IR 05000508/1982014

IE Insp Rept 50-508/82-14 on 820712-16.No Noncompliance Noted.Major Areas Inspected:Nondestructive Testing Aspects of safety-related Piping Installation,Installation of safety-related Electrical Components & 10CFR50.55(e) Items

ML20062J113
Person / Time
Site:	Satsop
Issue date:	07/30/1982
From:	Dangelo A, Dodds R, Eckhardt J, Haist D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V)
To:
Shared Package
ML20062J088	List: IR 05000508/1982014 ML20062J083
References
50-508-82-14, NUDOCS 8208160266
Download: ML20062J113 (8)

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U.S. NUCLEAR REGULATORY C0'1 MISSION

REGION V

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t l Report N /82-14 -

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Docket N License N CPPR-154 ' Safeguards Group Licensee: Washinaton Public Power Supply System P. O. Box 1223 J Elma, Washington 98541 Facility Name: WNP-3 Inspection at: WNP-3 Site (Satsop)

Inspection conducted: July 12-16,1982

. Inspectors: //#/l'['[ ///8 7 42

/ Dhte Signed IT.~ P. Haist,feactor Inspector Saxwf.'lbMhv

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7/5 /62 d.H.Eckhapt,RptorInspector / Bate Signed

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/ /Date Signed A. J. D'.Angpo, Rpetor Inspector l Approved by: t ,70 M

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R. T. Dodds, Chief, Reactor Projects Section 2 /Dat( Signed Reactor Construction Projects Branch Summary:

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Inspection during the period of July 12-16, 1982 (Report No. 50-508/82-14)

Areas Inspected: Routine, unannounced inspection by regional-based inspectors of construction activities including nondestructive testing aspects of safety-related piping installation; installation of safety-related electrical components and supports; licensee action on a potentially reportable 10 CFR 50.55(e) item; and licensee action ,

on inspector follow-up items and unresolved items.

4 The inspection involved 96 inspection-hours on-site arid 12 inspection-hours in office by three NRC inspectors.

Results: No items of noncompliance or deviations were identifie RV Form 219(2)

PDR ADOCK 05000500 0 PDR

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DETAILS t Persons Contacted The inspector interviewed various engineering, management, inspec-tion, craft, and construction personnel of the organizations listed belo Key personnel, including those who _ attended the exit interview, are specifically identified-below: Washington Public Power Supply System (WPPSS)

• S. Leddick, Program Director, WNP-3/5

• E. L. Stephens, Quality Assurance Engineer

• 0. E. Trapp, Project Quality Assurance Manager

• J. A. Puzauskas, Quality Assurance Standards and Performance Supervisor

• J. A. Vanni, Quality Assurance Engineer

Ebasco Services, Inc. (Ebasco)

• J. P. Sluka, Manager of Engineering

• R. Harris, Project Quality Engineer

• L. A. Bast, Quality Assurance Engineering Supervisor

• J. F. Killian, ESSE Project Engineer

• J. Ruimerman, ESSE Lead Discipline Engineer, Mechanical

• C. M. Kim, Principal Engineer

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• P. J. Massman, Quality Assurance Engineer Peter Kiewit Sons, Inc. (PKS)

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• E. Tosh, Quality Assurance Administration Manager S. Scott, Quality Control Manager D. Ebmeyer, Quality Assurance Engineer GE0 Construction Testing (GE0)

• B. Penley, Project Manager M. Toomer, Quality Control Monitor i Fischbach and Moore, Inc. (F/M)

l l *B. G. Ashby, Project Quality Control Manager l

K. Bryden, Project Manager t J. Wiley, Construction Manager L. Bailey, Assistant Project Manager  :

• Designates those attending exit interview on July 15, 198 . Construction Status The licensee considered WNP-3 to be 56 percent complete on July 1, 198 O-2- Site Tour _

The inspectors conducted a tour .of Unit 3 on July 12,1982 to observe completed work, work in progress, and storage and main-tenance of safety-related equipmen No items of noncompliance or deviations were identified. Licensee Action on Previous Unresolved and Follow-up Items (Closed) Unresolved Item (50-508/509/81-04/03) Inconsistencies between Support Fabrication Drawings -and Design Drawings During a previous inspection (IE Inspection Report No. 50-508/81-04),

