ML17053A863
| ML17053A863 | |
| Person / Time | |
|---|---|
| Site: | Nine Mile Point  |
| Issue date: | 04/24/1979 |
| From: | Mcgaughy R, Narrow L, Walton G NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML17053A860 | List: |
| References | |
| 50-410-79-02, 50-410-79-2, NUDOCS 7907300385 | |
| Download: ML17053A863 (24) | |
See also: IR 05000410/1979002
Text
U.S.
NUCLEAR REGULATORY COMMISSION
OFFICE
OF INSPECTION AND ENFORCEMENT
Region I
0
0
4
. ~50-410 19-02
Docket No.
50-410
License
No.
CPPR-112
Priority
Category
Licensee:
Nia ara
Mohawk Power Cor oration
300 Erie Boulevard,
West
Syracuse,
13202
Facility Name:
Nine Mile Point Nuclear Station, Unit 2
Inspection at:
Scriba,
Inspection
cond
ted:
March 20-23
1979
Inspectors:
arro
Reactor
Inspector
G. A. Walton, Reactor
Ins ector
p.~y- 7g
date signed
date signed
date signed
Approved by:
R.
W. McGaughy,
'
Construction Projects
Section,
RCBES Branch
dat
s'ned
Ins ection
Summar
Ins ection
on March 20-23,
1979
Re ort No. 50-410/79.-02
~A:d,d019910d
inspectors,
of gC programs for fabrication and erection of the contain-
ment liner; structural
steel erection;
automatic stud welding; con-
formance to the requirements
of 10 CFR 21; observation of outdoor
storage;
and review of the status of outstanding
items.
The inspection
involved 56 inspector-hours
on site
by two regional
based
inspectors.
Results:
Of the five areas
inspected,
one apparent
item of noncompli-
ance
was identified in one area(Infraction
- Failure to comply with
code requirements for NDE of certain welds,
Paragraph
4).
zeov3Oo> K
Region I Form 12
(Rev. April 77)
fI' j q
', $~ c 4 f5 j
DETAILS
Persons
Contacted
Nia ara
Mohawk Power Cor oration
- L. G. Fenton,
Senion Site
gA Representative
(Acting)
- S.
H. Haybrook, Senior Site Construction Representative
- C. G. Honors,
gA Engineer
I. Stupal,
Manager of Construction,
NM-2
- K. D. Ward,
gA Engineer
Stone
and Webster
En ineerin
Cor oration
S&W
R. Baudet,
gC Engineer
- B. F. Gallagher,
Senior Resident
Engineer
- C. E. Gay, Superintendent,
Field gC
J.
E. Karr, Project
gA Manager
- M. R. Matthews, Field gC Senior Engineer
- J.
E. Rogers,
Chief Office Engineer
- L. E. Shea,
Head
- F. M. Sheldon, Assistant Superintendent,
Construction
Chica
o Brid e and".Iron
Com an
- T. J.
Dougherty, Project Welding and
gA Superintendent
R. Ferguson,
Auditor
C. Hall, Project Superintendent
K. Wayman, Assistant Construction
Welding and gA'Manager
(New
Castle,
The inspector also interviewed other licensee
and contractor
employees
during the inspection.
- denotes 'those present at the exit interview.
Plant Tour
The inspectors
made
a tour of the site to observe
work activities
in progress,
completed
work and the status of construction.
The
inspectors
examined work items for any obvious defects or noncompli-
ances with regulatory requirements
and observed
gC activities
and
evidence of quality control of the work.
Specific activities
and
items observed
by the inspectors
included stud welds on miscellaneous
and structural steel;
storage of reinforcing 'steel,
~and electrical
cables.
General
Mr. C. Terry, formerly Senior Site
gA Representative,
has
been
appointed
Manager of Nuclear Projects
Engineering.
Mr. L. G.
Fenton is temporarily acting
as Senior Site
gA Representative.
Mr.
I. Stupal
has
been appointed
Manager of Construction,
Nine Mile 2.
