IR 05000460/1980003
| ML19323C463 | |
| Person / Time | |
|---|---|
| Site: | Washington Public Power Supply System |
| Issue date: | 04/02/1980 |
| From: | Haynes R, Toth A NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V) |
| To: | |
| Shared Package | |
| ML19323C461 | List: |
| References | |
| 50-460-80-03, 50-460-80-3, 50-513-80-03, 50-513-80-3, NUDOCS 8005150565 | |
| Download: ML19323C463 (14) | |
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U. S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT
REGION V
50-460/80-03 Raport No.
50-513/80-03 4-
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Docket No.
50-46 L 50-513 License No. CPPR-134, CPPR-174 Safeguards Group Licensee:
Washington Public Power Supply System P. 0. Box 968 Richland, Washington 99352 Facility Name:
Washington Nuclear Projects Nos.1 and 4 (WNP 1 & 4)
Inspection at:
WNP 1 & 4 Site. Benton County, Washinaton Inspection conducted:
February 1-29, 1980
[k/g Inspectors:
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A. D M Resident Reactor Inspector Date signed Date Signed Date Signed kL/'dP Approved By:
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o R.C.Haynd(Chief,ProjectsSection,RC&ESBranch Date signed sum ary: Inspection on February 1-29, 1980 (Report No. 50-460/80-03)
Areas Inspected: Routine, unannounced inspection by the resident inspector of construction activities relating to: containment structural concrete, safety-related component supports, safety-related piping, reactor pressure vessel storage, reactor vessel internals storage, safety-related piping welding, structural steel, general services building concrete, previously identified unresolved items, specific employee concerns directed to the inspector, concrete testing correlation tests, and general site activities. The inspection involved 79 inspector-hours onsite by the NRC resident inspector.
Results: No items of noncompliance or deviations were identified.
Inspection on February 1-29, 1980 (Report No. 50-513/80-03)
Areas Inspected:
Routine, unannounced inspection by the resident inspector of construction activities relating to: reactor pressure vessel storage, reactor vessel internals storage, safety-related piping testing, containment structural concrete, concrete testing correlation tests, and general site activities.
The inspection involved 13 inspector-hours onsite by the NRC resident inspector.
Results: No items of noncompliance or deviations were identified.
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Persons Contacted WashingtonPublicPowerSupplySystem(WPfSS)'
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- A. D. Kohler, Project Manager
- M. C. Carrigan, Construction Manager
- T. J. Houchins,. Project Quality Assurance Manager
- G. D. Dyekman, Engineering Manager United Engineers and Constructors (UEC)
- G. E. McIntosh, Assistant Deputy Project Manager
- E. C. Haren, Deputy Project Quality Assurance Manager
- R. H. Bryans, Field Project Engineering Manager Schurtleff and Andrews (S/A)
R. Byrd, Superintendent K. Engstrom, Quality Assurance Manager J. A. Jones Construction Company W. Roe, Quality Assurance Manager T. Robinson, Project Manager, Unit #1 Peter Kiewitt and Sons (PKS)
H. Crane, Quality Engineer C. Kistler, Project Manager Royal Insurance Company D. Starr, Authorized Nuclear Inspector W. Kemp, Authorized Nuclear Inspector Atkinson, Wright, Schuchart, Harbor (AWSH)
F. W. Reed, Project Manager M. Latch, Quality Assurance Manager The inspection also included discussions with craft, quality control, supervision and middle management personnel.
- Principal licensee and contractor representatives to whon inspection findings were presented at exit interviews.
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Plant Tours - Unit #1 and Unit #4 4-
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The inspector was on-site February 1, 4-8, 11-15, 19-22, 25-29, 1980.
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The inspector made plant inspections during day shift and swing shift at various times each week during this reporting period. Craft personnel, supervisors, and quality control inspectors were interviewed as they were encountered in the various work areas and in-process records, such as work control forms, inspector logs, calibration tags, quality release tags, and equipment identification tags were examined during these inspections. These inspections included observations of work for compliance with general and specific codes and standards, regulatory guides and requirements, and imple-mentation of quality assurance program requirements.
