IR 05000518/1982001
| ML20042B285 | |
| Person / Time | |
|---|---|
| Site: | Hartsville  |
| Issue date: | 02/25/1982 |
| From: | Merriweather N, Upright C, Wright R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML20042B277 | List: |
| References | |
| 50-518-82-01, 50-518-82-1, 50-519-82-01, 50-519-82-1, 50-520-82-01, 50-520-82-1, 50-521-82-01, 50-521-82-1, NUDOCS 8203250178 | |
| Download: ML20042B285 (11) | |
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o UNITED STATES 8'
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. NUCLEAR REGULATORY COMMISSION g
a REGION il
o 101 MARIETTA ST., N.W., SUITE 3100 ATLANTA, GEORGIA 30303
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Report Nos. 50-518/82-01, 50-519/82-01, 50-520/82-01 and 50-521/82-01 Licensee:
Tennessee Valley Authoritu 500A Chestnut Street, Towar II Chattanooga, TN 37401 Facility Name: Hartsville Nuclear Plant Docket Nos. 50-518, 50-519, 50-520 and 50-521 License Nos. CPPR-150, CPPR-151, CPPR-152 and CPPR-153 Insoection at Hartsville site near Hartsville, TN
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Inspector:
R. W." Wright
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4Yr A- $5-L2 Ni Merrifea'ther
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Date Signed
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Approved by:
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C. M. Upright, Secfion ief
[Dat(Signed Engineering Inee..io ranch Engineering and Technical Inspection Division SUMMARY Inspection on January 25-29, 1982 Areas Inspected This routine, unannounced inspection involved 70 inspector-hours on site in the areas of QA inspection of structural concrete performance; site procurement; and receiving, storage and maintenance.
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Results
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Of the three areas inspected, no violations or deviations were identified.
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REPORT. DETAILS 1.
Persons Contacted
Licensee Employees j
- R. T. Hathcote, Project Manager
- H. S. Sheppard,. Assistant Construction Engineer, QC
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- R. E. Young, Assistant Construction Engineer, Project Engineering
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- G. A. Gonsalves, Supervisor, Project QA Unit
- B. E. Huffaker, Supervisor, Materials QC
- R. E. McClure, Supervisor, Mechanical QC
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- T. O. Wilkinson, Supervisor, Materials Services Unit
- C. E. Sparks, Supervisor, Warehouse Service Unit
- B. F. Painter, General Construction Superintendent
- J. R. Gelzer, Supervisor, QA Training
- J. T. McGehee, Engineering Management Assistant
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- C. A. Partlow, Supervisor, Electrical QC t
- D. J. Cowser, Supervisor, Management Services W. T. Quinn, Construction Engineer.
L. E. Wallace, QA Engineer, Construction QA Unit
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J. W. Davenport, Supervisor, Civil QC L. Ledbetter, Receiving Inspection Supervisor, Materials Service Unit
J. P. Jackson, Preventive Maintenance Supervisor, Materials Service Unit W. R. Nevin, Materials QC, Placement Inspector L. A. McMahan, Materials QC, Placement Inspector
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L. G. Goodwin, Materials QC, Batch Plant Inspector
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J. A. Lawhorne, Materials QC, Laboratory Testing Inspector H. R. Walrond, Electrical QC, Materials Services Unit J. W. Mabee, Supervisor QA Audit Section, ENDES-QA D. W. Mack, Supervisor QA Engineering Section, Construction Division
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M. Rudolphi, Supervisor, Hanger Engineering Unit, Project Engineering
- S. Grey, Compliance Engineer, PWR, Knoxville
- R. Roe, NEB-NLS Engineer, ENDES I
Other licensee employees contacted included construction craftsmen, technicians, and QA/QC personnel.
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Other Organizations
- Attended exit interview
- Participated in exit interview by Telecon
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2.
Exit Interview The inspection scope and findings were summarized on January 29, 1982, with
'those persons indicated in paragraph I above.
3.
Licensee Action on Previous Inspection Findings Not inspected.
4.
Unresolved Items Unresolved items are matters about which more information is required to determine whether they are acceptable or may involve violations or devia-tions. New unresolved items identified during this inspection are discussed in paragraph 5.c.
5.
Site Procurement (350658)
a.
