IR 05000461/1983005
| ML20024A706 | |
| Person / Time | |
|---|---|
| Site: | Clinton  |
| Issue date: | 06/03/1983 |
| From: | Hayes D, Livermore H NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML20024A699 | List: |
| References | |
| 50-461-83-05, 50-461-83-5, NUDOCS 8306220076 | |
| Download: ML20024A706 (7) | |
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U.S. NUCLEAR REGULATORY COMMISSION
REGION III
Report No. 50-461/83-05(DPRP)
Docket No. 50-461 License No. CPPR-137 Licensee:
Illinois Power Company 500 South 27th Street Decatur, IL 62626 Facility Name: Clinton Power Station, Unit 1 Inspection At: Clinton Site, Clinton, IL Inspection Conducte - March 18 through May 15, 1983 TH.
'A y
a Inspector:
. L vermore Date
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3 Approved By:
. W.
a Reactor Projects Section IB
'Dafe Inspection Summary Inspection on March 18 through May 15, 1983 (Report No. 50-461/83-05(DPRP))
Areas Inspected: Routine safety inspection by the Senior Resident Inspector of construction activities including material laydown and storage areas, program control, licensee action in previous inspection findings, welding, heat treat and NDE activities, and numerous stop work recovery activities.
The inspection involved a total of 145 inspector-hours onsite by one NRC
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inspector, including 16 inspector-hours onsite during offshifts.
Results: No items of noncompliance or deviations were identified.
8306220076 830606 PDR ADOCK 05000461 O
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t DETAILS 1.
Persons Contacted Illinois Power Company (IP)
- W. C. Gerstner, Executive Vice President
- W. Cannell, Manager, QA B. F. Gallagher, M nager, Recovery Team a
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G. Sprague, QA Specialist F. C. Edler, QA Engineer E. E. Connon, Director, Compliance J. S. Spencer, Director, Design Engineering NSED G. N. Motsegood,-Engineering Supervisor -Construction L. Brodsky, Director Recovery Programs
- F. G. Schwarz, Supervisor, Civil Engineering
- R. Campbell, Supervisor, Programs and Procedures D. E. Korneman, Manager, HVAC G. W. Bell, Supervisor, Audit and Surveillance
- D. P. Hall, Vice President
- J. H. Mackinnon, Project Manager
- J.-E. Loomis, Construction Manager J. G. Cook, Assistant Plant Manager H. E. Daniels, Assistant Project Manager J. D. Geier, Manager, Engineering, NSED J. Schottel, Supervisor, QE R. Baldwin, Supervisor, Overinspection Baldwin Associates (BA)
- J.
E. Findley, Manager, Quality and Technical Services
- W. J. Harrington, Project Manager and Vice President H. R. Swif t, Project Engineer G. Chapman, Manager, Technical Services D. R. Murphy, Sr., Electrical Engineer P. Bryant, Assistant Manager, Quality and Technical Services M. E. Daniell, Assistant Manager, Technical Services C. Anderson, Manager, Quality Control D. Selva, QA Supervisor Authorized Nuclear Inspection (ANI)
.M. L. Tracey, ANI L. Malabanon, ANI
- Denotes those attending at least one exit meeting.
2.
Action on Previous Inspection Findings a.
(0 pen) 10 CFR 21 Report (461/81-01-PP (DPRP)).
Incorrect Reactor Vessel Water Level Transmitters and Trip Units. The replacement narrow range (was wide range) transmitters were received by licensee
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in early 1983. An additional problem was encountered in that re-placements were not environmentally qualified. Rosemont #1153 Narrow Range environmentally qualified transmitters are on order.
This item remains open until final receipt.
b.
(Closed) 10 CFR 50.55(e) Report (461/83-03-EE (DPRP)): Certifica-tion of Startup Personnel. The licensee's report of February 18, 1983, determined that there were no adverse safety implications and that the subject ita.m was considered to be not reportable under the provisions of 10 CFR 50.55(e). The licensee's report of February 18, 1983, did note that several problems were uncovered in regard to the Startup Program for certification of test personnel.
Six items of corrective action were delineated. Additional details were provided at the request of the Senior Resident Inspector.
Corrective action and the additional information were adequate.
This item is considered closed.
3.
Functional or Program Areas Inspected a.
Site Surveillance Tours At periodic intervals during the report period, surveillance tours of areas of the site were performed. These surveillances were intended to assess:
the cleanliness of the site; the storage and maintenance conditions of equipment and material being used in site construction; the potential for fire or other hazards which might have a deleterious effect on personnel or equipment; and to_vitness construction activities in progress.
In general, the storage and maintenance of safety related material and equipment is acceptable throughout the laydown areas and the Power Block.
No items of noncompliance or deviations were identified.
-b.
