ML19208D121
| ML19208D121 | |
| Person / Time | |
|---|---|
| Site: | Perry  |
| Issue date: | 08/01/1979 |
| From: | Hayes D, Julie Hughes, Maxwell G NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML19208D122 | List: |
| References | |
| 50-440-79-03, 50-440-79-3, 50-441-79-03, 50-441-79-3, NUDOCS 7909280015 | |
| Download: ML19208D121 (15) | |
See also: IR 05000440/1979003
Text
U.S. NUCLEAR REGULATORY COMMISSION
OFFICE OF INSPECTION AND ENFORCEMENT
REGION III
Report No. 50-440/79-03; 50-441/79-03
~
Docket No. 50-440; 50-441
License No. CPPR-148; CPPR-149
Licensee: The Cleveland Electric Illuminating
Company
P. O. Box 5000
Cleveland, OH 44101
Facility Name: Perry Nuclear Power Plant, Units 1 and 2
Inspection At: Perry Site, Perry, Ohio
Inspection Conducted:
July 10-12, 1979
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Inspectors:
Hu
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H. H. Livermore
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D .' 4fayes, Chief
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N 3 / /'77
Approved By:
Engineering Support Section 1
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Inspection Summary
Inspection on July 10-12, 1979 (Report No. 50-440/79-03; 50-441/79-03)
Areas Inspected:
Licensee action relative to previous items of noncompliance
sad unresolved items (Units 1 and 2); ongoing construction activities
(Units 1 and 2); concrete placement inspection activity (Unit 1); QA
implementing procedures relative to instrumentation components at l systems
(Units
and 2); installation of safety related components; work activities
relative o reactor coolant pressure boundary, safety related pipe and
welding (Units 1 and 2).
The inspection involved a total of 88 onsite
inspector-hours by four NRC inspectors.
Results:
Of the areas inspected, two items of noncompliance were identified
in two areas (infractions - (1) inadequate inspection of installation of
safety related components - Section III, Paragraph 2; (2) inadequate
protection, storage and maintenance of safety related components - Section
III, Paragraph 3).
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DETAILS
Persons Contacted
Principal Licensee Employees
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- M. Edelman, Managee, Nuclear QA Department
- G. Groscup, Manager, Nuclear Engineering Department
- D. Fitzpatrick, Site Construction Manager
- W. Kacer, CQS General Supervising Engineer
- A. Kaplan, General Supervisor Construction
S. Tulk, CQS Lead Electrical Quality Engineer
Other Personnel
- P. Gibson, CQS Quality Control Supervisor (KEI)
- R. Vondrasek, CQS Quality Engineering Supervisor (GAI)
J. Connelly, CQS Lead Civil Quality Engineer (GAI)
R. Croftman, CQS Lead Piping Quality Engineer (GAI)
W. Ware, CQS Civil Quality Engineer (GAI)
- G. J. Presby, CQS Mechanical Quality Engineer (GAI)
W. Eiff, CQS, Civil Quality Engineer (GAI)
R. Czyzewski, CQS Civil QC Inspector (KEI)
R. Mauchline,
- E. V. Knox, Quality Assurance Manager (KEI)
N. R. Barker, Quality Assurance General Manager (GAI)
D. F. Cooper, CQSS Supervisor (KEI)
J. Miller, Quality Assurance Manager (Pullman)
R. Skidmore, Quality Control Supervisor (NNI)
D. Codney, Maintenance Supervisor (NNI)
R. Shelton, Field Engineer (NNI)
J. W. Mehaffey, GAI, QE
T. Bradshaw, GAI, QE
J. Staffiera, NNI, QA Manager
D. Basile, NNI, QC Manager
R. T. Durand, NNI, NSSS Manager
D. Dervay, NNI, NSSS Engineer
T. E. Bond, NNI, QA/QC Operation Manager
W. F. Newell, NNI, Welding Engineer
- K. S. Zidek, CQE Department Secretary (GAI)
- Denotes those who attendend the exit interview.
The insper tors also contacted other licensee and contractor employees,
including members of the quality, technical and engineering staffs.
