IR 05000553/1979003
| ML19269D366 | |
| Person / Time | |
|---|---|
| Site: | Phipps Bend  |
| Issue date: | 04/13/1979 |
| From: | Gouge M, Herdt A, Wright R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML19269D356 | List: |
| References | |
| 50-553-79-03, 50-553-79-3, 50-554-79-03, 50-554-79-3, NUDOCS 7906020144 | |
| Download: ML19269D366 (11) | |
Text
UNITED STATES
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NUCLEAR REGULATORY COMMISSION s
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101 MARIETTA STREET, N.W.
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s Report Nos. 50-553/79-03 and 50-554/79-03 Licensee: Tennessee Valley Authority 500A Chestnut Street Chattanooga, Tennessee 37401 Facility Name: Phipps Bend Nuclear Plant, Units 1 and 2 Docket Nos. 50-553 and 50-554 License Nos. CPPR-162 and CPPR-163 pec
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M. Thomas Approved by:
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A. R. Herdt, Section Chief, RCES Branch Date Signed SUMMARY Inspection on March 26 - 29, 1979 Areas Inspected This routine unannounced inspection involved 49 inspector-hours onsite in the areas of licensee action on previous inspection findings; observation of turbine building concrete wall placement (Unit 1);
follow-up on weirwall liner weld problem; QC investigation reports and NCR's; storage and preventive maintenance of permanent plant materials; safety related welding and welding records (Unit 1); ol:servation of cadwelding and rebar placement (Unit 2);
site procurement document control; geological site review; follow-up action on licensee identified items; 10 CFR 21 posting and the bandling of IEB's, IEC's and IN's.
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-2-Results Of the eleven areas inspected, no apparent items of noncompliance or deviations were identified in nine areas; three apparent items of noncompliance were found in three areas. (Infraction - failure to follow procedures for safety related service contracts, paragraph 7; Infraction preventive maintenance implementation, paragraph 5d; Deficiency - inprocess welding documentation, paragraph Se, Unit 1 only).
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DETAILS 1.
Persons Contacted Licensee Employees
- W. P. Kelleghan, Project Manager
- G. Wadewitz, Construction Engineer
- J. C. Cofield, Assistant Construction Engineer, P.E.
- D. E. Hitchcock, Site QA Unit Supervisor
- W. R. Andrews, Acting Supervisor, Materials Services
- L. Blevins, En Des, QA Engineer
- J. J. Ritts, En Des, MEB
- J. Wills, Power-Reg Staff Engineer
- W. L. Lindeman, Technical Services W. G. Linthicum, Electrical QC J. A. Crittenden, Electrical QC Supervisor W. K. Burner, Welding QC Unit Supervisor J. E. Rose, Welding QC Engineer W. R. Bailey, NDE QC Supervisor D. T. Rhea, Welding QC Engineer J. Houck, Storage Records Clerk, DCU G. P. Walker, QA Unit W. A. Herzog, QC Materials Services D. C. Berry, QC Materials Services S. Childers, Welding QC Other licensee employees contacted during this inspection included several construction craftsmen, technicans, and office personnel.
Other Organizations
- A. G. Bishop, General Elect -
Company Field Representative
- S. Wastler, NRC Geologist, dst
- Attended exit interview.
2.
Exit Interview The inspection scope and findings were summarized on March 29, 1979, with those persons indicated in Paragraph I above. The licensee acknowl-edged the three items of noncompliance discussed in paragraphs 5d, Se and 7 of this report and one new inspector follow-up item, "QCIR-NCR system corrective action", detailed in paragraph Sc.
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-2-3.
Licensee Action on Previous Inspection Findings (Closed) Unresolved Item 553/79-01-02:
Cement Manufacturer certified mill test reports. Penn-Dixie's letter dated January 25, 1979 contains the silicon dioxide, aluminum oxide, and ferric oxide percent contents of the Type II cement that was inadvertently left off some mill test reports by the manufacturer.
These percentages were compared to the allowables permitted by ASTM C-150 and found to be within prescribed limits. This item is closed.
(Open) Unresolved Item 553-554/79-01-01:
Pumped concrete sampling procedures.
The site has made the recommendation to its Knoxville Offices that ANSI N45.2.5-1974 be followed for the sampling of pumped concrete. TVA's final decision and any proposed changes to their concrete precedures addressing this matter should be forthcoming in approximately two weeks. The site has not pumped any concrete to date. This item remains open pending examination and evaluation of procedural changes.
4.
Unresolved Items Unresolved items were not identified during this inspection.
5.
Independent Inspection Effort Turbine Building (Structural Concrete II) - Observation of Work and a.