The Graver Tank and Manufacturing'ompany's
contract for fabrication
and installation of the containment liner has
been terminated.
Completion of this work has
been
awarded
to Chicago Bridge and Iron
Company (CBI).
The inspector audited
the activities associated
with this change of
subcontractors.
The licensee'
A/E-Contractor,
S&H, is performing
a review of on site work of the containment liner to determine
the
activities to be performed
by CB&I.
This review includes
a complete
record review as well as
a complete accounting of hardware.
At
present,
Graver Tank has turned over all records
except the "Erection
Control Sheets"
to Stone
& Webster
Company.
To establish
a checklist of activities performed or to be performed,
S&kl is documenting their review on
a "Status
Report" which lists
such function as:
fit-up; welded, inspection status,
repair status,
testing
documented;
and, final acceptance.
The inspector
reviewed
several
"Status
Reports"
and associated
supporting
data
and found
them adequate
to establish
documentation
and work requirements
important to safety.
The inspector
was informed by the licensee
and
S&ll representatives
that material
and partially fabricated
items
had
been, removed
from
the Graver
shop
and turned over to CBI at Greenville, Pennsylvania.
Graver
shop documentation
had
had
been turned over to
SM< at Cherry
Hill, New Jersey,
and was being reviewed prior to performance of
any shop work by CBI.
The subcontracts
for fabrication of the
hatches,
which had
been
awarded
by Graver,
have
been
taken over by
the licensee.
This item is unresolved
pending review of an
NRC inspector after
completion of the record review by
S&W (410/79-02-01).
CI
4.
NDE of Containment Liner Pi in
The inspector
reviewed
SKH s Specification
P283B,
Revision 3, for
nondestructive
examination
requirements.
The requirements
stated
in this specification were compared
against
the
ASHE Section III
code.
P265,
P270,
and
P275
and other piping penetrations
are
.identified by the specification
as
ASHE Code Class
1 or 2.
The
code boundaries
include the flued
As
defined in Specification
P283B
and detail
Drawing
NL 10795, the,
weld connecting
the flued head to outer sleeve
requires ultrasonic
and magnetic particle or liquid penetrant
examination.
n
Paragraph
NB 5231 of ASNE Section III including the
Summer
73
Addenda,
requires that all welded joints shall
be radiographed.
The welds identified above were fabricated at Graver shops
and
had
not been radiographed
as required
by the code.
This is considered
to be
an infraction of 10 CFR 50, Appendix B,
Criterion IX (410/79-02-02).
5.
S ecification for Control of Electrode's
The inspector
examined
S&H Specification
P283B,
Adendum 1, for
control of E8018-Cl weld filler material
and noted the following:
The E8018-Cl weld filler material shall
be furnished with 0.3
percent
maximum moisture.
Each lot of material shall
be
tested"and
results
made part of the certified material test
report.
An additional moisture test shall
be performed for
each lot of material
as part of the receipt inspection.
1
The specification further requires that the seller shall
employ
a
program for controlling the E8018-Cl weld filler material to assure
that the moisture content
does
not exceed
0.8 percent at the time
of use,
or
he shall
purchase
the E8018-Cl from a supplier
who is
prequalified,
to assure that this requirement is met.
The maximum
cumulative exposure
time out of the oven shall
be
10 hours1.157407e-4 days <br />0.00278 hours <br />1.653439e-5 weeks <br />3.805e-6 months <br />.
One
rebaking per
ADJS Dl. 1 is permitted,
which will allow an additional
10 hours1.157407e-4 days <br />0.00278 hours <br />1.653439e-5 weeks <br />3.805e-6 months <br /> cumulative exposure
time before the electrodes
must
be
discarded.
The electrode supplier,
Chemtron Corporation,
performed moisture
tests with three sizes of E8018-Cl to determine
the amount of
moisture in the initial flux, then after
an exposure of the electrodes
for 10 hours1.157407e-4 days <br />0.00278 hours <br />1.653439e-5 weeks <br />3.805e-6 months <br /> at 75 degrees
fahrenheit,
and
75 percent relative
humity.
