IR 05000483/1978014
| ML19294A748 | |
| Person / Time | |
|---|---|
| Site: | Callaway  |
| Issue date: | 01/26/1979 |
| From: | Hansen W, Hayes D, Schweibinz E NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML19294A744 | List: |
| References | |
| 50-483-78-14, NUDOCS 7903130033 | |
| Download: ML19294A748 (14) | |
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U.S. NUCLEAR REGULATORY COSD11SSION OFFICE OF INSPECTION A';D ENFORCDIENT
REGION III
Report No. 50-483/78-14 Docket No. 50-483 License No. CPPR-139 Licensee:
Union Electric Company Post Of fice Box 149 St. Louis, MO 63166 Facility:
Callaway, Unit 1 Inspection At:
Callaway Site, Callaway County, MO Inspection Conducted:
December 4-6, 1978
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c Inspectors:
E. R.
Schweibinz
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A. Hansen
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Mattia (Region I)
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Approved By:
D'. ti. Haye's, Chief
/ ll / 7 7 Projects Section Inspection Summary Inspection on December 4-6, 1978 (Report No. 50-483/78-14)
Areas Inspected: Licensee action on Bulletins and Circulars; site tour; safety related piping records, observation of work, welding and NDE.
The inspection involved a total of 75 inspector-hours onsite by three NRC inspectors.
Results:
Of the areas inspected, no items of noncompliance or deviations were identified.
7903130033
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DETAILS Persons Contacted Union Electric Company (UE)
- W. H. Weber, Manager, Nuclear Construction
- M. E. Doyne, General Superintendent, Callaway Construction
- R. L. Powers, Site Quality Assurance Group Leader
- W. H. Stahl, Quality Assurance Engineer
- J. Laux, Quality Assurance Assistant Enginee r A. C. Passwater, Supervising Engineer-Nuclear Daniel International Corporation (Daniel)
- H.
J. Starr, Project Manager
- E. D. McFarland, Construction Engineering Manager J. A. Holland, Project Quality Assurance Manager
- J. N. Kaelin, Project Audit Coordinator
- W. G. Westoff, Quality Control Supervisor W. L. Petrie Quality Assurance Supervisor J. H. Draughon, Lead QC Inspector / Calibration D. Arnold, Project QC Engineer / Mechanical and Piping E. Sterzinger, QC Supervisor-Welding Technical Services Laboratory J. Boan, NDE Technician, Level II R. Manganello, NDE Technician, Level II and contractor The inspectors also contacted and interviewed other licensee personnel, including craf tsmen, QA/QC, technical and engineering staf f members.
- Denotes those attending the exit meeting.
Licensee Action on IE Bulletins and Circulars fol-Licensee actions and associated correspondence with regard to the lowing bulletins and circulars were reviewed:
Circular No. 76-01, July 29, 1976 Union Electric letter to SNUPPS, ULS-916, August 9, 1976.
SNUPPS letter to Bechtel, SLBE 6-626, August 17, 1976.
Bechtel letter to SNUPPS, BLSE-3578, September 22, 1978.
Union Electric letter to NRC, ULNRC-172, September 30, 1976.
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Circular No. 76-02, August 17, 1976 Union Electric letter to SNUPPS, ULE-952, August 24, 1976.
SNUPPS letter to Bechtel, SLBE 6-685, September 1,1976.
Bechtel letter to SNUPPS, BLSE-3551, September 15, 1976.
Union Electric letter to NRC, ULNRC-169, September 27, 1976.
Union Electric letter to NRC, ULNRC-299, December 14, 1978.
Circular No. 76-05, October 8, 1976 Union Electric letter to SNUPPS, ULS-1052, October 15, 1976.
SNUPPS letter to Bechtel, SLBE 6-848, October 25, 1976.
Bechtel letter to SNUPPS, BLSE-3833, December 15, 1976.
Union Electric letter to NRC, ULNRC-180, January 3, 1977.
Circular No. 76-06, November 26, 1976
- SNUPPS letter to Bechtel, SLBE 6-976, December 17, 1976.
