IR 05000483/1981012
| ML20009E733 | |
| Person / Time | |
|---|---|
| Site: | Callaway  |
| Issue date: | 07/22/1981 |
| From: | Hansen W, Konklin J, Martin L, Vandel T NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III), NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20009E725 | List: |
| References | |
| 50-483-81-12, NUDOCS 8107280398 | |
| Download: ML20009E733 (7) | |
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U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT
REGION III
Report No. 50-483/81-12 Docket No. 50-483 License No. CPPR-139 Licensee:
Union Electric Company P. O. Box 149 St. Louis, MO 63166 Facility Name: Callaway, Unit 1
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Inspection At:
SNUPPS Home Office, Gaithersburg, MD Inspection Conducted: May 20-22, 1981
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Inspectors:
. Hansen, Region III 7-22-8/
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,n T. Vandel, Region IV 7.22 Y/
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, cx L. Martin, Region IV lI-21-d$/
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%Y Approved By:
J. Konklin, Projects 7-jll-(7/
Section 2A Inspection Summary:
Inspection on May 20-22, 1981 (Report No. 50-483/81-12)
Areas Inspected: Routine, unannounced inspection of Aspects of the quality assurance program relating to equipment testing, Design and Procurement activities, and Conduct of the audit program as well as Follow-up o previous inspection findings. The inspection involved 51 inspector-hours by three NRC inspectors.
Zero hours during off-shifts.
_esults: Of the five areas inspected, no items of violations or deviations R
were identified.
8107280398 810724 PDR ADOCK 05000483 G
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0 Details 1.
Individuals Contacted SNUPPS Organization - (Gaithersburg, Maryland)
- W. W. Baldwin, Administrative Manager
- C. W. Hultman, Manager Mechanical Equipment
- N. A. Petrick, Executive Director
- S. J. Seiken, QA Manager
- R. L. Stright, Licensing Manager R. P. White, Nuclear and Fuel Engineer
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Bechtel Corporation - (Gaithersburg, Maryland)
C. Herbst, Mechanical / Nuclear Group Supervisor T. DiPerna, Control Systems Assistant Group Supervisor N. Grel, Project Engineer Systems J. Smith, Project Engineering Manager
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J. Koehler, Project QA Manager G. Goddard, Deputy Civil Group Supervisor E. Thomas, Civil Group Supervisor J. Wong, Civil Engineer M. Stuchfield, Manager, Materials and Quality Service G. Trosman, Engineer, Materials and Quality Service l
E. Akkoush, Civil Engineering Supervisor N. Porter, SNUPPS Supplier Quality Manager
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B. Meyers, Project Manager T. Fonner, Mechanical Engineer
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B. Kenner, Electrical Designer i
D. Gasda, Electrical Designer
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J. Moseley, Electrical Designer L. Rotonado, Project Engineer Facilities J. Mihos, Project Quality Engineer 0. Moran, Quality Engineer H. Williamson, Civil Engineer J. Robertson, Electrical Engineer
- Denotes those present at the exit interview.
2.
Licensee Action on Previous Inspection Findings (Closed) Unresolved Item (80-01-01):
SNUPPS review of the Bechtel Audit Program was beyond the annual basis.
The NRC inspector reviewed the results of a report dated February 28, 1980, of the audit performed on January 24 through February 26, 1980.
Two concerns identified were l
responded to by Bechtel Corporation and closed out by SNUPPS on May 20, 1980.
It was further learned that the program was again audited on March 25-30, 1981, as scheduled.
This item is considered resolved.
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O (Closed) Unresolved Item (80-01-02):
Lack of clarity of the Administrative Control Procedure (ACP) 10.2, Revision 3, regarding reporting of deficiencies to the NRC.
It was learned by the inspector that this concern was considered at the next several QA committee meetings (i.e., February 1980, March 19-20, 1980, and further January 9-10,1981).
It was recognized that judgement had to be exercised by QA committee review as to who and how reported.
Currently, the deficiency at the affected site is immediately reported, and then the QA committee and SNUPPS staff review the item for generic application.
When considered generic, the SNUPPS staff then assumes the reporting role for both sites.
The NRC inspector indicated that he had no further questions regarding this item.
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(Closed) Unresolved Item (report 80-01, paragraph 11):
Reactor building containment wall coating of only the botton 12 inches.
The inspector learned that Bechtel has proposed to epoxy coat the floor and wall surfaces to a height of eight feet in the containment.
It was further learned that Bechtel was requested to submit a letter to the technical committee for consideration at the next committee meeting.
The NRC inspector indicated that he had no further questions regarding this item.
(Closed) Unresolved Item (80-01, paragraph 9):
Concern regarding the NRR review of the SNUPPS Quality Assurance Program update.
a Submittals to NRR for updating the Chapter 17 Quality Assurance rogram began with an original issue in May 1980.
These changes through Revi-sion 3 have been based upon discussions with the NRR QA Branch and have been approved by NRR currently through Revision 2 by NRR letter dated May 19, 1981.
Revision 3 is anticipated to be approved by mid-June 1981.
lhe inspector indicated that he had no further questions regarding this subject.
3.
Inspection of Control Panels and Consoles Welding A review was conducted by the NRC inspectors regarding the concern of adequate structural welding of all the control panels and consoles
supplied by Comsip Customline Corporation (comsip) for both the Calloway and Wolf Creek sites.
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0 The results of the review are as follows:
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Bechtel visited both job sites to determine scope of problem and define the problem resolution.
b.
Resolution consisted of preparing a mockup test panel which had welds consistent with the welding encountered on the panels and consoles.
Comsip drawing CICD-MP-1, Revision 1, dateo October 2, 1980, was utilized for the test panel fabrication.
