IR 05000508/1979006
| ML19275A291 | |
| Person / Time | |
|---|---|
| Site: | Satsop |
| Issue date: | 08/08/1979 |
| From: | Dodds R, Hutson T, Kirsch NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V) |
| To: | |
| Shared Package | |
| ML19275A289 | List: |
| References | |
| 50-508-79-06, 50-508-79-6, 50-509-79-05, 50-509-79-5, NUDOCS 7910030738 | |
| Download: ML19275A291 (11) | |
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U. S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGloN V 50-508/79-06 50-509/79-05 Report No.
CPPR-154, CPPR-155 safeguards croup 50-508, 50-509 treens, no, Docket No.
Washington Public Power Supply System Licensee:
P. O. Box 468 Richland, Washington 99352
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Facility Name:
WNP-3 and WNP-5 WNP-3 and WNP-5 Site (Satsop)
Inspection at:
Inspection conducted:
July 9-12,1979
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Inspectors:
D. E Kifsch, Reactor Inspector Dat'e sigried
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8/Af79 T< W. Hutson, Reactor Inste'c'tof Datepigned
.t 0,. /h1/ n Xbu 9 / 7 /79 Gj[Hernandez-ReardorInspector Date signed
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t u + cM1 t--c s 8!8 77 Approved B :
rw R/T. Dodds, Chief, Enginehitng Support Section D8te/ signed Reactor Construction and Engineering Support Branch Surrma ry :
Inspection during period of July 9-12, 1979 (Report Nos. 50-508/79-06 and 50-509/79-05)
Areas Inspected; Routine
_nannounced inspection by regional based inspectors of construct'
activities including:
Licensee action on previous inspection finuings; licensee action on IE Bulletins; Q.A.
procedures review, observation of work and work activities, and Q. A.
record review for structural steel and supports; site ~ preparation and foundations quality record review; work and work activities and quality record review for safety-related structural concrete; and nonconformance report review and Q.A. audit review. The inspection involved 71 inspector-hours onsite by three NRC inspectors.
Results: No items of noncompliance or deviations were identified.
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RV Form 719 (?)
1C72 004 7910030778 1
DETAILS 1.
Individuals Contacted 2.
Washington Public Power Supply System (WPPSS)
- C. E. Love, Deputy Division Manager
- J. E. Werle, Project Engineering Manager
- J. C. Lockhart, Q.A. Manager
- R. R. Quimby, Lead Project Quality Engineer
- R. M. Simons, Senior Project Quality Engineer
- tl. Johnson, Q.A. Secretary E. L. Stefhens, Project Quality Engineer b.
Ebas o Services, Inc.
- D. L. Quamme, Manager of Construction
- C. B. Tatum, Senior Resident Engineer
- A. M. Cutrona, Assistant Q.A. Manager
- L. A. Bast, Project Quality Engine?r
- L. F. Adams, Senior Project Quality Engineer
- N. Graham, Q, A. Secretary
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E. L. Chatham, Contract Manager T. A. Letchford, Senior Project Quality Engineer P. J. McGrath, Dccument Specialist C. McClasky, Q.A. Engineer G. McGibbon, Level II NDE Examiner c.
Chicago Bridge and Iron (CP&I)
J. W. Cain, Project Welding and Q. A. Superintendent M. W. Loible, Q.A. Engineer G. M. Arnett, Q.C. Inspector R. E. Nelson, Level II NDE Examiner d.
Associated Sand and Gravel (AS&G)
P. J. Meservey, Quality Control Technician e.
Morrison-Knudsen (M&K)
D. D. Reader, Q.C. Supervisor J. M. Sallee, Level II Q.C. Inspector D. Colbert, Welding Inspector P. Martin, Document Control Supervisor J. Williams, Senior Document Control Clerk f.
Boecon-Fegles R. A. Davis, Q.C. Supervisor g.
Guy F. Atkinson Co. (GFA)
D. G. Summers, QC Supervisor h.
State of Washington
- G. Hansen, Engineer (EFSEC)
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- Denotes those attending exit interview.