Work Activities, Unit 1 The Region II inspector observed the preparation, partial delivery, placement, inspection and testing of Unit l's turbine building wall placement No. T1-BG07-85. Although this placement is not considered safety related (Q), TVA treats these non-Q pours similar to Q placements as far as QC inspection is concerned; hence, the con-tinued effectiveness of the licensee's concrete QA program can be measured by witnessing and evaluating such placements.
The activities associated with the subject concrete placement were inspected for conformance to the following acceptance criteria:
(1) Sections 3.8 and 17 of the PSAR (2) Work Package E008-11C-85 (3)
C. F. Braun Specification 300-01 " Concrete" (4) TVA Specification G-2 " Plain and Reinforced Concrete" (5) Drawings 4TE1316-T7-01R1, 4GWO300-59-01 2265 286
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-3-(6) Procedures:
QCI's C-201, C-204, C-205, C-208 CEP 2.10, 9.02,12.01,17.01 An examination of the batch plant indicated materials were being controlled, accurate batch records were being generated and activities were continually monitored by a QC inspector.
No items of noncompliance or deviations were identified.
b.
- (Open) Inspector Follow-up Item 553-554/78-08-01, Stellar Manufac-turing Company (SMC) - Inspection of Weirwall and Fuel Pool Liners.
Noncomformance Condition Report (NCR) PBNP-011 concerning 44 weirwall liners has been initiated to identify and rectify non-full penetration welds and weld profiles not to full cross section as required by C. F. Braun's Specification 300-11. The licensee and his technical
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engineers (GE and Braun) are currently considering two possible options to perfo rm the required rework to correct the defective welds.
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c.
Quality Control Investigation Reports (QCIR) and Nonconformance Reports (NCR) (Units 1 and 2)
The Region II inspector reviewed the system established by the licensee to control nonconforming materials, parts or components as required by Criterion XV of Appendix B to 10 CFR 50. The following procedures are applicable to this area:
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CEP 15.01 R8 Control of Quality Control Investigation Reports CEP 15.03 R0 Control of Nonconformance Reports The above procedures specify requirements for the identification, documentation, segregation, disposition and notification of noncon-forming materials, parts, components and practices. The following site QA documents were reviewed by the inspector:
(1) completed QCIR's 3001 through 10363 (2) master QCIR log (DCU)
(3) Welding QC Unit Supervisor's QCIR log (4) NCR's 001 through 011 2265 287
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-4-(5) master NCR log (DCU)
The overall QCIR/NCR system at Phipps Bend has been implemented in accordance with CEP 15.01 and CEP 15.03. The Region II inspector identified the following areas that were not in accordance with CEP 15.01 or CEP 15.03:
(1) QCIR's were frequently not prepared in accordance with CEP 15.01. Data such as affected unit, affected area, and identi-fication of component was observed to be missing.
(2) A quarterly check of outstanding QCIR's was not conducted.
(3) The licensee's approach to the handling of QCIR's written to document gradation problems with fine and course aggregate was not consistant.
(4) QCIR hold tags in the warehouse area frequently were not completely filled out.
(5) The Assistant Construction Engineer or the individual acting for him did not always sign QCIR's as required by CEP 15.01.
(6) The QCIR number was not indicated where applicable on the associated NCR as required by CEP 15.03.
The licensee's site QA unit had conducted an audit in this area immediately prior to the review conducted by the Region 11 inspector.
This audit was PB-G-79-04, "Nonconformance Reports and Quality Control Investigation Reports". A draft of this audit was reviewed.
The licensee has identified 13 deficiencies in the QCIR/NCR area that included the problems discussed above.
The licensee was implementing corrective action to improve the QCIR/NCR system that included a training program for employees. Pending implementation of the licensee's corrective actions in this area and another overall review of the QCIR/NCR system by Region II this item is identified as Inspector Follow Item 553-554/79-03-02, QCIR-NCR System Corrective Action.
No items of noncompliance or deviations were identified in the above area inspected.
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-5-d.
Storage and Preventive Maintenance of Permanent Plant Materials (Units 1 and 2)
The following warehouses were inspected:
Warehouse Storage Level A
C B
B PW B
The definitions of storage level are in ANSI N45.2.2..
The ware-houses inspected were clean, free of rodent activity, and controlled for access. The licensee was using a tag system implemented February 23, 1979, by CEP 14.01 to control the inspection status of received materials. Materials were observed to be properly identified and stored in an orderly manner. Nonconforming items were identified by QC hold tags and stored in segregated areas.
The Region II inspector reviewed preventive maintenance records for residual heat removal (RHR) pump motors, diesel generators and RHR heat exchangers. Five of the RHR pump motors had been received on site during the period April-June 1978.