The NRC licensing project manager accompanied the inspector to observe the recently defined fault at a Finley quarry southeast of Kennewick and to observe the operator training simulator for Unit 1.
During the plant inspections the inspector observed that several large bore stainless steel pipe spools temporarily stored in the plant structures under construction were covered with dust and debris from sandblasting, sweeping, concrete form removal, or other general construction activity. The chemical composition of the contaminating materials was unknown and this was of concern to the inspector because of possible corrosion effects on the pipe. This matter was brought to the attention of the licensee and his corrective actions will be reviewed by the inspector.
(460/80-03-01)
The inspector also made inspections during inclimate weather (snow, ice, rain) to observe protective actions employed by the constructor during steel welding and reinforcing steel splicing work.
Protective actions employed were acceptable.
No items of noncompliance or deviations were identified.
3.
Licensee Action on Previous Inspection Findings a.
(Closed) Unresolved Item (460/79-10-04): Availability of weld joint fitup gages to welders.
This item was identified in October 1979, and since then the inspector has routinely checked with pipefitter-welders working in the containment and general services building areas and ascertained that the craftsmen now have such gages to use during fitup operations.
The inspector had no further questions on this matte.
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(Closed) Unresolved Item (460/79-10-05): Availability of weld procedures to welders.
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The piping contractor has posted prominent signs at the tool room
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and welding material distribution rooms in the containment and general services building advising that weld procedures are available at those locations.
The inspector interviewed several welders since October 1979, and ascertained that they are aware of the location of the procedures and their access to them. The inspector had no further questions at this time.
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(0 pen) Unresolved Item (460/79-12-04):
' Chloride content of fire retardant paint.
The piping contractor has obtained an analysis from the vendor that the halogen content of the paint mav be as much as 2000 ppm and the sulphur content as much as 58,000 ppm. The licensee's engineering organization requested further analysis to define the quantities of leachable chlorides before reaching conclusions regarding the acceptability of the use of painted wood shims under stainless steel piping.
4.
Containment Structural Concrete Unit 1 The inspector audited work activities for placement of reinforcing steel for the containment building walls. This involved inspection of diagonal layers G and H at elevation 456' and between azimuths 330 to 360 degrees beneath the equipment hatch. The following cadwelds were assessed relative to the data in the contractor's computer:
112184/Nos. 11, 21, 21A, 21B, 29, 29A, 298; ll2153/Nos. 12, 12A, 12B, 21, 318, 235; and ll2184/No.
Also, the inspector visually examined twenty completed splices in each of three locations (under the fuel transfer tube, under the equipment hatch and under the personnel hatch).
Applicable codes, standards and quality requirements applicable to these components are described in PSAR sections 17 and 3.8, contract procedure QCP-ll, and drawings F-112152, F-ll2153 and F-112184.
Observations, examination of records and interviews of personnel were conducted relative to:
number of bars and location of cadwelds, cadweld fill appearance, production testing of cadwelds for crew qualification, craft personnel compliance with cadwelding procedures regarding preheat, packing, spacers, orientation, venting, cadweld sleeve-powder matching for the #18 bar splices, QC inspection
' documentation, and splice identification.
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-4-The contractor QA manager informed the inspector that approximately 3000 cadweld splices have been tensile tested at the Unit 1/4 sites,
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representing about 66,000 production splices;of the splices which met the visual inspection criteria, only one failed the tensile test.
No items of noncompliance or deviations were identified.
5.
Safety Related Supports - Unit 1 The inspector audited work activities for the installation of the supports (part nos. 275-N0038-ll and 12) for the two core flood tanks. This involved review of the applicable procedures and drawings, materials documentation, and partially installed legs. Applicable codes, standards and quality requirements are described in PSAR Section 17, ASME Code Section III NF, contract specifications 211 and 134, procedures (JAJ) WI-6 and NSS-020A, and drawings F-101327,101329, and 101350 and FP-50843, 51042, 50060 and 52355.