The inspector questioned
whether the
75% relative humidity is
representative
of the conditions which might be experienced
on
site.
Records
reviewed
by the inspector,
which were taken at
Syracuse,
N.Y., indicated the relative humidity frequently exceeds
75 percent.
This item is unresolved
pending further analysis
and test to be
performed
by the contractor
(410/79-02-03).
6.
Stud Weldin
Procedures
and
Records
The inspector
reviewed procedures
for performance of automatic
stud
welding on site
and
gC records of this work as
shown below, for
conformance to the requirements
of Appendix
D of the
FSAR and the
S8W "Standard
Nuclear guality Assurance
Program
(SWSOAP) 1-74," as
modified for the Nine bile Point, Unit 2 project.
Section
1-40 of the Specification for Placing Concrete
and
Reinforcing Steel,
No.
S 203-C, Revision 4, concerning
stud
welding which references
AWS Dl.l.
Construction
Methods Procedure
(CMP) No. 6.3-5.73,
"Auto-
matically Time'd Stud Welding."
guality Standard
gS-9. 1, Revision A, "Automatically Timed Stud
Welding."
guality Assurance
Directive gAD-9.3,
Change
2, "Stud Weld
Inspection."
A selected
group of pre-production
and final inspection reports
of stud welding including IR No. W9015176,
dated
February 9,
1979, for inspection
and testing of repairs of previously
.identified defective
stud welds.
gAD-9. 3 requirements
for gualification, Pre-Production,
Production
and Repair Weld Tests
are not in conformance with the test require-
ments of CNP 6. 3 and
AWS Dl. l.
gA Procedure
Change
Request
Log No.
B 470-2 for correction of these
discrepancies
had
been
approved
by
the Procedure
Revision
Review Board on ~hrch 7,
1979.
In addition, the
gC inspection reports did not list the attributes
identified in gAD-9.3.
This item is unresolved
pending review of the revised
OAD-9.3 by an
NRC inspector
and resolution of the requirement for a stud welding
attribute list (410/79-02-04).
7.
Structural
Steel
Weldin
Procedures
The inspector
examined
the procedures
listed below for conformance
to the requirements
of Appendix
D of the
PSAR and
AllS Dl.l.
CMP 4. 1-5.78, "Structural Steel Erection."
CMP 6. 2-5. 78, "Structural Welding. "
CMP 6. 4-5. 78, "Melding Material Control. "
CMP 6. 9-10. 78,
"Performance gualification of Helders."
OS 8. 11, Revision A, Change Notice 1, "Melding Material Control."
gS 9.2, Revision
C, "Structural Field fielding."
gS 9.31, Revision A, "Welding/fielding Operator gualification."
gS 9.41,
Change Notice 2, "Nondestructive Testing Program."
gAD 2.5, Revision
C, "gualification and Certification of
Personnel
Performing
equality
Assurance Activities."
gAD 9.31, Revision 0, "Liquid Penetrant
Examination,
General
Requirements."
gAD 9.41,
Revision 0, "Radiographic
Examination,
General
Requirements."
gAD 9. 42, Revision 0, "Radiographic
Examination,
Pipe Helds."
gAD 9. 51, Revision 0, "Ultrasonic Examination,
General
Requirements,"
which is applicable to the examination of ferrous
and nonferrous
materials
and weldments for thickness
and volumetric integrity.
8.
gAD 9. 54, Revision 0,
"UT of Helds. "
Although gS 9-41 states
that all
NDT performed
by
OA shall
be in
accordance
with procedures
prepared
and approved
by gA,
a procedure
for performance of visual inspections
was not available.
I
This item is unresolved
(410/79-02-05).
S ar er Rin
Su
ort Cadweld Sleeve
s.
The licensee's
report of February
28,
1979,
on the investigation of
to the containment liner stated that
a
structural
analysis of the sparger ring support will be conducted
when the loading criteria
has
been determined
and corrective action
taken if required.
This item is unresolved
pending review by an
NRC inspector of any
corrective action required to be taken
(410/79-02-06).
