IR 05000457/1987002

Insp Rept 50-457/87-02 on 870105-0416.No Violations or Deviations Noted.Major Areas inspected:safety-related Structures,Review of Work Activities,Quality records,safety- Related Structural Welding & QA Implementing Procedures

ML20215L524
Person / Time
Site:	Braidwood
Issue date:	05/07/1987
From:	Danielson D, Liu W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
To:
Shared Package
ML20215L513	List: IR 05000457/1987002 ML20215L509
References
50-457-87-02, 50-457-87-2, NUDOCS 8705120273
Download: ML20215L524 (9)

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U. S. NUCLEAR REGULATORY COMISSION

REGION III

Report No. . 50-457/87002(DRS)

Docket No. 50-457 Construction Permit No. CPPR-133 Licensee: Commonwealth- Edison Company

' Post Office Box 767 Chicago, IL 60690 Facility Name: Braidwood Station, Unit 2 Inspection At: Braidwood Site, Braidwood, Illinois-Inspection Conducted: January 5-8, 13-14, 21-22, 27-28; March 17-19, 24-27; and April 13-16, 1987 In'spector: W. C. Liu [k d6 Date

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Approved By: D. H. Danielson, Chief 6 7)f7 Materials and Processes Date Section Inspection Sunmary Inspection on January 5 through April 16, 1987 (Report No. 50-457/87002(DRS))

Areas Inspected: Routine unannounced inspection of safety-related structures including review of work activities (480648) and quality records (48065B and 480668); safety-related structural welding including review of -

work activities (550638 and 550648), quality assurance implementing procedures (55061B) and quality records (550658); and training and qualification effectiveness in conjunction with the above activitie Results: Of the areas inspected, no violations or deviations were identified,

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DETAILS 1. Persons Contacted Commonwealth Edison Company (CECO)

• D. Shamblin, Assistant Project Manager

• C. Schroeder, Service Superintendent

• R. Kyrouac, Station QA Superintendent

• Vahle, Project Construction Superintendent

• Barnes, Regulatory Assurance Supervisor

• Brown, Quality Assurance Supervisor

• Bartes, Training Group Leader

• Tanouye, Project Construction Engineer

• Zolan, Quality Assurance Engineer

• M. Takaki, Regulatory Assurance Engineer E. Martin, Quality Assurance Superintendent C. Bedford, Licensing Engineer D. Throne, Quality Assurance Engineer Sargent and Lundy Engineers (S&L)

• A. Lunardini, Structural Coordinator

• F. Shallwani, Senior Structural Engineer G. K. Newberg Construction Co. (GKN)

• C. Reynolds, Quality Engineer R. Donica, Quality Assurance Manager C. Zavada, Quality Control Supervisor Pittsburgh Testing Laboratory (PTL)

T. Frazier, Assistant Site Manager S. Bank, Quality Assurance Supervisor NRC Resident Inspectors

• Kropp, Senior Resident Inspector, Construction

• T. Taylor, Resident Inspector, Operation

• Denotes those attending the final exit interview on April 16, 198 . Safety-Related Structures - Observation of Work and Work Activities [480648), and Review of Quality Records (480650)

and (48066BJ Review of procedures / instructions / specifications

• GKN QC Procedure 9, Receipt, Storage, and Issuance of Safety-Related Materials Revision 16, October 3,1986.

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• GKN QC Procedure 29-1, Records Review, Revision 7, July 11,198 * GKN QC Procedure 29-1-5, Design Change Traveler Document Review, Revision 1, December 18, 198 * GKN QC Procedure 31, Erection and Inspection of Structural Steel, Revision 15, April 8, 198 * GKN QC Procedure 55, AWS Visual Welding Inspection, Revision 8, February 21, 198 S&L Star:dard Specification for Visual Inspection Requirements for Structural Welding, Revision 2, January 21, 198 S&L Standard Specification for Welding in Steel Construction, December 20, 197 * S&L Standard Specification for Fabrication of Structural Steel, May 10, 197 * Pullman Sheet Metal Works (PSM) QA Procedure B2.8.F, Equipment Installation and Inspection, Revision 3, July 28, 1986, h

PSM QA Procedure B10.2.F, Visual Weld Inspection, Revision 14, February 19, 198 PSM QA Procedure B10.3.F, HVAC Installation Inspection Procedures, Revision 13, June 10, 198 PSM QA Procedure B17.2.F, Records Review, Revision 48, August 11, 198 * PTL QC Procedure SR-1, Structural Steel Inspection, Revision 5,

October 15, 198 * PTL QC Instruction 19-BC, Torque Inspection of Bolted Connections, Revision 1, May 1, 198 The NRC inspector reviewed the relevant portions of the above procedures / instructions pertaining to the area of structural l

