IR 05000518/1978016
| ML19308A292 | |
| Person / Time | |
|---|---|
| Site: | Hartsville  |
| Issue date: | 12/15/1978 |
| From: | Conlon T, Crowley B, Lenahan J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML19308A287 | List: |
| References | |
| 50-518-78-16, 50-519-78-16, 50-520-78-16, 50-521-78-16, NUDOCS 7903080440 | |
| Download: ML19308A292 (14) | |
Text
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%,.....f Report Nos.: 50-518/78-16, 50-519/78-16, 50-520/78-16 and 50-521/78-16 Docket Nos.: 50-518, 50-519, 50-520 and 50-521 License Nos..
CPPR-150, CPPR-151, CPPR-152 and CPPR-153 Categories:
A2, A2, A2 and A2 Licensee: Tennessee Valley Authority 830 Power Building Chattanooga, Tennessee 37401 Facility Name: Hattsville Nuclear Power Plants A and B Inspection at: Hartsville, Tennessee
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Inspection conducted: November 27-30, 1978 Inspectors:
B. R. Crowley J. J. ~ nahan
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Revieued by:
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Da'te Engineering Support Section No. 2 Reactor Construction and Engineering Support Branch Inspection Summary Inspection on November 27-30, 1978 (Report Nos. 50-518/78-16, 50-519/78-16, 50-520/78-16 and 50-521/78-16)
Areas Inspected:
Routine, unannounced inspection of constraction status; 10 CFR 50.55(e) items; work perfonnance and QA/QC controls en structural concrete; Class D storage areas; QA/QC controls (proceduret.) for site preparation. lakes, dams and canais; containment structural steel welding activities and procedures; reactor coolant pressure boundary pipe welding procedures; safety-related pipe welding procedures. The inspection involved 53 inspector-hours on-site by two NRC inspectors.
Results:
Of the eight areas inspected, no apparent items of noncompliance or deviations were identified in seven areas, one item of noncompliance (Inf raction-failure to control issue of specification changes) was identi-fied in one area.
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RII Rpt. Nos. 50-518/78-16, 50-519/78-16, 50-520/78-16 and 50-521/78-16 1-1 15!7 [
DETAILS I Prepared by:
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B.R.Crowley,MetallurgicflEngineer
'Date Engineering Support Section No. 2 Reactor Construction and Engineering Support Branch Dates of Inspection:
November 27-30, 1978 Sf~ "7 7 Reviewed by
, y i m,c d W L9 T. E. Con 1 Chief 2g'
Date
,
Engineering Support Section No.
Reactor Construction and Engineering Support Branch 1.
Persons Contacted Tennessee Valley Authority (TVA)
- R. T. Hathcote, Project Manager
- W. R. Brown, Construction Engineer, Plant A
- W. T. Quinn, Construction Engineer, Plant B
- J. W. Wilson: Assistant Manager, OEDC
- L. H. Jackson, Assistant Construction Engineer, Plant A, QC
- R. S. Sheppard, Assistant Construction Engineer, Plant B, QC S. P. Stagnolia, Supervisor Welding QC Unit, Plant A E. D. Loope, Supervisor, Welding, QC Unit, Plant B R. M. Jesse, Supervisor, Materials and Welding Engineering, MEB D. J. Etzler, Metallurgical Engineer, MEB M. N. Bressler, Supervisor, Nuclear Standards and Materials Section, MEB J. Cox, Supervisor, Licensing Group T. Tyler, Licensing Engineer, Hartsville D. J. Cowser, Supervisor, Mechanical QC Unit, Plant A P. F. Gillespie, Construction Engineering Associate In addition to the above, other licensee inspection and craft personnel were interviewed.
- Denotes those present at the exit interview.
2.
Licensee Actions on Previous Inspection Findings Actions on previous findings were not examined during this inspectio.
RII Rpt. Nos. 50-518/78-16, 50-519/78-16, 50-520/78-16 and 50-521/78-16 I-2 3.
