IR 05000508/1979005
| ML19225C349 | |
| Person / Time | |
|---|---|
| Site: | Satsop |
| Issue date: | 06/21/1979 |
| From: | Dodds R, Hutson T, Kirsch D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V) |
| To: | |
| Shared Package | |
| ML19225C347 | List: |
| References | |
| 50-508-79-05, 50-508-79-5, 50-509-79-04, 50-509-79-4, NUDOCS 7907270306 | |
| Download: ML19225C349 (12) | |
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U. S. f;UCLEAR REGULATORY COT 1ISSI0ft OFFICE OF If4SPECTI0fl AUD EflFORCEMEflT REGI0ft V 50-508/79-05
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Report fio. 50-509/79-04
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CPPR-154
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Docket flo. 50-503, 50-509 License fio. CPPR-15S Safeguards Group
Licensee: W shington Public Power Supply System l
P. O. Box 468
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Richland, Washington 99352 WflP-3 and WtlP-5 Facility flame:
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WT4P-3 and Wf1P-5 Site (Satsop)
Inspection at:
I # I4~I7' I979 Inspection Conducted:
Inspectors:
,s<b
/- 4 / M 9 D. F. Kirsch, Heactor Inspector Date Signed N TC No t ~d 1. W. Hutson, Keactor Inspector.
- Date Signed
[ I.' /ka 6/nhe D. P. Efaist, Reactor Inspector
' Date Signed c ompanied kj g(f7 y
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R. T. Dodds, Crlief, Engineering Support Section Ddte Signed Reartgr Constrgetion and Engineering Support Brap#//7f.
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/b/ // (7CnI
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Approved By:
R. T. Dodds, Chief. Engineering Support Section Date Signed Reactor Construction and Engineering Support Branch Su:miary:
Inspection during period of May 14-17,1979 (Report tios. 50-508/79-05
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and 50-509/79-04)
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Areas Inspected:
Routine, unannounced inspection by regional based inspectors of construction activities including:
licensee action on previous inspection findings; licensee action on IE Bulletins and
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Circulars; structural steel and supports QA procedures review, obser-vation of work and work activities and QA record review; site preparation QA procedures review, observation.of work and work activities and QA record review.
The inspection involved 106 inspector-hours onsite by
three flRC inspectors and a regional supervisor.
Results: flo iteus of noncompliance or deviations were identified.
One unrrsolved item was identified in the area of sieve calibration / verification
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checking (Paragraph 4.b).
IE:V Form 219 (2)
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7 907270 3 c6 3.:: p:.-.
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DETAILS, 1.
Persons Contacted Washington Public Power Supply J stem (WPPSS)
- W. J. Talbott, Division Manager, Wi;P 3/5 Project
- C. E. Love, Deputy Division Manager
- J. C. Lockhart, Project QA Manager
- R. M. Simons, Senior Project Quality Engineer
- J. M. Walker, Senior Project Quality Engineer
- R. C. Douglas, Licensing Engineer
- R.
P,. Quimby, QA Engineer
- il. Johnson, QA Department Secretary E. L. Stephans, Project QJality Engineer K. A. Kirkwold, Electrical Engineer Ebasco Services Inc. (Ebasco)
- D. L. Quaame, Manager of Construction
- C. B. Tatum, Senior Resident Engineer
- A. M. Cutrona, Assistant QA Manager E. L. Chatham, Cortract Manager T. E. Cottrell, Resident Engineer - Field C. H. Swan, Site Support Engineer - Soils J. Dekker, Instrument Technician E. A. Letchford, Senior Project Quality Engineer R. A. Mehnert, QA Engineer K. McClaskey, Quality Engineer Chicago Bridge and Iron (CBI)
J. W. Cain, Proje t Welding and QA Superintendent M. W. Loible, QA Engineer L. Smith, Level II Radiographer G. M. Arnett, QC Inspector R. O. Fad, Quality Pusher J. Larson, Welder R. L. Brown, Welder Morrison-Knudsen (M&K)
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F. C. Edler, Project Quality Engineer D. D. Reader, Lead Quality Control Inspector
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D. G. Colbert, QC Inspector R. B. Balthazor, Lead Auditor J. M. Sallie, QC Inspector Foundation Services, Inc.
D. Rubio, Instrument Technician 427 05')--
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Persons Contacted (Continued)
Pittsburg Testing Laboratory (PTL)_
M. R. Tallent, Jr., Site Manager R. Steele, Level 1 Technician J. Davis, Level 1 Technician K. Michols, level 11 Technician State of Washington
- W. L. Fitch, Engineer (EFSEC)
- Denotes those attending the exit interview.
