ML19256A330
| ML19256A330 | |
| Person / Time | |
|---|---|
| Site: | Wolf Creek  |
| Issue date: | 11/29/1978 |
| From: | Crossman W, Gilbert L, Mattia J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19256A323 | List: |
| References | |
| 50-482-78-12, NUDOCS 7901050036 | |
| Download: ML19256A330 (11) | |
See also: IR 05000482/1978012
Text
U
S. flUCLEAR REGULATORY COMMISSIO?1
0FFICE OF ItiSPECTIO1 A:iD ENFORCEMEilT
REGIOt1 IV
Report f;o. STil 50-482/78-12
Docket flo. STN 50-482
Category A2 ,
Licensee:
Kansas Gas & Electric Company
Post Office Cox 208
wichita, Kansas
67201
Facility flame:
Wolf Creek, Unit fio.1
Inspection at:
Burlington, Coffey County, Kansas
Inspection conducted:
flovember 6-9, 1978
Inspectors:
-
// f!7F
1 L. D. Gilbert, Reactor Inspector, Engineering
Date'
Y'
Support Section (Paragraphs 1, 2, 3, 7 & 8)
xh
y/h?^
y
[<d.C.Mattia,ReactorInspector, Region 1
Date
(Paragraphs 4 & 5)
.
!
p/ubi
t. E. Martin, Reactor Inspector, Engineering Support
Date
,,/g Section (Paragraph 6)
Reviewed),
[N6$ -
// E9f78
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MC. R. Oberg, Reactor Inspector, Projects Section
Date
/
Approved:
[ M [ % -
//!29
8
W. A. Crossman, Chief, Projects Section
Date
i
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// _Lff
R. f. Hall, Chief, Engineering Support Section
Date '
790105CDS4
Inspection Summary:
Inspection on f;ovember 6-9,1978 (Report !!o. STil 50-482/78-12)
[ Areas Inspected:
Routine, unannounced inspection of construction activ-
ities including review of quality implementing procedures, observation of
work, and review of records relating to safety related structures; review
of records relating to reactor vessel supports; review of quality imple-
menting procedures relating to safety related components; and review of
procedures and records and observation of work relating to Class IE cable
and electrical equipment receiving and storage activities. The inspection
involved sixty-nine inspector-hours by three flRC inspectors.
Results:
Of the five areas inspected, no items of noncompliance were
identified in three areas. One item of noncompliance was identified
in each of the other two areas (infractions - failure to control special
processes - paragraph 3.a; and failure to follow approved procedures -
paragraph 6).
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DETAILS
1.
Persons Contacted
Principal Licensee Personnel
- M. E. Clark, Manager, QA-Site
- G. W. Reeves, QA Engineer
- D. W. Prigel, QA Engineer
Daniel International (DI) Personnel
- W. E. Hi tt, Project Manager
- C. T. Kinney, Construction Manager
- G.
W. Pointer, Assistant to Project Manager
- I. Hussain, Assistant to Project Manager
- A. S. Harper, Engineering Manager
- M. E. Tanner, Service Manager
- D. L. Jones, QC Manager
- V. J. Turner, QA Manager
- D. J. Dennison, QC Engineer
T. Green, Civil QC Manager
L. Truelove, QC Training Coordinator
E. Taylor, Chief, Field Engineer
D. Goetz, Survey Party Chief (Reactor Building)
E. Dixon, QC Services Engineer
L. Feldkamp, Field Maintenance Foreman
C. Delong, Warehouse Maintenance Foreman
C. Perry, QC Receiving Inspector
E. Cheary, QC Lead Receiving Inspector
C. A. Gukeisen, Area Engineer
Bechtel Personnel
R. C. Shovil, Mechanical Liaison Engineer
G. Mutwell, Site Liaison Engineer
Richmond Engineering Company (RECO) Personnel
B. W. Dillard, QC/QA Manager
The IE inspectors also contacted other construction personnel in-
cluding members of the technical and engineering staffs.
- denotes those present at the exit interview.
