IR 05000456/1979002
| ML19263D688 | |
| Person / Time | |
|---|---|
| Site: | Braidwood  |
| Issue date: | 03/06/1979 |
| From: | Clint Jones, Knop R, Naidu K NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML19263D684 | List: |
| References | |
| 50-456-79-02, 50-456-79-2, 50-457-79-02, 50-457-79-2, NUDOCS 7904130145 | |
| Download: ML19263D688 (11) | |
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U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT
REGION III
Report No. 50-456/79-02; 50-457/79-02 Docket No. 50-456; 50-457 License No. CPPR-132; CPPR-133 Licensee:
Commonwealth Edison Company P. O. Box 767 Chicago, IL 60690 Facility Name: Braidwood Nuclear Power Station, Units 1 and 2 Inspection At: Braidwood Site, Braceville, IL Inspection Conducted: February 7-9, 1979 0E0n Inspectors:
C. E. @ones 3-d-7f 7"
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Approved By:
R.
. Knop, Chief
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Inspection Summary Inspection on February 7-9, 1979 (Reports No. 50-456/79-02; 50-457/79-02)
Areas Inspected: Observation of the installation of containment steel supports, observation of the structural welding and review of the quality records of the structural steel for Unit 1.
Observation of nondestructive examination on safety related structures and component installation, Unit 1.
Review QA/QC implementing procedures for transfer and placement of major components of the NSS System and review of the status and storage procedures for these components. Discuss status of construction and plans to review the adequacy of the QA/QC program of the replacement electrical contractor. The inspection involved a total of 48 inspector-hours onsite by two NRC inspectors.
Results: No items of noncompliance were observed.
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DETAILS Persons Contacted Principal Licensee Employees
- R'. Cosaro, Project Superintendent
- J. Homoly, QA Supervisor
- C. Mennecke, Lead Electrical Engineer
- J. Merwin, Lead Mechanical Engineer
- C. Gray, Field Engineer, Station Construction
- S. Giaconis, QA Engineer
- R.
- G. Tanner, QA Inspector Phillips Getchow Company (PG)
- T. Gugliuizza, QC Supervisor Nepolean Steel Company Incorporated (NSCI)
- K. Besse, QA Manager
- Denotes those present at the exit interview on February 9,1979.
Licensee Action on Previcus Inspection Findings (Closed) Unresolved Item (456/78-13-03; 457/78-13-03; 456/79-01-02; 457/79-01-02):
Licensee's failure to complete the review and approval of procedures for transfer and setting in place components of the NSS System.
The inspector completed his review of these and found them to be acceptable. Also, he observed the approval by the licensee's engineers, Sargent and Lundy.
(Closed) Noncompliance (456/78-06-06; 457/78-06-06):
Lack of a special procedure to radiograph material less that.75 inch in thickness with an Iridium 192 source. The inspector has reviewed the ASME response to the licensee's inquiry concerning the radiographic technique above and concludes the matter does not appear to involve noncompliance. The records have been revised to indicate the change.
This fact was confirmed by letter Gaston Florelli to Byron Lee, Jr. dated February 21, 1979.
Functional or Program Areas Inspected Details of functional and program areas inspected are documented in Sections I and II of this report.
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Section I Prepared by C. E. Jones Reviewed by R. C. Knop, Chief Projects Section 1.
Nuclear Steam Supply System Components The inspector was informed that the quality procedures prepared by Reliance Truck Company for offloading, transporting and final set of components in the NSSS had been reviewed an approved.
These procedures included those necessary for handling the reactor pressure vessel and vessel internals, steam generators and pressurizer.
The reliance Truck Company Procedures, Specification 2781, including procedure title and approval date are as follows:
Adminstrative Procedures Procedure Revision Approval by No.
No.
Title S&L Date
0 Control of Calibrated and Test 11-21-78 Equipment
1 Training of Personnel Performing 1-4-79 Activities Affecting Quality
0 Document Control 11-21-78
0 Inspection and Test Status 11-21-78
0 Control of Nonconforming Materials 11-21-78 Parts and Components
0 Corrective Action 11-21-78
0 Quality Assurance Records 11-21-78
0 Audits 11-21-78
Control of Measuring and Test 11-21-78
Use of Calibrated Torque Wrench 11-21-78
Torque Wrench Calibration 11-21-78
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e Work and Quality Procedures Procedure Revision Approval by No.
No.