Unresolved Items Unresolved items are matters about which more information is required in order to ascertain whether they are acceptable items, items of non-compliance, or deviations.
Unresolved items identified during this inspection are discussed in paragraph 6.
4.
Independent Inspection Effort The inspector made a site tour and observed storage, general house-keeping and overall welding and inspection activities.
The follow-ing specifics were observed:
a.
Unit Al equipment storage yard was toured and storage of contain-ment plate as well as general storage conditions were observed.
b.
Unit Al containment building was inspected and general house-keeping conditions were examined.
c.
The completed lower assembly of the Al reactor vessel pedestal was observed and the as finished surfaces of the vertical welds were examined.
5.
Containment (Structural Steel Welding)- Observation of Work and Work Activities (Unit A1)
The inspector observed field welding of containment structural steel at various stages of weld completion.
The applicable code for containment welding, as required by Braun and Company specification 300-13, Revision 7 and TVA "C+'c v1 Retord" letter dated October 23, 1978, is the ASME Boiler and '. essure Vessel Code,Section III, Division 1, Subsection NE,1974 Edition, Summer 1974 Addenda for the shell and Division 2, Subsection CC, 1975 Edition far the bottom liner.
Observation of field welding activities included, where applicable, the following areas; weld identification and location, joint preparation and alignment, evidence of QC verification, use of specified weld procedure, welder qualification, use of specified weld material, specified NDE being performed at the proper state of fabrication, and evidence of periodic welding variable checks. The following activities were observed:
a.
Joir.t Fitup Welds AICS00136 and AICS00ll2 1st Ring to Base Plate Weld AICS00124 1st Ring Vertical
RII Rpt. Nos. 50-518/78-16, 50-519/78-16, 50-520/78-16 and 50-521/78-16 I-5 N-201, Revision 2, " Magnetic Particle Examination of ASME Welds Prod and Yoke Dry Powder Method" N-301, Revision 0, " Radiographic Procedure No. 3" N-403, Revision 0, " Thickness Measurements" W-101, Re ision 0, " Specification for Visual Examination of Weld Joints" W-105, Rev. O, " Post Weld Heat Treatment" W-109, Revision 1, " Weld Repair ASME B&PV Code,Section III" d.
General Construction Specification G-29M Process Specification 1.M.I.2.(a), " General Welding Procedure Specification" Process Specification 1.M ,2.(a), " Welder and Welder Operator Performance Qualification" e.
Surveillance Procedure (SOP)
SOP-11, Revision 1, " Welding Surveillance" During review of the above procedures, the inspector identified three problems as described below:
(1) Procedures for the control and documentation of welding do not clearly define requirements and/or actual practices in the following areas:
(a) Documentation of welders is accomplished by recording welders assigned at fitup on the fitup inspection card and recording the welders who actually weld the joint on the final visual inspection card.
Every welder who welds on a particular joint paints his symbol on the base material near the joint :md QC transfers these symbols to the final visual inspection card at the time the inspection is performed.
However, this pro-cess of welder documentation is not covered in any procedure.
(b) Welding filler material is recorded on the fitup inspection card and on the final visual inspection card.
These cards only make provision for one entry of filler material heat number and size.
Control procedures do not specify a method for keeping track of filler material that is used in a joint
RII Rpt. Nos. 50-518/78-16, 50-519/78-16, 50-520/78-16 and 50-521/78-16 I-4 a.
" Nuclear Components Quality Assurance Manual" (NCM)
Section 2.3, Revision 5, " Preparation, Review and Approval of EN DES Process Specifications" Section 3.6, Revision 7, " Receiving Inspection Storage, Preserva-tion and Issuing of. Code Items" Section 4.3, Revision 0, " Automated Process Control at Hartsville and Future Nuclear Plants" Section 5.1, Revision 9, " Welding Control'
Section 6.1, Revision 9, " Nondestructive Examination Control" Section 7.1, Revision 11, " Calibration of Measuring and Test Equipment" Section 8.1, Revision 8, " Post Weld Heat Treatment" b.
