ML17138A456
| ML17138A456 | |
| Person / Time | |
|---|---|
| Site: | Susquehanna  |
| Issue date: | 10/17/1978 |
| From: | Gallo R, Mcgaughy R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML17138A455 | List: |
| References | |
| 50-387-78-15, 50-388-78-13, NUDOCS 7812110291 | |
| Download: ML17138A456 (16) | |
See also: IR 05000387/1978015
Text
U.S.
NUCLEAR REGULATORY COMMISSION
OFFICE
OF INSPECTION
ANO ENFORCEMENT
Region I
5 .5~
5
-388/78-13
License
No.CPPR-101
CPPR-102 Prior ity
Licensee:
Penns
lvania
P wer and Li ht
Com an
Category
A
2 North Ninth Street
Allentown
Penns
lvania
18101
Facility Name:
Sus
uehanna
Steam Electric Station, Units
1
and
2
Inspection at:
Berwick, Pennsylvania
Inspection conducted: August 21-September
21,
1978
Inspector
. al
.
M. Gallo,
'i
nt Reactor
Inspector
date
signed
date
signed
date signed
y/
R.
W. McGaughy,
ef
Projects
Section,
dat
si
ned
s gned
Reactor Construction
and Engineering Support
Branch
Ins ection
Summar
Ins ections
on Au ust 21-Se
tember
21
1978
Re ort Nos.
50-387 78-15 and 50-388 78-13
Approved by:
Unit
1
and
Common, Areas
Ins ected:
Routine inspection
by the resident inspector of work
activities relative to: installation
and welding of reactor coolant pressure
boundary
and
other piping; installation of reactor
vessel
internals;
storage of reactor
vessel
8 inter
nals;
site calibration control; and Spray
Pond concrete
placements.
The inspector also
performed plant tours
and revierled licensee
action
on previously identified items.
The
inspection involved 87 inspector-hours
by the
NRC resident inspector.
Results:
Of the six areas
inspected,
no items of noncompliance
were identified in four
..
areas;
two apparent
items of noncompliance
were identified in two areas.
(Infraction-fai 1
ure to qualify welders for the welding process
in use-Paragraph
7.c.(2); Infraction- fail-
ure to use specified curing compound for Spray Pond-Paragraph
9.b.)
Unit 2 Areas
Ins ected:
Routine inspection
by the resident. inspector of work activities re
lative to: installation
and welding of reactor coolant pressure
boundary piping; handling
d storage of reactor, vessel
internals;Rand
storage of reactor vessel.
The inspector al-
performed plant tours
and reviewed licensee
action
on previously identified items.
The
nspection
involved 28 inspector-hours
by the
NRC resident inspector.
Results:
No items of noncompliance
were identified.
1Feg>on
1
Form 12
(Rev. April 77)
DETAILS
Persons
Contacted
Penns
lvania Power and Li ht
Com an
L.
R.
E.
J.
H.
R.
A.
Ballard, Site
QAE
Beckley, Site
QAE
Carroll,, Site
QAE
Green,
Resident
NQA 1/2/3/4/5
Harris, Protect Construction
Manager
Prego, Site
QAE
R. Sabol,
Manager,
Nuclear Quality Assurance
Bechtel
Cor oration
Y.
M.
J.
P.
D.
K.
R.
M.
G.
H.
J.
J.
A.
R.
H.
K.
E.
J.
J.
H.
J.
A.
Ananda, Civil QAE
K. Boone,
Lead. Welding Engineer
A. Dahnert,
QC Engineer-Piping
R. Delorme, Welding Engineer
Dharia, Subcontracts
Engineer
Durland,
QC Engineer-Welding
Drake, Superintendent-Night Shift
A. Drucker, Electrican
QAE 2/3/4/5
Gelinas,
QC Lead Engineer Piping/Mechanical
Goodvin,
QC Engineer-Civil
Hoagland,
Construction Assistant
Khandar,
Mechanical
OAE
Kontura, Mechanical
QAE
Lamb,
QC Assistant
Lead Engineer-Welding
Lilligh, Project
QAE 1/3/5
Stout, Assistant Project Field Quality Control Engineer 2/5
Strzelecki,
QC Lead Engineer Instrumentation
Van Omen, Subcontractor Administrator
5
Vidunas,
Oman,. Field Engineer Storage
and Maintenance
O'ullivan, Assistant Project Field Engineer
3
Spielhagen,
Project Field Engineer
2
General Electric, Com an
Nuclear Ener
Division
NED
E.
