IR 05000553/1980015
| ML20002C523 | |
| Person / Time | |
|---|---|
| Site: | Phipps Bend  |
| Issue date: | 11/20/1980 |
| From: | Economos N, Herdt A NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML20002C494 | List: |
| References | |
| 50-553-80-15, 50-554-80-16, NUDOCS 8101100410 | |
| Download: ML20002C523 (7) | |
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o, UNITED STATES
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NUCLEAR REGULATORY COMMISSION N
Eg lE REGION 11
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101 MARIETTA ST.. N.W.. SUITE 3100 ARANTA. GEORGIA 30303
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Report Nos. 50-553/80-15 and 50-554/80-14 Licensee: Tennessee Valley Authority
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500A Chestnut Street Chattanooga, TN 37401 Facility Name: Phipps Bend Docket Nos. 50-553 and 50-554 License Not. CPPR-162 and CPPR-163
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Inspection at Ph* p B nd site near Kingsport, Tennessee Inspecto ?
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// B 81D N. Economos Date S'igned Approved by:
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- 'M'![0 A. R.'Herdt, Section Chief, RC&ES Branch Dite Signed
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SUMMARY Inspection on September 29 - October 2,1980 Areas Inspegted This routine, unannounced inspection involved 29 inspector-hours on site in the areas of steel structures a'nd supports (Unit 1); review of contracted services (VSL Corp.) QA Manual and record storage facilities; review previously iden-tified items; storage.
Results Of the (4) four areas inspected, no items of noncompliance or deviations were identified in two areas. Three noncompliances were identified in two areas.
(Infraction - Welding material control, paragraph 7; Infraction -contract service evaluation / audit, paragraph 5.b.3.; Deficiency - VSL QA manual revision documen-tation, paragraph 5.b.1).
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DETAILS 1.
Persons Contacted Licensee Employees
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- W. P. Kelleghan, Project Manager
- G. W. Wadewitz, Construction Engineer W. H. Brown, Assistant Superintendent
- D. E. Hitchcock, Supervisor, Site QA Unit
- T. V. Abbatiello, Assistant Construction Engineer, QC J. C. Cofield, Assistant Construction Engineer - Project Engineering
- J. J. Ritts, ENDES, Licensing Engineer
- R. Hagood, Project Engineering - Welding
- A. A. Richardson, Construction Superintendent
- J. E. Rose, Project Engineering - Welding J. Mauro, Technical Services W. C. Hatmaker, Quality Control - Welding Other licensee employees contacted included construction craftsmen, technicians, and of fice personnel.
Other Organizations VSL Corporation R. McCrossen, Field QA Manager
- Attended exit interview P
2.
Exit Interview The inspection scope and findings were summarized on October 2, 1980 with those persons indicated in Paragraph I above.
The inspector identified the areas inspected, and discutaed in detail the items of noncompliance and the unresolved items.
No dissenting comments were received from the licensee.
3.
Licensee Action on Previous Inspection Findings a.
(Closed) Infraction 553/80-07-02, 554/80-06-02, Failure to control welding material. TVA letter of response dated June 12, 1980 has been reviewed and determined to be acceptable by Region II. The inspector held discussions with Project welding and QC personnel and examined the corrective actions as stated in the letter of response.
The inspector performed the necessary surveys and reviewed the corrective actiops to preclude recurrence of similar circumstances. Within these areas the inspector noted that the revision of procedure CP 8.03 Rev.
l 11 issued to control welding flux requires more specific instructions regarding this matter as discussed in paragraph 7 of this report.
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(Closed) Unresolved Item 553, 554/80-07-04, Fabrication traceability for symmetrical piping assemblies.
Welds on shop fabricated sym-metrical pipe spools are aow being icentified by paint stick and will be subsequently stenciled e % material prior to installation. This procedure will be incorporated in SDP M-1.
c.
(Closed) Unresolved Item 553/80-09-01, Recording of partial inspec-tions. The inspector reviewed operation checklist cards (OCC) of randomly selected welds on the vent structure, reactor vessel pedestal and containment vessel liner. In process type inspections resulting from fabrication related problems are being recorded on the reverse side of the OCCs as required by procedure CEP 9.07 Rev.1.
4.
Unresolved Items Unresolved itens are matters about which more it. formation is required to determine whether they are acceptable or may involve noncompliance or deviations.
New unresolved items identified during this inspection are discussed in paragraphs Sa, Sb and 7.
5.
Independent Inspection Effort a.
Construction Activities Unit 1 The inspector conducted a general inspection of the Unit I turbine, fuel, auxiliary and reactor buildings, boilermaker shop, pipe fabrica-tion shop to observe construction progress and construction activities such as welding, nondestructive examination, material handling and control, housekeeping and storage. Within this areas the inspector noted the following:
In the turbine building around the 44.0 elevation level in the
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condenser bay area the inspector observed two condensate outlet spools with protective covers r. moved, except for a few strips of tape on the edge of the openings.