Documents Examined (1) Hartsville PSAR, Section 17.1A.4 - Procurement Document Control (2) QA Program Requirements Manual (PRM), Commitment Sheet QASM N45.2.13 (3) PSAR Section 1.4, Identification of Agents and Contractors (4) Procedure CEP 4.01, RIS, Procurercent Document Control (5) ?rocedure CEP 7.01, R7, Evaluatior, and Selection of Suppliers (6) Quality Assurance Program Policy, QAPP-4, R1, Procurement Document Control (7) QAPP-7.3, R4, Evaluation and Selection of Suppliers (8) Quality Assurance Procedure, QAP 4.01, R7, Procurement Document Control (9) Construction - Field Purchasing of QA Material, Equipment and Services - Supplier Index R13, (11/24/81)
(10) Purchase Requisition 594316, Structural Tubing, C. F. Braun Specification 300-46 (11) Purchase Requisition 594549, Cadweld Material, C. F. Braun Specification 300-42 (12) Purchase Requisition 594561, Stainless Steel Angles and Bars, C. F. Braun Specification 100-51 (13) Request for Delivery 733258, Carbon Steel Welding Rods, TVA Specification PF-1040 (14) Request for Delivery 777698, Bulk Portland Cement (15) Transfer Requisition 594515, Steel Conduit Couplings b.
Quality Assurance Program Hartsville PSAR and commitment sheet number QASM N45.2.13 of the PRM commit to implement Regulatory Guide No.1.123 which endorses ANSI N45.2.13-1976 for the control of procurement of equipment, materials, and service *
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TVA purchased the Standard Reactor Island Design (STRIDE) package froni General Electric which consists of detailed designs for the. reactor building, fuel building, auxiliary building, radwaste building, control building and the diesel generator buildings.
C. F. Braun is-subcontracted to GE to provide engineering services related to the design of these STRIDE buildings.
TVA's Division of Engineering Design (ENDES) has responsibility for
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design of the turbine building and the balance of plant.
TVA's Division of Construction (CONST) has the responsibility for construction of the entire plant.
The NSSS is provided by GE and Brown-Boveri Company (BBC) will supply the turbine generators for the Hartsville Nuclear Plant.
The site may purchase equipment / materials for which the site has an ENDES approved specification and QA requirements.
The site may make " Requests for Delivery" for equipment / materials on already existing Indefinite Quantity Term (IQT) contracts.
Ir general, contractor service contracts are prepared by ENDES for the site unless prior agreements were established which directed site procurement to requisition, award, and administer the contract.
Selection of suppliers furnishing site generated procurements-is accomplished by at least one of the following methods:
concurrence with suppliers acceptability by ENDES Quality
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Assurance Branch (QAB) Audit Section ENDES QAB Suppliers Index
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holders of a valid ASME " Quality System Certificate"
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based on supplier's past performance (not applicable for. ASME code
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items)
for construction initiated service contracts with suppliers not
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previously evaluated by ENDES, review of the supplier's QA program
and obtain site QA unit concurrence.
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'by an ENDES preaward survey.
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c.
Implementation The inspector reviewed the documents listed above - and discussed procurement functions and-results of audits conducted of procurement l
activities with responsible TVA personnel at the site.
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The inspector selected. various contracts, purchase requisitions, transfer requisitions, requests for delivery, and related procurement specifications (5.a(10) through 5.a.(15)) for review to determine the following if applicable:
that specified design parameters were in accordance with SAR or
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other AE/ licensee specifications
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that procurement specifications identify applicable-codes and
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standards 10 CFR 21 requirements were imposed where applicable
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the supplier was on the approved list of suppliers
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applicable QA requirements were imposed
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if source inspections were required
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the information required by the licensee to be documented on
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Certificates of Conformance was acceptable.
RD 777698 (TVA IQT Contract 76K50-91504) a request for delivery of 266.97 tons of bulk cement from Marquette Company was written 12/3/81; however, reference 5.a.(9) in effect at that time stated that Marquette Company's certification as an approved supplier had expired as of 11/24/81. Discussions. with responsible Knoxville vendor inspection personnel revealed that this may be an error by Construction Services Branch and Marquette Company may have been improperly classified. Due to the need to research this matter further, this item was identified as Unresolved Item 518,519,520,521/82-01-01, Evaluation. of Marquette Company.