Construction Engineering Procedures (CEP)
CEP 2.05, Revision 2, " Qualification, Training, and Certification of Nondestructive raamination Personnel" LEP 2.11, Revision 1, " Qualification of Welders and Welding Operations" CEP 5.04, Revision 0, " Work Packages" CEP 7.02, Revision 1, " Receiving Inspection" CEP 8.03, Revision 3, " Control of Welding Material" CEP 9.03, Revision 0, " Qualification of Welding Procedures" CEP 12.01, Revision 3, " Control of Measuring and Testing Equipment" c.
"QC Instructions" (QCI)
N-101, Revision 2, " Liquid Penetrant Examination Solvent Removable Method of ASME Welds"
RII Rpt. Nos. 50-518/78-16, 50-519/78-16, 50-520/78-16 and 50-521/78-16 I-3 b.
Welding in Progress Weld AICBLP0037 Bottom Liner Weld AICBLP0038 Bottom Liner Weld A1CBLP0029 Bottom Liner Weld AICS00113 1st Ring Vertical c.
Completed Welds Weld AICS00229 2nd Ring Vertical Weld A1CS00233 2nd Ring Vertical Weld AICS00235 2nd Ring Vertical Weld A1CS00236 2nd Ring Vertical d.
Weld Material Control Welding areas were examined for the presence of uncontrolled filler material.
Rod shack "A" was examined for storage conditions, tem-perature control, issue records and handling of returned materials.
e.
Welding Areas Welding areas were observed to determine if a suf ficient number of QC personnel were present.
In the areas inspected, no items of noncompliance or deviations were identified.
6.
Containment (Structural Steel Welding) - Review of Quality Assurance Implementing Precedures The inspector reviewed the quality assurance implementing procedures listed below, relative to containment structural steel welding, to determine whether adequate procedures are included or referenced in the QA manual.
See paragraph 5 above for the applicable code.
The procedures were reviewed in the areas of; witness or inspection hold points, qualification of welding procedures and personnel, quali-fication of NDE procedures and personnel, calibration and maintenance of welding and NDE equipment, control of contamination in KDE materials and equipment, control and documentation of welding and NDE processes, control of heat treatment, evaluation of weld quality by the proper NDE method, defect repair, and welding material contro RII Rpt. Nos. 50-518/78-16, 50-519/78-16, 50-520/78-16 and 50-521/78-16 I-6 where a joint is welded over a period of several shifts or where a joint is welded on one shift and the visual inspec-tion card completed on another shift.
Does the inspector take the weld material identity from the withdrawal chits before they are destroyed or is the identity taken from the material each shift and a" umulated until the final visual inspection card is filled c at?
(c) Procedures provide for only one preheat check and that is at the time the fitup card is filled out.
There is no provisions for recording other preheat checks should a joint be welded over several shifts. There is a requirement in a surveillance procedure (SOF) to monitor preheat, but this is a check of a general work area to see if preheat is being used in that area and not a specific check of a joint.
Interpass temperature checks are not called for in any of the welding control proce-dures or the surveillance procedure.
In reviewing the welding inspection program, it appears that most individual inspection areas are covered, but there is no " tie-to-gether" implementing procedure to tie the program together and cover problem areas such as those discussed above.
However, discussions with TVA Welding QC personnel and TVA memorandum dated November 20, 1978, indicated that the welding inspection program is in the process of re-evaluation. The Assistant Construction Engi-neer-QC (Plant A) states that the above types of problems will be considered in the evaluation.
This matter is considered unresolved and is identified as item number 518/519/520/521/78-16-03.
(2) The site is using Code Case 1714 on the containment as specified in C F. Braun specification 300-13.
This code case relaxes Post Weld Heat Treatment requirements for materials 1-3/4 inch thick.