The test panel was tested by Acton Laboratories with a series of c.
tests as follows:
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(1) Resonance search test conducted. The results were determined to be consistent with the analysis performed.
(2) To meet the SSE requirement, a series of fictitious SSE levels were established beginning with two times the stress level and increasing by g of the base floor level acceleration
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(ZPA) for each increased stress level test to failure (after 5 g ZPA level, failure noted).
(3) The Acton test report was available to the inspectors for review.
d.
Site visits to both Callaway and Wolf Creek were conducted by Comsip and Bechtel inspection personnel.
The inspection was performed utilizing an inspection procedure prepared by Comsip and approved by Bechtel (Procedure CICD-P-02) and documented on Comsip drawings of the panels and drawings.
The NRC inspectors reviewed the inspection procedure, inspector qualitications, and results of inspection on the Comsip drawings without comment.
The NRC inspectors understood that the final Bechtel analysis would be completed soon and that it was expected that the panels and consoles should be acceptable to two SSE levels.
No violations or deviations were identified.
4.
Designer Activity Regarding II/I The NRC inspectors conducted a review of the designer's activity regarding the II/I concern for all disciplines of design.
The results of the
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review are as follows:
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e a.
A task force approach is being utilized by Bechtel with Mechanical Control Systems, Electrical, Plant Design, and Licensing personnel being involved as a group.
b.
A data sheet system was developed t;here by each component is listed separately.
The model was utilized to identify each of the com-ponents, whether safety related or not, and to set the impact of -
each component on safety-related equipment.
Acton items were then generated and sent to plant design and discipline involved.
Closecut is required of all action items responding back to the task force.
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c.
The Power Block has been gone over once with the resulting data sheets and design action items not all complete yet but they are down to approximately 622 items remaining out of 2200 plus originati g items.
d.
Certain areas have not been completely dealt with yet, such as:
(1) Field run items have not been listed on data sheets.
Only notes on drawings list the II/I needs.
(2) Control room gravity items have been identified, but the side by side items remain to be identified.
The NRC inspectors visited the model shop, observed several plant e.
areas in model and selected several trays and conduits for discus-
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sion with Bechtel designers; however, no specific comments or
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concerns were generated.
f.
An estimate for completion of the whole activity was offered to the NRC inspectors of July 1981.
No violations or deviation were identified.
5.
Post Tensioning System Contractor The NRC inspectors reviewed activities rc:garding designer controls, review and approval of submittals for the Post Tensioning System -
supplier and installation contractor (Inryco, Inc.).
The results of the review are as follows:
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C Bechtel Department Project Instruction Number EDPI 6.10-01, Revision a.
7, " Suppliers QA Program Selections and Evaluation" was utilized in the contractor evaluation and selection process for the Post Tension-ing System.
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b.
Bechtel Specification 10466-C155 Supplier Spec. and C 156 Field Installation Spec, was issued with the purchase order to Inryco, Inc.
for the supplying and installation of the Post Tensioning Systems of Callaway and Wolf Creek.
The standard G 321-D form was included in the specification which outlined the submittals to be sent to the designer for review and approval.
Among the required submittals reviewed and approved by Bechtel were:
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(1) The vendor QA Manual.
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(2) The shop QC Manual.
(3) Shop and field requirements to be approved by Bechtel include buttonhead criteria, tendon assembly test, all drawings, inpection and test plans, hardness tests and certified mill test reports.
c.
The Bechtel " Supplier Print Control Register" listing the status of all submittals received and reviewed by Sechtel was reviewed.
The review and approval by Bechtel appeared to be complete for both sites.
Discussions with Bechtel Engineering personnel established that the installation contract QC Manual provided for random inspection and that Bechtel. had approved the manual with this provision.
It was learned, from further discussions, that the licersae of the Callaway site had entered into a contract adder with Inryco for increased inspection with definitive sample sizes, even though the inspections continue to be random sampling.
In response to questioning, the NRC inspectors were informed that the Wolf Creek licensee was unaware of the Callaway inspection increase and that this did appear to be a departure from the standardization concept.
Subsequent to the completion of this inspection, the NRC inspector was informed that the upgraded information had been provided to the Wolf Creek licensee and they are studying the information.
No violations or deviations were identified.
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6.
Construction Variance Requests /Nonconformance.toorts Reviey A review was conducted of the Wolf Creek Construction Variance Requests (CVR) file and of the Wolf Creek Nonconformance Reports (NCR) file.
It was learned that the CVR file is up to data with all CVR's having been dispositionad.
The NCR file was reviewed with NCR's 2974 through 3000 surveyed.
Of these NCR's, five had been dispositioned " repair" while the remaining seven had been dispositioned use-as-is.
No violat~ons or deviations were identified.
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Audit Program Review
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The SNUPPS Program for determinir.g that Bechtel's contract QC award, and vendor surveillance was reviewed.
Union Electric, Kansas Gas and Electric, and SNUPPS have submitted Construction Deficiency Reports resulting from problems with sub-vendor performance.
For example:
(1) Gulf Western piping assemblies, (2) Dravo weld NDT, (3) Comsip Electrical Panels, and (4) Bunker Ramo electrical penetration work.
SNUPPS staff audits in the past few months have identified that Bechtel's surveillance of spare parts suppliers is inadequate.
Based on problems that have occurred with vendors in the past, the short comings identified by SNUPPS in Bechtel's ongoing program and the contracts and purchases yet to be computed, the actions taken to improve this area by the licensee's, SNUPPS, and Bechtel will be reviewed in future audits.
No items of noncompliance of deviations were identified.
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Exit Interview (
The NRC inspectors met with the licensee representatives (denoted in
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paragraph 1) at the conclusion of the inspection on May 22, 1981.
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inspectors summarized the areas inspected and indicated that there were l
no adverse findings as a result of the inspection.
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