The inspector conducted discussions with selected TVA personnel concerning procurement procedures to' verify that they were knowledgeable of their responsibilities and duties.
No violations or deviations were identified in the procurement area.
6.
Receiving Inspection, Storage, and Maintenance (35065B)
a.
- Documents Examined (1) Hartsville PSAR Section 17.1A.7, Control of Purchased Material, Equipment and
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Services Section 17.1A.8, Identification and Control of Materials,
Parts and Components i
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Section 17.1A.13, Handling, Storage, and Shipping
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(2) Procedure CEP 5.01, R9, Construction Engineering Procedures;
Quality Control Instructions and Receiving, Storage and Preventive Maintenance. Inspections (3) Procedure CEP 7.02, R8,- Receiving Inspection (4) Procedure CEP 7.04, R3, Transfer of Safety Related Items (5) Procedure CEP 8.01, R4,. Identification and Marking of Materials, Parts and Components (6) Procedure CEP 8.02, R7, Materials, Parts and Component Control (7) Procedure CEP 13.01, R4, Handling of Nuclear Components (8)- Procedure CEP 13.02, R4, Storage and Preservation of Materials Components, and Systems (9) Procedure CEP 13.03, R2, Warehouse Storage Area Inspection (10) QAPP 7, R2, Control of Purchase Materials, Equipment and Services (11) QAPP 7.1, R0, Transfer of Items for Construction Use
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-(12) QAPP 8, R0, Identification and Control of Materials, Parts and Components (13) QAPP 13, R0, Handling, Storage and Shipping (14) Procedure SOP-15, R0, Receiving Inspection
.(15) RS & PMI Manual - Receiving, Storage and Preventive Maintenance Inspection Manual (16) Memorandum to B. F.
Painter from R. T. Hathcote dated 7/7/81, Hartsville Nuclear Plant - Continued PM on Plant B Items-(17) Memorandum HPP 811217004, Hartsville Nuclear Plant A, Phipps Bend Nuclear Plant Unit 1, and Yellow Creek Nuclear Plant Unit.1 -
Preventive Maintenance Requirements of the RS & PMI's (18) Audit HT-G-80-09, Receiving Inspection (19) Audit HT-G-80-24, Preventive Maintenance (20) Audit HT-M-81-01, Receipt and Storage of Stainless Steel (21) Audit HT-G-81-08, Receiving. Inspection
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(22) Audit HT-G-81-22, Preventive Maintenance b.
Quality Assurance Program Commitment Sheet No. QASM N45.2.2 of the Program Requirements Manual commits to implement Regulatory Guide 1.38 which enderses ANSI N45.2.2-1972. The licensee receives, stores, and handles equipment and materials at the site for items procured by either TVA or its NSSS supplier.
c.
Implementation The inspector examined the licensee's system established as detailed in -
the above listed procedures for conducting receiving inspection, handling, storage, and maintenance of materials and equipment.
The facilities utilized were examined; hoisting, rigging tools and equipment. Typi_ cal documentation for several receiving packages to inc_luded receiving reports, receiving inspection checklists, certificates of conformance, material test reports, and shipping releases which were checked for acceptability, legibility, completeness and review by QC. The inspector conducted discussions with responsible TVA material services and warehouse services unit supervisors, QC -
receiving and preventive maintenance inspector personnel pertaining to their procedural responsibilities and found them competent, knowledgeable, and experienced in their respective duties performed.
Several certificates of conformance were ' chosen from various contracts at random for examination and were found to properly identify the purchased items, identifying specific requirements the items met or did not meet, and were signed by an appropriate member of the supplier's QA group where applicable.
The inspector examined the storage facilities of warehouse "AWS" and -
the paint storage building "CWL" (Level A), warehouse "AWF" (Level B),
warehouse " AWN" and the cadweld powder storage building (Level C), and various field laydown areas (Level 0).
Random items and materials selected in these areas were found stored in their proper environment as described by RS & PMI manual or by the manufa'cturer's recommendation.
The subject storage facilities were examined for proper controlled access, that protection from damage during storage was adequate, cleanliness, proper stacking and cribbing of items, proper use of dessicant humidity indicators and purging systems for required equipment, that shelf life of materials were adequately controlled, and that records were being maintained of storage conditions and were current.