Receiving Inspection, Storage and Preventive Maintenance (RIS & PM) Procedure E-100 requires a monthly insulation check of all safety related motors above 4KV. Records indicated that these pump motors had been meggered only during September 1978 and February 1979. One diesel generator serial 27-200 had been received on site 12/27/78. RlS &
PM M-535 requires monthly inspection of the diesel engine and generator and specifies the recording of data such as megger readings from the generator field coils. No record of any preventive mainten-ance could be found for the above diesel generator which had been stored on site for three months.
Three RHR beat exchangers serial numbers 818417, 818418, and 818421 had been on site since April 1978.
RIS & PM H-756 requires a monthly check of nitrogen blanket pressure on the shell and tube sides of these heat exchangers.
Records indicate this inspection had only been conducted during the month of December 1978. CEP 13.02 R0, " Storage and Preservation of Materials, Components and Systems" describes the licensee's system for prese rvation and maintenance of items.
The computer program " Prevent" used to control preventive maintenance of stored items had been established at the site. The examples cited above indicate that the licensee's system for control of preventive maintenance has not been effective in ensuring periodic, required maintenance is performed on safety related items in storage. Criterion V of Appendix B to 10 CFR 50 states in part " Activities affecting quality sbil b, prescribed by 2265 289
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-6-documented instructions, procedures, or drawings.
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be accomplished in accordance with these instructions, procedures or drawings."
Failure to perform the preventive maintenance inspections required by applicable RIS & PM procedures as discussed above is contrary to Criterion V of Appendix B to 10 CFR 50 and is identified as infraction 553-554/79-03-03, Preventive Maintenance Implementation.
Safety Related Welding and Welding Records (Unit 1)
e.
ane Region II inspector observed welding of cadweld sleeves to the Unit I weir wall baseplate. The applicable weld procedure for this carbon to carbon steel weld is DWP SM11-B-9 Areas inspected included application of preheat, control of welding filler material, welding technique, in process records, and qualification of welding personnel. Welding was conducted by qualified personnel in accordance with the applicable procedure and was closely monitored by welding quality control personnel.
Welding records for the repair of defects found in the welds joining radial shear bars to the Unit I reactor pedestal baseplates 2-1PI-1, 2-1P1-2, 2-1P1-3 and 2-1PI-4 were reviewed.
These nonconforming documented on Quality Control Investigation Reports welds were (QCIR's) 3213, 3215, 3216, 3217 and 3232. These five QCIR's speci-fied a weld repair per DWP SM11-B-9 and a final magnetic particle (MT) examination of the repaired areas. The records available on the weld repairs could only document visual and MT inspection.
There were no records of the welding repair to document welder identification, pre-heat application, filler material used, or weld procedure.
TVA Construction Engineering Procedure (CEP) 9.05,
" Welding Control", describes the use of operation checklists to record data such as welder identification, pre-heat application, filler material and weld procedure.
Criterion XVII of Appendix B to 10 CFR 50 states in part " Sufficient records shall be maintained to furnish evidence of activities affecting quality.
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records shall also include closely related data such as qualifications of personnel, procedures, and equipment."
Failure to document in-process welding is contrary to Criterion XVII of Appendix B to 10 CFR 50 and was identified tc, the licensee as deficiency 553/79-03-04, Repair Welding Documentation. During the course of the inspection the licensee retrieved data to document the weld repairs discussed above. Weld maps and operation checklists were generated from this retrieved data. The Region II inspector reviewed these records and determined that they document adequately weld repairs conduct p on the Unit I reactor pedestal baseplate.
The licensee has imp 1 pented a welding control system using operations
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-7-checklists and data cards subsequent to the weld repairs discussed above. Observation of this implemented system for the control of welding and discussions with welding QC personnel indicated corrective action has been implemented to preclude recurrence. No response is required for this deficiency.
6.
Containment (Structural concrete I) - Observation of Work and Work Activities, Unit 2 The inspector observed placement of reinforcing steel in the bottom mat of Unit 2 reactor building. Acceptance criteria examined by the inspector appear in Section 3.8 of the PSAR and response to NRC questions 323.2 through 323.5 in the PSAR.
Controlling specifications, procedures and drawings examined by the inspector were:
C. F. Braun Specification, TVA Stride a.
b.
TVA Specification G-2, Plain and Reinforced Concrete Procedures QCI-C-301, 401, 402, CEP-2.12, and 9.04 c.
d.
Drawing Numbers Y 0022 R2 Observations included the placement of portions of the fourth layer of circular reinforcing steel in the bottom mat; the cadwelding operations performed for the above circular steel layer and the completed work for the first three layers of the bottom mat.
Cadweld operations and QC inspection thereof were witnessed for cadwelds Z-18-HC-0033R, -0034R,
-0035R; D-18-HC-0069R, -0070R, -0071R, J-18-HC-0041R, -0042R. Cadwelder operator certifications for cadwelders D, Z, L and J were examined and these men were found qualified in the position and bar size they were observed working at.