Bechtel letter to SNUPPS, BLSE-4980, September 30, 1977.
Circular No. 77-01, January 6, 1977 Circular No.77-02A, February 18, 1977 Circular No. 77-03, March 4, 1977 Circular No. 77-05, March 29, 1977
- Union Electric letter to SNUPPS, ULS-1341, Ap-il 4, 1977.
- SNUPPS letter to Technical Committee, SLT 7-85, May 5, 1977.
Circular No. 77-06, April 5, 1977 Bulletin No. 77-01, April 29, 1977 Union Electric letter to SNUPPS, ULS-1413, May 5, 1977.
SNUPPS letter to Bechtel, SLBE 7-389, May 17, 1977.
- Bechtel letter to SNUPPS, BLSE-4510, June 14, 1977.
Circular No. 77-10, July 18, 1977 Circular No. 77-11, September 6, 1977 SNUPPS letter to Bechtel, SLBE 7-830, September 20, 1977.
Bechtel letter to SNUPPS, BLSE-5117, November 7, 1977.
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Bulletin No. 77-02, September 12, 1977 and Bulletin No. 77-03, September 12, 1977 Union Electric letter to SNUPPS, ULS-1705, September 19, 1977.
SNUPPS letter to Bechtel, SLBE 7-833, September 22, 1977.
Bechtel letter to Westinghouse, BLWE-734, October 6, 1977.
Westinghouse letter to SNUPPS, SNP-1539, October 25, 1977.
Bechtel letter to SNUPPS, BLSE-5091, October 31, 1977.
Union Electric letter to NRC, ULNRC-204, November 4, 1977.
SNUPPS letter to licensees, SLSAR 7-19, November 7, 1977.
Circular No. 77-13, September 23, 1977 SNUPPS letter to Operating Committee, SLOS 7-60, October 6,1977.
Circular No. 77-14, November 28, 1977
' Union Electric letter to SNUPPS, ULS-1896, December 23, 1977.
SNUPPS letter to Bechtel, SLBE 78-40, January 12, 1978.
Circular No. 77-15, November 29, 1977 Union Electric letter to SNUPPS, ULS-1896, December 23, 1977.
SNUPPS letter to Bechtel, SLBE 78-39, January 12, 1978.
Bechtel letter to SNUPPS, BLSE-6264, July 27, 1978.
Circular No. 77-16, December 13, 1977 Union Electric letter to SNUPPS, ULS-1896, December 23, 1977 SNUPPS letter to Becthel, SLBE 7-1175, December 21, 1977.
Circular No. 78-03, May 12, 1978 SNUPPS letter to Operations Commit tee, SLOS 78-22, May 18, 1978.
Circular No. 78-04, May 18, 1978 SNUPPS letter to Bechtel, SLBE 78-559, Fby 23.1978.
Circular No. 78-05, May 26, 1978 SNUPPS letter to Bechtel, SLBE 78-588, June 5, 1978.
Union Electric letter to SNUPPS, ULS-2283, June 6, 1978.
Circular No. 78-06, May 31, 1978 Union Electric letter to SNUPPS, ULS-2293, June 7, 1978.
SNUPPS letter to Bechtel, SLBE 78-624, June 12, 1978.
SNUPPS letter to Bechtel, SLBE 78-708, July 5,1978.
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Circular No. 78-07, May 31, 1978 SNUPPS letter to Bechtel, SLBE 78-609, June 8, 1978.
Bechtel letter to SNUPPS, BLSE 6453, September 20, 1978.
Circular No. 78-08, June 2, 1978 SNUPPS letter to Bechtel, SLEE 78-610, June 8, 1978.
Bechtel letter to SNUPPS, BLSE-6518, November 9, 1978.
Circular No. 78-09, June 8, 1978 SNUPPS letter to Bechtel, SLBE 78-635, June 14, 1978.
Circular No. 78-13, July ' ),
1978 Union Electric letter to Bechtel, ULB-152, July 20, 1978.
Bechtel letter to Union Electric, BLUE-551, August 28, 1978.