Observations, examination of records and interviews of personnel were conducted relative to procurement of material for the legs, welding materials and attachment bolting in
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accordance with design requirements (including vendor repairs, material certifications, post-weld-heat-treatment and magnetic particle examination of welds), identification of material on-site, inspection records, review of the installa+. ion procedure and its approval by the UE&C staff, general adequacy of the procedure measures to avoid damage and to assure proper orientation, elevation and fastening of the supports, and general condition of the partially installed supports.
The applicable procedure JAJ-NSS-020A step 5.8 calls for protection of anchor bolt threads and verification of cleanness of bolt threads prior to the application of lubricant. The floor mounted bolts and nuts were exposed to water and debris with some slight rust evident. However, the items did not appear deteriorated such that cleanup effort would be ineffective.
No items of noncompliance or deviations were identified.
6.
Safety Related Pipino Installation Unit 1 The inspector audited work activities for the installation of piping from the spray pond pump house to the spray headers.
This involved review of the pipe layout and sizes for the test and bypass line and the spray header..
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Applicable codes, standards and quality requirements are described in PSAR Section 17 and 9.2.5 and figure 1.2.2.5 and UE&C drawings
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202787 and 202789.
Observations, examination of records, and interviews of personnel
were conducted relative to flow directions, presence of valves,
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line sizes, number of spray lines, provisions for hydrotest, grading and backfill compaction, handling of pipe spools, design and construction provisions for heat tracing and draining. The inspector also interviewed the field design engineer regarding his field observa-tions and the basis for minor departures from drawings contained in the PSAR.
No items of noncompliance or deviations were identified.
7.
Reactor Pressure Vessels - Unit #1 and #4 The inspector audited work activities for the in-place storage of the reactor pressure vessel at Unit 1 and the yard storage of the reactor pressure vessel at Unit 4.
Applicable codes, standards and quality requirements are described in PSAR Sections 17 and 3.12 (Regulatory Guides 1.38 & l.39), and job specification No. 211 and contractor procedure No. FS-II-2.
Observations, examination of records, and interviews of personnel were conducted relative to covers on nozzles and other openings, condition of dunnage, protection from construction hazards, desiccant indicator status for the vessel in yard storage, access room locks at the installed vessel and cleanliness of the installed vessel.
No items of noncompliance or deviations were identified.
8.
Reactor Vessel Internals, Unit 1 and 4 The inspector observed storage conditions for the Unit 1 reactor vessel internals assemblies, which are stored in a locked metal building onsite. Applicable codes, standards and other special requirements are described in PSAR Sections 17 and 3.12 (Regulatory Guides 1.38 and 1.39), contract specification 211 and contractor procedures (B&W) FS-II-2 and III-la. The following aspects of the work were considered:
control of access, protection from the environmental conditions, rodent protection, use of desiccant and
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indication of low humidity within the covered structures.
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-6-The inspector also observed the receipt of the Unit 4 assemblies at the job site and the preparations for mov,ing.the. core barrel into the metal storage building. The inspector observed the removal work on the internal shipping jig and the desiccant box. The three l
assemblies were wrapped and protected from environmental conditions.
No items of noncompliance or deviations were identified.
9.
Safety Related Piping Welding - Unit 1 The inspector audited work activities for welding of three pipe joints in the emergency shutdown service water system at the spray pond. This involved fit-up inspection of groove weld joints A11054-12, A11055-12 and A-11053-4, and intermediate weld pass inspection of a groove weld joint on a 30-inch diameter pipe.
Applicable codes, standards and quality requirements are described in PSAR Sections 17 and 9.2.5 and Table 3.2.2, and job specification No. 246, drawings 202787 and 202789, and contractor procedures Nos. (PKS) QA-3, QA-4, CP-12 and WP-5.
Observations, examination of records, and interviews of personnel were conducted relative to: cleanliness and fitup of the weld joints, appearance of tack welds and completed weld passes, conformance to the weld data sheet instructions, conformance of the combination GTAW/SMAW process procedure WP-5 to ASME Code requirements, avail-ability of procedures to foremen and welders, provision for weld repair control, filler metal certification conformance to SFA specifications, identification and qualification of the welders, availability of weather protection and tools and fitup gages, preheat, joint gap / alignment, interpass cleaning, provision for magnetic particle nondestructive testing, use of proper shielding oas, establishment of and adherence to inspection hold points (includingauthorizednuclearinspectorholdpoints),weldmaterial storage and control, and availability of QC inspectors.