Code Case 1714 is listed as an acceptable code case in Regulatory Guide (RG) 1.85.
However, paragraph D of the RG 1.85 requires that the applicant request specific authorization to use code cases listed in the RG.
A list of code cases, including number 1714, to be used on the Hartsville plants has been compiled (see TVA letter MAMD4769, dated August 25, 1977) for submitting to NRC.
However, this list has not been submitted because NRC has indicated to General Electric (GE) that code case requests relative to the Standard Reactor Island Design (STRlDE) equipment should not be submitted until the final GESSAR is submitted.
Discussions with NRR, Project Management Division, indicate that Code Case requests applicable to a particular site should be submitted independent of what GE is doing with the GESSAR.
This information was given to TVA Licensing Division (J. Cox) on December 8, 1978 by telephone
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RII Rpt. Nos. 50-518/78-16, 50-519/78-16, 50-520/78-16 and 50-521/78-16 I-7 and he stated that a list of Code Cases would be submitted.
This matter is considered unresolved and is identified as item number 518/519/520/521/78-16-04.
(3) Paragraph 5112 of the various subsections of Section III of the ASME Code requires that "all nondestructive examinations performed under this subsection shall be exe.cuted in accordance with detailed written procedures which have been proven by actual demonstration to the satisfaction of the inspector" The site has not interpreted this paragraph to require formal documentation of demonstration and therefore no specific documentation exists at the site.
However, revised NDE procedures, which were in the process of being issued at the time of the inspection, specify that NDE procedures be demonstrated. Welding QC personnel indicated that procedure demon-stration will be documented when procedures are issued. Therefore, this item will be reviewed on a future inspection and is identified as inspector follow-up item number 518/519/520/521/78-16-05.
In the areas inspected, no items of noncompliance or deviations were identified.
7.
Reactor Coolant Pressure Boundary Piping (Welding) - Review of Quality Assurance Implementing Procedures The procedural review and inspection results of paragraph 6 above also apply to reactor coolant pressure boundary piping in that this piping is being welded under the same control procedures as the containment structural steel.
The applicable code for reactor coolant pressure boundary piping is the ASME Boiler and Pressure Vessel Code,Section III, Subsection NB, 1974 Edition with Addenda through the Summer of 1974.
8.
Safety-Related Piping (Welding) - Review of Quality Assurance Implementing Procedures The procedural review and inspection results of paragraph 6 above also apply to safety-related piping in that this piping is being welded under the same control procedures as the containment structural steel.
The applicable code for safety-related piping is the ASHE Boiler and Pres-sure Vessel Code,Section III, Subsections NC and ND,1974 Edition with Addenda through the Summer of 1974.
9.
Exit Interview The inspector met with licensee representatives denoted in paragraph 1 at the conclusion of the inspection and summarized the scope and findings
RII Rpt. Nos. 50-518/78-16, 50-519/78-16, 50-520/78-16 and 50-521/78-16 I-8 of the inspection. T:= t unresolved items and inspector follow-up item of paragraph 6 were discussed and the licensee had no comments or questions.
The inspection included containment structural steel welding procedures and activities, reactor coolant pressure boundary pipe welding procedures, and safety-related pipe welding procedure.
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RII Rpt. Nos. 50-518/78-16, 50-519/78-16, 50-520/78-16 and 50-521/78-16 II-1
^'/e c /7a DETAILS II Prepared by:
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J.FJ. Lenahan, Civil Engineering Date Engineering Support Section No. 1 Reactor Construction and Engineering Support Branch Dates of Inspection: November 27-30, 1978 J.
j ITryant,
_
fy/g/ff-Reviewed by:
_ lief Date En ineering Support Section No. 1 Reactor Construction and Engineering Support Branch 1.
Persons Contacted a.
Tennessee Valley Authority (TVA)
- R.
T. Hathcote, Project Manager
- H. S. Sheppard, Assistant Construct. ion Engineer, Plant B
- G. A. Gonsalves, QA Supervisor
- W.