Circular No. 78-15, July 24, 1978 Bechtel letter to SNUPPS, BLSE-6204, July 11, 1978.
SNUPPS letter to Bechtel, SLBE 78-780, July 28,1978.
Circular No. 78-16, July 26, 1978 SNUPPS letter to Bechtel, SLBE 78-850, August 22, 1978.
Circular No. 78-18, November 6, 1978 SNUPPS letter to Bechtel, SLBE 78-1077, November 20, 1978.
- These letters were not observed but the contents were discussed during telephone conversations.
The above documents were reviewed to see if the Bulletins and Circulars were received by the licensee and reviewed for applicability.
If they are appli-cable that the corrective actions have been taken or are scheduled to be taken.
If a written response was required they were reviewed to see if it:
was within the stated time period; included the information required; included adequate corrective action commitments; and was accurate. The follcwing comments are a result of this review:
1.
The RIII inspector noted that the licensee response to IE Circular No. 76-02 (Westinghouse BF and BFD Relays) was not adequately supported with regard to the use of these relays in those safety related systems that are not in the Westinghouse NSSS scope of supply. A commitment was made to provide a revised response. The revised response, dated December 14, 1978 has been received and determined to be acceptable.
(483/78-14-01)
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2.
With regard to IE Circular lio. 77-01 (Malfunctions of Limitorque Valve Operators) a review f or applicability was pea formed and a cop:. of this circular sent to the operations group.
The copy was not placed in a file for further action. As a result of questions raised by the inspec-tor, Circular No. 77-01 is now in a suspense file in the operations group and will be considered in the preparation of the operating pro-cedures.
3.
With regard to IE Circular No. 77-06 (Effects of Hydraulic Fluid on Electrical Cables) it was not evident that an adequate review for applicability was performed. The licensee has subsequently contacted Bechtel by telepaone on December 14, 1978 to request assistance in evaluating this circular. This is an open item.
(483/78-14-02)
4.
With regard to IE Circular No. 78-02, titled " Proper Lubricating 011 for Terry Turbines," April 21, 1978 review of UE records indicate that they did not receive this circular.
Our records indicate that the circular was sent.
An additional copy has been sent to UE by separate cover. This is an open item pending review during a future inspection.
(483/78-14-03)
No items of noncompliance or deviations were identified.
Functional or Program Areas Inspected Details of functional or program areas inspected are documented in Sections I and II of this report.
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Section I Prepared by W. A. Hansen Reviewed by D. W. Hayes, Chief Projects Section Review of Installation and Work Activities 1.
Safety Related Piping, Pipe and Fitting Storace a.
laydown areas The inspector observed storage of piping in the and in the auxiliary building. The p1pe was coated or wrapped with ends correctly blanked in accordance with requirements.
The inspector observed the following field welds to determine b.
installation and control was accomplished as that the 10466-M-204(Q), Field Fabri-req" ired by specification No.
cation and Installation of Piping and Pipe Supports to ASME III for the Standardized Nuclear Unit Power Plant System.
(1) Weld No. 2-BN-01-F013 Assembly PC-23 to LCU-112D Drawing FSM-D M-03BN01Q Code Section III, Class 2 Material P-8 Size 8",.322 wall thickness Inspection /NDE Verification Requirenents Argon Purge Preheat Interpass temperature Radiograph completed weld (2) Weld No. 2EF 02F-019 Assembly 2EF-02 S-022/112 to V029 Drawing FSM-D-M03EF-2Q Code Section III, Class 3 Material P-1 Size 4",.337 wall thickness Inspection /SDE Verification Requirements Argon Purge Preheat Interpass temperature Radiograph completed weld
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(3) Weld No. 2EM-02-F014 Component 2EM-02-S-011/134 to 2EM-02-S-012/134 Drawing FS:1-D-M03 EM02Q, Rev. 3 Code Section III, Class 2 Material P-8 Size 4",
wall thickness.531" Inspection /NDE Verification Requirements Argon Purge Preheat Interpass temperature Radiograph completed weld (4) Weld No. 2BG-01-F017 Drawing FSM-D-M03 BG01Q Code Section III, Class 2 Size 3",.438" wall thickness Inspection /NDE Verification Requirements Argon Purge Preheat Interpass temperature Radiograph completed weld The inspector reviewed the traveler for the above welds; recorded on form F101, Revision 2, weld control record.