2.
Site Tour Upon arrival, the inspectors conducted a site tour to observe the activities of constructicn, housekeeping and general compliance with the PSAR and apolicable codes and standards.
The inspectors noted that reinforcing steel stored on the baserats appeared to be properly protected, identified and stored on dunnage.
The inspectors observed the concrete placement activities for Uni t 3 placement ABW-019-349 and examined these activities for compliance with applicable procedural requirements.
The following inprocess PTL records were examined:
field inspection test report, identification tags or. concrete cylinders, checklist of equipment and personnel, the specification of test acceptance criteria and recording of test results.
Examination of six com-pressive strength cylinders prepared and stored during the inspection disclosed that all six identification tags were improperly dated and the PTL inspector's names were missing on two of the tags.
The inspector noted that cylinder traceability was maintained by reference to the truck trip ticket from which the samples were obtained.
The licensee took immediate action to correct the discrepancies.
The inspectors had no further questions.
A tour Nas ccnducted of the M&K structural steel laydown area, the Saginaw storage area and warehouses 1, 2 and 3.
Standing water was
'bserved inside the lower protective covering of a reactor coolant pump casing which was stored at the Saginaw storage area.
The licensee took immediate corrective actions to eliminate the water and assure that the storage conformed to Class D conditions as required by ANSI standards.
The stocage conditions for the safety injection accumulators, high pressure safety injection pumps (HPSI), shutdown heat exchanger s, letdown hea+. exchanger and other Class 1 material inside warehouses 1, 2 and 3 appeared to conform 427 053
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The licensee stated that in the future, nonconforming material would be positively segregated in a marked area from conforming Class I material.
The licensee stated, in response to the inspector's questions regarding the megger testing of HPSI pumps, that an fiCR had been written and that procedure fio. ASP-III-4.4 (Standard Requirements for Maintenance of Equipment and Materials During Storage) was being revised to provide more detailed guidance and acceptance criteria.
The inspector examined material maintenance documentation for the HPSI pumps and boric acid eductor.
f;o items of noncompliance or deviations were identified.
3.
L_i_censee Action on Previously Identified Items of flonconoliance a.
(Closed)
lioncompliance (508/7_8-09-04):
Failure of PTL to submit and Ebasco to review all shop test records.
An Ebasco contract engineer was relocated to the PTL facility to resolve engineering problems, oversee testing activities and review quality documentation.
The inspector examined the PTL testing documentation for eight concrete placerrents and noted that the rcquired Ebasco reviews had been performed within the required seven day period after test performance.
The licensee had approved a PTL submitted field change (flo.
FC-SSP-6 of April 23,1979) requesting that procedure QC-DC-1 be revised to require that all onsite test / inspection reports be submitted to the purchaser within seven calendar days after test completion.
b.
(0 pen)
fioncompliance (5_08/78-09-01):
Falsification of personnel qualification records by PIL.
The inspector examined the licens'
actions regarding the review / revision of PTL certification and training programs.
The licensee had completcd a total review of the PTL personnel qualification documentation and has established the following additional control measures:
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(1) A personnel status board was placed in the office of the Ebasco PTL contract manager at the PTL facility listing the tests that each PTL individual is qualified to perform.
This board can be changed or updated only by the Ebasco personnel responsible to oversee PTL's activities.
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(2) The official PTL personnel qualification records are noa being retained by WPPSS/Ebasco in the QA records vault.
(3) A card file system hc:1 been established to assure that PTL personnel and/or equipment will complete the necessary eye examinations, requalifications, recalibrations and certifications prior to the expiration of their qualifi-cations or certifications.
The inspector sampled FIL test documentation and compared these with personnel qualification records, specified ac:eptanct criteria, and equipment certifications.
It appeared that the quality systems instituted by the licensee were functioning properly. The licensee was in the process of assigning Ebasco personnel to the PTL facilities with the specified respon-sibilities of qualified document control / review and field supervision. The inspector had no further questions with regard to the PTL certification and training program management.
The PTL program for equipment preventive raintenance and repair was examined.
PTL procedure QC-CAL-3, Tool, Gauge and Instrument Control, requires that equipment shall be visually inspected for damage or defects which might impair the desig-nated use of the device.
PTL personnel also noted that test equipment was required to be visually inspected prior to use.
PTL had established an area devoted tc test equipment calibration and repair.
The inspector examined a number of test instruments /
equipment at the PTL facility and noted that each was prcperly tagged as to calibration status, and that damaged /uncalibrated test equipment was tagged to properly reflect this status and stored in a segregated area.
