear coatings contre-tor '
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to be adequate to resume nuclear coatings activities. Per tele-phone conversation (February 12, 1981) with RIII Staff concerning releasing the Stop work Order of the nuclear coatings contractor, RIII gave their concurrence and will follow up this conversation with a confirmation letter (February 26, 1981) to the licensee.
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On February 13, 1981, RIII called the licensee and released the i
Stop Work Order for the nuclear coatings contractor, On February 13, 1981, the licensee issued a partial Stop Work e.
Release to the nuclear coatings contractor to complete QC in-spections and finish painting of Unit #1 containment dome.
The-RI observed the contractor's QC operations and interviewed QC inspectors to determine if they had achieved the necessary level of competency to perform their broad range of tasks for which they are assigned responsibility as Level I and Level II in-spectors. During this reporting period the RI monitored the in process coatirgs activities for the unit 1 containment dome and determined that the activities were satisfactory.
The licensee has implemented a continuing 100% QC overview of Metalweld activities by the Construction Quality Control Organi-
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zation.
This overview will continue until the licensee has confidence in Metalweld's performance.
No items of noncompliance or deviations were identified.
5.
Installation of Safety-Related Penetrations The inspector observed in process and completed work activities in-cluding welding, grinding and liquid penetrant (PT) testing of safety-related penetration P-404 (chilled water supply piping).
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a. The inspector observed the in process and completed welding and grinding of the root pass and final pass of penetration number P-404 in accordance with ISO-IP50-7, weld process sheet for FW10, Pullman Power Products (PPP) welding procedure WPS 13/IT-8A and ECN 4970-44-366.
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b. During this inspection period, the inspector observed the liquid penetrant (PT) examination 'of the root pass for FW10 in accordance with PPP procedure IX-PT-1-W75 dated February 12,'1979.
Thel field-
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weld appears to be satisfactory.
c. The inspector reviewed-the tollowing' documents pertaining to FW10:
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weld rod issue ticket which included weld rod - type E6010-3/32, weld rod heat no. OF205814, welder's ID no. H-1 and date issued; ISO drawing no. IP-50-7; drawing no. - B-312-633,- revision E, weld prccedure no.13/IT-8A and Engineering Change NoticeL (ECN)
'4970-44-366 for type "D" penetration field welds.
No items of noncompliance or deviations were identified.
6.
Safety Related Piping - Observaticn of Work and Work Activities a. The inspector observed the. fit-up, tack welding,' and root pass welding of Feedwater System FW18 on -ISO-1N27-2 revision 5 and in accordance with PPP welding procedure 11T1.
b. The inspector. reviewed radiographic film -(RT) for.the:above mentioned weld. Radiography-technique was in accordance with PPP procedure IX-RT-5.
. Film review was satisfactory.
No items of nonco=pliance or deviations were identified.'
7.
Reactor Coolant Pressure Boundarv Piping - Observation of Welding Activities - Unit 1 The inspector observed welding of the Reactor Recirculation System Weld No. B33-1-A2 on traveller No. TI-B33-29.
It was dstermined that (1) work was conducted in accordance with traveller; '(2) proper welding materials were used; (3) welding procedure (WPS8.2.4.5 rev. 3)
require =ents were met; (4) work area was free of weld-rod stubs; and (5) physical appearance was acceptable.
No ite=s of noncompliance or deviations were identified.
Exit Interview The inspector met with licensee representatives (denoted in Persons Con-
l tacted) on February 6,13, 20 and 27, 1981.
The. inspector su=marized the
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j scope and findings of the inspections performed.
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