Program Control At periodic intervals, the SRI reviewed Nonconformance Reports (NCRs), Discrepancy Reports (DRs), S&L Specification Revisions, BA Audit Reports, Construction Procedure Revisions, IP Quality Procedure Revisions, Trend Analysis, IP Surveillance Reports, Findings, Audits, and plant problems identified by Corrective Action Requests (CARS), and other means. Numerous informal comments were discussed with the licensee and contractor. The SRI attended numerous. status and/or problem discussion meetings with IP and BA.
-The SRI reviewed and approved individual Stop Work Order (SWO)
exceptions and Partial Release Plans as allowed by NRC Confirmatory Actiin Letters (CAL).
No 1: ems of noncompliance or deviations were identified.
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c.
Potential Problem Identification
'The following item was forwarded to the. licensee for information-and " follow-through" action. The item consists of generic problem
'information obtained by the NRC~from other power reactors. The NRC inspector explained that the information may identify a
? potential problem of a similar nature at Clinton. The licensee is requested to investigate the~ problem,1 determine its applicability, and denote action-to be taken.
-(1) During a review of Borg-Warner Valve' radiographs at the Perry, lDhio site, the licensee found radiographs ~that may have been artificially _ enhanced by using a penetrameter which did not-meet Code' requirements for. thickness, size and number of holes.
Details'were provided to Illinois Power for investigation of the presence of.Borg-Warner Valves onsite.
This is Open item 461/83-05-01.
l(2) The NRC released notification of an Unusual Occurrence PNO-III-83-26 on April 8, 1983, that grease had been used on valve seating surfaces to aid in passing leak tests at Dresden Unit 2.
This practice is not acceptable in that it will distort leak rate test results. All available information was passed on
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to Illinois Power for investigation and preventative action.
The licensee took action presenting his intended preventative actions. This item will remain open until completion of investigation and preventative action.
This is-'Open Item-461/83-05-02, d.
.Weldina, Heat Treat and Non-Destructive Examination (NDE)
Activities-(1) During the reporting period, the inspector observed general weldita activities associated with electrical hangers and structural attachments in the Power Block. For the welding examined one or more of the following activities was observed.
Protection of nearby electrical ~ cable was satisfactory.
Electrode control and handling was satisfactory. The welding areas were free of~ contaminants. The welders were certified as qualified for the thickness and the process specified.
Technique and weld results were satisfactory.
No items of noncompliance or^ deviation were identified.
.(2)
10 CFR 50.55(e) 461/83-02 addresses the uncertainty of some counterbore dimensions inside safety related piping installed in containment. Methods to determine these dimensions, without cutting out the pipe welds, are being explored. The Senior Resident Inspector viewed such a demonstration - that of specialized' Ultrasonic Testing capability with transducers
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Lspecifically designed to identify internal pipe surface counter-
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bore configuration. Prepared samples with hidden known counter-bore tapers were. tested and results compared to the known values.
The summary demonstration results were encouraging.
. Effort'in the area of plans, procedures and training is being pursued.
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No items of noncompliance or deviation were identified.
(3) 'The Senior Resident Inspector conducted a surveillance of a Post Weld Heat Treatment Stress Relief of a Safety Related 20" Feed Water pipe weld. The traveler was FW-1-C, weld
- 1-FW-1-8-3-Q1, pipe spools # 1-FW-1-8A to i 1-FW-1-8, thick-ness 1.969", P1 to-P1 material. The procedure BTS 404 Rev.
16 was located in'the work area, was being followed, and was reviewed by the. Resident Inspector.. The recorder being used
.was inspected, and.was within'the calibration dates of 1/6/3 to.7/6/3. The-temperature blanket installation was within-code requirements - covering a 2"~ band each side of the weld.
Thermocouple requirements were met for the large diameter pipe - two plus two spares spaced 180* apart at top and bottom.
Thermocouples were calibrated. Test requirements specified a 100*/ hour minimum and 400*/ hour maximum heat-up and cool-down rate with a 2 hour2.314815e-5 days <br />5.555556e-4 hours <br />3.306878e-6 weeks <br />7.61e-7 months <br /> soak time._ Heat-up and cool-down was per-formed at approximately 200*/ hour with a 2 hour2.314815e-5 days <br />5.555556e-4 hours <br />3.306878e-6 weeks <br />7.61e-7 months <br /> soak time at 1150*F. The cooldown rate was verified by the inspector at the time of the surveillance to be approximately 15*/5 minutes -
translating to approximately 180*/ hour.
No. items of noncompliance or deviation were identified.
e.
10 CFR 50.55(e) Notification During a review of Licensee Quality Assurance Surveillance Reports, the Senior Resident Inspector noted that some rather serious find-ings had not been reported to the NRC as required by 10 CFR 50.55(e).