P00R ORGINAL icn 005
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Plant Tour Shortly after arrival onsite, the inspectors toured various areas of the plant to observe work activities in progress, completed work and constru; tion status. The inspectors examined in-process and completed concrete placements, reinforcir.g steel placements and structural steel placement activities foi obvious defects or non-compliance with regulatory requirements. The inspectors interviewed selected craf t supervision and quality inspection personnel in the conduct of these examinations.
No items of noncompliance or deviations were identified during this general tour inspection.
3.
Licensee Action on Previously Identified Enforcemen+ Items a.
(Closed)(508/78-08-01) Infraction:
Falsification of personnel quality records by PTL.
The licensee submitted a discussion of actions taken to correct the discrepancy on May 30,1979 -(letter G03-79-631).
The inspector had verified the licensee's actions and documer.ted the inspections in previous inspection reports. This item is closed.
b.
(Closed)(508/79-01-03 and 509/79-03-01) Infraction: Testing of grout not performed as required by specifications.
The licensee identified and resolved the discrepancies in accordance with their nonconformance system.
The nonconformances were dispositioned " accept-as-is," based upon the small amount of grout utilized and the history of acceptable test results obtained on similar grout used in subsequent placements.
PTL site management, Ebasco field supervisors and receiving engineers were reinstructed regarding grout test frequency requirements. Attendance sheets were examined documenting this reinstruction. An Ebasco field laboratory engineer with specific laboratory and field experience, war, assigned to monitor PTL's activities and is now located at the PTL laboratory.
Examination of quality records indicates that the corrective action was effective. This item is closed.
4.
Licensee Action on Previously Identified Followup and Unresolved Items a.
(Closeo)(508/79-04-01) Unresolved Item: Apparent failure to provide continuing structural steel anchor bolt protection.
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By memorandum of May 23, 1979 to responsible individuals, the licensee implemented measures to assure protection and monitoring of e.r. bedded structural steel anchor bolts. These measures 102 006
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included daily observation of all anchor bolt locations and the daily reporting to the Construction Superintendent of the results of the daily observations.
Contractors werc directed to grease and tape all structural steel anchor bolts.
Inspector observations of embedded structural steel anchor bolts during the site tour indicated that these measures had been effective.
The inspector examined selected daily inspection reports and verified that the required observation and reporting activities were being fulfilled.
14 0 items of noncompliance or deviations were identified.
b.
(Closed)(509/79-02-01) Followup Item:
~..sining of construction personnel b.nding of embedded rebar.
Boecon-Fegles, GFA and M&K all either issued instructions to, or held training sessions for, site construction personnel re-emphasizing the prohibition against the bending of embedded rebar without prior written authorization and the reporting of nonconforming conditions. Observations by the inspectors indicated that these measures were effective.
!!o items of noncompliance or deviations were identified.
c.
(Closed)(508/79-05-01) Followup Item: M&K procedures for bolt tensioning specity practices in addition to the turn-of-nut method.
Discussions with M&K and licensee personnel indicated that only the turn-of-nut method will be used for structural steel bolt tensioning at the WNP 3/5 site.
This item is closed.
d.
(Closed)(508/79-01-07) Followup Item:
f4DE procedure qualifications did not referer.ce the applicable f4DE procedure _._
The inspector reviewed the Visual Inspection Procedure VT-10 and Liquid Penetrant Procedure PTP-74-3431, Revision 1.
PTP-74-3431 procedure qualification has been referenced by the procedure and has been included in the Proct. dure Qualifications folder.
CB&I has re-evaluated Visual Inspection Procedure VT-10 and determined that a procedure qualification is not required as no acceptance criteria are specified in the procedure.
No items of noncompliance or deviations were identified.
c.
(Closed)(508/79-04-02) Unresolved Item:
Calibration check of~ ~ ~
gradation seives.
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The lic.ensee intends to purchase a set of seives which are to be used only for the verification of accuracy and service-ability of production seives.
These naster controlled seives 1C72 007
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will be stored separately from the production seives.
The licensee was writing a procedure to establish seive verifi-cation frequency requirements and acceptance tolerances.