Sister splices Z-18-HC-0028R and D-18-HC-0063R were visually examined by the RII inspectors and the certifications of the two QC cadwelding inspectors were checked. No items of noncompliance or deviations were identified.
7.
Procurement Document Control - Site The inspector discussed with the Materials Expeditor, QA Engineer, and Construction Engineer the procedures applicable to the PBNP site procure-ment.
The inspector examined site QA Audit PB-G-79-02 " Procurement Document Control" conducted January 11-18, 1979 which disclosed the site was not operating in accordance with approved procedure CEP 4.01 Rev. 6,
" Procurement Document Control". Subsequently CEP 4.01, Rev. 6, Draft 2 was written detailing the exact manner which the PB site was to procure materials and services. This procedure was implemented by a memorandum signed by the Construction Engineer dated January 26, 1979. The examined subject procedure defines the sequence of actions to be accomplished for 2265 291
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-8-preparation, review, approval, and control of site originated procurement documents required for the procurement of permanent materials, angineering-controlled materials, or contractor's services.
By procedure, Unit Supervisor, is responsible for reviewing all permanent plant site originated procurement documents for justification, quantity, technical, quality assurance and 10 CFR 21 requirements. The Construction Engineer verifies that all permanent plant site originated procurement documents contain the necessary technical and QA requirements. All site originated permanent plant procurement documents that are not forwarded to Knoxville QA for review and approval are required to receive site QA unit review and approval for QA requirements, 10 CFR 21 applicability and assignment of receiving inspection, storage and preventive maintenance instruction. The Region II inspector selected the following permanent plant purchase requistions, requests for delivery of material on existing indefinite quantity term (IQT) contracts, and purchase requistions for personal services contracts to determine compliance with procedure requirements.
PR 583371, 583372, 583373, 583374, 583378, 583379, 583384 a.
b.
RD 654712, 615190, 636039 c.
PR 566870, 567469, 567532 Construction Engineering Procedure CEP 4.01, Section 2.4.3 requires the Site QA unit to ensure that purchase requisitions for personal service contracts for safety related activities be reviewed to ensure adequate quality assurance requirements and 10 CFR 21 applicability is included and to indicate the applicable RIS and PM number. The purchase requisi-tions for the service contracts identified in paragraph 7c. above were executed without obtaining site QA units review and approval. This item is identified as an infraction, 553-554/79-03-01, Failure to follow procedures for safety related service contracts.
8.
Geologic Fault in Unit 2 South CCW Trench TVA notified NRR's Geology Section (DSE) on March 22, 1979 that they had identified a fault located in the floor and walls of the South CCW Trench.
The fault has been described as an apparent reverse fault displaying right lateral movement, dipping 60 degrees to the west and striking N 25 W. The fault is, defined by an extremely narrow (less than one-half inch) fractured zone of fsetting beds a maximum of 3 inches.
TVA's memorandum CDB 790320005 states, "the fault shows no evidence which would indicate that it did not occur during the early tectonic development of the Paleozoic (250 + million years) folding and faulting in this area.
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-9-The RII inspector, TVA's project geologist and NRR's geologist visually examined the above subject feature on March 29, 1979. The NRR geologist also inspected some features of licensee concern identified in the CCW pumping station.
9.
Licensee Identified Items 50.55(e)
Prior to this inspection the licensee had identified the following under terms of 10 CFR 50.55(e):
(0 pen) Item 553-554/78-08-02:
Personnel airlock components procured to non-safety Class 2 requirements.
The licensee has issued two interim reports in this matter, dated November 2, 1978 and February 15, 1979.
The licensee's last report indicated that a final report will be trans-mitted on or before February 15, 1979.
This item will remain open pending receipt and review by Region II of the licensee's final report in the matter.
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10.
IE Bulletins, Circulars and Information Notices Discussions conducted with responsible management personnel revealed that when IEB's, IEC's and IN's are received on-site they are reviewed by the project manager and/or the construction engineer and copies are then sent to the affected site disciplines. The RII inspector examined applicable IEB's78-12A, 12B through 79-03; IEC's 78-16 through 79-05; IN's 79-01 through 79-05 and found the above review cycle had been implemented.
11.
10 CFR Part 21 Inspection The site facilities were inspected to determine if the posting requirements specified in 10 CFR 21.6 were continuing to be implemented. The licensee had posted notices prepared per 10 CFR 21.6(b) in a conspicuous location within the construction administration building. The posting requirements of 10 CFR 21.6 are continuing to be implemented at the PBNP.
No items of noncompliance or deviations were identified.
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