IR 05000460/1978008
| ML19274D764 | |
| Person / Time | |
|---|---|
| Site: | Washington Public Power Supply System |
| Issue date: | 01/09/1979 |
| From: | Eckhardt J, Haist D, Haynes R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V) |
| To: | |
| Shared Package | |
| ML19274D763 | List: |
| References | |
| 50-460-78-08, 50-460-78-8, 50-513-78-08, 50-513-78-8, NUDOCS 7902260026 | |
| Download: ML19274D764 (8) | |
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U. S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT
REGION V
50-460/78-08 Report No. 50-513/78-08 Docket No. 50-460 & 50-513 License No. CPPR 134 & CPPR 174 safeguards Group Licensee: Washington Public Power Supply System P. O. Box 968 Richland, Washington 99352 Facility Name:
WilP 1 and 4 Inspection at:
WilP 1 and 4 Site, Richland, Washington Inspection conducted: flovember 28-December 1,1978 Inspectors:
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// 9/7.9 di. Eckhardt, Reactor Inspector Date signed
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/!9[79 D. P./Haist, Reactor Inspector D'2tb Signed 0. Anuhr i/9/4 g. Hernandez, R(dctor Inspector Ifate signed Approved By:
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//9/7f R. C. Haynef/ Chief, Projects Section, Date Signed Reactor Construction and Engineering Support Branch Summary:
Inspection on flovember 28 - December 1,1978 (Report flos.
50-460/78-08 and 50-513/78-08 Areas Inspected:
Routine, unannounced inspection by regional based inspectors of construction activities including:
open items from pre-vious inspections, licensee identified items, containment steel structures and supports, and structural concrete.
The inspection involved 66 inspector-hours onsite by three f1RC inspectors.
Resul ts : Of the four areas inspected, no items of noncompliance or deviations were identified.
gg RV Form 719(?)
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DETAILS
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1.
Persons Contacted Washington Public Power Supply System (WPPSS)
- 0. L. Renberger, Assistant Director, Generation and Technology
- M. W. Hultgren Division Manager, WitP l-4
- J. P. Thomas, Project Manager, Wi4P 1-4
- T. J. Houchins, QA Manager, WitP 1-4
- M. E. Witherspoon, Division llanager, Quality Assurance
- M. C. Carrigan, Construction Manager, WriP l-4
- R. C. Mertens, Senior QA Engineer
- G. G. Renfro, Field Engineer Supervisor J. Carson, Senior QC Engineer (Civil)
P. Magbool, QA Engineer J. R. flickolaus, QA Engineer R. D. Crisp, QA Engineer T. Gilbert, QA Engineer A. Fisher, Document Control
, United Engineers and Constructors (UE&C)
- E. C. Haren, Deputy QA Manager
- S. B. Barnes, Project Manager D. J. Reinert, Supervising Engineer (Philadelphia) tide Level III H. G. Domschke, QA Engineer - Level II R. L. Peters, Mechanical Superintendent T. C. Gibbs, QA Engineer Shurtleff and Andrews (S&A)
D. L. Fitzgerald, Site QA Manager Acme / Control J. England, QA Manager B_oecon Construction Company (Boecon)
T. ti. Shaw, QC Engineer J. A. Jones D. Higginbotham - Level III Examiner (UT)
G. F. Atkinson/ Wright /Schuchart/ Harbor (AWSH)
H. D. Latch, QA Manager Klinger Steel R. Burns, QA Manager
- Denotes those attending exit intervie.
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2.
Licensee Action on Previously Idcntified Inspection Items a.
Open - Unresolved item (50-460/78-07): Certain equipment storage and maintenance records (forms entitled " Equipment /
llaterial Storage and Preventative liaintenance Requirements")
were found to have less than 10% of the sections entitled
"Special Storage and Preventative liaintenance Instructions" completed.
The licensee initiated action to resolve this matter and indicated that for equipment / material delivered to the site, the special storage and preventative maintenance instructions had been specified on the forms as of byember 7, 1978.
Similarly, the instructions for equipment /caterial to be shipped in the next six months (based on shipping schedule)
were completed as of flovember 27, 1978.
Content and impie-mentation of the storage and maintenance instructions as well as instructions for controlling the preparation and use of the form will be examined during a subsequent inspection.
b.
Open - floncompliance (50-460/78-07) Stud Welding:
The licensee's actions pertaining to this item were reviewed although the licensee's written response to the flotice of Violation was in preparation. The licensee stated that a representative of the stud manufacturer had visited the site and demonstrated proper stud welding techniques. Thestudweldspreviouslymtdewgre undergoing addftional bend testing (either 100% bent to 15 or 20% bent to 15 with additional requirements for any failures)
to ascertain the quality of the welds.