The inspector examined the " Warehouse Storage Area Inspection Checklists" performed by QC for the period June 1981 through December 1981. The inspector also examined QA audits (6.a(18) through 6.a(22)) conducted in the areas of receiving inspection, storage, and
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'7 preventive maintenance. These reports reflect that receiving, storage, and preventive maintenance conditions were being met _for Plant A and that any. discrepancies noted received proper and timely corrective action.
Site QA audit report HT-G-81-22 deficiency No. 2 disclosed that the preventive maintenance for all Plant "B" QA items was not: being performed.
Further investigation into this matter by the. inspector revealed that as of 7/7/81 the Plant B preventive maintenance program l
prescribed by reference 6.a.(15) was being limited to only-very l
expensive, hard-to-replace items identified in reference _ 6.a. (16).
Correspondence reviewed and telephone discussions conducted with responsible Knoxville construction QA supervision personnel revealed that efforts were underway to make necessary changes to the storage, preventive maintenance, and inspection requirements for both active and deferred units which should be implemented in the RS & RMI manual by March 1, 1982. These procedural changes will be examined when approved and this matter will be tracked under inspector followup item 518,519, 520,521/82-01-02, Revised Preventiv_e Maintenance and Inspection Requirements.
The inspector selected QA components from levels A, B, C, and D storage areas to review the preventive maintenance inspection documentation
.naintained in the QA records vault.
These records were examined for the period June 81 through December 81 to determine whether, the required maintenance had been scheduled and performed in accordance with the RS '& RMI manual.
The following is a listing of the components reviewed:
i 8" Gear Operated Globe Valve, MPL-G41-F0358, Serial Number (SN)_
64954 RCIC Turbine with Compressed Air Gland Set, MPL-E51-C002, SN
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T38184A 12" Motor Operated Gate Valve, MPL-E12-F042A, SN 2418 Filter Demieneralizer Control Valve, MPL-G36-F105, SN 10078-12-8 3" Manual Operated Gate Valve, MPL-G17-F2868, SN 320290 3" Swing Check Valve 150 lb. Rating, MPL-P56-FF208 3" Motor Operated Gate Valves, MPL-P55-FF011, SN 49126 and MPL-P56-FF036, SN 49127 Reactor Pressure Vessels MPL-813-D002, SN T59 and T71 Electrical Penetration R61-TT-218, SN 810513
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No violations or deviations were identified in the-receiving inspection, storage, or preventive maintenance areas.
7.
QA Inspection of Civil Work Performance (350618)
The inspector observed the preplacement condition, partial placement, batch plant inspection, placement inspection, and testing of plastic concrete _for pour numbers A2K-ESW/PS 104, 105,102 and 88 which are in the essential service water pumping station roof slab for Unit A2. This inspection was conducted to determine whether site work is being performed in accordance with NRC requirements and SAR commitments, whether the QA/QC program is functioning in a manner to assure that requirements and commitments are met; and to assure that prompt and effective action is taken to achieve permanent corrective action on significant discrepancies.
The following acceptance criteria were examined to verify the inspection objectives:
a.
PSAR, Specifications, Procedures and Drawings (1) Section 3.8 of the PSAR (2) TVA Specification G-2, Plain and Reinforced Concrete (3) Procedures QCI 201, 202, 204, 207, 208 and 212 (4) Drawing Numbers:
4KN11687 R1 Concrete Pour Designations 4KN61828 R0 Concrete Pour Designations 4KE1406-K6-02 General Concrete Notes 4KE1406-K6-06,07 Concrete Additional Sections The inspector reviewed the above listed acceptance criteria utilized for the subject concrete placement to determine if the latest revisions were employed and in agreement with the SAR; to determine if these documents adequately described critical points and methods of installation as well as inspection and test hold points - to properly-reflect design intent.
b.
Field Inspectiore The inspector found the forms to be tight, clean and level.
Observations indicated the rebar was properly installed and clean.
Placement activities pertaining to delivery time, free. fall, flow distance, layer thickness and consolidation conformed to specifications. Examination of truck numbers at the batch plant and placement area indicated that the specified design mix was being delivered.
Concrete activities were continuously monitored by QC personnel.
Samples for temperature, slump, air content, unit weight and test cylinders met frequency and acceptance criteria. Examination of the batch plant and storage facilities showed that inspection,
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1 materials, and record controls were in accordance with acceptance criteria.