A Manual
Review
The inspector
examined the
CBI gA Manual
and procedures
as
shown
below.
These
documents
had
been
approved
by
SEW for work under
contract to CB8I for fabrication
and erection of the Biological
Shield Wall Assembly and/or
the containment liner.
a ~
Nuclear Quality Assurance
Manual for ASME III Products
Issue
No.
8 dated
March 22,
1978, Division 4, which includes
the
following procedures:
Section l. 0, Scope, 'Revision 8.
Section 2.0, Authorized Inspection,
Revision 3.
Section 3.0, Organization,
Revision 8.
Section
4. 0, Control of Items
and Calibration Services,
Revision
6.
Section
5. 0, Print Control, Revision
6.
Section 6.0,
gA Handbook
and Procedure
Control, Revision
7.
Section 7.0,
Process
Control, Revision 8.
Section 8.0, Welding, Revision 8.
Section 9.0, Nondestructive
Examination,
Revision 7.
Section 10.0,
Heat Treating,
Revision 7.
Section 11.0, Calibration (of MME), Revision 6.
Section 12.0,
Records,
Revision 6.
Section 13.0,
Dimensional Control, Revision 7.
Section 14.0, Nonconformities
and Corrective Action,
Revision 8.
Section 15.0, Certification, Revision 8.
Section 16.0, Miscellaneous
Construction Controls,
Revision 7.
b.
Project guality Assurance
Manual, Revision
1
(Containment
Liner).
c.
Nuclear guality Assurance
Manual, Supplement
No.
1 (Contain-
ment, Liner) .
d.
Project guality Assurance
Manual - Issue
No.
3 (Biological
Shield Wall).
e.
gA Manual, Supplement
1, Revision
2 (Biological Shield Wall).
f.
Training, Indoctrination,
and qualification Program,
TIP-1,
Revision 3.
The inspector discussed
performance of audits with CBI site personnel
and with a CBI auditor who was performing an audit on site and
was informed that the entire program
was audited at least
once
each
year.
Audits of work performance,
gC performance
and records
were
performed in addition to the program audit.
No items of noncompliance
were identified.
10.
Outdoor Stora
e Conditions
The inspector observed
the condition of storage of structural
steel,
piping and containment penetrations.
The material
was
stored
on wood blocking in a fenced
area
away from traffic.
Items
were marked or tagged for identification and to denote
the quality
classification,
pipe ends
were capped
and sealed.
No items of noncompliance
were identified.
11.
Conformance to 10 CFR 21
The inspector
examined
the licensees
procedures
listed below which
require review of quality problem reports for possible
reportability,'nalysis
of problems,
reporting
as necessary,
'and maintaining
records
in. accordance
with 10 CFR 21.
gA Procedure
No.
15. 10, 'Revision
2,
"Review of Reports
Concerning
Nonconforming Items."
OA Procedure
No.
16. 30,
Revision 3, "Preparation of guality
Reports
on Significant .Deficiencies."
The inspector observed that the posting requirements
of the regu-
lation had
been complied with at the licensee's
site office and,.
also the requirements
of the regulation
had
been
imposed
on CBI.
No items of noncompliance
were identified.
12.
En ineerin
and Desi
n Coordination
Re orts.(E8DCR's
The inspector
reviewed
7 E&DCR's,
Numbers
V15016,
V15017,
V15039,
P10215,
P10233,
P10259,
and
P10296, for disposition of deviations
by Graver Tank Company.
The review was performed to determine if
cot rective actions
were being taken.
This review was
compared to
the licensee's
commitments in the
PSAR,
and applicable
ASHE codes.
D
No items of noncompliance
were identified.
k
10
13.
Primar
Containment
Procedures
The inspector
reviewed the below listed procedures
relative to
Chicago Bridge and Iron Company field fabrication of the primary
containment.
~
GWPS-SMAWX,,Revision 1, General
Welding Procedure.
~
VT5X, Revision 1, Visual Examination Procedure.