the inspector found that Fischbach and Moore (F/M) generated fabrication drawings did _not contain,all necessary design information to correctly fabricate welded cable tray support In March 1982, F/M generated " Alternate Steel Connection Manual for Seismic Supports" for use by F/M design drafting personnel. This controlled document lists all the allowable connections to be used by F/M for cable tray supports. In addition, a drawing cross reference list, Report No. 00C-504, was established to track revisions of Ebasco design' drawings and identify the F/M drawings which would be affecte The addition of the two above mentioned documents should provide for adequate verification of conformance to Ebasco design drawings. This item is considered close (Closed) Follow-up Item (50-508/509/81-08/06) - Trending System for Quality Related Indicators The inspector had identified, on a previous inspection, the lack of a formal quality trending program to identify con-ditions adverse to quality and implement effective corrective actio In response to this identified weakness, the Ebasco quality assurance organization has' developed Quality Assurance Instruction No. QAI-15-4, " Trend Analysis," which provides instructions for monthly trend analysis. Trend analysis is performed on nonconformance reports and on quality finding reports resulting from audits and surveillances. Nonconformance report trending consists of: (1) assignment of deficiency codes to each nonconformance report by the appropriate quality assurance engineer; (2) determination of the nonconformance ratio (nonconformance reports per baseline percentage of actual work completed) for all major contractors; (3) review of nonconfor-mances for repetitive deficiencies if the nonconformance ratio falls within an acceptable range; (4) investigation of a

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-3-contractor's nonconformance program if the nonconformance ratio indicates.the possibility that nonconformances are not being properly documented as such, and (5) evaluation of nonconformance reports for deficiency trends if the noncon-formance ratio exceeds the established " normal" rang Quality finding reports issued for the preceding six months are reviewed by the audit supervisor and surveillance super-visor each month for deficiency trends. Trends identified by this review or the nonconformance review are reported to quality assurance management and the license Trends are also discussed with the applicable contractor who is given the opportunity to initiate corrective actio Nonconformance reports are also reviewed for deficiency trends associated with pre-purchased equipment so that vendor quality assurance representatives can be notifie The inspector reviewed the results of three months of trend analysis. Although no definite trends were identified, the analysis did identify the fact that one contractor was not properly reporting nonconformances to the licensee. The effectiveness of the trending program will be examined during future routine inspections. This item is considered close . Licensee Action on Potential 10 CFR 50.55(e) Construction Deficiency Welding Deficiencies - Steel Door Frame Fabrication The licensee notified the NRC on November 20, 1981 of a poten-tially reportable construction deficiency involving failure by a supplier to perform specified surface examination of full '

penetration tee welds on various steel door frame Additio n-ally, other weld deficiencies such as undercut, undersize welds, and cold laps were identified on frames that were not yet installe Licensee actions regarding this deficiency included ultrasonic examination of installed door frames to assess the quality of tee welds and determine the need for repair or engineering analysis. Welds on 44 of the 48 installed door frames were found to be acceptable. Four frames with icss than required weldment were analyzed by Ebasco engineering and found to be acceptable as installed. Based upon this analysis, the licensee determined the deficiency to be not reportable under the provisions of 10 CFR 50.55(e).

Door frames that were not installed were returned to the vendor for the required examination and repair in accordance with the specification requirements. Other weld deficiencies

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-4-were analyzed by Ebasco Engineering and determined to be insignificant (the " tee" welds being the prime load carrying members). Ebasco vendor quality assurance representatives were given additional training on-site in the area of visual welding inspection, and vendor inspection plans were reviewed to assure verification of nondestructive examinatio The inspector examined the documentation associated with deficiencies on typical door frames, including ultrasonic test data, and verified that an engineering analysis was performed on those tee welds which exhibited lack of fusio This item is considered close . Electrical Equipment Installation Examination of Installed Equipment The inspector examined selected installed / partially installed electrical equipment to ascertain compliance with the following F/M Construction / Quality Control Procedures:

(1) C/QCP-507S3, " Installation and Inspection of Electrical Equipment" ,

(2) CP-301S3, " Material Control / Receiving, Storage, and Issuance" (3) CP/QCP-52353, " Bolted Field Connections"

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(4) QCP-303, " Handling, Rigging, and Transporting of Elec-trical Equipment" (5) CP-403, " Welding of Steel' Str'ictures" The equipment selected for examination included equipment in the Division I portion of the Class 1 electrical system. The following equipment was examined:

(1) Emergency Diesel Generator A-SA. This diesel generator was set in place and was being levele (2) 4160 V ESF Switchgear A3-SA. This switchgear was set on dunnage on its foundations. The cabinets were to be bolted to existing embedded anchor bolt (3) 480V Load Centers SA 31 and SA 32. These load centers were set on dunnage on their foundations and were to be attached by existing embedded anchor bolt .