This item will be further evaluated upon receipt and after review of the licensee's written response to this item.
3.
Licensee Identified Items a.
Ultrasonic Examination of Cadweld Splices The licensee's contractor, UE&C, has developed an ultrasonic technique to verify cadweld sleeve centering and reinforcing bar gap in completed cadweld splices.
UE&C stated that UT examinations of ten sample cadwelds splices were accurate to within 1/16" as verified by milling the samples after exam-ination.
UE&C stated that only Level II and Level III certified examiners, who have been indoctrinated in this particular technique, will perform production testing and that five (5)
cadweld splice samples with various bar gaps and end conditions are used to qualify the examiner.
The llRC inspector examined the ten (10) sample cadweld splices that had been milled to verify the accuracy of ultrasonic examination. Accuracy appeared to be within the tolerance stated by UE&C. The flRC inspector observed calibration on the test block and examination of a sample splice by a Level III examiner. The examiner located the bar ends and marked them on the cadweld sleeve.
The examiner was unaware of the actual gap and his examination results were checked against the actual gap as part of his qualification.
The calibration and examination met procedural requirements.
The inspector will review the results of testing of completed cadweld splices during a subsequent inspection.
(50-560/78-08/01)
b.
Testing Frequency of Cadweld Splices During the course of this inspection, the licensee informed the flRC inspectors of a possible problem regarding the testing frequency of cadweld production splices.
The civil contractor, AWSH, had informed the licensee that a possibility existed that too few production splices had been tested to meet the requirements of ASME Boiler and Pressure Vessel Code,Section III, Division 2, CC4333.0.
AWSH is in the process of a record review in order to resolve this question.
This item will be reviewed by the inspector upon completion of the record review.
(50-460/78-08/02)
4.
Structural Concrete a.
Batch Plant The inspector conducted a tour of the concrete batch plant and storage areas.
During the tour, batch plant operation, back-up batch plant availability, and aggregate stockpiling were observed. The following items were examined in detail.
(1) Approximately twenty-five mill test reports from Lehigh Portland Cement were reviewed for conformance with ASTM C-150, Specification for Portland Cement.
The inspector verified that adequate provisions exist for control and separation of the two types of cement (type II and V)
that are used onsite.
Only type II is used for quality class I work.
The cement was observed to be stored in weather-tight containers and properly identifie.
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(2) Aggregate was confirmed to be procured from an approved source and tested by an independent laboratory for con-formance with ASTil C-33, Specification for Concrete Aggregate. The contractor also does a sampling of in-coming aggregate to verify the laboratory certification.
The aggregate appears to be stockpiled in such a manner to prevent segregation and inclusion of foreign material.
Records relative to aggregate including gradation, steve analysis, scratch hardness, flat and elongated particles, clay lumps and friable particles, and lightweight pieces in aggregate were reviewed.
(3) Admixture storage was examined to verify that admixtures were properly segregated and protected from dampness and freezing.
The admixtures were found to be properly identified by proprietary name and type.
Admixture certifications from Protex Industries for water reducing and air entrainment admixteres were reviewed and found to meet the requirements of ASTil C-494, Chemical Admixtures for Concrete and ASTM C-260, Air-Entraining Admixtures for Concrete.
These are the only types of admixtures used onsite.
Users test of the admixtures performed by Lauck's Testing Laboratories were also reviewed.
(4) A review of approximately thirty water and aggregate analysis records indicated that the chloride ion content and total dissolved solids met the requirements of ASME Boiler and Pressure Vessel Code,Section III, Division 2, CC2223.0 for concrete mixing water.
(5) Records of monthly scale checks for the regular and back-up batch plant, as well as records of the tri-monthly independent laboratory checks, were reviewed.
The scale records were reviewed to assure conformance with the requirements of ASTM C-94, Specification for Ready-mixed Concrete.
Certifications of weights traceable to the flational Bureau of Standards for the batch plant and the independent laboratory were also reviewed.
(6) The qualification records of three batch plant inspectors were reviewed.
flo items of noncompliance or deviations were identifie.
b.
Observation of Work and Work Activities During this inspection, Klinger Steel cadweldirg activities on the south wall of the General Services Building of Unit 4 were observed to ascertain compliance with the licensee's work and inspection procedures.
The cadwelding observations included rebar cleaning, marking and centering of the splice sleeve, and inspection of completed cadwelds.
Approximately ten partially and completed cadwelds in the containment t.7ea of Unit 1, performed by AWSH, were also examined.
fio items of noncompliance or deviations were identified.
c.
Review of Quality Records Records relative to cadwelding activities observed in Unit 4 were reviewed to ascertain compliance with the licensee's pro-cedures and specifications.