Title S&L Date 101
Offloading Steam Generator from 1-4-79 Barge and Transporting to Temporary Storage 102
Offloading Reactor Pressure Vessel 1-18-79 from Barge and Transporting to Temp-orary Storage 103
Offloading Reactor Head from Barge 1-4-79 and Transporting to Storage 104
Offloading Pressurizer from Rail Car 1-4-79 and Placing in Storage 105
offioading Upper Internals from Barge 1-4-79 and Transporting to Temporary Storage 106
Offloading Lower Internals from a 1-4-79 Barge and Transporting to Temporary Storage 107
Transporting Upper Internals from 12-19-78 Barge to Braidwood Station by Trailer 108
Transport Lower Internals from 1-4-79 Barge to Braidwood Station by Trailer 109
Transport Steam Generator from Barge 1-18-79 to Braidwood Station by Trailer 110
Transport Reactor Head from Barge 12-19-78 to Braidwood Station by Trailer 111
Rolling Steam Generators 11-21-78 112
Transport Reactor Pressure Vessel 12-19-78 from Barge to Braidwood Station by Trailer 113
Transport Steam Generators from 1-11-79 Jobsite and Setting in Containment 114
Transport Reactor Pressure Vessel 1-11-79 from Jobsite and Setting in Con-tainment-4-
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115
Transport Lower Internals from 1-11-79 Jobsite and Setting in Containment 116
Transport Upper Internals from 1-11-79 Jobsite and Setting in Containment 117
Transport Pressurizer from Jobsite 1-11-79 and Setting in Containment 118
Load Testing Construction Hoist 1-4-79
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Equipment in the Containment Building 119
Load Testing the Polar Cranes in the 1-4-79 Containment Building
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120
Containment Building Gantry Crane 1-4-79 122
Upending the Upper Internals Removal 1-4-79
from Shippins Stand, Placing and Setting in Temporary Storage 301
Transport Steam Generator from Byron 11-21-78 to Savanna Barge Slip 302
Transport Steam Generator from 11-21-78 Savanna Barge Slip and Loading on Barge The inspector completed his review and considered these procedures acceptable.
2.
Receipt Inspection and Handling of NSSS Components The licensee has established the component inspection, conformance with specifications, handling and storage requirements and record keeping that are required for the reactor pressure vessel. The inspector was informed that Westinghouse has provided recommenda-tions in these areas but the licensee has the responsibility for final action.
Procedures listed previously have been issued for crane and rigging testing and vessel lifting. The fact that much of the lifting will be performed with the aid of an A frame erected over the component prevents test lifts other than on the equipment being moved. The contractor appears to be taking special effort to insure visual and nondestructive testing of hoisting equipment is current and performed on schedule.
3.
Storage of NSSS Components The reactor pressure vessel and two steam generators were observed at the Dresden barge dock. The reactor pressure vessel was loaded-5-
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on the trailers ready for transfer to Braidwood station. All vessel nozzles were protected and the moving equipment appeared ready for the move.
Two of the steam generators were on the barge at the barge dock. The Westinghouse serial numbers for these generators were 1711 and 1712.
All nozzles were protected.
Both units were being purged with Nitrogen and were under positive pressure.
The height and angle of the pressure guages made it difficult to get an accurate reading.
Steam generators, serial Nos. 1713 and 1714 were still loaded on a barge and were being held in the holding area.
Steam generator serial No. 1714 was dropped during loading on the barge at Savanna, Illinois.
Inspection and repairs are scheduled to be performed at Braidwood. This is considered an open item.
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Section 11
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Prepared by K. R. Naidu
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Reviewed by D. W. Hayes, Chief Engineering Support Section 1 1.
Observation of Containment Steel Supports Installation Activities (Unit 1)
The inspector observed steel support installation activities in Unit I containment. The installation including welding was being performed by Nepolean Steel Company (Nepolean).
The Structural Steel was supplied by American Bridge Company (AB).
Specifications F/L 2735 and F/L 2722 cover the supply of steel and installation respectively.
By direct observation and independant evaluation of work activities, the inspector determined that the above activities were being accomplished in accordance with established procedures in the following areas:
a.
Receipt inspections had been performed on the structural components when they were received two years ago.
b.
Beam identified as A159B1 was installed as specified in AB drawing E109; box beams identified as B113BB1, A125BB1 and H139BB2 were installed as specified in drawing E101.
c.