The Forney machine weekly naintenance records were examined and observed to be incomplete for the period from April 12, 1979 to May 14, 1979.
PTL and licensee personnel stated that this inspection checklist had been recently institutad and was in the process of implementation.
Further, a more detailed weekly inspection checklist for the Forney machine was being issued by the PTL corporate office and would be implemented upon racei?t.
The inspector examined the Forney machine and noted that the equipment appeared to be operational and that the calibration of the Heise test gauges was current.
The inspector had no further questions with regard to the 'PTL program for preventive maintenance or equipment repair. ~
A report was examined that documented a Cement and Concrete Reference Laboratory (CCRL) inspection conducted of PTL site activities on February 23, 1979.
The relatively minor deficiencies identified in the report had already been corrected.
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This item remains open pending the licensee's submittal to the flRC documenting additional corrective actions taken since or not included in the original response to the item of noncompliance.
4.
Licensee Action on Jreviousl< Identified and Unresolved Items
_ Closed)
Fullcwup_ Item (503/79-03-01).
Completion of receiving (
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inspection reports by f1&K.
The inspector reviewed the records of the tr;ining sessions conducted on the completion of receiving inspection reports and inclusion of applicable documents used or acceptance criteria on the reports.
Receiving Inspection Reports P,-143, R-145, R-150, and R-151 were reviewed to verify the above corrective action.
flo items of noncompliance or deviations were identified.
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Followup 1 tem (508/_79-04_0M:
Calibration check of b.
gradation sieves.
The !!ational Bureau of Standards (fibs) informd an !;RC inspector by telecen that glass spheres for checking sieves were in stock and immediately cya iable.
The f3S notified the PTL district office by letter, Jated February 2,1979, that SRM-1019 glas spherv sere out of s wck.
ASTM-E-ll, Standard Specification ar Wire Cloth Sieves for Testing Purposes, specifies sieve opening tolerances and the sieve manufacturer certiflas compliance to th 4 standard.
ASTM-STP-447A,fianual on Test Sieving Methods, in Paragraph 14.6, states thet "if properly hcndled, a test sieve should retain the accuracy of its openings throughout the life of the sieve since....no m asurable wear occurs in the openings." The above information, coupled with the fact that testing personnel arc required to visuall) inspect test equipment for damage prior to use, forned t'e licensee's basis for removing the sinves from the PTL equipment calibration / verification program.
The licensee stated that their position regarding sieve control and calibration would be evaluated and submittcd to IE Region V for consideration.
This item is unresolved.
The sieves being used by the PTL laboratory were visually examined by the inspector.
They were red in a protective cabinet and appeared to be in excellent condition.
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c.
(0 pen) Unresolved Item (508/79-04-01)-
Appa' :nt failure to provide continuing structural steel anchor bolt protection.
During a tour of the Unit 5 basemat area, it was observed that some structural steel column anchor 'olts had damaged protective coverings.
The licensee took immediate corrective action to correct the discrepancies.
Anchor bolts in the Unit 3 basemat 427 056
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area appeared to be adequately protected.
Licensee personnel stated that the protruding anchor bolt protective coverings were subject to damage due to construction activities in the area and that a program would be developed to provide periodic inspections in order to assure and verify enchor bolt protection.
This are will be examined further during a future inspection.
5.
Bulletins and Circulars Licensee actions in response to the following IE bulletins and circulars was examined.
Circular 78-13:
This circular is not applicable to the WriP 3/5 project since the ultimate heat sink is ambient air heat exchangers for the component cooling water.
This circular is closed.
Circular 78-18:
Ebasco indicated by letter to the licensee, dated March 9,1979, that the areas of potential concern pointed out by the circular had been considered in the design of WNP 3/5 and that Specification 233 (Fire Pretection Eystems) requires that the vendors' design treet the standards of and be approved by American Nuclear Insurers. This circular is closed.
Bulletin 79-02:
Ebasco had responded to licensee requested review actions by stating that, while concrete expansion anchors were not designed into the systems, it would be naive to 6ssume that they would not be used in modifications or repairs.
The response also indicated that Ebasco was conducting studies en the use of concrete expansion anchors.
Licensee representatives committed to notification of IE Region V if concrete expansion anchors are utilized in pipe support base plate designs. This bulletin is closed.
6.
Safety-Related Structures (Structural Steel and Supports)
a.
Review of Quality Assurance Implementino Procedures (M&K)
The inspector examined Morrison Knudsen procedure fio. CP-05
" Structural Steel Erection, Quality Class I, II, and G,"
Revision 2, to ascertain conformnce with PSAR, specification, and AISC requirements.
