IR 05000461/1980002
| ML19305C580 | |
| Person / Time | |
|---|---|
| Site: | Clinton  |
| Issue date: | 02/22/1980 |
| From: | Knop R, Livermore H, Wescott H NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML19305C575 | List: |
| References | |
| 50-461-80-02, 50-461-80-2, NUDOCS 8003310114 | |
| Download: ML19305C580 (11) | |
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O U.S. NUCLEAR REGULATORY COMMISSION
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OFFICE OF INSPECTION AND ENFORCEMENT REG!nN III Report No. 50-461/80-02 Docket No. 50-461 License No. CPPR-137 Licensee:
Illinois Power Company 500 South 27th Street Decatur, IL 62525 Facility Name:
Clinton Power Station, Unit 1 Inspection At:
Clinton Site, Clinton IL and Illinois Power Company, Decatur, IL Inspection Cond cted: January 29, February 1 and 4-5, 1980
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Inspectors:
H. M. Wescott d c2/ -[O
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Z. C.
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Approved By:
R. C. Knop, Chief 7 ^,
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Projects Section 1 Inspection Summary '
Inspection on January 29, February 1 and 4-5, 1980 (Report No. 50-461/80-02)
Areas Inspected: Routine unannounced inspection: followup of previously identified noncompliances and unresolved items, reactor coolant pressure boundary piping-work activities, reactor coolant loop piping-welding material, review of IE bulletins, circulars, immediate action letters, nonconformances and corrective action, safety related components observation of work activi-ties, observation of special coatings storage and use, safety related com-i ponents - QA records. The inspection involved a total of 93 inspector-hours by three NRC inspectors.
Results: Of the eight areas inspected, two items of noncompliance were t-identified (infractions - control of documents and corrective actions).
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Persons Contacted
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P. Barganier, Construction, Structural, Supervisor
- R. J. Canfield, Construction Department
- J. F. Hampton, Construction QA Supervisor
- J. D. Geier, Manager,. Generation Engineering
- M. O. Tindill, Construction QA Engineer Baldwin Associates C. Berry, Welding Materials Supervisor W. Carson, Manager, Technical Services J. Chestney, Lead Welder, Containment M. Daniels, Senior Heat. Treatment Engineer M. Cann, Storage and Maintenance Engineer
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- J. Hilding, QA Manager
- J. Linehan, QC Manager
- T. Selva,. Technical Services, QC Manager
- J. Smart, Senior QA Engineer
C. Staffeld, QC Engineer
- T. F. Walker, Senior QC Engineer
- C. Winfrey, QC Engineer C/S
- W. Woolery.. Welding Engineer
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- T. F. Walker, Senior QC Engineer General Electric Company
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G. Hall, Site QC
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Reactor Control Incorporated
- C. Granieri, QC Supervisor
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- J. Klaus,' Site Manager Midway Industrial R. V. Hotton, QC Inspector Hartford Steam Boiler Insurance
- M. J. King, Authorized Nuclear Inspector
- Denotes those present at the exit interview.
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' Licensee Action on Previous Identified Items (Closed) Unresolved Item (461/79-06-06): Records not on site to enable verification of piping that had been through a hot bending process met the ovality requirements of the ASME Code, subarticle NB-4223.2. The inspector reviewed Baldwin Associates Mechanical Reports 2520 and 2521 that stated recirculation loop headers A and B met the ovality require-ments of_NB 4223.2 ASME Ill, 74 Summer Addenda. A system of Go-No-Go using present outside micrometers to the maximum and minimum tolerances was used. This item is considered closed.
(Closed) Noncompliance (461/79-06-02):
Licensee not following BAP 2.3
" Receiving and Issuance". The inspector reviewed BAP 3.1.3 " Structural Steel Erection", Revision 3 dated December 7, 1979, with attachment A, and the following inter-office memos concerning the reinspection of structural steel:
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DMC 22-79 dated July 12, 1979 DMC 23-79
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DMC 24-79
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DMC 25-79
DMC 26-79
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DMC 27-29 DMC 28-29
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DMC 30-79
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Dhc 31-79 DMC 32-79
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The inspector randomly selected three NCR's (Nos. 2365, 2364, and 2353)
concerning the repair of structural steel and traced them to their in-stalled location to verify closcout of the NCR's, and further inspected the laydown area for storage of structural steel. This item is consid-cred closed and in conformance with IPC's response letter 11-01-02 dated August 15, 1979.