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Licensee Action on Previous Inspection Findings
(Closed) Noncompliance (440/77-07-09; 441/77-07-09): Newport News records
for inspection / test devices not containing necessary information to
ascertain traceability to the National Bureau of Standards or equivalent.
The inspector reviewed Newport News revised Instruction 701-NC-S1 (Rev. F)
and spot checked the most current calibration records for inspection / test
equipment and found the records to show traceability to the National
Bureau of Standards. This item is closed.
(Closed) Unresolved Item (440/79-02-02; 441/79-02-02): Numerous Corrective
Action Requests (CARS) writte i against Newport News Industrial Corporation
(NNI); reference CARS numb .ed 0450, 6'52, 0463 and 0464. On March 26
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and 27, 1979, CEI held a management meeting with NNI and as a result of
the meeting; as of May 10, 1979, all of the concerns noted in the afore-
mentioned CARS have been resolved. This item is closed.
(Closed) Unresolved Item (440/78-13-01; 441/78-12-01): Handling of
returned welding materials. The inspector reviewed the revised Pullman
Power Products (PPP) procedure No. VIII-3 and determined that handling of
returned welding materials was clarified.
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Section I
Prepared by J. Hughes
G. F. Maxwell
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Reviewed by D. W. Hayes, Chief
EngineerinF Support
Section 1
1.
Instrumentation - Implementing Procedures (Johnson Controls)
Units 1 and 2
The inspectors compared the below listed Johnson Controls
a.
Incorporated implementing procedures with the Johnson Controls
QA/QC Program, job specifications No. SP90 (Rev. II) and No.
SP709 (Rev. III).
(1) Procedure for " Indoctrination and Training of Key Personnel,"
SP-201-DNPP (Rev. 1).
(2) Procedure for " Auditor Training and Qualification,"
QAS-202-PNPP (Rev. 1).
(3) Procedure for " Design Control," QAS-401-PNPP (Rev. 1).
(4) Procedure for " Preparation and Approval'of Procedures,"
QAS-402-PNPP (Rev. 1).
(5) Procedure for " Document Control," QAS-701-PNPP (Rev. 2).
(6) Procedure for " Control of Field Questions, Field Variance
Authorization and Engineering Change Notices," QAS-702-PNPP
(Rev. 1).
(7) Procedure for " Vendor Evaluation," QAS-501-PNPP (Rev. 1).
(8) Procedure for " Weld-Rod Control," QAS-904-PNPP (Rev. 2).
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(9) Procedure for " Training and Qualification of Inspection
and Testing Personnel," QAS-201-PNPP (Rev. 1).
(10) Procedure for " Receiving Inspection," QAS-802-PNPP (Rev. 4).
(11) Procedure for " Storage of Items of Materials," QAS-1401-PNPP
(Rev. 1).
(12) Procedure for "Nonconformance Control," QAS-1601-PNPP
(Rev. 2).
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(13) Procedure for " Visual Inspection," QAS-1001-PNPP (Rev. 5).
(14) Procedure for " Liquid Penetrant Examination," QAS-1002-PNPP
(Rev. 3).
(15) Procedure for " Welding Procedure and Performance Qu,alification,"
QAS-1005-PNPP (Rev. 0)
(16) Procedure for " General Welding Requirements," QAS-1006-PNPP
(Rev. 0).
(17) Procedure for " Training and Qualification of NDE Personnel,"
QAS-1003-PNPP (Rev. 1).
(18) Procedure for " Control and Calibration Program for Measuring
and Test Equipment," QAS-1301-PNPP (Draft).
(19) Procedure for " Pneumatic Testing," QAS-1202-Pnpp (Rev. 1).
(20) Procedure for " Conditional Release of I. ems / Material,"
QAS-803-PNPP (Rev. 0).
(21) Procedure for " Handling, Rigging and Transporting of
Safety Related Items," SP-1402-PNPP (Rev. 0).
(22) Procedure for " Identification and Control of Materials,"
QAS-902-PNPP (Rev. 3).
b.