No items of noncompliance or deviations were identified.
c.
Material Control The inspector reviewed two pieces of material used for System Fabrication to determine that the material being installed was as specified by Drawing.
(3 ) Piece No. M03-BN01-PC-23/112 of Dwg FSM-D, M03 BN 01(Q),
Rev. 6 Heat No. M0890 The pipe met the ASME Code Section III requirements as specified by the purchase order (66030).
(2) Piece 2EM-02-S012/134, 4" schedule 160.531" wall thickness tee Specification SA-403-WP304S Heat No. 4441-8-
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The pipe Tee installed was traced by piece number and heat number through ghe fabricator " Dravo Corporation" sketch E-3002-336 to Bechtel drawing M-03E M02 Q,
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Revision 3.
The Bechtel drawing provided traceability to pipe class sheet 79-BCB-4 which specified the code requirements.
The material installed met the identification, drawing, and specification requirements.
No itens of noncompliance or deviations were identified.
d.
Qualification of Inspection and Nondestructive Examination Personnel The inspector reviewed certification and qualification records of the following Daniels personnel.
(1)
R. P. Manganello ASNT-TC-1A Level II Radiography Level II Ultrasonic Level II Magnetic Particle Level II Liquid Peaetrant (2)
J. R.
Boan ASNT-TC-1A Level II Radiography Level II Magnetic Particle Level II Liquid Penetrant (3)
G. W.
Spitzkeit ASNT-TC-1A and ANSI-N-45. 2. 6 Level II Liquid Penetrant Level II Magnetic Particle No items of noncompliance or deviations were identified.
e.
The inspector reviewed the basis for the NDE specified for three weld joints.
(1) Drawing FSM-D-M03 BN01(Q)
Weld No. 2BN-01-F013-9-
(2) Drawing FSM-D-M03 EM02(Q)
Weld No. 2EM-02-F014 (3) Draving FSM-D-M03 BG01(Q)
Weld No. 2 BG-01-F017 The weld control records (Form F101) required completed weld RT for each weld. The requirement was traced through the Bechtel pipe class sheet to tiie code Section III requirements and determined to be correct.
No items of noncompliance or deviations were identified.
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Section II Prepared by J. C. Mattia (Region I)
Reviewed by R. W. McGaughy (Region I)
1.
Safety Related Piping (Welding) Observation of Werk Activities The inspector observed welding of safety related piping at various stages of weld completion to determine
_t the requirements of the Techt.ical Specification (10466-M-204(Q) Revision 16), Quality Control Procedure (No. 200 Revision 3) and Work Procedure (No. 205 Revision 5) requirements were adhered to.
The inspector observed the fol-lowing weld joints at various stages of completion:
a.
We*
int Fitup was completed and no welding started Weld Joint No. 2-BG-02-F009 Size-8", 0.322 wall Section III, Class 2 Material - P-8 Tack Weldor - Stamp No. K-11 The inspector reviewed the traveler card for this weld joint and also observed the QC Engineer's inspection of the fit-up.
No items of noncompliance were identified.
b.
Root pass (only) completed Weld Joint No. 2-EN-02-FW66 Size-12", 0.375 wall Section III, Class 2 Material - P-8 Weldor - Stamp No. M-17 The following attributes were inspected for the above weld:
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Specified weld procedure was used
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Physical appearance of weld weldor identification and qualification
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Weld traveler card data
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Use of specified purge and weld material No items of noncompliance were identified.
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c.