T.
R.
A. Gustafson,
Site Manager
2
M. LeVasseur,
QC Representative
2/5
M. Pulsifier, Mechanical
Engineer
Installation
and Service
En ineerin
IPSE -Reactor Internals
F. Forsythe,
Si te Manager
D. Hess,
QC Engineer
T. Sartain,
Welding Engineer
Dick Cor oration
J. Borst,
FQC Manager
R. Hudak,
QC Inspector
Peabod
Testin
Com an
M. Whalen,
NDE Supervisor
l.
/ denotes
those present at Exit Interview August 25,
1978
2.
/ denotes
those present at Exit Interview September
1,
1978
3.
/ denotes
those present at Exit Interview September
8,
1978
4.
/ denotes
those present at Exit Interview September
15,
1978
5;
/ denotes
those, present at'xit Interview September
21, 1978',
The inspector also interviewed other
PPSL employees
as well as
employees of Bechtel,
Dick Corporation,
Peabody Testing
Company,
and General Electric Company.
Plant Tour
The inspector
observed
work activities in-progress,
completed
work
and plant status
in several
areas of'he plant during general
inspection of'he plant.
The inspector
examined
work for any
obvious defects or noncompliance
with- regulatory requirements or
license conditions. Particular note was taken of presence
of
quality control inspectors
and quality control evidence
such
as
inspection records,
material identification, nonconforming material
identification, housekeeping
and equipment preservation.
The
inspector
interviewed craft. personnel,
supervision,
and quality
inspection
personnel,
as
such personnel
were available in the work
areas.
No items of noncompliance
were identified.
3.
Licensee Action on Previous
Ins ection Findin
s
(Cl'osed)
Unresolved
Item (387(388(78-02-02):
Improved maintenance
of items released
from the warehouse
but not yet installed.
The licensee
had initiated Deficiency Report
No.
0085 to document
specific conditions previously observed
by
NRC inspectors.
Valves HBB-BF-15703R and GBB-'T-F010A and
B were observed with end
caps in place.
Final inspection of these
valves for internal
cleanliness
is done prior. to closure in accordance
with QCI
P 1.10
Revision II.
The response
to Deficiency Report 0085 states
that the corrective
action regarding this, matter included meetings with craft and
supervision
to emphasize
the importance of maintaining
and re-
placing end caps,
assignment of craft personnel
to replace
end caps
at the end of each shift, and
a daily survey
by Field Engineering
prior to the start of the day shift to verify that end caps
are
replaced
and to identify discrepant conditions.
The inspector
verified by discussions
with assigned
individuals that Field
Engineering
personnel
are conducting the required surveys that
personnel
are monitoring this activity. Field Engineering
and
personnel
stated that their surveys
included observation of the
condition of all safety related
equipment in temporary or in-place
storage.
Nonconforming conditions noted are processed
in accor-
dance with Project Special
Provisions
Notice SF/PSP
8G-6.1
Revision
0 or field inspection
procedure
G-3 as appropriate.
The inspector
reviewed the following additional
documentation
regarding this
matter:
Nonconformance
Report
No.
2953
In Process
Rework Notice Nos.
2540,
2543,
2544,
2545
PPSL: letter to. Bechtel
PLB-8575
Bechtel letter to PP8L
BLP 9374
QCIR 73.0-M 204-HBB-116-1
(1)
QCIR 49.0-M 204-GBB-115-1
(2)
The inspector
had no fur ther questions
on this matter at this time.
4.
Reactor Coolant Pressure
Boundar
and Safet
Related
Pi in
Weldin
)
The following listed activities were examined
and verified that
they were being pei formed in accordance
with the
and IX codes,
PSAR Appendix D, the Bechtel guality Assurance
Manual
Section III, Site Specification
M 204,
and drawings
M-198 and
M-
199.
W~iN
-U i
Fitup, alignment
and welding of joint GBC-101-1
FW 14.
Welding of joint HRC-'2-4
16.
Welding of joint SP-DCA-M 78-35-BW 8 R-2.
-Unit 2
Welding of joint DLA-201-1
FW 3.
The inspector verified selected
detailed
drawings, welding
procedure,
base
and filler metal certifications, welder
qualification, quality control documentation,
weld appearance,
welding variables
such
as
gas flow and amperage,
and non-
destructive testi'ng activities
as appropriate.
b.