During review of licensee specifications SP-90 and SP-709, the
inspector was unable to determine how the Class IE instrument
racks were going to be identified to the channel level (example:
color coded). The inspector was informed by the licensee's
Lead Instrument Control Engineer that licensee purchased instru-
ment racks were purchased with color coding of the instrument
tubing on the racks and that all racks purchased by other
contractors will be color coded the same.
This matter will be
reviewed further during subsequent inspections (440/79-03-01;
441/79-03-01).
No items of noncompliance were identified.
2.
Observation of Concrete Work Activities and Related Quality Records
- Units 1 and 2
Pre-Placement Inspection (AX2-W13-650) - On July 11, 1979, the
a.
inspector performed a pre placement inspection of concrete
Placement No. AX2-W13-650. The placement area was located in
the Auxiliary Building II interior wall; contained approximately
200 cubic yards of concrete aid was placed by the National
Engineering Contracting Companj (NECC).
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The RIII inspector witnessed the pre placement inspection with
the NECC and CEI QC inspectors for cleanliness of the reinforcing
steel, horizontal and vertical construction joints, and formwork
in accordance with NECC procedures. The pre placement inspection
record was signed off by the NECC and CEI QC inspectors after
the pour area was satisfactorily prepared and concrete placement
commenced.
b.
Placement Inspection (AX2-W13-650)
(1) In-Process Concrete Testing
(a) United States Testing field QC personnel performed
slump, temperature and precent entrained air tests as
follows:
Ticket No.
Slump (in.)
Temp. ( F)
% Ent. Air
41030
3
68
4.0
41031
3 1/2
68
5.0
41035
4
69
--
41035
2 3/4
70
--
41044
4 1/2
71
--
41046
3 1/2
70
5.4
41048
4
70
--
41054
3 1/4
70
--
41057
3 1/4
68
--
41067
3
71
--
All test results were within the allowed limits and
performed at the frequencies specified.
(b) Field curing houses which were suitably equipped to
maintain freshly cast compressive strength cylinders
at the intital curing temperature specified by ASTM
C31 were inspected.
(c) The inspector reviewed the calibration data sheets
for the test instruments used for the aforementioned
pour as follows:
Thermometer (TH-113) due date October 9,1979; Unit
weight bucket (UW-6) due date August 3, 1979; Flow
Meter (F/M-16) due date August 8, 1979; Temperature
Record (TR-11) due date November 23, 1979.
(2) Delivery and Placement
(a) Concrete was pumped to the placement area and deposited
via concrete drop chutes which adequately confined
the concrete to a maximum five foot free fall.
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(b) Concrete was observed to be properly consolidated
using internal concrete vibrators which had been
checked to verify the 8000 VPM required by ACI 301-72,
Chapter 8.
These checks had been documented on the
NECC placement checklist as required by NECC procedures.
c.
Post Placement Inspection
.
On July 12, 1979, the inspector observed that the curing of
pour AX2-W13-650 for moisture, temperatures (concrete and
ambient) were in accordance with specification SP-201.
No items of noncompliance were identified.
3.
Other Areas Inspected
During the inspectors tour of the plant it was observed that several
cable trays when welded to the cable supports (hangers) where burned
through to the inside of the cable pans; the galvanize material was
blistered. The inspector asked the licensee if these blistered
areas would be wire brushed and re painted with galvanizing material.
The licensee informed the inspector, that they would add this item
to there checklist prior to final inspection of the cable tray
systems.
This matter will be reviewed during a subsequent inspection.
(440/79-03-02; 441/79-03-02)
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Section II
Prepared by E. W. K. Lee
Reviewed by D. H. Danielson, Chief
,
Engineering Support
Section II
1.
Reactor Coolant Pressure Boundary Piping - Review of QA Procedures
(Units 1 and 2)
The inspector reviewed Newport News Industrial arporation (NNI)
Nuclear Quality Assurance Manual, Rev. C, dat a October 10, 1978,
included Perry Addenda B, dated April 18,10.3, nine NNI procedures
and one General Electric Company procedure relative to reactor
coolant pressure boundary piping activities.
The documents reviewed
included document control; receiving inspection; identification;
handling; storage; cleanliness control; erection and installation;
generation and record keeping. The inspector determined that the QA
Manual and the procedures meet the PSAR commitments, 10 CFR 50,
Appendix B and the applicable code requirements.