Inside the spools the inspector noted t".*t
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dirt, debris and a considerable amount of water had been accummulated.
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In this same area the inspector observed the end cap missing from the
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end of an installed portion of the sump and radwaste line. Storage of I
permanent plant material, equipment and housekeeping requirements over this area are established by standard operating procedure (SOP), ES-9 Revision 0 9/2/80. ANSI standards N45.2.2 and N45.2.3 are applicable by reference. Paragraphs 5.0 and 6.3 of the aforementioned procedure state in part that "the material services unit (MSU)" shall perform storage area inspections for all items outside the warehouse con-l trolled area to the criteria listed in CEP 13.03 section 2.1.
Thes criteria provide that protective covers are in place to prevent damaga or the accumulation of dirt and moisture.....
In discussing this matter ' the licensee representative stated that these spools were subject' to ANSI B31.1 power piping code requirements, they were not a part of safety related systems and therefore the QA requirements applicable to safety related systems did not apply. In response, the inspector stated that although these systems were not safety-related,
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their storage, protection, proper installation and testing could have an impact on the performance of safety related systems.
In subsequent conversations with cognizant licensee personnel it that in addition to the approved site procedures and referenced ANSI standards N45.2.2 sad N45.2.3 the licensee was also committed to N45.2.8.
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standard provides requirements and guidelines for protection, installa-tion intpection of mechanical items (piping systems not covered by
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ASME Section III) in a manner that will provide adequate confidence that they will perform satisfactorily in service. Paragraph S.5 of N45.2.8 states in part that inspections as appropriate shall '-
performed to verify that.... precautions have been taken to prevent conditions adverse to quality.... inspection shall verify that protec-tion from inclement weather is being provided. The licensee agreed that the aforementioned storage conditions would be evaluat 2d to the provisions of N45.2.8 and the licennae's approved procedures. This item was identified as Unresolved II.em No. 553/80-15-06, " Pipe storage -
Balance of plant".
b.
Reactor Pressure Vessel Lift Preperations (Unit 1)
VSL Corporation has been contracted to transport, lift and place the reactor vessel (RV). At the time of this inspection the RV was on site in storage resting on VSL's transporting gear (crawler). The inspector checked the nitrogen purge and physical appearance of the RV for possible damage. Also the inspector interviewed VSL's site suoer-vision, 'eviewed the QA program and related lifting, transporting procedures and records.
The QA program had been approved by the licensee on November 26, 1979. VSL's on site activities procedures and records were audited by TVA's onsite QA group between March 11 and August 5.
The audit was documented under number PB-S-80-02. Within these areas the inspector noted the following:
(1) As stated in the VSL QA manual, the VSL QA program is required to be reviewed and revised as necessary every six months. Foreover, minutes of these meetings are to be documented and maintaited in i
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the QA file. When the inspector asked to review these minutes i
the VSL representative could not produce them. In addition the inspector noted that althought the QAM had been signed, the signature had not been dated and references regarding the Com-mission were in terms of the Atomic Energy Commission. These discrepancies were discussed with the VSL and TVA's represent-
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ative who agreed with the findings. VSL stated that in addition to these were other problems with the manual that required correc-tive action. The inspector discussed this matter with the licensee and stated that failure to review, revise and distribute documents
, including changes to the locations where the activity is being performed is in noncompliance with Criterion VI of Appendix B to l
10 CFR 50 as implemented by Phipps Bend PSAR, Section 17.1A.6.
l This noncompliance was catagorized as a deficiency and was identified as ites No. 553/80-15-02, "VSL QA Manual Revision Documentation".
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l-4-l (2) The inspector requested and VSL's representative produced se-lected QA/QC records, and/or procedures listed below, for a review in order to ascertain compliance with applicable NRC requirements, completeness and accuracy.
Documents reviewed were:
(a) RPV Lifting Procedure Rev. 1 (b) Receiving Inspection Reports 1_
RPV Closure Head, Shroud and Separators 2_
RPV Hardware (many) date 9/21/79 contract 74-Cl32 and 74-C131 (c) Audit (VSL Evaluation) 5/13/80 Within these areas the inspector noted that VSL's on site facil-ities for sLrage of QA/QC documents, including records, proce-dures and drawings consisted of a metal filing cabinet which had no fire rating. In response to questioning, VSL's representative stated that site generated records we e stored in this cabinet through the life of the project (RPV lift) and then shipped to the corporate offices for permanent storage. No effort was made to duplicate records for safekeeping purposes during the life of the project. The inspector discussed this matter with VSL's and licensee's representatives and expressed concern over the lack of adequate fire protection facilities.
In response VSL's repre-sentative stated that steps would be taken to secure better record storage facilities.