Provided that the master set of seives can be procurred in a timely manner, the licensee stated that the procedure would be established and implemented by September 15, 1979.
5.
Licensee Actions on I.E. Bulletins and Circulars Bulletin 79-09: The licensee's response to the subject bulletin, submitted by letter dated June 25, 1979, indicated that no G.E.
Type AK-2 circuit breakers are used or planned for use at the WNP 3/5 facilities. This bulletin is closed.
6.
Steel S.ructures and Supports (CBI)
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a.
Welding Material Control The control of welding filler metal inside containment and in the fabrication shop was observed b.
the inspector.
The Daily Weld Material Distribution Logs for July 10 were reviewed and the filler metal storage conditions were checked for compliance with procedural requirements. All filler metal was properly stored and issued and stubs were disposed of as required.
The welding material certifications for DS8000-Ni2 wire (lot H7016 ABD and H7016C), Linde EH14 wire /585 flux and Linde 40B wire (HT 402016)/860 flux were reviewed for compliance with the purchase specifications and ASME code requirements.
No items of noncompliance or deviations were identified.
b.
Valding Prc;edure Specification Welding Prxedure Specification WPS-DS-8000-Ni2 and the associated procedure qualification record 3742 were reviewed for compliance with the ASME code Section IX and procedural requirements.
WPS-DS8000-Ni2 was being used only for root passes on the horizontal seams of the steel containment. The filler passes may be either shieldcj metal arc or submerged arc welding.
Tne WFS-DS8000-Ni2 was qualified separately as allowed by the ASi1E code Section IX. Welding Procedures WPS-E7018 and WPS-EH14/585 were revised to include provision for a root pass with WPS-DS8000-Ni2.
No items of noncompliance or deviations were ider.tified.
c.
Observation of Welding Activitias t
The welding activities associated with Unit 3 seams A-15, A-17, W-17, y-26 and selected areas of the ring 1 to ring 2 shell plate horizontal joint were examined.
The activities observed included joint prep, fitup alignment, root pass, 102 008
-5-filler passes, grinding, cleaning of passes, preheat, and pickup work in various areat of fitup lug removal.
The welding processes obse.ved included shielded metal arc, gas metal arc and submerged arc welding.
All welders observed were using the proper filler material and were qualified for the process and position being employed.
In addition, the inspector observed the Q.C. inspectors monitoring burnoff rate, bead size, preheat and interpass temperatures.
The inprocess work records kept by the Q.C. inspectors were reviewed and appeared to accurately reflect the status of the inprocess work.
A visual examination wat conducted of welds W-3, W-5, W-7, and selected areas of the knuckle to ring 1 weld.
All welds examinea met tne requirements of subsection NE of the ASME code and applicable procedures concerning surface appearance, reinforcement, grinding surface defects and acceptability for non-destructive examination.
fio items of noncompliance or deviations, vere identified.
d.
Review of Quality Records The following quality records were reviewed for compliance with the applicable procedural requirements and to determine if they acct.rately document the status and quality of the work:
(1) Welds W-1, W-2, W-3, W-4 and W-8:
Read Drawing Tables, Work Records for the Record Drawing Tables, Work Records for .;rnoff Rate, Preheat, Interpass Temperature and Bead Size, Daily Weld Material Distribution Logs, and Magnetic Particle Test Reports (2)
Production Test Plate Test Results for Plates B5A, BilB, B8B, T9A, A7, T15A, V8, T25C, and V-11 (3)
13 Welders Qualifications (4)
Calibration Records for Stepwedge Density Strip SDS-2 and SDS-3; Electrode Ovens C, G, F, 4 and 5; Voltmeters 18, 20, 22, 24, 26, 29; Anmeters 19, 21, 23, 25, 27: and Densitometer SN 1001 (5)
Radiographs of Welds W-4, W-5, W-8 and selected areas of the knuckle to ring 1 horizontal seam (6) Nanconformance Control List (7)
Repair Checklists
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The records reviewed appeared neat, well organized and docu-mented the quality of the work as required by applicable procedures.
fio items of noncompliance or deviations were identified.
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7.
Steel Structures and Supports (M&K)
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a.