It was further
determined that the procedures meet the QA Manual requirements.
No items of noncompliance or deviations were identified.
2.
Reactor Coolant Pressure Boundary Piping (Welding) - Review of
QA Procedures (Units 1 and 2)
The inspector reviewed Newport News Industrial Corporation (NNI)
Nuclear Quality Assurance Manual, Rev. C, dated October 10, 1979,
included Perry Addenda B, dated April 18, 1979, 14 NNI procedures
relative to the welding activities of reactor coolant pressure
boundary piping.
The documents reviewed included control of weld
data sheets including hold points; qualification of welding procedures,
welders and inspection personnel, calibration of equipment; repair
of defects and control of welding materials. The inspector determined
that the QA Manual and the procedures meet the PSAR commitments, QA
Manual, 10 CFR 50, Appendix B and the applicable code requirements,
except the following:
a.
Acceptance criteria for undercut of welds needs to be certified.
b.
Qualification requirements for Level III NDE personnel need to
be addressed.
The inspector stated that this matter is considered unresolved
pending a review of the revised procedures.
(50-440/79-03-03;
50-441/79-03-03)
No items of noncompliance or deviations were identified.
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3.
Safety Related Piping - Welding Material Control (Units 1 and 2)
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a.
Review of Documents
The inspector reviewed the following documents:
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(1) Pullman Power Products (PPP) procedure No. VIII-3, dated
Februa ry 20, 1979, " Control of Welding Materials."
(2) PPP procedure No. VI-5, dated March 27, 1979, " Control of
Process Sheets and Weld Rod Stores Requisitions."
(3) PPP procedure No. IV-502, dated April 29, 1977, " Purchasing
Specification fcr Corrosion - Resisting and Chromium-Nickel
Steel Covered Arc Welding Electrodes."
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(4) PPP procedure No. X-5, dated May 25, 1978, " Field Receiving
Inspection Procedure."
(5) Receiving Inspection Report, Material Certifications and
Purchase Order for E308L-16 electrodes with Heats No.
761127 and No. 761407; E309-16 electrodes with Heats No.
743288 and No. 743244; ER308L welding rod with Heats No.
776983 and No. 742487; ER309 welding rod with Heats No.
741994 and No. 744153; E70S-2 consumable inserts material
with Heat No. 3789B131; and E7018 electrodes with Heats
No. 401B4021 and No. 432A7641.
It was determined that the above documents met the PSAR, 10 CFR 50,
Appendix B and the applicable code requirements.
b.
Control of Materials
The inspector toured PPP welding material issuing station
located at the control complex.
It was determined that (1) the
welding materials are properly identified and segregated; (2)
the temperature of the rod ovens is maintained; (3) records are
properly kept; and (4) issuance and return of welding materials
are controlled in accordance with approved procedures.
No items of noncompliance or deviations were identified.
4.
Safety Related Piping - Observation of Welding Activities (Unit 1)
The inspector observed the following welding activities:
Essential Service Water System Weld No. 05 on Isometric No.
a.
1-P45-24.
b.
Control Complex Chilled Water System Weld No. 06 on Isometric
No. 0-P47-3.
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c.
Essential Service Water System Weld No. 07 on Isometric No.
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1-P45-20.
It was determined that (1) work was conducted in accordance with
traveler; (2) proper welding materials were used; (3) welding procedure
requirements vete met; (4) work area was free of rod-stubs; and (5)
physical appearance was acceptable.
No items of noncompliance or deviations were identified.
5.
Safety Related Piping - Visual Examination of Welds (Unit 1)
a.
Visual Exanination
The inspector visually examined the following completed welds:
(1) Condensate Transfer and Storage System Weld No. 7 on
Isometric No. 1-P11-8.
(2) Essential Service Water System Weld No. 21 on Isometric
No. 1-P45-1.
(3) Low Pressure Core Spray System Weld No. 06 on Isometric
No. 1-E21-6.
(4) High Pressure Core Spray System Welds No. 9 and No. 8 on
Isometric No. 1-E22-7.