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installations and inspections to determine whether appropriate procedures have been established and whether they comply with NRC requirements and the licensee commitments. The NRC inspector noted that the procedures / instructions appeared to be acceptable in terms of controlling work activities associated with structural installations and inspection b. Structural Steel Assemblies for Safety-Related Equipment The NRC inspector reviewed the design drawing for safety-related axial flow fan support 2VA08CA. The corresponding S&L structural drawings M-1320 (Sheet 63 of Revision 8 and Sheet 48 of Revision F

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were examined with respect to the general configuration, member size, weld size and connection details to determine whether the actual installations were consistent with the design requirements. Further, the QA records pertaining to material receiving inspection, welding inspection and structural members inspection were reviewed for conformance to procedural requirements and licensee commitment The NRC inspector determined that work activities performed for the structural assemblies appeared to be acceptable as a result of the document review and a field verification of the equipment suppor c. Field Inspection of Structural Steel Members The NRC inspector selected the following safety-related structural members for a verification inspection to detenaine whether the structural members installed were consistent with the applicable design drawing Steel Beam N Shop Drawing N S8L Drawing N AB489 97484 S-1312 8AB549 956B1 5-1312 8AB555 93284 S-1312 9AB603 983B1 S-1328 9AB604 983B2 S-1328 9AB696 978B2 S-1328 The above six steel beams were inspected by the licensee QC personnel and the NRC inspector with respect to the corresponding structural drawings for general configuration, member size, weld size, and connection details. Results of this inspection reveal that the aforementioned structural members were installed in accordance with design drawing d. Review of Structural Steel Traveler (SSIT)

The NRC inspector randomly selected the following safety-related SSITs for a verification review to determine whether work activities contained in these SSITs were properly performed in accordance with established procedures / instruction SSIT N Work Activity 7156 Modification of connections for blockwall column Beam modification by adding one steel plat _

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10182 Beam modification by adding two steel angles for an electrical suppor Modification of steel beam end connectio Beam end connection modification by adding two tube steel member Modification of beam connection by adding one steel membe The relevant portions of the above SSITs were reviewed with respect to location of structures, applicable detail drawings, material verifications, and welding inspections. It was found in general, that work activities identified in the SSITs appeared to be performed in an acceptable manner in terms of meeting licensee commitments and the NRC requirement Review of Nonconfromance Reports (NCR)

The NRC inspector reviewed the following nonconformance reports pertaining to structtral welding to determine whether appropriate dispositions have been made in accordance with applicable procedures / instruction Nonconformance Problem Identification Report N Welding problem associated with beam modificatio t 213-1455 Inaccessible wel Inaccessible wel Inaccessible wel Weld procedure specification not liste The above nonconformance reports were reviewed for conformance to applicable codes, specifications and procedures / instructions. In general, work activities identified in the NCRs were performed in accordance with the specifications and the procedures with the exception of the findings listed below:

(1) NCR No. 213-1857, Page 21 of 38 showed that a 7/16 inch single bevel weld was used. However, the plate that was to be welded has a thickness of 3/8 inch. This is inconsistent with the AWS code requirement .

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(2) Page 25 of 38 in the same NCR contained a 5/16 inch wel However, no weld symbol was provided. This is also inconsistent with the AWS code requirement (3) NCR No. 213-1462, Page 8 of 16 contained a bolting inspection request which was not signed by QC per sonnel as required by the procedure although final document review was complete The NRC inspector held discussions with licensee representatives regarding the above findings. The licensee representatives committed to perform further evaluation to determine whether the aforementioned concerns were generic in nature. Results of the sample programs initiated by the responsible licensee organization revealed that discrepancies identified in items (1), (2), and (3) above were isolated cases and imposed no safety significance relative to the hardware. These concerns are considered to be resolve f. Review of Material Receiving Report (MRR)

MRR N Material Identification 15134 Structural steel plate Structural steel plate Structural steel member Welding materia Welding materia Welding materia The NRC inspector reviewed the relevant portions of the above material receiving reports pertaining to structural steel and welding materials for conformance to procedural requirement Further, the review included the verification of heat numbers for each item received and the material descriptions contained in the certified material test reports (CMTR). The NRC inspector found that, in general, receiving inspection activities performed by licensee representatives appeared to be acceptable in terms of meeting the requirements of the applicable procedures and the NRC regulations with the exception of the following findings:

The certificate of conformance dated March 29, 1984 included in MRR No.15134 contained an error in that the purchase order Item No.10 for a three inch plate was written as the purchase order Item No. 2 which referred to a 5/8 inch steel plate. In addition, a review of the U. S. Steel Corporation's metallurgical test report revealed that two pieces of 5/8 inch steel plates (48" x 240") were delivered to the Braidwood Site through Hagerty Brothers Compan However, licensee receiving inspection personnel received four