Welding Procedure Specifications and Q. A. Procedures The inspector examined Morrison-Knudsen procedures establishing the preparation, qualification, approval, distribution and revision of welding procedure specifications and examined five selected welding procedure specifications for conformance to ASME or AWS code requirements. The inspector observed that while the M&K document control office was applying "For Information Only" stamps to uncontrolled copies of quality documents, procedure AI-04 did not specifice ;y require this practice.
Licensee personnel took immediate action to revise Al-04 to require this practice.
No items of noncorpliance or deviations were identified.
b.
Observation of Work and Work Activities
The inspector examined the welding of about 200 studs attached to embed plates and the inprocess work of attaching structural steel columns to base plates located in the WNP-3 basemat for compliance with procedural and regulatcry re'quirements.
fio items of noncompliance or deviations were identified.
c.
Welder Qualification The inspector examined the following M&K documentation for compliance with the ASME code, AWS code and Q.A. implementing procedures:
(1) WP-300, Revision 2:
Procedure for Qualification of Welders (2) Welding Procedures WP-01, 02, 05, 06, 73 and associated welding procedure qualification records (3) Welder qualification list and status (4) Welder qualification records for four welders (5)
Personnel qualification documentation for two NDE examinors and five Q.C. inspectors The inspector observed that upper limit (2Ti thickness that the welder was qualified for was not specified on some welder qualification records, as is required by the ASME code.
This oversight was immediately corrected by M&K personnel and the corrected documents were reviewed by the inspector.
It was also ascertained that none of the welders in question had welded material in excess of the thickness for which they were '
qualified.
tio items of noncompliance or deviations were identified.
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8.
Safety-Related Equipment - Storage The inspector toured the licensee's level A and B storage areas located at the onsite and Aberdeen wareh'ouses and examined the areas for compliance with ANSI and procedural requirements.
The following equipment and documentation was examined:
a.
Four low-pressure safety injection pumps, selected material receiving inspection reports, and care and maintenance records.
b.
Four high-pressure safety injection pumps, selected in-process material receiving inspection reports, and care and maintenance records.
A c.
Four reciprocating charging pumps and associated care and maintenance records.
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The inspector observed the status of all motor heaters, oil levels, equipment identification and storage conditions.
No items of noncompliance or deviation's were identified.
9.
Containment Structural Concrete a.
Observation of Work and Work Activities (1) Boecon-Feoles The inspector observed reinforcing steel and concrete placement activities assnciated with the slipformin of the Unit 5 shield wall.
The observations includer rebar installation, concrete preplacement cleanup, placement of concrete, consolidation, and Q.C. coverage.
The sampling and testing of fresh concrete by PTL personnel was observed.
The proper mix was delivered, the concrete samples were taken at the appropriate times, and the concrete temper-ature was being controlled within specification limits.
The slipforming activities were conducted in accordance with Boecon-Fegles procedures CP-219-005 (Material Placement and Inspection - Shield Wall) and CP 219-006 (Concrete Placement and Inspection).
The testing of fresh concrete performed by PTL appeared to conform to ASTM pr :edures and the reinforcing steel installation to the requirements of Ebasco specification 3240-219.
During the placement, the inspector questioned certain activities in the conduct of the concrete preplacement and placement inspection. These questions were brought to the attention of the licensee, who immediately cor-rected the items and directed that two additional Q.C.
inspectors be assigned to the placement.
Observations of the shield wall placement by the NRC inspector the
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following day disclosed no deficiencies or deviations from acceptance criteria and verified that the licensee's correctiva actions had been effective.
No items of noncompliance or deviations were identified.
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Batch Plant The inspector conducted a tour of the concrete batch plant and storage areas.
During the tour, batch plant operation, backup availability and aggregate stockpiling were observed for compliance with the ASTM and NRMCA specifications.
In the batch plant, the inspector ob-served that three of the nine volumetric admixture dispc.
did not have calibration stickers on them.
Licensee representatives stated that these dispensers were backups to the backup dispensers and'had never been used.
The licensee stated that they would correct this situcion irrediately.
No items of noncompliance or deviations were identified.