-3-
P. .
Site Tour
The IE inspectors walked through the various construction areas
to observe construction activities in progress and to inspect
the general state of cleanliness and adherence to housekeeping
requi remen ts.
During the walk through, one of the IE inspectors observed that
the beam shelf brackets for the accumulator base structure con-
tained dimensional and fillet weld inconsistencies.
It was later
determined that the inconsistencies had been documented on Deficiency
Report 1500 901C and Daniel Surveillance Report (11/1/78) and final
acceptance was pending resolution of these items.
The IE inspector
hdd no further questions concering the beam shelf brackets.
Another IE inspector, during the walk through, observed that ncne
of the space heaters for the IE electrical equipment stored in
place were energized. This subsequently resulted in an item of
noncompliance as noted in paragraph 6.d.
3.
Safety _ Rel ated gructures
a.
Review of Implementing Procedures
The IE inspector reviewed the RECO Quality Assurance manual,
Revision 7 and the following implementing procedures for
compliance with KG&E/Bechtel Contract 10466-M-109(Q)-1-C:
Procedure
Title
Fl/ASA-2C-1, Rev. 3
SAW - Auto
Pl/MMA-1, Rev. 2
SMAW - Manual
ES-123, Rev. 2
Weld Repair Procedure
ES-106N, Rev. 8
Radiographic Examination
ES-107 tlc, Rev. 2
Liquid Penetrant Examination
Procedure ES-106N does not contain the requirement of flD-5420(b)
of the ASME Code,Section III,1974 edition through Winter 1975
Addenda to take additional spot radiography as needed to include
each welder.
Review of spot radiograph records did not reveal
any noncompliance with the code requirement; therefore, this item
is considered unresolved pending issuance of a procedure change
containing the noted requirements.
-4-
Procedures controlling welding do not include the requirements
of HD-4400, in that cleanliness and protection of welding
surfaces, as well as peening, have not been specified.
Two seams on each tank, Seam 16 and 23 on Job 233 and Seam 19
and 20 on Job 238, were observed by the IE inspector for evidence
of base metal cleaning prior to welding.
There was no evidence
that the base metal had been cleaned of mill scale prior to
welding on any of the four seams.
Seam 20 was in the process of
being welded and the other three seams were in the final welded
condition.
This is an apparent item of noncompliance, in that measures
were not established to assure that special processes were
controlled and accomplished in accordance with paragraph N04412
of the ASME Code,Section III,1974 edition through Winter 1975
Addenda.
b.
Observation of Work
The IE inspector observed the automatic submerged arc welding
of Seam 20 on the emergency fuel oil storage tank, Dwg. D-76-83,
for Job No. RCN 238.
Welding parameters and materials observed
were in compliance with Weld Procedure Specification Pl/ASA-2C-1.
The welder qualification documentation was consistent with
Section IX of the ASME Code.
No items of noncompliance or deviations were identified.
c.
Review of Records
The IE inspector reviewed the records for making and examining
Seam 16 on Job RCN-233.
The records documented the fitup in-
spection, welding procedure specifications, welders, filler
metal, root and final visual inspection, spot radiography, repair
welding, and re-radiography.
In the areas inspected, no discre-
pancies from the requirements of Sections III and IX of the ASME
B&PV Code were noted.
The RECO Audit Report of July 21, 1978,
was reviewed and contained records to indicate canagement review
and that proper, timely and adequate corrective action had been
taken.
Two nonconformance reports were reviewed and found to be
complete, legible, and properly closed out.
No items of noncompliance or deviations were identified.
-5-
4.