Non-Destructive Testin -Unit
1
testing of weld joint Nos.
SP-DCA-M 78-4-FW"8 (c) R-l.
GBB-109-2
FW l-l (Excavation).
GBB-109-2
FW 12 (Excavation).
VNB-B21-2
FW A15.
The inspector verified'surface preparation,
qualification of
examiners,
and testing technique.
No items of noncompliance
were identified.
5.
Reactor Coolant Pressure
Boundar,
and Safet
Related
Pi in
a.
Piping System Activities.
The inspector
examined
work activities for the Main Steam
System- Line
B inside containment- and Main Steam Relief Lines
for Line B.
The inspector verified that the activities
exam-
ined were in accordance
with the
Appendix D,
FSAR Sections
5.4.9
and 10.3,
the Bechtel guality
Assurance
Manual Section III, GE Specification
22A 4628,
Bechtel Specifications
M-201, M-204 and drawings
M-199,
VNB
B21-2,
GBC 101-12-1
and GBC-101-30-1.
The inspector observed
handling, installation, protection,
initial alignment,
and identification.
The inspector
reviewed
associated
gC inspection records, verified material certifications,
and reviewed
gC Engineering certification records.
b.
The inspector
examined
two partially completed piping runs
and
verified that they were installed in accordance
with approved
drawings
and specifications.
Piping runs
examined were:
(1)
The 20"
RHR piping. from containment penetration
X-12 to
.pipe spool
DCA-108-1-3.
The inspector verified conformance
to
FSAR Section 5.4.7
and
drawings
DCA-108-1
and M-151.
(2)
The
RHR Service Water System Spray
Pond Network B-l.
The inspector verified conformance with FSAR Section 9.2.6
and
drawings
HRC-2-4, HRC-2-11,
M-80-1 and M-80-2.
No items of noncompliance
were identified.
6.
Reactor
Vessel Installation Units
1
and
2
The inspector
examined protection of the installed reactor vessels
and stored closure heads'for
compliance with site procedures
and
PSAR Appendix
D commitments.
The inspector
reviewed the procedural
requirements for vessel
protection
and verified that required
inspections
and preventive maintenance
were being completed.
The
inspector observed
that openings
were covered
as required,
work
platforms inside the Unit I vessel
were nonflamable
and that Unit I
access
was controlled.
The inspector also observed
the condition
of a selected
closure
head stud hole to verify freedom from rust
and condensation.
Documentation
reviewed
by the inspector included
Field. Inspection
Procedure
6-5, Revision 0.
Project Special
Provisions Notice SF/PSP
G-5.1, Revision 3.
Equipment Maintenance
Requirement
and Record
Form for
Unit
1
and
2 Reactor Vessels
and for Reactor
Vessel
Closure Heads.
No items of noncompl.iance
were identified.
7.
Reactor Vessel
Internals
a.
Protection of Stored
Vessel Internals-Units
1
and
2
The inspector
examined protection of the stored reactor vessel
internals for compliance with site. procedures
and
PSAR Appen-
dix D commitments.
The inspector
reviewed the procedural
require-
ments for internals protection
and verified that required inspec-
tions were being completed.
The inspector
observed
the in-plant
storage of the Unit
1
Steam Dryer and the shroud
head
and separator.
The inspector
also observed
the movement
and subsequent
in-
plant storage of the Unit 2 Steam Dryer and shroud
head
and
separator.
The inspector
noted that
NCR was issued
by guality
Control regarding
the storage 'ondition of these
components.
The. inspector also noted that the equipment maintenance
requirements
and record form for the aforementioned
Unit 2 components
had
not been rewritten to reflect their movement to in-plant
storage.
Documentation
reviewed by the inspector included:
Field Inspection
Procedure
G-5, Revision 0.
Project Special
Provisions Notice SF/PSP
G-5..1, Revision
3.
Equipment Maintenance
Requirements
and Record
Form for
Unit
1 and
2 Steam Dryer and the Shroud
Head
and Separ-
ator.
The inspector stated that the disposition of NCR and the
revised
equipment maintenance
requirements
and record form for
the aforementioned
Unit 2 components
would be examined during
a future inspection.
(388/78-13-01 )
II
b.