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The inspector stated that ANSI Standard N45.2.9, Paragraph 5.6 of this Standard states that permanent and temporary storage facilities shall be so constructed or located as to protect contents from...
fire... a one (1) hour rated filing cabinet will be provided along with an adequate fire protection system.
The licensee agreed to evaluate this condition relative to their commitments and QA requirements. This item was identified as Unresolved Item No. 553/80-15-03, "VSL Record Storage Facilities".
(3) While discussing VSL's QA program procedures, activities etc.
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l with the licensee representative, the inspector asked whether VSL had been evaluated prior to contract award and whether they (VSL)
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appeared on TVA's approved vendar list. Also the inspector asked to review TVA's source evaluation report on VSL and TVA's vendor audit report.
In response to these requests the licensee's representative stated that no preaward survey and/or vendor
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9ource evaluation audit had been performed on VSL's contracted i
service, and that VSL did not appear on TVA's approved vendor list.
The licensee provided and the inspector reviewed the report of a QA audit performed by Phipps Bend site QA on VSL site
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-5-i activities between March 11 to August 5, 1980. No. PB-S-80-02.
Failure to perform preaward survey / audit to evaluate and verify compliance with and effectiveness of all aspects of the QA program it in noncompliance with Criterion XVIII of Appendix B to 10 CFR 50 as implemented by Phipps Bend PSAR Section 17.1A.18.
This noncompliance was categorized as an infraction and identified as item No. 553/80-15-04, " Contracted Services Evaluation / Audit".
6.
Steel Structurcs and Supports - Observation of Velding Activities within Containment - (Unit 1)
Welding inside containment at the time of this inspection was centered around the containment steal structure (repairs) and on the dry wall vent structure (DVS). Codes controlling these activities included ASME sections III, (74, S74) Division 1 NE-5100, NE-5300,Section V and IX; AWS DI.1-74.
The applicable code for containment (CS) welding, is the ASME Boiler and Pressure Vessel Code,Section III, Division 1, Subsection NE, 1974 Edition, Summer 1974 Addenda for the shell and Division 2, Subsection CC, 1975 Edition for the bottom liner.
Observation of field welding activities included, where applicatie, 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, use of specified preheat, control of interpass temperature, cleanliness, removal of are strikes and weld s?atter. The following activties were observed:
a.
DVS, to base P1 MK1 between verticle welds 13J and 14J b.
DVS, verticle weld V-31 c.
Containment Vessel Liner horiz. weld 1579 In addition the inspector reviewed receipt inspection reports and quality records for plate numbers MK1 and MK-12.
Within the areas inspected no items of noncompliance or deviations were identified.
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7.
Welding Material Control (Units 1 and 2)
l The inspector reviewed the TVA program for control of welding materials to determine whether materials were being purchased, accepted, stored and handled in accordance with QA procedures and ASME code requirements. Welding material purchasing and receiving records for the following materials were l
reviewed for conformance with applicable procedures and code requirements:
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_Typet Size Heat, Lot or Batch No.
308L 3/32" 760427 l
1/16" 742717 7018 5/32" N93916 1/8" M96733 Within these areas the inspector noted the following.
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a.
In the rod issue station which services the boilermaker shop the inspector noted two portable flux warmers filled with flux.
The warmers had not been energized wl.4ch made the flux susceptable to moisture pick-up. When the inspector questioned the wisdom of storing flux in this manner the attendant energized both warmers. In the boilermaker shop near the weld area the inspector observed, upon investigation, that the flux hopper was approximately half full with flux material. In response to questioning the licensee representative stated that the machine had not been used to weld for about a week.
In reference to this condition procedure CEP 8.03 Revision 11 control of Welding Materials, is rather vague in that it states that "any flux not contained in the mechanical dispensing system of the welding equipment shall be returned to the issue station". The interpretation of the above statement was that the hopper was not a part of the mechanical dispensing system and therefore leaving the flux in the hopper was procedurally acceptable.
The inspector stated that al-lowing the flux to remain in unheated containers over extended period of time, especially during periods of wide temperature fluctuations was not a good practice since it was subject to moisture pickups in addition to the fact that it could be used without rebaking as re-quired. The inspector stated and the licensee agreed that CEP 8.03 needed to be more specific in this area. The inspector stated this matter would be identified as unresolved item 553/80-15-05, " Storage and Handling of SAW Flux Material".
b.
In rod issue station No. 5 and warming oven No. 7 the inspector found 308-L welding electrodes mixed together on the same shelf with 309-L type electrodes.
Procedure CEP 8.03 Rev. 11 " Control of Welding Material" states that the " welding QC unit supervisor ensures that segregation of different types of welding material is maintained in all instances". This finding was discussed with TVA site management who took immediate corrective action on the matter. The inspector stated that failure to follow procedures for activities affecting quality in in noncompliance with Criterion V of Appendix B, to 10 CFR 50.
This noncompliance was categorized as an infraction and was identified as item 553/80-15-01 " Welding material control".
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