(Closed) Unresolved Item (461/80-01-01): Midway Industrial has estab-lished a base reading of.5 mils on uncoated steel surfaces for use with the Microtest magnetic dry film thickness gauge. The reading was deter-mined per SSPR-PA2 methods using at least 7 reports with at least 5 readings for each 25 ft of steel per report. Midway has reviewed all past steel coating reports (140), factoring in the.5 mils correction factor, and has determined the minimum dry film coating thickness of 3 mils has been met.
The correction factor will be measured and fact-ored in for all future coating thickness calculations. The inspector has requested the licensee to continue to monitor this measurement.
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Prepared by Z. C. Cordero Reviewed by D. Danielson, Chief Engineering Support Branch Section 2 1.
Reactor Coolant Pressure Boundary Piping Observation of Work Activities a.
Reactor Recirculation Pump Loop B, Weld 6 The inspector observed the root pass welding of the above weld joint using the Diametrics Automatic Welding Machine.
The weld is stainless steel to' stainless steel with consumable insert joint design. WPS-8-2ME Revision 2 welding procedure is used using ER308L filler metal. The weld surface and contour appeared to be visually acceptable. The inspector determined that the welding activity meets the established requirements in the following areas:
(1) The three welders were qualified and were identified on the traveler (2) The welding procedure is qualified (3) Verification / sign off hold points were observed on the traveler (4) The consumable insert material meets the chemistry and ferrite requirement of the' filler metal (5) The fit-up alignment is acceptable and with the required 3-1 inch maximum window (6) Welding parameters were observed and are within the range of the welding procedure specification No item of noncompliance or deviation is noted.
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Reactor Recirculation Pump Loop A, Weld 6-The inspector reviewed the documentation associated with the above weld joint. The following were verified:
.(1) Welder's stamp on the pipe corresponded with traveler log.
Welder is qualified to the required welding procedure used.
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'(2) - Proper welding procedure.is employed.
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-(3) Verification and hold points on the traveler are properly signed off
. (4). There were six radiograph exposures taken on this weld using a 0.025 ' inch penetrameter on a 1.110 inch thick pipe.
RT procedure UST-RTC-1 Revision 1 is used. The film showed slight porosity which is acceptable to the ASME-code standard used.
(5) _The welding material used_is properly identified.
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(6) The' weld surface and contour is acceptable.
No item of noncompliance or deviation is noted.
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Reactor Coolant Loop Piping - Welding Material Control a.
The inspector reviewed the CPS Quality Assurance Manual on Document Control and Baldwin Associates Technical Services
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Procedure Manual, Manual Copy No. 4 dated November 8, 1979.
The inspector noted that a calibration instruction No. 009,
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Revision 2, dated March 8, 1979 on the BA manual requires a
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100 F minimum portable rod caddy temperature prior to issuance for service. Section 6.0 - Field Control L'elding Materials
of the BA Procedure Specification for the Procurement, Storage and Control of Welding Filisr Materials requires a 130 F minimum temperature of the hartable_ Rod Caddies. A revision (Revision 3 dated May 16, 1979) to the calibration instruction was generated to correct this discrepancy but is not incorpor-ated on BA Manual, Manual Copy No. 4.
This is considered an item of noncompliance with 10 CFR 50, Appendix B, Criterion VI (461/80-02-01).
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The inspector noted that Calibration Instruction No. 009, Revision 3, dated May. 16, 1979 for Portable Rod Caddies re-quires a verification of the operating temperature of 130 F minimum and 450 F maximum prior to issuance for service.
It is further noted that the actual verification of the operating temperature accuracy is done only once - during receipt of new i-or repaired caddies. No records were made available to the inspector during this inspection on subsequent operating temperature requirement verification. The inspector is concerned about the " hand-feel" method (Go-No-Go) employed by the Weld Material Field Control Attendant to satisfy.the 130 F to 450 F temperature range requirement for the caddies.