Handlin
of Internals-Units
1
and
2
The inspector
observed,. lifting and handling of the Unit 2
Steam
Dryer
and the shroud
head
and separator
from temporary
storage silos to in-plant storage.
The inspector also observed
the installation
into the reactor pressure
vessel of the
Unit
1 shroud.
The inspector verified that the lifting and
handling were consistent with established
requirements, lifting
equipment
was
as specified
and testing
completed prior to
lifting, and placement
and installation
were in conformance
with requirements.
Documentation
reviewed
by the inspector
included:
GE I8SE Procedures
160 A71211 Revision 0,
160 A71210 Revision 1,
160 A81201 Revision l.
Bechtel
FCI-M-156, Revision
1 for dynamicload testing of
crane.
No items of noncompliance
were identified.
c ~
Installation of Internals-Unit
1
(1)
The inspector
observed
completed
work and work in progress
relative to the installation, of'elected reactor internals
components.
Items inspected
included:
jet pump
beam
bolt tensioning,. jet pump head
beam bolt-tack welds,
and
jet pump riser to brace
arm welds.
Except
as noted in
Paragraph
(2) below the inspector
determined that work
procedures
were being followed; installation
was in
accordance
with specifications
and
gC inspection activ-
ities were in accordance
with established
procedures.
The
inspector
reviewed selected
documents relative to this
work including:
FSAR Section
3.2
GE drawings
197F 633, Revision 8;
117C 4354, Revision
8
GE Specification
22A 4273 Revision
2
GE I8SE Jet
Pump Installation Travelers
11T
GE IPSE Jet
Pump
Head Bolt Tensioning Special
Beam
Process
Control Sheets
No. 115-15.
GE IPSE Jet
Pump
Beam Bolt Tack Weld Joint Process
Control Sheets
Except as noted below,
no items of noncompliance
were identified.
(2)
The inspector
examined the completed jet pump riser to
jet pump brace
arm welds for jet pumps A,B,C,D,F,G, and
H.
The welds examined
met the requirements
of the following
General Electric Drawings:
GE Drawing 117C 4354 Revision 8.
GE Drawing 197R 633 Revision
8
The welds required
by these
drawings are partial penetration
single bevel flush contour groove welds.
The inspector
also
reviewed records relative to these
The records
included jet pump installation travelers,
joint process
control sheets,
visual
and liauid penetrant
examination. results,
material certifications for weld
electrode, certificationof conformance for base material,
welder qualification records,
and welder mock-up test
records.
Documents
examined were:
Jet
Pump Installation Traveler llT
Joint Process
Control Sheets
and
13 for Jet
Pumps
A, B,
C,
D, F,
G, and H-includes record of
visual
and
PT examination
Material Certification for Weld Filler Metal-Heat
No.
C3548
R308L
GE Cerfiticates of Conformance
for Riser Brace
Arm
and Jet
Pump Risers
PgC Nos.-SJ
3371,
01249,
01237
Record of Welder Performance
Test in Accordance with
Welder gualification ISE-Wg-31.
10
Record of Mock-up Testing in Accordance with Mock-up
Test ll NU-3
IPSE Weld and
NDE Information Spread
Sheet
160-
77E-D155 Revision
5
Detail
Weld Procedure
ISE-DWP-3004 Revision
1
Welder Qualification ISE-WQ-32 Revision 0-A
Welder Qualification
ISE-WQ-31. Revision 0-A
During this review the inspector
noted that Detail Welding
Procedure
ISE-DWP-3004,
a
Gas Tungsten
Arc Welding
(GTAW)
Process,. is specified for the jet pump riser to brace
arm
weld by GE Weld identification diagram 160-77E-0154.
This
GE Weld identification diagram requires
Welder
Qualification ISE-WQ-31 for this weld.
However, Detail
Welding Procedure
ISE-DWP-3004 requires
Welder Qualifi-
cation
ISE-WQ-32.
ISE-WQ-31 specifies
the use of a
consumablc insert,
where
as
ISE-WQ-32 does not.
, Welders
who had welded the jet pump
riser to jet pump brace
arm,
a weld with no consumable
insert or other backing,
were qualified only in accord-
ance with ISE-WQ-31.
The
ASME Boiler and Pressure
Vessel
Code Section IX, 1974 Edition, QW-356.1 lists
QW 404.22
as
an essential
variable for the performance qualification
of Gas Tungsten
Arc Welding.