It was determined that (1) weld surface finish and appearance
were acceptable and there was no evidence of wall thinning due
to grinding; and (2) arc strikes and weld spatter were not
evident.
b.
Review of Records
The inspector reviewed weld data sheets for the above welds.
It was determined that (1) the records indicated specified
inspections were completed and (2) records are clear and legible.
No items of noncompliance or deviations were identified.
6.
Safety Related Piping - Observation of NDE Work Activities (Unit 1)
The inspector observed liquid penetrant examination of Essential
Service Water System Weld No. 5 on Isometric No. 1-P45-20.
It was
determined that:
(1) surface condition was acceptable, (2) procedure
requirements were met and (3) personnel were properly qualified.
No items of noncompliance or deviations were identified.
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7.
Safety Related Piping - Welder Qualification (Unit 1)
.
The inspector reviewed the following documents:
PPP procedure No. II-8 dated May 12,1978, " Welder Performance
a.
Qualification."
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b.
Qualification records of welders performed welJing on welds
stated in Paragraph 4 of this report.
The inspector determined that the above documents met the requirements
of ASME &PV Code,Section IX.
No items of noncompl.ance or deviations were identified.
8.
Safety Related Piping - Observation of Work and Work Activities
(Units 1 and 2)
The inspector toured the pipe storage area.
It was determined that
(1: spools are identified; (2) spools are resting on dunnage and (3)
ends are covered.
No items of noncompliance or deviations were identified.
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Section III
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Prepared by H. H. Livermore
Reviewed by D. H. Danielson, Chief
.
Engineering Support
Section 2
Functional / Program Areas Inspected
1.
The areas inspected were:
Reviewed four installation procedures of safety related components
a.
to ascertain if installation and inspection signoffs met applicable
specifications and established procedures.
b.
Visually inspected four assemblies of safety related components
to insure compliance with applicable requirements for handling,
storage and maintenance.
Visually inspected two components of safety relattj equipment
c.
and their records to insure required maintenance inspections,
audits, and records are per applicable requirements.
2.
A review of four (4) Newport News Industrial (NNI) installation
procedures revealed the following:
Note: These procedures are for installation / inspection of safety
related equipment in Units 1 and 2
- iliary Building.
Procedure 1240-NC-IO10, Manu
ing Installation Instruction
a.
(hII), the installation and
etion of six (6) RHR discharge
heads and suction barrels,
a z LPCI discharge heads and
suction barrels.
(Items 1E12-C002A, B, and C; 2E12C002A, B,
and C and I and 2E21C001.)
(1) In steps 10 through 180 there were 17 instances of a QC
signoff without a prior Trade Supervision signoff (2E21-C001).
(2) In Operation Step 305 where specifically indicated that QC
required, there were no QC signatures on completed work
for Unit 1 RHR A, B, and C and Unit 1 and 2 LPCI (5 instances).
There was no indication on the procedure of any Nonconformance
Report information/ action.
(3) Operation Steps 320-450 indicate "QC Required" for the
complete grout operation. No QC signatures were present
for 37 completed work steps (except noted IE21-C001). No
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nonconformance information was noted in these steps.
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Seven (7) steps in the grout operation for LPCI 1E21-C001
were signed off, but were signed one half month prior to
the trade supervision signoffs (June 6,1979, versus
May 17, 1979).
(4) QC Required is indicated on Operation Steps 460, 47'O and
475 alignment of head and barrel for RER 1E12-C002B.
There are no QC sign ffs for the completed work. There is
no indication of any related nonconformances (NCR).
b.
Procedure MII 1240-NC-IOO9, Baseplate Mod / Installation for
Control Complex Chiller, P/N P47B001A, B, and C (Safety Related).
Step 40.
QC signature signed 3 days before Trade Supervision
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signoff for completed work.
c.
MII Procedure 1240-NC-IO05, Unit 1 Reactor Pressure Vessel
Installation.
(1) Steps 130 and 300 (Vessel alignment and installation
preps) are signed off by QC only.
No Trade Supervision
signoff is present. These steps involve dowel alignment,
lubrication, and completion of vessel preparations for
installation.
(2) From Operation Step 490 and on (through 600 etc.), there
are no signoffs although work is complete.