Information is
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required regarding the manufacturer's requirements on the re-
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calibration frequency. This is an unresolved' item and will-be
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,a SECTION II
Prepared by H. M. Wescott H. H. Livermore Reviewed by R. C. Knop, Chief Projects Section 1 1. Review of IE Bulletins, Circulars,-and Information Notices The inspector reviewed the licensee's action on IE Bulletins, Circulars, Immediate Action Letters, and Information Notices to verify that they had been received and that appropriate action had been taken as recommended.
a.
The following was reviewed by the inspectors and considered to be adequate:
(1)
IE Bulletins 76-01, BWR Isolation Condensor Tube Failure IPC letter RIII (U-0008) date March 16, 1976 states that Clinton Power does not incorporate BWR isolation condensor.
79-03, Longitudinal Weld Defects in ASME 5A-312 type 304 55 Pipe Spool Manufactured by Youngstown Welding and Engineering Company IPC letter to G.E. (G-0345) dated March 23, 1979 requesting G.E. to provide the subject bulletin requested information.
BA letter to IPC (RLN-2-79) dated April 16, 1979 G.E. letter to IPC (IP-1315) dated May 10, 1979 stating that recirculation loop piping was 5A-358.
Southwest Fabricators letter to BA (SF-BA-0037) dated July 25, 1979 with attached SWF report IPC letter to RIII (U-0103) dated August 20, 1979 stating that no subject piping is used or will be used in safety related systems.
79-25, Failure of Westinghouse BFD Relays in Safety Related Systems-6-
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IPC letter to RIII (U-0115) dated January 3, 1980 states
that Westinghouse BFD Relays referenced in IE Bulletin 79-25 will not be used with any safety related services at Clinton.
b.
The following were reviewed by the inspectors and considered to be inadequate:
(1) IE Bulletins77-02A Potential Heavy Spring Flooding 77-05 Liquid Entrapment in Valve Bonnets 77-10 Vacuum Conditions Resulting in Damage to Liquid Process Tanks 77-12 Dropped Fuel Assemblies at BWR Facilities 77-15 Degradation of Fuel Oil Flow to the Emergency Diesel Generator No documentation action on the above appeared to have been taken. On Bulletins and Circulars that had been routed to
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others within IPC there was no provision for feedback to the sender that the action recommended by the Bulletin or Circular had been performed.
This item is considered to be unresolved pending corrective action by the licensee. Unresolved item (50-461/80-02-03).
c.
The licensee did not have the following IE Bulletins and Circulars in his possession:
Bulletins Circulars 78-03 77-11 79-09 78-05 79-10 The above were mailed to the licensee on February 6, 1980 from RIII.
No items of noncompliance or deviations were identified in this area of the inspection.
2.
Nonconformances and Corrective Actions The inspectors reviewed nonconformances and corrective actions to ascertain that the licensee is in conformance with NRC requirements and PSAR commitments.
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The inspectors reviewed corrective action reports-as follows:
(1) CAR'No. 048 approved September 19, 1979 This CAR referenced nonconformance reports (NCR's) as follows:
NCR's Date Logged j
1938 5/8/79 1951 4/29/79
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2042 5/7/79 2214 8/8/79 2234 7/10/79 2341 8/8/79 2461 9/7/79 2501 9/18/79 The above NCR's had to do with the general subject of improper curing of concrete.
(2) CAR No. 042 approved February 9, 1979 This CAR referenced NCR's as follows:
NCR's Date Logged 1426 9/8/78 1663 11/8/78 1670 11/21/78 1675 11/16/78 1732 12/8/78 1735 12/15/78 1738 1/10/79 1754 1/11/78 1776 1/17/79 1806 3/1/79 1811 2/28/79 The above NCR's had to do with the general subject of improper. concrete placement.
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(3) CAR No. 040 approved December 18, 1978 This CAR referenced Mechanical Inspection Reports as follows:
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MIR Dated 1170, 6/8/78 1171 6/8/78 1423 9/26/78 1424 9/26/78 1484 10/26/78 1498 11/2/78 1551 11/17/78 157/
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1664 12/14/78 1665 12/18/78 The above MIR's had to do with general housekeeping re-quirements.
(4) Additional NCR's were reviewed as follows:
NCR's Dated 2707 11/14/79 2709 11/13/79 2710 11/13/79 2717 11/15/79 2718 11/15/79 2729 11/9/79 2730 11/19/79 2731 11/20/79 2732 11/20/79 2733 11/20/79 2734 11/19/79 Although disposition of the above NCR's had been initi-ated, no corrective action to preclude repetition was apparent.