Nondestructive examinations (NDE) were being performed by Pittsburgh Testing Laboratories (PTL), the licensee's indepen-dant testing agency.
d.
The qualification of the PTL inspection personnel were reviewed and determined acceptable during previous inspections.
No items of noncompliance were identified.
2.
Review of Containmant Structural Steel Quality Records (Unit 1)
The inspector reviewed the quality records relative to box beam B113BB1 and determined that one 12" x 8" x 2' 1 3/8" stiffener plate was fabricated from two heat numbers identified as K 1747 and IR 4370. The AB bill of material indicates that this material is ASTM-A-570. Sargent and Lundy (S&L) letter dated August 15, 1977, indicates that Material Test Reports OHTR) with the heat numbers were reviewed and determined to meet requirements of ASTM-A-570. However, the actual MTR from U. S. Steel (USS) indicates-7-
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that the material identified with the above heat numbers meet requirements of ASTM-A-36-70A.
The licensee was unable to explain the discrepancy. Similarly, for a 27" x 1" x 19' plate, with heat number 70 E 607, a S&L letter dated July 19, 1977, indicates that the MTR with heat number 70 E 607 was reviewed and determined to meet requirements of ASTM-A-572 grade 50; however, the USS MTR did not indicate the type of material certified even though results of the chemical and physical tests were furnished.
The inspector informed the licensee that additional information is required to evaluate the above discrepancies. This is considered an unresolved item.
(50-456/79-02-01)
3.
Observation of Containment Structural Steel Welding Activities (Unit 1)
The inspector observed welding activities in progress inside containment associated with welds identified as 383, 400, 663, and 634 end determined that the following meet applicable specification and procedures:
a.
Shielded Metal Arc Welding (SMAW) process was beit.g used on the welds described below:
(1) Weld No. 383 on beam A159B1 was illustrated in drawing E 117 as detail 988.
(2) Weld No. 400 on column 190R20 was illustrated in drawing Ell 8 as detail 1019.
(3) Weld No. 663 on box beam B113BB1 was illustrated in drawing E 119 as detail 959.
b.
Flux Cored Arc Welding (FCAW) prccess was being used on welds described below:
(1) Weld No. 617 on box beam B133BB1 illustrated in drawing E 119 as detail 959.
(2) Weld No. 634 on box beam H139BB2 as illustrated in drawing E 199 as detail 954.
Weld Procedure Specifications (WPS) NSGW-2 and NSGW 3 were being c.
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followed for SMAW and FCAW processed respectively.
d.
Weld rod types E-7018 and E 70T were being used for SMAW and FCAW processes respectively.
Specified NDE was being performed at the proper stage of weld e.
pass. For example, welds detail No. 959 which originally required Ultrasonic Test (UT), were being subject to Magnetic-8-
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Particle (MT) examination after the root pass and cover pass.
S&L in letter dated August 7, 1978, suggested this recommen-dation in addition to visual inspection for full penetration welds which cannot be examined using either RT or UT.
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Periodic checks were being made to assure that the welding varibles were within specified limits; at the in6pector's request, the current and voltage were checked at two weld locations. The values measured were 120-140 Amperes (A),
20-24 Volts (V), and 130-140A,20-24V and were within the WPS NS-GW-2 specified limts of 105-175A,22-28V.
g.
The inspector witnessed the guided bend tests performed on specimens welded during veldor qualification using WPS NS-GW'2.
The bent specimens exhibited no cracks in the welds.
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Depleted weldrod type E-7018 were being discarded in containers.
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The qualification records of ten weldors actively performing welding 'rere reviewed; five weldors were qualified to both SMAW ano FCAW processes and five others were qualified to SMAW process.
No items of noncompliance were identified.
4.
Review of Containment Structural Welding Records (Unit 1)
The inspector reviewed the following inspection records relative to the welding activities performed by Nepolean and determined that the records reflect work accomplishment consistent with the specifi-cation requirements. The inspections were performed by PTL personnel, a.
PTL reports No. 223 VW, 225 VW and 226 VW, dated February 7, 1979, documented the visual inspections on welds identified as 340A, 340B, 380A, 380C, 380B, 380F, 424D, 4240, 427G, 427G, 523A, 523C, 523E, 523G, 523B, 523D, 523F, 523H, 735K, 735L.
755K and 763B. PT instuction sheet No. IS-BRD-9-AWS, Revision 1, dated August 6, 1978, was used to visually inspect the welds to the requirements of Sections 3 (workmanship) and 8.15 (visual inspection) of AWS D1.1-75.
