ML19210B599
| ML19210B599 | |
| Person / Time | |
|---|---|
| Site: | Crane  |
| Issue date: | 04/14/1972 |
| From: | Folsom S, Howard E, Varela A NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML19210B596 | List: |
| References | |
| 50-289-72-04, 50-289-72-4, 50-320-72-01, 50-320-72-1, NUDOCS 7911110034 | |
| Download: ML19210B599 (8) | |
See also: IR 05000289/1972004
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U. S. ATOMIC ENERGY COMMISSION
DIVISION OF COMPLIANCE
REGION I
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CO Inspection Report No. 50-289/72-04 and 50-320/72-01
Subject:
Metropolitan Edison Company
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Three Mf?.e Island Units 1 and 2
License Tc. CPPR-66
1location: Near Middletown, Pennsylvania
Priority
Unit t-B
Category Unit 2 - A
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Type of Licensee:
Type: of fInspectf.on: Special, Announced
'D' tes of. Inspection:
March 9, 1972
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Dates of' Previous Inspection:
February 16, 1972
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Pi-incipal Idspector:
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S.IA..:Folsom, Reactor Inspector
Accompanying. Inspectors:
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A..A.
Varela, Reactor Inspdctor
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H. E. H. Schierling (DRL)
Other Accompanying Personnel:
D. F. Sullivan (DRS) __.
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R. L. Cudlin (DRL)--------
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Date
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- Reviewed By:
, M, Myur:::44
g.fg.72
E. M. Howard, Se*1 Lor Reactor Inspector
Date
- NONE
Proprietary Infor=ation:
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7911110G37
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SECTION I
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Enforcement Action
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The applicant hus failed to conform to the Unit No.1 FSAR require-
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ments governing cable routing and channel identification of redundant
engineered safeguard and reactor protective system cables between
the control' room console and the cable spreader room, and also in the
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ESF actuation cabinets.
(Section II, Paragraphs 2 and 3)
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Licensee Action on Previously Identified Enforcement Matters
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None
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Unresolved Items
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A.
Several. lighting fixtures of doubtful seismic integrity were sus-
pended directly over the batteries in the battery rooms.
(Section II, Paragraph 4)
B.
Cadwelding. on the. Unit i containment ring girder exhibited numerous
defects.
(Section II, Paragraph 5 and Section III, Paragraph 5)
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Status of Previously Reported Unresolved Items
A1 The review off the dynamic stress analyses on the main steam and
pressurizer relief ~ valves is in progress and nearing completion.
This: item remains -unresolved.
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H.
The applicant is pursuing the documentation of valve wall thick-
ness information.
Discrepancies of an unspecified nature are
currently being investigated. This item remains unresolved.
C.
The repair work on Unit 1 containment ring girder is still in
progress, with four out of an estimated 22 concrete placements
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completed.
(Section III, Paragraphs 1-5)
Design Changes
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None
Unusual Occurrences
None
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Fersons Contacted
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Metropolitan Edison Company /GPU
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Mr. R. W. Heward, Jr., Project Manager *
Mr. B. G. Avers, QA Manager *
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Mr. J. R. Thorpe, Licensing Engineer *
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Mr. T. E. Hreczuch, Resident Mechanical Engineer *
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Mr. J.
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Wright, Resident Civil Engineer *
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Mr. D. .H.
Reppert, Safety and Licensing Health Physicist *
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Mr. W. F. Schmauss, Electrical Engineering Manager *
Mr. W. T. Gunn, Project Engineer, Unit 1*
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United Engineers and Constructors (UE&C)
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Mr. G. Ferguson, Project Superintendent *
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Mr. R. W. Liscom, QC Electrical Engineer *
Mr. J; C. McKee, Assistant Project Superintendent, Unit 2
Mr. W. Ecugen, Ring Girder Repair Supervisor
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Mr. R. Moyer, QC Supervisor
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Mr. H. Finlan, QC Welding
Mr. P. Dailey, QC Structural
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Babcock & Wilcox (B&WT
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Mr. J; E. Hill *
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Gilbert Associates (GAI)
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Mr. W. F; Sailer, Project Manager *
Mr. E. Stauffer, Electrical Design Supervisor *
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Mr. J. M. Smith, Project Electrical Engineer *
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Mr. V. H. Williams, Instruments Engineer *
Management Interview
The following items were discussed on March 9, 1972:
A.
The inspector requested information on the status of the review of
the dynamic stress analyses on the main steam and pressurizer safety
and relief valves on Units 1 and 2.
The applicant stated that the
review was underway and nearing completion.
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- Attended Management Interview
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B '. The itispector stated that la i.he exainlaatica of the Unit 1
electrical installation the following items 'ere observed:
1.
There is no evidence of color coding ta ensure redundant
channel separation in that portion of the cable installation
between the control room and the cable spreading area in the
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room below.
(Section II, Paragraph 2)
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2.
There was no evidence of three color coded separate channels
feeding from the three sensors to the ESF logic cabinets.
(Section II,_ Paragraph 3)
3.
Fluorescent lighting fixtures of questionable seismic integrity
had been observed directly above the batteries in the battery
room.
The applicant acknowledged the inspector's cotaments, and stated
.that each item would be examined and corrective action taken
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where required.
C.
The inspector stat'ed that several instances of apparently unsatis-
fsetory cadwelding had been observed on the ring girder repair
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work. Excessive voids were observed at the sleeve ends.
In other
instances, metal was extruded an inch or more outside the sleeve,
indicating improper packing. The applicant stated that a number
- of.the deficiencies observed by the inspector had already been
identified as rejectable by the constructor's inspectors.
Some
difficulty in maintaining desired cadwelding quality was acknowledged,
but the applicant agreed to review the cadwelding quality control
program for adequacy.