The inspector also examined the contractor's(Peter Kiewitt and Sons)
QA manual and associated procedures, and discussed typical process /
inspection control forms with one of the contractor's quality control engineers. The inspector interviewed the ASME authorized nuclear inspector regarding his inspections of the PKS work and activities of WPPSS/UEC welding and piping surveillance personnel.
In response to the inspector's inquiry, contractor personnel stated that welding electrical parameters are not inspected and the contractor did not have a tong-ammeter onsite for this purpose. The UE&C QA surveillance staff does not make such checks. This does not appear to be a specific requirement of the ASME Code, nor a PSAR commitment.
No items ~of nonco:npliance or deviations were identified.
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Safety Related Piping Testing - Unit 4
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The inspector audited work activities for nondestructive magnetic
particle testing (MT) of emergency shutdown service water system shop welds. This involved inspection of the onsite activities of the NIX Company nondestructive examiners relative to examination of pipe spools 18047-165 and 18047-167 in the Unit 4 laydown area.
Applicable codes, standards and quality requirements are described in PSAR Sections 17 and Table 3.2.2, and job specification No. 246.
Observations, examination of records, and interviews of personnel were conducted relative to: qualifications of the team of two examiners, examination technique, environmental conditions, calibration of the MT-yoke and its power supply, and surface condition and temperature of the pipe.
No items of noncompliance or deviations were identified.
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Structural Steel Welding - Unit 1 The inspector audited work activities for welding of structural steel at elevation 420' of the mainsteam and feedwater piping isolation area. This involved inspection of completed welds on steel beams supporting the electrical vault floor. Applicable codes, standards and quality requirements are described in PSAR Section 17 and job specification No. 207.
Observations were conducted relative to:
size and wrap around of of the fillet welds, uniformity of the weld, absence of visual defects, and absence of significant degradation due to surface rust from moist conditions in the area.
No items of noncompliance or deviations were identified.
12. Containment Structural Concrete - Unit 4 The inspector audited work activities for epoxy filler repairs of the Unit 4 grout at the exterior of the containment liner knuckle plate.
Applicable codes, standards and quality requirements are described in PSAR Section 17 and job specification No. 253, Division 3, Section 3B, Appendix A.
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Observations, examination of records, and interviews of personnel were conducted relative to: nature and frequency of tests to ascertain proper proportions of mix ingredients at the end of the pump line, qualification of the material, control of material lot, availability of test devices, presence of quality control inspector and quality records, conformance of application technique to the specification, lighting and equipment condition, and experience of personnel in the technique.
No items of noncompliance or deviations were identified.
13.
Structural Steel - Unit 1 The inspector examined records of licensee actions taken to correct defects identified in shop fabricated structural steel. The records indicate that corrective actions were initiated, progress toward resolution monitored and additional corrective actions implemented, including field reinspections by the vendor representatives and field rework. The inspector concluded that the minor slag identified on beam No. 4273A (ref. 460/80-01-03) was an isolated item and not indicative of a current quality program deficiency. The inspector advised that he had no further question on this matter at this
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The following documents were examined relative to the above:
Nonconformance Reports 1-NCR-207-15 9-28-78 1-NCR-207-25 12-15-78 1-NCR-207-1 9-28-78 Capital Steel Corp, QAI NCR-7511 Contract 10-17-78 (T-081A)
Interoffice Memoranda WQA-1/4-78-431 9-29-78 QA-1/4-78-475 10-17-78 WQA-1519 10-17-78 PM-79-0017 1-03-79 PM-79-0141 1-30-79 PM-79-0271 2-22-79 QA-l/5-79-101 2-16-79
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-9-Field Daily Inspection Acceptance Record fCapf'tal 1 teel Corp.)
p Records dated 10-16-78 19 pages 10-18-78 28 pages 2-26-79 thru 3-6-79 8 pages Correspondence Between UEAC and Allied Structural Steel Co.