The type, size and length of the welds were indicated. Welds identified as 755J, 761L and 761M were inspected and rejected. Subsequently the welds were repaired, reinspected and accepted.
b.
MT reports No. 358 MT and 373 MT dated November 1 and 7,1978, respectively documented the MT performed on the root pass and
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cover pass respectively on field welds No. 617B, D and H; no unacceptable indications were identified.
The MT was performed with a Parker Probe serial No. 3052 with prod spacing 3 to 6" utilizing MT procedure QC-MT-1.
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c.
UT report No. 57UT dated Janaury 23, 1979, documents the UT examinations of welds 89E, 89J, 158C, 158E, 158J, 302C, 302E, 302J, 417, 418A and 418E. Nortec 131 type test eguipment
serial No. 131D/175 with SMHz, 90 and 2.25MHZ 70 transducers and Exosen 30 type couplant was used during the UT.
The examination rejected one weld identified as 89C; the veld is
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pending rework and re-examination. Procedure QC-UT-1 was used for the UT examination.
The above records were ligible and retrievable.
The inspector did not review the qualifications of the PTL inspection personnel during this inspection.
No items of noncompliance were identified.
5.
Observation of Nondestructive Examination on Safety-Related Structures (Unit 1)
The inspector observed Liquid Penetrant (PT) examination being performed by Pittsburgh Des Moines (PDM) personnel on verticel buttwelds 1, 2 and 3 and horizontal butt welds 10, 11, 12 and 13 in the Refuelling Transfer Canal aree. The welds are identified on PDM drawing E53B Revision A titled Transfer Canal elevation 409' to 425'-7 1/2".
Spotcheck dye type SKL-S, cleaner type SKC-S and developer type SKD-S, were used for the PT.
Procedure LPTP301 was being used for the examination. The inspector witnessed the PDM Level III inspector identify unacceptable indications for rework. Correc-tive Action Request No. 11877 dated February 7, 1979, identifies that these seam welds need addition 1 welding rework where areas were marked with a felt pen.
Review of Fabrication Check List (FCL) RP-V27, which documents the inspections performed on the welds identified above, indicates the following:
a.
Fit up was checked by construction staff; QA verified and concurred that fit up was acceptable.
b.
WPS-77-8a Revison 0 (automatic) and WPS-74-80b Revision d (manual) were used as applicable for welding the seams; Tungsten Inert Gas (TIG) process was used with weldrod type ER 309.
c.
The seam welds were visually examined utilizing procedure VTP 501.
No items of noncompliance were identified.
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Observation of Safety-Related Component Installation (Unit 1)
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The inspector observed installation of the Regenerative Heat Exchanger and the Excess Letdown Heat Exchanger inside contain-ment Unit 1.
These heat exchangers are listed on page 3.2-6 of the Byron /Braidwood FSAR as Safety Category 1 Quality Groups B and C for the tube side and shell side respectively. The inspector determined a nonconforming condition on the acchor bolts; Detail "A"
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of drawing M-1226 titled " Equipment Foundations - Heat Exchangers" show the typical anchor bolts projecting 3 3/4" where as at least two bolts were measured to be projecting only 3" from the embedment.
These bolts which are part of an embedment in the primary concrete wall are used to hold down the regenerative heat exchanger support plates. The installation was performed by Phillips Getschow.
One bolt was observed to have been cross-threaded. Discussions with the licensee and contractor personnel indicated that the installation of the heat exchangers was not complete. A checklist to document the status of completion of safety-related equipment installation for Units 1 and 2 is being finalized. The contractor documented this condition in Nonconformance Report (NCR)
No. 335, dated February 8, 1979.
The inspector plans to review the corrective action taken to disposition NCR No. 335 and the proposed check list during a subsequent inspection. This item is considered unresolved.
(50-456/79-02-02; 50-457/79-02-01)
Unresolved Items Unresolved items are matters about which more information is required in order to ascertain whether these are acceptable items, items of ncncom-pliance or deviations. Unresolved items disclosed during this inspection are discussed in Section II, Paragraphs 2 and 6.
Exit Interview The inspectors met with the staf f representatives (denoted in the Persons Contacted paragraph) at the conclusion of the inspection on February 9, 1979. The inspectors summarized the scope and findings of the inspection including the unresolved items listed above.
The licensee achnowledged the findings.
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