The inspector also examined the test given to M&K QC inspectors tu ascertain their understanding of the construction procedure.
The construction procedure allows the use of turn-of-the nut, torque control or direct tension indicating methods for verifying the tightness of A-325 connections; however, detailed instruc-tions and acceptance criteria have not been provided for use with tension indicating method" The M&K project quality manager stated that only the turn
' the-nut riethod will be
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used.
The inspector questioned tSt..nclusion in the construction procedure of a tightening method that is incomplete and will not be used.
The licensee stated that the procedure will be 427 050
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evaluated for adequacy and conformance with actual practice.
This item will be examined in a subsequent inspection (50-508/79-05-01).
The inspector reviewed the following Morrison Knudsen quality assurance procedures to ascertain compliance with Appendix B of 10 CFR 50 and PSAR requirements.
(1) Administrative Instruction AI-01: Material Control (2) Administrative Instruction Al-07: Welding fiaterial Control (3) Weld Procedure fio.100:
General Requirements for Pipe and Structural Welding Weld Procedure fio.100 allows low hydrogen filler material frca hermetically-sealed containers showing evidence of damage to be used after the material has been baked in accordance with AWS requirements for A5.1 rod.
The M&K project quality manager stated that M&K will not be baking any rod because there are no facilities available.
A directive has been issued which allows vield rod from damaged containers to be used only for non-quality related " convenience" welding.
b.
Review of Welding Procedure Specifications (CB&I).
The inspector reviewed Welding Procedure Specification WPS EH-14/585 AGW II for the submerged arc process to be used for welding the horizontal seams in the Unit 3 and Unit 5 steel containments.
The essential variables and parameters meet the requirements of the 1974 edition of the ASME Code Section IX and Subsection fiE. The procedure qualification records (PQR's)
2632 and 2640 included the actual ranges of essentials variables as required by the ASME code and the test weldments passed the mechanical tests required for procedure qualification.
fio items of noncompliance or deviations were' identified.
c.
Welding Material Control The welding material control, issue and storage inside the Unit 3 containment and the CBI Fabrication Shop were obser.ved by the inspector. The rod issue records at both storage, areas for flay 15 and 16, 1979 were reviewed for compliance with procedural requirements.
During review of the electrode storage conditions inside the storage van located adjacent to the fabrication shop, the inspector observed that four pallets of E7018 electrode, heat numbers 421-C5631, 1/8 inch (3 pallets)
and 422-C5171, 3/16 inch (1 pallet) had not been receipt inspected, but were stored in the same area as electrode which had been inspected.
The four pallets of electrode were wrapped in plastic which had not been broken for use of the contained 427 05f
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electrode.
Hold tags were subsequently attached to the four pallets of electrode to prevent use until receipt inspected.
All rod storage ovens were properly marked, calibrated and controlled as required by Section 8.0 Welding, Revision 8 and the ASME Code Class MC components.
No items of noncompliance or deviations were identified.
The welding electrode issue and storage conditions in the M&K warehouse were observed by the inspector.
All electrodes were stored in ovens marked with contents or in hermetically-sealed cans in locked storage.
The filler metal issue records for May 17, 1979 were reviewed and found satisf actory.
The records of temperature checks of the holding ovens 1, 2 and 3 &nd portable ovens 62, 63, 65, 67, 70 and 74 were performed weekly as required until April 16, 1979, at which time the procedure was changed to require that the portable ovens be checked monthly instead of weekly.
d.
Observations of Welding Activities Within Containment The inspector observed the inprocess welding activities on weld joints 27C, Tl A5, T13B, A-1, A-5, A-10 and A-12.
The activities observed included back-gouging, grinding, fitup, preheat, cleaning prior to next pass, and weiding of filler and cover passes by the submerged arc and shielded metal arc processes. The inspector also observed the welding QC inspector monitoring burnoff rate, travei speed, preheat, interpass temperature, and checking of bead size.
The activities were conducted in accordance with the applicable Welding Procedure Specifications WPS-E7018 and WPS-408/860 and were within the range of essential variables specified in the above welding procedures. The back-gouging, preheat grinding and cleaning conformed to the procedures in the QA Handbook Division 4, Section 8.0, Welding and the General Welding Procedure Specifi-cations for the Submerged Arc and Shielded Metal Arc Processes.
The records examined showed that all eight welders observed were qualified for the processes and positions being employed.
Welds 721 A, 721C, 718A, and T18C were visually inspected for conformance to ASME code requirements for reinforcement, undercut and surface conditioning for nondestructive examination.