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-5-(4) 480 V Motor Control Centers SA 311, 312, 321, and 32 Installation of these motor control centers was complet The cabinets were attached by welding to existing embed-ded channel '

(5) 480 V Motor Control Center A-323-SA supplying the diesel i generator auxiliary equipment. Installation of this motor control center was cumplete. The cabinet was attached by welding to existing embedded channel Particular attributes examined included equipment protection and cleanliness, energization of equipment heaters, maintenance checks, location, and missile protection. Also, the welds attaching Motor Control Centers SA 311, 312, 321, 322, and 323 ,

to the embedded channels were inspected. The fillet welds ;

were measured and were of the size and location as specified in the applicable F/M drawings. The feeder breakers to this equipment and supply breakers from this equipment were inter-nal to the cabinets and were not examine The inspector observed construction debris on the top of the 4160 V Switchgear A3-SA and a piece of structural steel leaning against the 480 V Load Center'SA 31. The protective ,'

covers over this equipment were intact and no damage to the equipment was indicate The inspector also observed that the space heater power source to the 480 V Load Center SA 31 had an apparent loose connection as evidenced by the two indicator lights going out when the lead was moved, resulting in intermittent loss of power to the heaters. When these items were pointed out to F/M personnel, they took immediate corrective action. In general, the protection and cleanliness of the equipment was sa ti sfactory. There was evjdence that maintenance checks were being performed as required, and the space heaters were energize No deviations or items of noncompliance were identifie b. Review of Quality Records Quality records of the electrical equipment identified in paragraph 6.a were reviewed to ascertain compliance with the procedures indicated. The records reviewed included receipt inspection records, warehouse requisitions, material receiving reports, inspection reports, electrical equipment installation worksheets, welding data sheets, installation tickets, main-tenance records, and nonconformance report No deviations or items of noncompliance were identified.

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-6- Safety-Related Piping Welding - Nondestructive Examination Aspects - Contract 251 Observation of Work and Work Activities  !

The inspector examined the following completed welds in ASME Class 2 safety-related piping systems. Attributes examined included weld quality, surface finish, reinforcement and alignment, identification of field welds for radiographers, and evidence of completed radiography. Field welds were examined against the requirements of the ASME B&PV Code Section III, Subsection N (PKS) Weld Identification N ,

System j 3 CS- A13-17, FW-3 Containment Spray  !

3 SI- A13-005, FW-3 Safety Injection

3 CS- A13-9, FW-3 Containment Spray 3 SI- A13-11, FW-3 Safety Injection i 2 CH-A12-153, FW-2, R-2 Charging

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3 CH- A12-159, FW-1 Charging No items of noncompliance or deviations were identifie Review of Quality Records The inspector examined radiographs of the field welds listed in paragraph 7.a against the requirements of the ASME Code ,

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Sections III and V and GEO Construction Testing Procedure No. 20. A.1, " Radiographic Examination of Welds." Attributes  !

examined included weld identification on radiographs, use of correct location markers, use of proper penetrameters and shims, radiograph density and sensitivity, and interpretation against ASME Code acceptance standard The inspector also examined the radiograph technique sheets and reader's report associated with each set of radiographs against the applicable codes and procedure j No items of noncompliance or deviations were identified.

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The inspector examined the certification statements of Level III examiners, the quality control monitor, and radiographers associated with the radiographers examined above. All were certified in accordance with the proper ASNT-TC-1A level for the duties performed. The inspector noted that there are no written qualification requirements for the quality control

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-7-monitor, although the position is currently occupied by a certified Level II in magnetic particle, liquid penetrant, and radiographic testing. The quality control monitor is the quality assurance representative at the facility (Ref. GE0 Construction Testing Quality Assurance Plan, Section 1.0)

whose responsibilities and duties include monitoring inspec-tion activities, documenting the quality level achieved, verifying the quality of operations, and determining the suitability of test, examination, and inspection document The GE0 Project Manager committed to examine company policy regarding formal qualification and training requirements for the Quality Control Monitor position. This item will be examined during a subsequent inspectio Follow-up Item (50-508/82-14/01).

The inspector noted during review of the GE0 Construction Testing Quality Assurance Plan, Section 2.3, " Qualification and Certification of Nondestructive Examination Personnel,"

the absence of the requirement of ANST-TC-1A,1975 Section 8. that test objects shall be used in the practical examination, and at least 90% of the known indications should be foun GEO representatives were unable to explain how this require-ment is being met. The inspector examined a typical practical examination for a Level II radiographer which includes:

(1) set up and radiography of a typical pipe weld (to demon-strate technique and ability to produce an acceptable radio-graph) and (2) interpretation of a series of test radiographs with known defects. This practical examination for Level II-certification appears to meet the intent of the ANST-TC-1A requirements, which have been deleted from the 1980 Edition of ANST- TC- 1 The inspector learned that Ebasco has identified a similar finding regarding strict compliance with ANST-TC-1A by GE0 Construction Testing on another project and that a response to that finding is pending. GE0 committed to deter-mine the action being taken regarding this finding and whether the action should .be implemented on this project. This item will be examined during a subsequent inspection. Follow-up Item (50-508/82-14/01).

No items of noncompliance or deviations were identified.

l 8 Management Meeting The inspector met with the licensee and management personnel denoted in paragraph 1 at the conclusion of the inspection on l July 16, 1982. The inspector discussed the scope and findings of the inspection. The findings were acknowledged by the licensee.

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