Discussion of the above examples with the licensee established that the licensee was performing a trend analysis prior to taking corrective action to preclude repetition.
This item is considered to be in noncompliance with the requirements of 10 CFR, Part 50, Appendix B, Criterion XV1.
Infraction (50-461/80-02-04).
3.
Safety Related Components - Observation of Work and Work Activities By direct observation, independent evaluation of work performance, work in progress, and completed work, the inspector ascertained whether activities relative to safety-related components were being accomplished in accordance with KRC requirements and SAR commitments.
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The-inspector selected three representative components within the reactor coolant' pressure boundary and one component (safety related) in warehouse storage. The areas inspected were:
storage, handling, protection; installation; protection after installation; and utilization of QC personnel.
b.
The _ inspector performed a surveillance of four safety-related components of the A loop recirculation system inside containment.
The components were in various stages of installation and con-sisted of a 20" gate valve, spool pipe, recirculation pump volute, and a flow control valve. Component identification was visible and was recorded. Storage rigging on the gate valve was adequate.
Component protection and cleanliness was as good as could be ex-pected in an area of constant installation activity.
Baldwin QC was on-station and was knowledgeable of the componer.t activity and associated paperwork control systems status. The inspector reviewed the procedure.' status traveler B33-G001A of the Recircu-lation System A Loop. The A6 Spool to Volute weld signoffs were complete up to #10, waiting radiography results. The companion installation procedure (traveler fabrication / installation in-formation supplement) was signed off (4 steps) up to field weld A6.
The work and signoffs appeared to be in correct pro-gression. The inspectors reviewed the installation of the recirculation pump volute. The aforementioned traveler supple-ment references paragraphs of GE Procedure 22A 6794 for install-ation of the piping / component system. Revision 0, Figure 4, Sheet 25 was reviewed and I thru 5 location (work) points for the pipe / component installation were located on the contain-ment floor and visually checked in relation to the components.
Actual dimensions have been recorded previously.
The inspector performed a surveillance of one safety-related component outside containment. The HPCS Pump Motor was ade-quately stored in a warehouse environment, and was segregated and protected with proper cleanliness control.
Adequate ident-ification records were present.
No items of noncompliance were noted in the areas inspectcc.
4.
Safety Related Components - Review of Quality Records By review of quality related records relative to safety-related components, the inspector ar.certained that these records reflected work accomplished consister.t with NRC requirements and SAR commit-ments.
a.
The inspector reviewed the pertinent quality related work and maintenance recore s of tvo of the components in Section 3 - one of which is in th'.
rea.ccc coolant boundary. The inspector
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ascertained whether these records / system were in conformance with procedures / work accomplishments. The following areas were inspected: storage inspection, installation inspection, material certifications, and maintenance surveillance.
b.
The inspector performed a surveillance of the Baldwin component maintenance surveillance system. The five components previously mentioned in Section 3b were checked against the maintenance surveillance system records. Maintenance had been perforned and signed off as specified. The system was in order are appeared to have good centrol over component maintenar e.
The inspector then followed two of the subject components back to the basic documentation packages. The data packages were re-viewed and appeared to be complete.
Component identification, receiving inspection reports, document checklists, and GE certifications were present and in order. The inspector has no concerns in regard to the aforementioned material.
No items of noncompliance were noted in the areas inspected.
5.
Observation of Protective Coatings Storage Facilities and Activities a.
The inspector performed a surveillance of the Service Level I protective coatings storage trailer. All coating containers were segregated as to type and use sequence; were off the trailer floor on skids; and were temperature controlled..The recording thermometer was located next to the floor representing the coldest temperature in the trailer.
The inspector had no further concerns in this area.
No items of noncompliance were noted in the areas inspected.
Unresclved items are matters about which more information is required in order to ascertain whether they are acceptable items, items of non-compliance, or deviations. Unresolved items disclosed during this inspection are discussed in Section 1, paragraph 2b and Section II ptragraph lb.
Exit Interview The inspectors met wit'
ite staff representatives on February 1, 1980.
The inspectors discus. e the scope and findings of the inspection, which were acknowledged by the licensee.
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