QW-404.22 states,
"The
omission or. addition of preplaced
consumable
inserts.
Qualification in a singled-welded butt joint, with or
without consumable
inserts, qualifies for fillet welds
and single-welded butt joints with backing."
The failure to qualify welders for the welding process
used is'contrary. to the requirements
of 10 CFR 50,
'Appendix B, Criterion IX.
(387/78-15-01)
By letter. dated 'August 31,
1978,
to the Bechtel Field
'onstruction
Manager,
the
GE Installation
and Service
Engineering Site Manager stated that the brace
arm to
riser welds are considered
to be sound
and will perform
their intended fuction based
upon:
(1) Welder quali-
fication on
a brace
arm mock-up
(11
MU-3) prior to
welding the brace;
(2) inspection of the sectioned
mock-
up -indicated that deposited
welds were sound
and
had full
(3) the'welders
were qualified to a proce-
dure similar to the one required;
(4) welders'erform-
ance
on these
and other welds
has
been excellent;
(5) the welds
had liquid dye penetrant
examination
(PT)
of the root and final pass
and were found acceptable.
The inspector
examined
the sectioned
mock-up and noted
that in addition to the requirements
of the procedure
used
in the production welding, one weld pass
had
been
made from
the opposite side of the weld.
It did appear that adequate
to meet the requirements
of the design weld
had
been achieved.
8.
Control of Measurin
and Test
E ui ment
The inspector
examined Bechtel's
program
and activities relative to
the control of measuring
and test equipment.
The inspector verified
that these activities were in accordance
with commitments
in the
PSAR Appendix D; Field Inspection
Procedure
G-4, Revision 6; Project
Special
Provisions Notice SF/PSP
G-4.1, Revision 2.
The inspector
examined the following relative to the above:
Measuring
and Equipment List, gC-G-4-1
Calibration Record
Card File
Out of Calibration Notices for CT 676 and
CT 538
Instrument Calibration Instruction 5, Revision
2
Calibration Test Report for CT 1243
No items of noncompliance
were identified.
9.
S ra
Pond Concrete
Work
a.
Concrete Activities
The inspector
examined
concrete
work activities in progress
for Spray
Pond placement
S-60.
The inspector verified, except
as noted in b. below, that these activities were in accordance
with commitments in the
PSAR Appendix D;
FSAR Section 9.2.7;
Bechtel Specification
C-36 and Dick Corporation Procedures.
12
The inspector
examined
the following activities relative to
the above:
placement
preparation,
delivery and placement,
wire mesh installation,
and curing.
Documents
reviewed
by the
inspector included:
Bechtel
Drawings
C-65 and C-66
Dick Drawings
SK 1-2
Concrete
mix test results truck 15 ticket 52322
Dick gC in process
records
including Pre-placement,
Placement,
Concrete
Placement
Release,
Concrete
Testing Record,
and Concrete
Curing Record.
Except as noted below,
no items of noncompliance
were identified.
C~id
d
During the inspection,
on September.6
and 7, 1978, of the
concrete acti vities in a.
above the inspector noted that the
contractor,
Dick Corporation,
was using
a c~ring compound
identified as
Horn Clear Seal
150.
The inspector
determined
that this product was
a Type
1 curing compound in accordance
with ASTM Specification
C309.
However,
Bechtel specification
C-36 Paragraph
7.4.9 (b) states
"Liquid membrane
curing com-
pound shall
be Type
2 in accordance
with ASTM C309-58."
On September
13,
1978,
Bechtel
approved Supplier Deviation
Disposition Request
No.
034 permitting the
use of the Type
1
curing compound.
On September
21,
1978,
the inspector
examined
40 completed
concrete
slabs
on the Spray
Pond. slopes.
Of these
40,
8 were
observed
to have
one or two hairline cracks of varying length.
Representatives
of the licensee
stated that the Spray
Pond
cracks
had
been noted previously and would be documented
and
dispositioned.
The inspector stated that the failure to use
the curing compound required
by Specification
C-36 was contrary
to the requirements
of 10 CFR 50, Appendix B, Criterion V.
(387/78-15-02;
388/78-13-02)
d
13
10.
Exit Interviews
At periodic, intervals.- during the course of this inspection,
meetings
were held with facil.ity management
('ates
and attendees
are denoted
in Detail 1) to discuss
inspection
scope
and findings.