Pipe to fitting weld (beyond root pass) joints (1) Weld joint No. 2-BN-01-F013 Size-8", 0.322 wall Section 111, Class 2 Material - P-8 Weldor - Stamp No. 0-4 (2) Weld joint No. 2-EJ-01-F012 Size-10", 0.365 wall Section III, Class 2 Material - P-8 Weldor - Stamp No. J-16 (3) Weld joint No. 2-EN-v2-FW66 Size-12", 0.375 wall Section III, Class 2 Materia P-8 Weldor - Stamp No. M-17 The following attributes were inspected for the above weld joints:
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Specified weld procedure was used
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Physical appearance of weld, use of specified weld materiel
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Correct heat treat (pre and inter pass) used
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Weldor identification and qualification
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Weld traveler card data No items of noncompliance were identified.
d.
Nondestructive testing of completed weld joint The inspector observed magnetic particle examination of a completed weld joint No. 2-EF-02-F019 (size 4", 0.337" wall).
The equipment used was magnaflux type P-90, serial No. 791152, calibrated December 4, 1978.
The testing sas performed in accordance with applicable procedure and code requirements.
No items of noncompliance were identified.
e.
Shop weld During the observation of field welding activities the inspector observed that two completed (2-EJ-02-S039-B 6 D) welds were
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ground down below the surtace of the outer pipe diameter.
It appeared that the required minimum wall thickness may have been exceeded. The licensee could not determine from the vendor records if the wall thickness had been measured in the questionable areas. During this inspection period, the licensee ultrasonically measured the wall thickness in the questionable areas and found them to be acceptable. The inspector reviewed Ultrasonic Report No. 00031 dated December 6, 1978. No items of noncompliance were identified.
2.
Safety Related Piping (Welding) Review of Records The inspector selected various records associated with welcing of pipe to ascertain that these records reflect work accomplishments consistent with NRC requirements and PSAR commitments.
a.
For completed weld joint No. 2-EF-02-F019 the inspector reviewed the following rec rds:
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Weld history data
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Weld material reports
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NDE equipment calibration record
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Weldor qualifications
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NDE technician qualifications and certifications No items of noncompliance were identified.
b.
The inspector reviewed the calibration records for two oxygen analyzers being used to determine the oxygen content for weld joint purges. The meters were determined as follows:
(1) Gas Tech Model IP-204, Serial No. 581, Calibration No. ICH-WQ-065 (2) Bacharach Serial No. 7B311, Model K525, Calibration No. ICN-WQ-070 The inspector noted that the Daniel calibration procedure QCP-20 Appendix I-F had a calibration interval of six months for both of the abovm models. The manufacturer of the gas tech instrument in their instruction manual recommended that their meter be calibrated at a monthly interval.
Daniel produced an inter-office memorandum dated May 19, 1978 addressing this six month calibration interval for the gas tech instrument.
Daniel stated they will either change the calibration interval or justify the six month f requency based upon their completion of the evaluation. This item is unresolved pending review of licensee action.
(482/78-14-04)
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The inspector reviewed the delta ferrite logs maintained by c.
Daniel QC to verif y compliance with Daniel procedure QCP-509, Revision 0, titled " Determining Delta Ferrite Content in Stainless Steel Welding Consumables and Welds."
The procedure is based upon the requirements for ferrite measurement as delineated in the Bechtel Specification 10466-M-204(Q). Daniel is currently experiencing difficulties in maintaining this consecutive log of production welds. There is a requirement to check every one-hundred production weld for delta ferrite content for each heat or lot of welding materials. Many of the weld joints have several heats per weld. The licensee is to evaluate technical specification requirements with Bechtel to determine if specification should be. revised to accommodate dif ferent heats in a single weld joint. This item is con-sidered unresolved pending review of the licensee's action.
(483/78-14-05)
Unresolved Items Unresolved items are matters about which more information is required in order to ascertain whether they are acceptable items, items of noncompli-ance, or deviations. Unresolved items disclosed during the inspection are discussed in Section II, paragraphs 2.b and 2.c of the Details Section of this report.
Exit Meeting The inspectors met with site staff representatives (denoted in the Persons Contacted paragraph) at the conclusion of the inspection on December 6, 1978.
The inspectors summarized the scope and findings of the inspection.
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