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pieces of the 5/8 inch steel plate as specified from the purchase order. As a result, the other two pieces of the 5/8 inch steel plates could not be verified from the CMT In response to the above findings, the licensee's QA group initiated a sample program to review ten more material receiving (inspection)

reports (MRR) to verify whether the above discrepancies were generic in nature. Results of the review indicated that the aforementioned findings apppeared to be isolated cases and had no safety impact relative to the hardware. In addition, it was determined that tho aforementioned vendor has generated a CMTR to confirm the above two pieces of the 5/8 inch steel plates meet quality requirement Wittin the areas inspected, no violations or deviations were identifie . Safety-Related Structures (Welding) - Review of QA Implementing Procedures (550618), Observation of Work and Work Activities (550638 and E 6618), and Review of Quality Records (55065B) Review of Procedures

• GKN QC Procedure 26. Welding, Revision 31, September 10, 198 ' GKN QC Procedure 26-1, Weld Repairs, Revision 2 September 29, 198 * GKN QC Procedure 55, AWS Visual Welding Inspection, Revision 8, February 21, 198 Tne NRC inspector reviewed the relevant portions of the above procedures pertaining to the area of structural installations and irspections to determine whether appropriate procedures have been established and whether they comply with NRC requirements and the licensee connitments. It was noted that these procedures appeared to be acceptable in terms of controlling work activities relative to structural installations and inspection M tew of QA Surveillance Reports The licensee's QA Surveillance Reports No. 6788 and No. 6959 dated Jangary 5 and February 23, 1987, respectively, were reviewed. These sucieillance reports documented various welding activities associated with structural installations and inspections. Activities contained in the welding surveillance report are as follows:

(1) General Infonnation - Specification No., Drawing No., Location and Welding Procedur (2) Pre-weld Item (3) In-process Item ,

(4) Post Weld Item .

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(5) Filler Material Contro (6) Welder's Identification and Qualificatio (7) Documentatio (8) Weld Rod Contro Each of the above specified items contain various subitems which are required to be verified in accordance with the applicable procedures and instructions. On the basis of the above review, the NRC inspector determined that the licensee's controls with respect to the welding activities and welding materials appeared to be adequate in terms of implementation of licensee connitments and NRC requirement Review of Welder's Qualification The NRC inspector reviewed the records for the following welders to determine wicther they were qualified for the work they performed in accordance with the applicable codes and the procedure Welders identification N Weld Positions Qualified 6276 3G, 4G 6368 3G, 4G 6389 3G, 4G 6405 3G, 4G 6443 3G, 4G The above welder's qualification test records were reviewed with respect to welding process, position, weld procedure specification, material specification, and the applicable welding code. Further, the period of effectiveness for each of the above welders was verified in accordance with the AWS D1.1 code requirements. The NRC inspector found that licensee's records pertaining to welding activities in the area of structural installation and inspection appeared to be effective and acceptabl Within the areas inspected, no violations or deviations were identifie . Training and Qualification Effectiveness Review of Training Procedures / Instructions l * CECO Site QA Instruction 501-5, Personnel Training Folders, Revision 2. February 19, 1987, i

• CECO Instruction 501-22, QA Review of Site Contractor ANSI N45. Personnel Qualification and Certification, Revision 3. July 9, 1985.

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' GKN QC Procedure 28, Training Program, Revision 3, June 6,198 * GKN QC Procedure 37 Personnel Qualifications, Revision 7 January 4,198 * S&L Instruction PI-BB-67, Project Instruction Training, Revision 1, March 30, 198 * S&L General Quality Procedure GQ-1.04, Employee Experience Records and Qualification Statements, Revision 6, December 28, 198 The NRC inspector reviewed the relevant portions of the above procedures / instructions pertaining to training requirements to determine whether appropriate procedures have been established dnd whether they comply with NRC requirements and the licensee commitments. It was noted that the procedures and instructions appeared to be acceptable in terms of controlling training activities associated with the personnel involving structural installations and inspections, Review of Individual Training Records The NRC inspector reviewed eight individual training records portaining to work performance in the area of structural installations and inspections to ensure that these personnel were trained and qualified in accordance with the applicable procedures and instructions. The individual training records selected for review were two from CEcos QA group, two from G. K. Newberg's QC group, two from the Pittsburgh Testing Laboratory's QC group, and two from S&Ls Structural Engineering group. The NRC inspector noted that the training records, in general, were adequately documented in ten 11s of meeting the requirements of the licensee comitments and the NRC regulation Within the areas inspected, no violaticns or deviations were identifie . Exit Interview The inspector met with site representatives (denoted in Persons Contacted Paragraph) at the conclusion of the inspection. The inspector suninarized the scope and findings of the inspection noted in this report. The inspector also discussed the likely informational content of the inspection report with regard to documents or processes reviewed by the inspector during the inspection. The licensee did not idcntify any such documents / processes as proprietar _ _ _ _ _ _ _ _ _ _ _ - _ - _ _ _