O. Brown, Assistant Construction Engineer, Plant A
- J. W. Davenport, Civil / Materials QC Supervisor, Plant A
- W.
W. Davis, Materials Engineer, Plant A M. Rodgers, Materials Engineer, Plant B L. Hollard, Assistant Supervisor, East Issue Warehouse
- A. G. Debbage, QA Audit Supervisor
- W.
T. Quinn, Construction Engineer, Plant B
- W.
R. Brown, Construction Engineer, Plant A
- L.
H. Jackson, Assistant Construction Engineer, Plant A
- K.
H. Stewart, Supervisor, Engineering Services, Plant A
- E. O. Charlton, QA Engineer
- W.
E. Huffaker, Civil / Materials QC Supervisor, Plant B G. England, DCU Supervisor, Plant A
- Denotes those present at the Exit Interview.
2.
Licensee Action on Previous Insyection Findings This area was not inspected.
3.
Unresolved 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.
An unresolved item identified during this inspection is discussed in paragraph.
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RII Rpt. Nos. 50-518/78-16, 50-519/78-16, 50-520/78-16 and 50-521/78-16 II-2 4.
Independent Inspection Effort Thn inspector examined the following areas:
a.
Overall construction status.
b.
Partial placement of pour numbers B1KESWPS12F and B2KESWPS3F in Unit B1 and B2 pump stations.
These pours were fill concrete.
c.
Storage of piping in the Main Receiving Class D storage areas.
d.
Storage of Fuel Pool Heat Exchangers.
Storage of liner plate in East Issue Class D storage areas.
e.
f.
Curing of pour number A2A3 in the Unit A-2 Auxiliary Building.
g.
Currency of calibration of laboratory equipment in the concrete and soils laboratory.
h.
Partial placement of pour number B2A2 for the Unit B2 Auxiliary Building base mat.
Examination of this pour included pre-placement inspection, inspection of the batch plant and testing of fresh c(ncrete, and inspection of concrete placement, consolidation, and finishing.
Controls were in effect for placement of concrete during cold and inclement weather.
i.
Specification N6C-875, Revision 5, " Earth and Rock Foundation and Fills", was reviewed in the Document Control Units of Plants A and B.
The controlled copies of this specification maintained by the Civil / Materials QC Units in Plants A and B were also reviewed. Examination of this specification disclosed that revisions to specifications were not being controlled as required by procedure numbers EN DES EP 3.04 and CEP 6.03.
Examples are:
(1) Plant A Document Control Unit Master File did not contain Specification Revision Notice (SRN) 3, SRN 4, SRN 6 and SRN 7 to Revision 5 of Specification N6C-875.
(2) Revisions to Specification N6C-875 were not being formally revised and reissued within 60 days of issuance of a Specification Revision Notice.
SRN 3 was issued on May 23, 1978, SRN 4 on June 22, 1978, SRN 5 on July 12, 1978, and SRN 6 on August 21, 1978. Sixty days had not elapsed as of the day of inspection from the issuance of SRN 7, SRN 8 and SRN 9.
Failure to issue formal specifi-cation revisions in a timely fashion requires inspectors
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RII Rpt. Nos. 50-518/78-16, 50-519/78-16, 50-520/78-16 and 50-521/78-16 II-3 and construction personnel to control the work using the current specification revision (Revision 5) and the 7 SRN's (SRN 3 through SRN 9) which have been issued for Revision 5.
This requires review of the current revision of the basic specification and the 7 SRN's in order to determine the work requirements.
Since the SRN amends the basic specification, and in some cases, previously issued SRN's, delays in issuing revised specifications can result in confusion and possible misinterpretation of the specifications.
(3) Quality control personnel in Plant A did not have access to SRN 3, SRN 4 and SRN 7 to Revision 5 of Specification N6C-875.
This was identified to the licensee as Noncompliance Item 518-78-16-01, 519-78-16-01, 520-78-16-01 and 521-78-16-01.