No reference
to any other document is present.
(The work involved was
reactor vessel alignment.)
(3) Step 610 requires completion of MMI 1240-NC-1006, Anchor
Stud Installation. There is no signoff by Trade or QC,
although this procedure has been completed.
d.
MII Procedure 12' - C-I0O6 Rev. A, Reactor Pressure Vessel
n
Anchor Stud Installation.
Signoffs on this procedure appeared
to be complete.
The above conditions (except Paragraph d.)are considered to be in
noncompliance with Criterion X of 10 CFR 50, Appendix B; Chapter 17
of Perry PSAR Section 17.1.10; and Newport News Industrial ASME
Nuclear QA Manual Rev. C, October 10, 1978, Section 10.1500.
(440/79-03-04; 441/79-03-04)
3.
A visual inspection of safety related equipment installation in
Unit 1 Auxiliary Building indicated the following:
a.
1E12-C002C RHR discharge head and suction barrel.
Two of fcur
connecting flanges were not protected or sealed.
The machined
mating surfaces were not protected by caps or covers of any
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kind. Visible coatings of rust were on all the internal surfaces
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of the discharge head. Visible rust was present on the two
exposed flange surfaces.
Installation stud threads were exposed
and unprotected from possible damage.
(The stud interfaces
were located on the floor for the barrel and on the discharge
head at motor interface.)
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b.
1E21-C001 LPCI discharge head and suction barrel. Three of
four connecting flanges were not protected or sealed. Same as
Item a. above. Rust was visible internally and on mating
flanges as previously noted in Item a.
Equipment in same
condition as Item a.
c.
IE51-C001 and C002 RCIC pump and turbine. The equipment was in
a temporary place of storage in a framed plactic enclosure for
temperature stabilization purposes.
The required space heater was not operating at the time of
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inspection (July 10, 1979 AM). The attached maintenance
record indicated that it was satisfactorily operating that
morning. The heater was working the next day, but the
enclosure was open at one end, thus, cancelling all heat
retention capabilities.
d.
An NNI maintenance inspection on the previously noted equipment
was performed and recorded on the morning of July 10, 1979,
just prior to the NRC visual inspection of July 10, 1979.
The
presence of rust, the exposed unprotected flanges, and the
unsealed internal openings on the RHR and LPCI discharge heads
were not recorded, nor was the absence of heater operation on
the RCIC pump, as is required by NNI Procedure 1240-F-S002
Paragraph 7.1.
There was nothing recorded in the special
comments / problem section of the maintenance form, nor was there
any reference to any Nonconformance Report. The NRC inspector
also observed that the duplicate Maintenance Record Forms 3155
and 2095 attached to the equipment (IE12-C002C and IE21-C001)
were not filled out correctly to the forms requirements (in ink
and full name). Also noted was that the duplicate form attached
to the equipment did not contain the same information as on the
original record copy (office) as required by NNI Procedure
1240-F-S002, Enclosure 1, Paragraph 3.2.5.1.
Recorded entries
were missing on the original, and the inspection dates did not
coincide.
The above conditions are considered to be in noncompliance with
Criterion XIII of 10 CFR 50, Appendix B; the Cleveland Electric
Illuminating (CEI) Corporate QA Manual, Introduction Section and
Section 1300; CEI Contract Specification SP 38-4549-00, Paragraph
5:06.2.c; American National Standard ANSI N45.2.2 Sections 3 and 6;
and Newport News Industrial Equipment Maintenance Instruction
1240-F-S002 Section 7 and Enclosure 1.
(440/79-03-05; 441/79-03-05)
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Unresolved Items
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Unresolved items are matters about which more information is required in
order to ascertain whether they are acceptable items, items of noncompliance,
or deviations. An unresolved item disclosed during the inspection is
discussed in Section II, Paragraph 2.
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Exit Interview
The inspectors met with site staff representatives (denoted under Persons
Contacted) at the conclusion of the inspection on July 12, 1979.
The
inspectors summarized the purpose and findings of the inspection.
Each
of the noncompliance items in Appendix A was identitied and discussed.
The licensee acknowledged the findings reported herein.
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