All welds inspected appeared to meet the requirements of the code and were suitable for nondestructive examination.
m No items of noncompliance or deviations were identified.,
e.
Review of Quality Records The following quality records were reviewed by the inspector:
welder qualifications for eight welders, nonconformance reports and the nonconformance control list, selected radiographs of welds B2A, A-7, A-3 and T33A, record drawing tables, preheat
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and interpass temperature checks, burnoff rate, travel speed, bead size and inprocess work records for welds BIA, 82A, and B4C.
The welders' qualifications and radiographs appeared to meet the requirements of the ASME Code Section IX and Section V, respectively. The records conformed to the quality require-ments in the applicable procedures and appea' ed to accurately document the status of the work.
flo items of noncompliance or deviations were identified.
M&K receiving records were examined including Material Receiving Instruction (MRI) forms, inspection reports, and material and test report documentation for the following welding material:
Specification Size Heat ilo.
SFA 5.1 7018 5/32 92003A000 SFA 5.1 7018 3/32 903917001 SFA 5.1 701S 1/8 903747004 SFA 5.1 7018 5/32 904137002 Documentation required by the MRI was available and conformed to specification requirements.
fio items of noncompliance or deviations were identified.
7.
Site Preparation a.
Review of' Quality Assurance Implementir.g Procedures The inspector revievied Appendix B of Ebasco Specification CS-24, Instrumentation Services, for content consistent with verification of PSAR assumptions. The specification appeared adequate for monitoring the stability of structural excavations, the cut slope of Unit 5, and groundwater levels.
b.
Observation of Work and Work Activities The inspector visually observed instrumentation used for '
monitoring excavation stability and groundwater, the ground-water control system, and readings by Foundation Sciences Inc.
of inclinometer / piezometer flo. 5-2.
Discussions with the Ebasco site geologist and Foundation Sciences instrument technician revealed that reliable groundwater level data has not been obtained from the combined inclinometer /piezometers due, in part, to surface inflow.
Heavy rainfall, the elevation of inclinometer /piezameter vaults, and a two-foot surfacing of gravel over the immediate site area have all contributed to inconsistent grounc:, vater level data.
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Corrective action in the form of additional piezometers in close proximity to the RAB excavation vertical faces has been undertaken; however, the Ebasco engineering geologist estimates that approximately two years of data and the completion of the RAB walls (currently a source of recharge during rains) will be required before the drawdown estimated in the PSAR can be confirmed. The Ebasco geologist also attributes the incon-sistent groundwater level reading to " perched" water tables that are not interconnected and do not reflect overall ground-water levels.
The inspector observed that Type III vertical drains at the Unit 3 RAB/ Turbine Building (west) wall were not flanged and sealed.
Ebasco engineering personnel stated that these drains are being reworked (NCR Ho. 0099, DCN C/H-023) to seismic Category I requirements as designed.
The licensee stated that these d'
is will be covered to prevent the entrance of water and debt.., into che drainage system.
The licensee notified the inspectors that a potential 50.55(e)
item has been identified at the Unit 5 RAB excavation east and south vertical gunnite faced walls.
Separations between the gunnite and sandstone ranging from 1/16 inch to 3/4 inch (all in vertical plane) were discovered during manual extensometer readings.
Twenty-five additional inspection holes were opened and additional separations were found.
Ebasco has postulated that frost penetration during the 'ast winter caused the separations.
Inspections have revealed no evidence of separa-tion at the Unit 5 north and west walls or at Unit 3.
Ebasco engineering is evaluating the findings and will notify NRC of any effect on safety-related Seismic Category I structures bearing directly on the gunnite/ sandstone vertical faces.
c.
Review of Quality Records The inspector reviewed the following reports on groundwater levels and excavation stability for conformance to licensee and Ebasco specifications:
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Review of Instrumentation Report No. 69 data for week ending April 2f,, 1979 (Foundation Sciences)
(2)
Summary of Instrumentation Measurements Reports No. 2, March, 1979 (Ebasco)
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(3) Groundwater Drainage System - Analysis of System Per-formance and Data to Date - Supplement No. 4 The reports reflect conformance with specification require-ments. The wide fluctuation of groundwater data is evident in the reports and is, in part, attributed to the conditions described in (b) above.
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8.
Unreselved 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. One unresolved item was identified during this inspection and is discussed in Paragraph 4.b.
9.
Exit Interview The inspectors met with licensee representatives (denoted in Para-graph 1) at the conclusion of the inspection on flay 17, 1978, and summarized the scope and findings of the inspection.
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