UEAL-78-5323 12-04-78 UEAL-78-5330 12-08-78 ALUE-78-5121 12-14-78 ALUE-79-5016 2-26-79 ALUE-79-5582 3-08-79 No items of noncompliance or deviations were identified.
14.
Concrete Placement in the General Services Building - Unit 1 On February 28, the inspector audited second shift work activities for concrete placement in the general services building.
This included inspect'~
- formwerk carpentry and survey operations, concrete truck
. ge, and concrete sampling and slump / air testing for placens... No. 1G-4034.
Applicable codes, standards and quality requirements are described in PSAR Sections 17 and 3.8.4, and job specifications No. 254 and 221, and contractor procedures No. QCCP-12.
Observations, examination of records, and interviews of personnel were conducted relative to: manner and results of the PTL inspector's slump and air-entrainment testing, documents used by surveyors and carpenters for formwork checks, familiarity of these personnel with the applicable procedures, interface of QC personnel with surveyors, and consistent criteria for each group. Two survey foremen, one survey general foreman, one carpenter foreman, four QC inspectors, a QA engineer, and other swing shift personnel were interviewed.
The AWSH QC inspectors found it impractical to review the line and grade parameters for concrete formwork, as prescribed by the applicable procedures QCCP-ll (5.2.1) and QCCP-12 (6.3.2). Apparently they were performing only general checks of parameters as a basis for the surveyor sign-off of the placement release card. The QC inspectors did not review surveyor's logs nor perform independent surveys.
The AWSH QA manager advised during a training session with the QC inspectors (attended by the NRC inspector) that he expected the QC inspectors to accomplish sufficient measurements and/or reviews t
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to establish reasonable confidence that the survey parameters had been achieved. The NRC inspector concluded that the less than
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rigorous adherence to the QC procedures requires a clarification of the role of the AWSH QC inspector and revision of AWSH inspection procedures as appropriate. This matter is unresolved pending further review by the inspector.
(460/80-03-02)
The night shift survey and carpenter foremen in the general services
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building were not familiar with the applicable formwork procedure, QCCP-12, and could not identify as applicable to their work when the NRC inspector showed it to them. They stated that they had not received any training on its applicability. They could not produce
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commensurate tolerance criteria other than the applicable drawings for each placement. They did produce some data sheets which were not controlled documents.
The inspector identified this matter to the licensee's QA organization at 1:00 p.m. the next day and the licensee then met with AWSH management. Thc inspector attended a consequent training session later that afternoon which AWSH conducted with senior personnel in preparation for the swing shift that day (Friday, February 29). The inspector subsequently examined records of a Monday morning trd ning session conducted on March 3, which involved foremen and 6 inspec6.
Further training and dissemination of procedures is anticipated.
This matter is unresolved.
(460/80-03-03)
15.
Inspector Followup on Allegation Concen11ng Pipe Material - Unit 1 A welder was discharged by the J. A. Jones Company for tsking four days to complete a weld on a non-nfety related roof drain 4" pipe in the turbine-generator building. As he was leaving th! site the welder stopped at the NRC inspector's office and left a 13-inch long section of pipe and made statements regarding lamirations and cold-laps in the pipe material. The inspector identified the location where the welder had been working and examined the weld joint which had subr,equently been completed by anc Qer welder.
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the foreman and general foreman and a QC inspector, all of which stated that they have not experienced general problems uith lamina-tions or other defects in this piping. The inspector could identify no basis for concluding that any materials problem exis ts with related piping supplied for quality class I systems of the plant.
No items of noncompliance or deviations were identifie ~_
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16. Concrete Correlation Data - Units 1 and 4p
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The inspector examined preliminary data presented to him by the licensee relating to correlation tests for concrete sampling.
i The test data was intended to show that compressive strengths of test cylinders obtained at the batch plant could be correlated with test results for cylinders obtained at the concrete pump discharge.
This is intended to support a pending decision to depart from ASTM-172 sampling point recommendations as provided for in ANSI-N45.2.5-1978, cart 6.11.