~
SHIN, Revision 1, Receiving
and Storage
Procedure of Nuclear
Product
Items Supplied
by Others.
WPS E308L, Revision 1, Welding Procedure Specification.
~
SI No. 3, Revision 2, Welders
Performance gualification Test
Instructions.
WPS E7018,
Revision 1, General
Welding Procedure
For the
Shielded
Metal Arc Process.
~
,
RT 2N, Revision 0, Radiographic
Examination Procedure
Welder
and Welding Operator gualification.
PT 851, Revision 1, Liquid Penetrant
Examination.
EMM, Revision 0, Electrode Moisture Monitoring.
This procedure
provides for establishing
the moisture content level of
E 8018-Cl
electrodes
in the as-received
condition.
Moisture content
samples
shall
be taken from each
heat
and lot of electrode
of each diameter in the as-received
condition.
The E8018-Cl
electrode shall
meet
a moisture content level of 0.3 percent
maximum in the as-received
condition
prior to use
on this
contract.
The above procedures
were reviewed against
the
PSAR, contract
specifications
and,
where applicable,
the
ASME Code Section III
and IX.
No items of noncompliance
were identified.
11
Nelson Studs
The inspector
informed the licensee that problems
had
been identified
at another site with defective attachment of nelson
studs
to
embed-'ents
and structural
steel
supplied
by Acme Steel
Company
and
Bethleham Fabricators,
Inc.
After review of site records,
the
licensee's
representative
stated that the companies
in question
had
not furnished
any items for this site
and that they were not included
on the list of acceptable
suppliers.
The inspector
had
no further questions
concerning this item.
Review of Nonroutine Events
Re orted
b
the Licensee
HT indications in welding of cadweld
to Knuckle Plate
Assembly.
The inspector
observed that all cadweld sleeves
which
had
been welded to the Knuckle Plate Assembly
had
been
removed.
Clean-up- and
NDE of the surface
areas
were partial.ly complete
and
rewelding of new sleeves
was in progress.
The inspector also
examined
S&H Report "Investigation of Structural Integrity of Nine
Nile.Point, Unit 2 Reactor Pedestal,"
dated
February
1979.
This
report substantiates
the information in the licensee's
letter of
February
28,
1979, concerning
the
55 cadweld sleeve
welds to the
baseplate
near its junction with the reactor pedestal.
The inspector
had
no further questions
concerning this item.
Breakdown in Dravo Shop
gA Program.
This item had
been reported
by
the licensee
as
a significant deficiency on
December
27,
1977.
Corrective action
by Dravo and results of re-audits
by S&H had
previously been
reviewed
by. the inspector
(Inspection 'Reports
78-02
and 78-06).
This item remained
unresolved
pending
issuance
of
revised
NDE instructions
by Dravo.
The inspector
examined
S&H report of the Corrective Action Audit
conducted
September
19,
1978, which shows that the identified
procedure
had
been replaced
by Procedure
The inspector
had
no further questions
concerning this item.
n
12
16.
Licensee Action on Previous
Ins ection Findin s
(Closed)
Unresolved
Item (78-09-0]):
Cleaning of Gadwel.d Sleeves.
The cadweld sleeves
identified as requiring cleaning
have all been
removed
as
a result of defects identified (Paragraph
15 above).
(Closed)
Unresolved
Item (79-01-02):
Method for control of prints
removed from distribution.
S&W memo dated
February
15,
1979,
and
entitled "Decreasing
Standard
Distri.bution of Level
1 Documents,"
and sent to all Department
Heads
and Contractors
provides the
necessary
control.
17.
Unresolved
Items
Unresolved
items .are matters
about which more information is required
in order to ascertain
whether they are acceptable
items, or items of
noncompliance,
Unresolved
items disclosed
during the inspection
are
discussed
in Paragraphs
3, 4, 5, 6, 7,
and 8.
18.
Exit Interview
At the conclusion of the inspection
on March 23,
1979,
a meeting
was held with representatives
of the licensee.
The inspector
sum-
marized the results of the inspection
as described
in this report.