The inspector reviewed cadweld material certifications for the cadweld rebar powder and splice sleeves.
The qualifications of the cadwelding crew and inspector were also examined.
fio items of noncompliance or deviations were identified.
5.
Containment Steel Structures and Supports a.
Equipment liaintenance and Storage The tiRC inspector visually examined storage conditions for the Unit I and Unit 4 refueling canal liner plate panels at the respective 204 laydown areas for conformance with the con-tractor's storage ar>d handling requirements.
The following items were noted:
(1) Two stainless steel liner plate panels at the Unit i laydown area were supported at both ends but not in the middle resulting in noticeable distortion of the panels.
The licensee's contractor, UE&C-QA, agreed that additional support was required and had the condition corrected.
A reinspection of the area by the fiRC inspector identified two additional panels with noticeable distortion.
The UE&C-QA representative stated that the condition would be corrected.
The flRC inspector reviewed the Boecon storage area inspection checklists for the Unit 1 and 4 laydown areas dated flovember 3, and riovember 8,1978 respectively.
The fiRC inspector noted that an incorrect inspection
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checklist form which did not address whether or not material is properly stored was used for both inspections.
The UE&C-QA representative stated that the correct storage area inspection checklist, as specified in Boecon QAP No. 9779-13.0, Revision 1, will be used in the future and that a Contractor's flotification Request (CNR) will be issued to Boecon on this item.
The support of liner plate sections and storage area inspectior.s will be reviewed at a future NRC inspection.
(50-460/78-08/03).
(2)
Fifteen out of approximately 100 liner plate sections at the Unit 1 laydown area were missing acceptance tags.
The inspector noted that it is difficult to attach tags to these sections due to a lack of attachment points.
Tags Fad apparently been attached to protected turfaces of the liner plate with tape.
The inspector verified that release of material for fabrication is controlled in accordance with Boecon Construction Procedure No. BO-CP-104, Revision 1, which requires items being released from storage to have green acceptance tags attached prior to issuance.
The NRC inspector reviewed the Boecon storage area inspection checklist for the Unit 1 and 4 laydown areas dated November 3, and November 8,1978 respectively.
The NRC inspector noted that for the Unit 1 storage area inspection, the Boecon inspector had not addressed item No. 2 on the checklist which reads "Is material identified with the appropriate tags?" The UE&C-QA representative stated that a CNR will be issued to Boecon for an explan-ation of this omission.
The NRC inspector will review this CNR and Boecon's response and storage area inspection checklist at a future inspection.
(50-460/78-08/04)
The items pertaining to storage of liner plate panels are considered unresolved pending review of the contractor's response to the CNR's and examination during a subsequent inspection of installed liner plate panels to determine if distortion tolerances are met.
b.
Observation of Work and Work Activities The NRC inspector visually examined a partially erected Unit 1 refueling canal subassembly located in the 204 laydown area and completed portions of the Unit 1 refueling canal.
The NRC inspector also examined completed weld joint No. 480 and partially completed weld joint No. 481, and observed removal of teaporary bracing welds on installed portions of the Uait 1 refucling canal.
No items of noncompliance or deviations were identifie.
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c.
Review of Quality Records (1) Refueling Canal Quality Records Quality records associated with the installation and welding of Unit 1 refueling canal were reviewed for compliance with the licensee's procedural requirements.
The records included fabrication checklists (construction work orders), weld electrode issuance records, weld summary inspection reports and liquid penetrant examination reports. The NRC inspector also reviewed the records associated with refueling canal liner plate weld Nos. 480 and 481. These records included: WPS No. 001, Revision 2, PQR N-008-01, welder qualifications, weld material control records, liquid penetrant examination report Nos.
008 and 011, liquid penetrant applicator, Level II examiner certifications and eye examination records.
The records appeared to accurately reflect and document the status of work.
(2) Major Equipment Support Quality Records Quality records associated with the fabrication of the following major equipment supports were reviewed for compliance with the quality program requirements.
(a) Unit No. 1 Steam Generator Lower Vertical Support No. 275-H0026-1 (b) Unit No.1 Reactor Support Embedment No. 275-H 0072-1 (c) Unit No. 4 Reactor Coolant Pump Embedment No. 275-N0032-2 The records included certificates of conformance, vendor surveillance check plans, quality shipment releases, certified mill test reports, weld summaries, Charpy test results, heat treat summaries, weld repair reports, ultrasonic, visuel, and magnetic particle examination reports, taasile test reports, mercury contamination certifications, and receiving inspection check plans and reports.
The records appeared to accurately reflect and document the status of components.
No items of noncompliance or deviations were identified.
6.
Exit Interview At the conclusion of the site inspection, the inspectors met with the individuals designated in Paragraph 1 and summarized the scope and findings of the inspection.
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