(3) Allegation Concerning a Concrete Vibrating Device In the course of the inspection, the licensee notified the inspectors of allegations they had received regarding a 2-inch vibrating concrete consolidation device and abou* 6-feet of air hose which had purportedly been stuck insi > a reinforcing steel placement and lef t inside a Unit 3 shield wall concrete foundation placement.
The licensee was investigating the allegation to,stablish the most probable location of the vibrator.
In addition, the li. nsee had written a nonconformance report docu-menting the situation and stated that the NCR would be evaluated and resolved in accordance with Q.A. program directives and requirements. This item will be examined during a future NRC inspection.
(508/79-06-01)
b.
Review of Guality Records (1) Unit 5 Basemat Records The inspector reviewed quality records associated with Unit 5 basemat concrete placements BMS-005-335, BMS-009-335, BMS-012-335 and BMS-016-335.
The review included the following recoro: Nr coinpliance with specifications and procedures:
reint ecing steel installation inspec-tion, reir forcing steel placing tolerances, conduit installations and inspection, grounding cable installation and inspectior. piping installation and in-place inspec-tion, piping fabrication and connection, embedded metals ar.d structural steel, operations preparatory to placing concrete, preplacement inspection of placing equipment, final inspection before placement, concrete placement
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card, concrete batch plant placement and finish of unformed surfaces, concrete acceptance checklist, concrete placement inspection, concrete consolidation inspection, post-placement inspection, concrete curing card, batch tickets, 1072 012
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inspection reports, applicable nonconformance reports, reinforcing steel receiving checklists, reinforcing steel receiving form, results of compressive tests, and six GFA, six PTL, and two AS&G Q.C. inspectors' qualification records.
No items of noncompliance or deviations were identified.
(2) Batch Plant Records Batch plant production and certification records for the placements selected above were reviewed for compliance with specification and procedural requirements.
Also reviewed, were the ce-tification, calibration, ano inspec-tion of the batch plant, cortcrete materia'._ and associated equipment. Records reviewed included the following:
cement certifications, coarse aggregate test reports, fine aggregate test reports, sieve analysis, sieve cali-bration, weekly batch piant inspection, scale certifications, certification for bc.+.ch plant weight, central mixe-uniformity tests, backup plant uniformity tests, trm r, mixer uniformity tests, n'ain plant and backup plant i1RMCA certification, admixturer certifications, water and ice analysis, and applicable nonconformance reports.
No items of noncompliance or deviations were identified.
(3) Audits The inspectors reviewed the following audits to ascertain compliance with the licensee's Q.A. program and procedures, QAI-16-2, Revision 1.0 (Preparation, Processing, Response, and Followup of Quality Findings Rep,rts (QFR's)) and QAI-18-1, Revision 0, Quality Assurance Audits 213-4, 263-2, 263-3, 216-16, 216-17, 204-13, and 209-7.
All audits reviewed appeared adequate in scope and all audit findings had been properly answered, reviewed, verified, and closed-out.
tio items of noncompliance or deviations were identified.
10.
Nonconformance Reports The Nonconformance Reports for Morrison-Knudsen, Associated Sand and Gravel and Ebasco originated NCR's for the period of May 15, 1979 through July 6,1979 were reviewed for compliance with the Q. A. program in the PSAR and procedure QAI 15-1, Revision 1, (Preparation, Processing, Review and Reporting of Nonconformance Reports Ebasco/WPPSS Originated and Contractor Originated).
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NCR's reviewed appeared to be properly reviewed, dispositioned, evaluated for 10 CFR 21 and 10 CFR 50.55(e) applicability, and closed-out in accordance with QAI-15-1.
No items of noncompliance or deviations were identified.
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Q. A. Audits The inspector selected and examined a number of the licensee's Q.A. audits performed since May of 1979. The audits appeared to be planned and comprehensive in scope. Audit findings were adequately documsted and resolved in accordance with the licensee's Q. A.
program.
12.
Exit Interview The ir,spectors met with 'icensee representatives (denoted in Para-graph 1) at the conclesion of the inspection on July 12,1979, and surmarized the inspectim, scope and findings.
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