This is an infraction.
5.
Licensee Identified Items (50.55(e))
Prior to this inspection, the licensee identified an item under 10 CFR 50.55(e). The item reported is as follows:
(open) Item (518-78-16-06, 519-78-16-06, 520-78-16-06 and 521-78-16-06):
Spray pond central and support earth fill; moisture content placed outside of limits. The licensee notified Region II on October 13, 1978 that some of the Category I earth fill which was placed in the central spray pond fill did not meet the specified moisture content limit (+ 2 percent of optimum) at time of compaction.
In addition, earth fill block samples and plasticity index tests were not taken as required in Hartsville Construction Specification N6C-875, Revision 5. Mathematical mistakes made by field inspectors in computing moisture contents were responsible for earth fill being placed which did not meet specified moisture content limits.
Earth fill block samples and plasticity index tests were not taken due to a misinterpretation of the construction specification requirements.
The licensee is evaluating safety implications of the failure to take the specified soil samples and placement of the earth fill outside of acceptable limits.
Corrective action will be specified by the licensee af ter saf ety implications have been determined and all investigations are completed. This item remains open pending NRC review of the licensee's final report.
6.
Site Preparation; Lakes, Dams and Canals; and Structural Concrete-Review of Quality Assurance Implementing Procedures The inspector performed a follow-up inspection of QA-QC controls for site preparation, lakes, dams, and canals, and structural
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RII Rpt. Nos. 50-518/78-16, 50-519/78-16, 50-520/78-16 and 50-521/78-16 11-4 concrete. The following procedures were examined to determine if work activities and quality control and quality assurance functions were provided for as stipulated in NRC requirements, PSAR sections 2.5.4 and 3.8, and SER Sections 2.5.3.3, 2.5.3.4 and 2.5.3.5.
a.
QCI C-102, " Percent Compaction and Moisture Content" b.
QCI C-108, " Earth Fill (A-1) Block Sample" c.
QCI C-109, " Drilling and Grouting Inspection" d.
QCI C-110, " Blasting Inspection and Monitoring" QCI C-204, " Aggregate-Fines, Gradation, Moisture Content" e.
f.
QCI C-205, " Aggregate" g.
QCI C-209, " Compressive Strength and Specific Gravity" h.
QCI C-210, " Mixer Efficiency Test" Examination of the above procedures disclosed the following unresolved item.
Civil QC inspectors are required to record results of QC acceptance tests performed on concrete materials and earth fill on prescribed forms and forward the completed forms to the Materials Engineer for his review.
In order to determine whether or not the materials tested are acceptable, simple mathematical computations and/or interpretations of graphs, charts, etc., are required in some test procedures (e.g., aggregate gradations, percent compac-tion).
However, the QC procedures do not require checking of the mathematical computations or data interpretations to verify their accuracy by either the inspector performing the initial calculations or by other inspectors.
Discussions with responsible engineers and inspectors indicated that verification (checking) of accuracy of calculations and data interpretations required to complete Civil QC tests is not being performed on some test results.
The inspector questioned the practice of using results of Quality Control tests which are derived from unverified calculations for determining if safety-related work and materials conform to specification requirements.
This was identified to the licensee as Unresolved Items 518-78-16-02, 519-78-16-02, 520-78-16-02, and 521-78-16-02.
This item is being evaluated by the licensee and NRC.
No deviations or items of noncompliance were identifie,
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RII Rpt. Nos. 50-518/78-16, 50-519/78-16, 50-520/78-16 and 50-521/78-16 II-5 7.
Exit Interview The inspector met with the licensee representatives denoted in paragraph I at the conclusion of the inspection.
The inspector summarized the scope and findings of his examination of QA-QC controls and work activities on structural concrete, review of QA-QC controls on-site preparation and lakes, dams, and canals, document controls and the licensee identified item.
The licensee acknowledged the one item of noncompliance and one unresolved item.