The surveillance item concerns vendor shop welding defects on certain structural steel members supplied by Rockwell Engineering to Baldwin Associates, the site Contractor. The welds in question are those'which attach connection angles to the structural steel members. The Contractor first reported the welding problem by Discrepancy Report 5815.. Licensee Surveillance Report Y16677 of May 7, 1983 further details the problem and notes that further investigatory efforts by the Contractor are uncovering more examples of unacceptable welds including some imbedded in wall columns. The
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Senior Resident Inspector expressed these questions to-the licensee:
Was the subject deficiency evaluated by the contractor and by the-licensee for a 10 CFR 50.55(e)? Did one or both contractor and licensee's systems'for evaluating construction deficiencies for 10 CFR 50.55(e) reportability break down? Licensee corrective action appears to be underway, in that 10 CFR 50.55(e) 461/83-06
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Lwas: called in to Region III on April 27, 1983. This item will i
remain open until the previously dated questions are answered and.
more information as to root cause.and corrective action to prevent-recurrence are presented.
This is Open ItemL461/83-05-03.-
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f.
Qualifications of' Vendor Service Representatives The Senior Resident Inspector reviewed the Licensee's Project Management Procedure-11.5, Revision 0.
There did not appear to be a function in place that ensures that vendor representatives are
. qualified to perform their intended function on safety related equipment or equipment important to plant safety. This concern wasiforwarded to Illinois Power Quality: Assurance.
This'is-Open Item 461/83-05-04.
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Refueling Bellows Stop Work 010 The Senior Resident-Inspector reviewed the.following in regard
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to the corrective action's required to lift Stop Work 010:
.(1) : Traveler B13-012B.
(2). Refueling Bellows-Weld Map detailing all radiographic, ultrasonic and liquid penetrant non-destructive examination
(NDE)' performed.on the bellows.
(3)
U.S. Testing Liquid Penetrant Examination Reports on 28 welds plus one repair veld (FW-2).- Repair procedure and repair form BTSF055 were reviewed.
(4) Southwest Research Volumetric Examination Report (UT) #7395
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as reviewed for applicability and-completeness.
w (5) Drawings of the installation were reviewed:
i 762E460 G.E.
S27-1943B Sargent &'Lundy
S27-1941 N Sargent & Lundy, Containment Building - Vessel uto Dry Well Seal 73-6735 CBI' Nuclear Co. Support Assembly
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72387Y Dl.1 Tube Turns, Inner Refueling Seal Bellows
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(6) Viewed radiographic film of bottom skirt plate for defect identification.
(7). Documentation revising the Refueling Bellows to Non Safety-Related Classification -(NRR' letter, ECN 3075, and FSAR
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Amendment).
(8). Proposed training'of applicable personnel for installation.
(9) Sargent & Lundy document SLS-I-3786 detailing the RT, UT, and LP results; their conclusions on crack propagation potential;
and their conclusions that the known flaws are stable, there-fore, the welds are' acceptable.
No items of deviation or noncompliance were identified.
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Corrective actions were appropriate.
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4.
Meetinas and Site Visits-
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10nLApril 13,1983, there was la meeting onsite with NRC representatives
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Mr. R. Knop'and Mr. D. Hayes of Region III, the Senior Resident, H. Livermore, and Mr. D.. Hall, Vice President of Programs for Illinois
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Power. ' Subjects-discussed were the status of the Clinton Improvement Program ~and scheduled predictions of forthcoming I.P. requests to lift
.the current Stop Works.- Also discussed was the transfer of respons-ibility of the site traveler tracking and control group from Baldwin
. Associates to. Illinois Power. The requirement to notify the NRC of any
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changes in commitment's prior to implementation was emphasized.
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Stop Work Chronoloav
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A summation of past Stop Work and Recovery Program events have been listed in NRC Reports 50-461/82-05
.-08, -14, -24, and 83-04.
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general. reporting period the following events have taken place:
a.
(h1 April 26,1983, NRC Region III concurred with Illinois Power's
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corrective action in regards to the Procurement Stop Work. Con-
.currence with.the. Recovery Plan actions was noted, and agreement
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was giveni o lift the Procurement Stop Work.
t b.
On May 19,;1983,- NRC Region III concurred in Illinois Power's lifting Stop Work Orders 017, 018, and 010 (Electrical Equipment, Instrumentation, and Refueling Bellows).
6.
Open Items
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.Open items are matters which have been discussed with licensee, which will be reviewed further by the' inspector,'and which involves some action
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-on the part of the NRC or-Licensee or both. Open items disclosed during
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the inspection are discussed in' Paragraphs:
3-c.-(1), 3-c.-(2),
3-e.,
and 3-f.
7.1 Exit Meetings The inspector met with IP representatives (noted in Paragraph 1)
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throughout the inspection period and summarized-the scope and findings of the inspections performed.
The' inspector attended the following NRC inspector exit meetings:
D. Keating on March 25, 1983 F. Jablonski on March 25 and April.7, 1983.
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