The inspector's discussions with various craftsmen and observation of their work performance during the subject concrete placement indicated the crafts level of. knowledge pertaining to their work tasks was adequate to provide the required quality of workmanship.
c.
Quality Control (1) The inspector reviewed the following inspection records associated with the subject concrete placement to determine their adequacy, whether deficiencies submitted by QC inspectors received proper
' corrective action.where applicable, and if work and work controls
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were adequate: the concrete placement form and inspection report, sieve analysis report of concrete aggregates, free moisture
calculation, mixing plant report, materials finer than No. 200 i
sieve and the concrete test specimen data work sheet.
(2) The inspector reviewed the applicable QA/QC procedures (paragraph 7.a) to determine if the frequency, timing, and. acceptance
criteria for the inspections is adequate.
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(3) The number 'of QC inspectors provided for the coverage of the subject placement was satisfactory.
Discussions were conducted with randomly selected batch plant, laboratory testing, and placement inspectors to determine if their knowledge of.the activities they were observed inspecting was adequate, and to
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determine whether they ' felt their findings received proper i
i management attention.
Examination of the subject inspectors'
training and qualification records revealed they were qualified in the duties they performed for the subject placement.
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Nonconforming Items Reports.
The inspector reviewed selected reports of concrete construction discrepancies that have occured during various concrete placements to verify as applicable that:
(1) the action taken corrected the items; (2) the items were considered for reportability to the NRC; i
(3) the instituted effective action prevented recurrence; and (4) the licensee has an adequate program to detect trends in l
discrepancies.
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Concrete related NCR's and QCIR's reviewed included the following:
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NCR's, HNPA-192 R1, 116 R1, 105, 093; and QCIR's 30401, 30402, 30405,
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30411, 30415, 30418, 30422, 35092, and 35096.
l The inspector examined the following Hartsville Nuclear Quality Trend
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Analysis Reports:
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l (1) Quality Trend Analysis Report of Audit Items (to include audits of Construction QA, Authorized Nuclear Inspector, OEDC-QA, and ASME Surveys) for the period April - June 1981.
(2) Quality Trend. Analysis Report of Significant and Reportable Items (to include NRC noncompliances,10 CFR 50.55(e) and 10 CFR 21 reportable items, significant nonconformances (NCRs), significant construction and OEDC audit deficiencies) for the period April -
June 1981.
(3) Quality Trend Analysis Report of Site QCIR's and Nonsignificant NCR's for the period January. - June 1981.
Reviews of the subject Trend Analysis Reports and discussions with
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responsible QA personnel revealed the licensee has an effective program
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to detect trends in discrepancies, the program does an excellent job in identifying the root cause of the problem and TVA's involvement in
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followup actions appears adequate.
e.
. Materials and Equipment Examination of the batch plant indicated materials were being-
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controlled and accurate batch records were being generated.. Storage of materials (aggregates, tement, and admixtures) were observed to be in accordance with specification requirements.
Batch plant activities were continuously monitored by a QC inspector.
The inspector noted
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truck bed clean-up operations underway prior to the start of the i
evening placement.
Various laboratory testing equipment, concrete curing room gages, plastic concrete testing equipment, and batch plant scales were examined for current calibration evidence.
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Audits (1) HT-C-81-06 -
Rebar and Embedments
(2) HT-L-81-04 -
Concrete Placement (3) HT-C-81-03 -
~Cadwelding
(4) HT-L-81-03 -
Sampling and Testing of Plastic Concrete and i
Concrete Cylinders (5) HT-L-81-01e-Batch Plant Inspection
. The inspector reviewed the above listed site QA audits performed on various phases of concrete activities to determine whether the licensee audit results indicate when applicable that:
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Drawings are in agreement with SAR
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Installation is according to drawings and specifications
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Craftsmen are qualified and competent to perform the work they are
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doing Field engineer's reports are technically accurate
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QC procedures and inspectors meet requirements c
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CDRs, NCRs and QCIRs are accurate
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Materiais and equipment meet specifications
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These audits were also examined to determine if they were meaningful, effective, reflect quality performance, and whether corrective actions taken as a result of audit findings were proper, timely, and complete.
Within the above areas of concrete placement activities examined, no violations or deviations were identified.
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