Records R2 View of Reactor Vessel Supports
The IE inspector verified that provisions of the Cechtel Technical
Specifications 10466-C202 and C202(a), Drawings C-052930 and C-052931;.
and the PSAR commitments were being adhered to in the following areas:
a.
lUnufacturer's Rocords and Site Receiot Insoection Recorts
In addition to a visual inspection of the installed reactor
vessel supports, the IE inspector reviewed the following records:
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Material Receiving Report (MRR) flo.15984
-
Receipt Inspection Report for MRR No.15985 (dated 5/17/78)
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Supplier's Deviation Disposition Reports flo. 5, 43, 8, 10,
27, 33 and 36
-
Coating Inspection Records dated 3/13/78, 4/27/78 and
5/10/78
-
Magnetic Particle Examination Reports for pieces numbered
2100-1, 2200-2, 2300-1, 2400-2 and 2500-1
-
Material Test Report for A533 material (Heat Code AOU, CQU
and CQV)
-
Welding Material Test Reports for E10018 electrodes (Lot No.
22722)
-
Heat Treatment Records for furnace loads flo. 283 and 300
-
Ultrasonic Testing Report far A533 plate material (Heat flo.
A5729)
flo items of noncompliance or deviations were identified.
b.
Installation and Inspection Records
The IE inspector examined the following records associated with
the installation of the reactor vessel supports:
-
Nonconformance Reports fio. I-0524 and 0541
-
Nondestructive Testing Reports ilo. PBT-MT-172 and 173
-
Pre and Post Placement QC Records for Concrete Placement
No. DC231W20
-6-
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Survey Field flotebooks ilo. 53 and 74
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Qualifications of inspector
ilo items of noncompliance were identified during the review of
the above documents; however the IE inspector informed the
licensee that the constructor's procedure QCP-IV-105, which
involves the inspection of embeds prior to concrete placeirent,
did not reference the Bechtel Technical Specification C202(a)
for the erection of embeds and restraints.
The licensee stated
that the procedure will be revised to incorporate this technical
speci fi cation. This item is unresolved pending review of the
revised procedure.
S.
Review of QA Implementing Procedures for Safety Relai.ed Components
The IE inspector determined that appropriate and adequate procedures
have been established to assure that the following activities asso-
ciated with safety related compo^ents are controlled and performed
in accordance with flRC requirements and PSAR cotanittrents:
-
Receipt inspection and storage of components
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Installation, testing and inspection activities
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Lifting and handling of components
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Post-installation cleaning, storage in-place and maintenance of
components
The following constructor's procedures were reviewed by the inspector:
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Quality Control Procedure I-01 (Revision 3)
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Quality Control Procedure VI-200 (Revision 0)
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Quality Control Procedure VI-201 (Revision 0)
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Work Procedure I-01 (Revision 5)
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Work Procedure VI-200 (Revision 0)
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Work Procedure VI-201 (Revision 0)
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Work Procedure IV-110 (P,evision 2)
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Administrative Procedure VIII-02 (Revision 2)
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Administrative Procedure VIII-05 (Revision 2)
L7 items of noncompliance or deviations were identified.
6.
Class TE Cable and Electrical Ecuicment Receiving and Storage
The IE inspector reviewed the following procedures and records per-
taining to receiving, storage and handling of Class IE cable and
electrical equipment:
QCP-I-01, Rev. 3, 8/16/78 " Receipt, Storage, and Preservation of
Safety Related Materials and Items"
AP-VIII-05, Rev.1, 7/5/77, " Material Storage and Control"
AP-VI-03, Rev.1,1/14/77, " Material and Equipment Receiving
Inspection and Status Control"
WP-I-02, Rev. O, 9/13/76, " Calibration of Specific Test and
Inspection Instruments and Equipment"
QCP-I-02, Rev. 2, 7/14/78, " Calibration of Specific Test and
Inspection Instruments and Equipment"
AP-VI-04, Rev.1, 6/14/78, " Calibration and Control of Construction
Instrumentation and Tools"
AP-VIII-02, Rev. 2, 3/20/78, " Material and Equipment Receiving"
WP-XI-302, Rev.1,12/8/77, " Protection of Electrical Equipment"
Purchase Order No.10466-E-057-1
Purchase Order No. 236931
Receiving Maintenance Instruction - 205H, Rev. 6
Receiving Maintenance Instruction - S-002, Rev. 2
Receiving Maintenance Records for Centrifugal Charging Pump Motors
PBG05A and PSG058
-8-
.