This would allow most test cylinders to be taken at the batch plant, with infrequent samples obtained at the pump discharge. The test data is compiled for thirty instances where samples were obtained at the batch plant, at the truck discharge, and at the end of the pump line. One concrete mix (No. 424, 4000 psi design strength) was involved. Strength of specimens was considered relative to variations in entrained air, slump and temperature. All specimens obtained at the end of the pump line showed 28-day compres-sive strengths of greater than 5390 psi, which is well above the design strength of mix No. 424.
However, in 13 of the 30 instances the samples obtained from the truck discharge showed compressive strengths lower than the samples obtained at the batch plant.
In the other 17 instances the strengths were higher. There appeared to be no explanation for this variability nor assessment of its implications regarding the correlation tests.
In some cases, truck discharge samples showed 28-day compressive strengths 500 psi lower than samples obtained at the batch plant. The inspector found that the correlation test results are presently insufficient to conclude that most test cylinders can be taken at the batch plant.
This matter is unresolved pending the inspector's review of sub-sequent licensee actions.
(460/513/80-03-04)
17.
Safety Related Equipment Storage - Unit 4, The inspector audited work activities for storage of containment spray system pumps and decay heat removal pumps on the cells below elevation 395' of the general services building.
Applicable codes, standards and quality requirements are dcscribed in PSAR Sections 17 and ANSI-N45.2.3 and job specification No. 257.
Observations, examination of records, and interviews of personnel were conducted relative to: maintenance of space heaters, rodent protection, cleanliness and general damage control.
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The inspector found that the DHR-1-A cell sump pump had apparently been de-energized and seven inches of watar had accumulated on the floor of the cell. This increased humidity conditions, but had not immersed the pump / motor components. Various debris floated in the water. The motor heater had also been de-energized and the motor vents were open. The inspector found dirt and debris in the cells of the other pumps but protective covers were generally intact, heaters energized and the cells dry. Upon notification the licensee issued CNR-631 on February 1 to effect corrective action. The inspector could not identify any specific damage having occurred to any of the pump / motor sets and had no further questions on this matter at this time.
No items of noncomplianca or deviations were identified.
18. Caseload Forecast Panel Review of Project Schedules The inspector attended meetings of the NRC caseload forecast panel representative at the corporate office and at the WNP-1/4 and WNP-2 sites on February 26-28. The licensee presented project status information and descriptions of problem areas.
The NRC representative indicated that the NRC would use June 1984 as a planning date for WNP-1 fuel loading.
Current project completions are 36.5% for Unit 1 and 13.9% for Unit 4.
Some project schedule reanalysis is also underway by the licensee.
19. Unresolved Items Unresolved items are matters about which more information is required in order to ascertain whether they are acceptable items, items of noncompliance or deviations. Unresolved items identified during this inspection are discussed in paragraphs 2, 14 and 16.
20.
Exit Interviews The inspector met with licensee management personnel approximately weekly (February 11, 15, 25'and March 3) to discuss the inspector's findings. Attendees at these sessions are so designated in Paragraph 1 of this report. The inspector summarized the scope of his activities and reviewed his findings as discussed in detail in this report.
Relative to unresolved items, the licensee representatives made no specific commitments.
The inspector informed the licensee of the following:
460/80-03-01: The inspector stated that he had not in his previous inspection experience observed surface contamination of stainless steel
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piping to the extent observed at this site. He stated that further j
study of the nature of the surface contamination will be necessary i
prior to a conclusion on acceptability of this condition.
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460/80-03-02: The inspector stated that proper implementation of the QA program requires that. individual QC inspecprs.~ rigorously adhere to inspection checklists. Where checklists are impractical to implement, these should be resolved.
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460/80-03-03: The inspector stated that prompt action was taken to convey survey criteria to foremen in the field. The inspector will review the extent of the training during future inspections.
460/513/80-03-04: The inspector stated that adoption of ANSI-N45.2.5-1978 at this time, involving departure from ASTM-172, would involve deviation from a PSAR commitment.