(Section II, Paragraph 5)
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Erepared by:
S. A. Folsom
Additional Subiects Inspected, Not Identified in Section I. Where No
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Deficiencies or Unresolved Items Were Found
1. . General
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Status of Construction
The applicant reported the following:
Unit 1
Unit 2
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Construction Percent Completion
78
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Start of;P~re-op Testing
3/72
No estimate
Fuel' Loading
2/73
7/74
Start of Commerical Operation
7/7/73
11/29/74
Electrical: Cabling Percent Completion
35
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Details of Subjects Discussed in Section I
21. Wiring. from the control console to the cable spreading area below is
vir vertical cable runs, thereby eliminating horizontal runs within
the.consolb. There was no evidence of site QA review of the separa-
tion oflthe redundant system cables in these vertical runs. No
col'or. coding was seen in the bundles of wires between the console
and the terminal strips located in the cable spreader room. There
appeared to be w idespread co-mingling of redundant wires in this
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area.
By contrast, thera appeared to be adequate scpar,tfan of
redundant cables both within the console and in the sprsader room
cable trays.
3.
The ESF actuation cabinets exhibited a lack of implementation of
the color coding and separation of the redundant instrument signal
wiring which should have had three distinct color coded sets of
conduits. At the exit interview, the applicant claimed that certain
of the containment pressure switch logic (two out of three) was
installed exterior to the ESF panels, leaving only two redundant
signals- (train A and 31 appearing at the cabinet. This statement
was not consistent with the statement that the logic for the re-
maining signals was installed in the cabinets; therefore, three
sets of conduit should have been observed.
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Ane applicaut agreed to pursue This mattar cnd tc cicrify
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which channels are actually being installed in these cabinets.
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Fluorescent lighting fixtures, each weighing 60' pounds,'were
seen to be sespended directly over the batteries in each
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battery room. The seismic integrity of these lighting fixtures
appeared questionable, presenting the possibility of their
damaging the batteries in the event of a seismic incident. The
applicant's architect-engineer stated th.at the fixtures had been
deened satisfactory to meet the seismic requirements, but agreed
to re-examine the design.
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Si cadwelding on the Unit 1 containment ring girder was observed to
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include a number of defects.
Instances of misalignment and ex-
cessive voids at sleeve ends were in evidence. Two sets of sister-
spliced rebars which were laying on the dome apparently in readi-
ness for movement to the testing laboratory exhibited excessive
sleeve-end voids. Three cadwelds had metal extruded an inch or
more beyond the sleeve due to improper or inadequate packing.
In most instances the iron workers'
foreman and the cadweld in-
spector claimed that these were known rejects, although they were
not marked as such.
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The applicant admitted that difficulty had been experienced in
maintaining . required cadweld quality and agreed to take the
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Subsequent (o.the inspection, on March 13, 1972, the inspector
was informed that a Cadweld Rebar Splices Company representative
had been call'ed to the jobsite to provide necessary cadwelding
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re-training, and a full-time cadwelding inspector had been as-
signed by the applicant.
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S;0TICM III
Prepared By:
A. A. Varela
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Additional Subjects Inspected, Not Identified in Section I, Where No
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D'eficiencies or Unresolved Items Were Found
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None
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Details of Subjects Discussed in Section I
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Ring Girder 180 North Repair
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l'. . construction Status
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Four concrete placements out of 22 total have been completed.
Their
locations are as follows:
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Segment
Azimuth Location
Lifts Placed
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I '. 15
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2 of 2
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II 30
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33
1 of 3
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3030
288
1 of 3
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No excavation or repairs have been undertaken on any Segment III
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area. Excavation in these areas is expected during April after
work on Segments I and II is completed. The first Segment III
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concrete placement is expected by the licensee to be made in May.
2.
Rebar Weld Repairs - Estimate Precentage Nicks Recaired
As of February 22, 1972, the licensee estimated percentage of nick
weld repairs on all bars was 2.227. and 0.427. on structural bars
excluding shear bars. At this inspection (3/9/72), based on total
number of critical bars covered and the number of nick-weld repairs
completed, the projection for entire repair area is as follows:
a..
Percentage of total nick-weld repairs - 1.577.
b.
Percentage of total nick-weld repairs (not including shear
bars) - 0.647.
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Summary o'f Repairs in C'omoleted 150
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Seement J.
D218/62'24
The total number of cadwelds .nade are 147 ef which 122 were in
Lift No.1 and-25 in Lift No. 2.
One bar n a nick-weld repaired
and eight butt weld rebar replacements wete performed.
Of the
latter, radiographic examination showed porosity in excess. of
Weld Procedure No. 25 requirements on five of them.
Review of
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records indicates that all eight butt welds were either replaced
with full length bars or cadweld spliced. No nick repair or butt
welds occur in Lift No. 2.
Five of seven dome tendon spirals
damaged in concrete excavation were removed and replaced with
one-inch square hoops of ASTM A441 material.
4.
Observation of Work Performance
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Work was observed in concrete excavation, ca dwelding splicing,
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grounding wire installation on trumplates, hoop welding for
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spiral replacement and moist cure of fresh concrete.
All work
observed appeared in conformance to Repair Procedure CCP-9.
5.
Record Review
A review of documentation for areas where concrete was placed
indicated conformance to Ring Girder Repair Procedure CCP-9 and
continuance of filing system identified in CO Report No. 50-289/72-03,
-- Paragraph 4,Section II.
Certain details on cadweld inspection
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reports were found different from the records reviewed at the
latt inspection. The identification of cadweld splice location
on work performed after February 17, 1972 lacked elevations. This
was spoken of in the management interview.
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