Results of this review were:
The IE inspector inspected the cable storage area and the Class
a.
B storage area for electrical equipment.
Four reels of cable
and two Centrifugal Charging Pump Motors were cross-checked
against receiving records to verify that IE cables and equipment
were properly identified and nonconforming equipment was separated
and identified as being on hold.
No items of noncompliance or deviations were identified.
b.
The IE inspector reviewed P.O.s No. 10466-E-057-1 and 236931.
Receiving records were complete and nonconforming items were
indicated and docunented with DRs and properly placed on hold.
No items of noncompliance or deviations were identified.
The IE inspector reviewed administrative, quality control and
c.
work procedures associated with receiving, storage and handling
of IE electrical equipment and cable for compliance with 10 CFR 50, Appendix B and ANSI M45.2 and its sister standards.
No items of noncompliance or deviations were identified.
d.
The IE inspector reviewed maintenance instructions and records
for the Centrifugal Charging Pump Motors PBG05A and PBG05B as
a result of finding the space heaters for these motors de-ener-
gized during plant tour.
The IE inspector's review of receiving maintenance records for
motors PBG05A and PBG05B indicated that the megger tests for
both motors were being done quarterly with one isolated exception;
and that shaft rotation and checking of space heaters were being
done quarterly on the A pump, but not at all on the B pump.
(1) QCP-I-01, Appendix I, Rev.1, paragraphs 9 and 9.6 require
that space heaters be continuously energized and monthly
inspections be made and documented.
WP-XI-302, Rev. 1, paragraph 3.6 requires a weekly check
of the operation of space heaters in electrical equipment.
The space heaters were found de-energized and the RMI records
failed to indicate that inspections and checks were being
made.
_9_
.
The licensee took immediate action to have the space
heaters -for the electrical equipment energized and
provided a more pennanent cabling arrangement to pre-
clude i:: advertent disconnection.
This is a partial
resoluticn of this example.
(2) The IE inspector reviewed P14I-205H, Rev. 6 and PJil-S-002,
Rev. 2, and found that these maintenance instructions
did not meet the requirements of the manufacturer's in-
struction book (I.B.) No. 236930 with regard to shaft
ro tati on.
The RMI required meggering every ninety days,
but did not include shaf t rotation requirements. The
manufacturer's instruction book requires shaft rotation
every thirty days to prevent rusting and corrosion of
bearings.
This is also a requirement in ANSI 45.2.2,
" Packaging, Shipping, Receiving, Storage and Handling of
Items for Nuclear Power Plants," - 1972.
Procedures
WP-XI-302 and QCP-I-01 require maintenance to be per-
formed in accordance with manufacturer's instructions or
every six months.
Discussions, between the IE inspector
and the Area Engineer responsible for these instructions,
indicated that this was an inadvertent omission in the
current procedures; and that previous revisions of these
instructions had met the manufacturer's requirements.
He
indicated that a revision would be initiated to correct
the error to comply with QCP-I-01.
(3) Review of RMI records for compliance with RMI-205H, Rev. 5
and RMI-S-002, Rev.1 revealed that, during the time (ap-
proximately eight months) that the requirement for shaft
rotation had been specified as thirty days, the maintenance
,
had only been performed and inspected at a ninety day
interval.
The above are examples of failure to follow approved procedures
as required by 10 CFR 50, Appendix B, since these criteria re-
quire that activities affecting quality shall be accomplished
in accordance with instructions and procedures developed for
these activities.
7.
Unresolved Items
Unresolved items are matters about which more information is required
in order to ascertain whether they are acceptable items, items of
noncompliance, or deviations.
Two un esolved items disclosed during
the inspection are discussed in paragraphs 3 and 4.
-10-
.
8.
Exit Interview
,
The IE inspectors met with licensee representatives (denoted in para-
graph 1) at the conclusion of the inspection on November 9,1978.
The IE inspectors summarized the purpose, scope and findings of the
inspection.
The licensee representatives acknowledged the statements
by the IE inspectors with regard to the items of noncompliance and
toe unresolved i tems.
.
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