ML19261C215
| ML19261C215 | |
| Person / Time | |
|---|---|
| Site: | Zimmer |
| Issue date: | 03/01/1979 |
| From: | Daniels T, Knop R, Wescott H NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML19261C211 | List: |
| References | |
| 50-358-79-01, 50-358-79-1, NUDOCS 7903200196 | |
| Download: ML19261C215 (14) | |
See also: IR 05000358/1979001
Text
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U.S. NUCLEAR REGULATORY COMMISSION
OFFICE OF INSPECTION AND ENFORCEMENT
REGION III
Report No. 50-358/79-01
Docket No. 50-358
License No. CPPR-88
Licensee:
Cincinnati Gas and Electric Company
139 East 4th Street
Cincinnati, OH 45201
Facility Name:
Wm. H. Zimmer Nuclear Power Plant
Inspection At:
Wm. H. Zimmer Site, Moscow, OH
Inspection Conducted: January 23-26, 1979
f C b. ry//n
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H. M. Wascott v
Inspectors:
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7 o a A n .-
4" 'y ,. ,
J. Hughes
55 Ss *(
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P. Barrett
Observer:
T. H. Daniels
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Approved By:
R. C. Knop, Ch ef
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Projects Section
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Inspection Summary
Inspection on January 23-26,1979 (Report No. 50-358/79-01)
Areas Inspected: Review of quality records for Class 1 and 2 valves, NDE
records for feedwater nozzle modification, observation of work activities
and QA records for instrumentation, calibration records, electrical
testing, design change control, NDE implementing procedures, piping QA
records and nonconformance reports, weld material control, RHR system, and
50.55(e) steam jet air ejector. The inspection involved a total of 112
inspector-hours onsite by four NRC inspectors.
Results: Four items of r.oncompliance were identified in four of ten areas
inspected.
(Infractions - use of unapproved procedures,Section II,
Paragraph 5 and Section III, Paragraph 5.b; Deficiencies - inadequate
review of test procedures,Section II, Paragraph 3.b, and thermometers
not installed in weld rod ovens.Section III, Paragraph 4c.
79032001%
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DETAILS
Persons Contacted
Cincinnati Gas and Electric Company (CG6E)
R. Cooper, Service Engineer, System Turnover
J. Crowe, Startup Engineer
- B. K. Culver, Project Manager
R. P. Ehas, QA6S Engineer
H. B. Gear, General Engineer Department
- J. W. Haff, QA6S Engineer
A. Pallon, Weld and NDE Engineer
I. Plavsik, Test Superintendent
- J.
R. Schott, Station Superintendent
- W.
W. Schwiers, Principle QA&S Engineer
J. F. Weissenberg, QA&S Engineer
General Electric, Nuclear Engineering Division (G E-NED)
T. Bloom, Site Manager
Kaiser Engineers, Inc. (K&I)
S. D. Tulk, QA Engineer, Electrical
- R. F. Turner, QA Manager
Reactor Controls, Inc. (RCI)
W. Mays, Supervisor Internals Installation
- Denotes those present at the exit interview.
Licensee Action on Previous Inspection Findings
(Closed) Unresolved Item (358/78-08-02) (updated 358/78-31): Procedures
for construction testing of instrumentation. The inspector reviewed
procedure IM. SAD.01 Revision 00 dated January 26, 1979, titled Instrument
and Control Program.
(Closed) Noncompliance (358/78-16-04):
Sargent and Lundy specifications
require that the manufacturers supply motors which are capable of starting
and accelerating load at 80% applied voltage and are capable of developing
breakdown torque of not less than 200% of their normal full load
running torque. The inspector reviewed associated data curves for
the Electric Machinery supplied service water motors and Westinghouse
,,
reactor building closed cooling water pump motors. The records indicated
that the torque values were in accordance with S&L specifications.
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(Closed) Noncompliance (358/78-16-05): Cables routed through flexible
conduit were located within three inches of each other.
The inspector
observed that the valves that are supplied by the above mention cables
were relocated. The cables were rerouted to meet the minimum separation
criteria.
(Closed) Noncompliance (358/78-16-06):
Requirements for qualification
and training of inspection and test personnel. The inspector reviewed
CG&E Audit Report lio. 218 which documents the results of audits conducted
on CG6E Electrical Operating and Test Department (EOTD).
The audit
indicated that certifications for CG&E employees meet the requirements
(0 pen) Unresolved Item (358/78-29-02): Tech-Sil, Inc. Quality Assurance
Program.
The inspector reviewed Tech-Sil, Inc. qualification and training
program, against the requirements of ANSI N45.2.6-1973.
Also, the inspector
reviewed, calibration of test equipment. This item remains open pending
CG6E's QA conducting an audit on Tech-Sil, Inc. for scheduling and perform-
ance of audits conducted by Tech-Sil, Inc.
They stated that they would
. evaluated these audits prior to Tech-Sil performing safety-related work.
(open) Noncompliance (358/78-09-05):
Electric cable No. VY-710 was not
installed in accordance with instruction KEI QACMI No. E-7, Revision 7.
Per CG6E letter dated November 1,1978 from W. W. Schweirs to 3. K. Culver
concerning sample testing of instrument cables, the scope of the noncom-
pliance includes 157 cables (both Raychem and Samuel Moore).
Twenty-five
percent of those cables will be tested in accordance with the Samuel Moore
letter dated January 9, 1979, from A. P Clements to J. Seibert to
verify shield integrity.
100% of the cables will be tested in accordance
with the Megger/Hi Pot Testing Procedure EC-1, Revision 2.
(Open) Unresolved Item (358/78-16-01): Nonseismically supported pipe
installed over Class IE cable tray.
Sargent and Lundy is performing a
review to determine where nonseismic installations effect safety related
equipment.
Where necessary the nonseismic installations will be upgraded
to seismic.
(Open) Noncompliance (358/78-16-02):
No documented evidence could be
provided to assure that 53 differential pressure switches met the
requirements of the purchase specification.
During this inspection, the
RIII inspector reviewed partia) documentation supplied to CG&E (site)
for the cited instrumentation.
The documentation appeared to be
inadequate and incomplete in that in some cases there was no direct tie
between the supplied instrumentation and in some cases the documentation.
The documentation did not indicate testing in accordance with design
parameters specified.
The licensee has also started receiving documentation from other instru-
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ment suppliers (three uf at least nine suppliers).
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The CG&E Audit of Sargent and Lundy dated November 27-30, 1978
Report No. 78/10,Section II, Paragraph 3 indicates that checklists
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based on purchase specification submittal requirements for all
safety related equipment at Zimmer are being prepared to assure, by
S6L engineering verification, that all necessary documentation is
received and complies to the purchase specifications. The licensee
stated that these actions will be reaffirmed and that an additional
audit will be performed by CG6E to assure the effectiveness of the
actions. The questionable equipment will be controlled in accordance
with the licensee's QA program.
(Closed) Unresolved Item (358/78-19-01): Quality Documentation -
Feedwater Safe End Modification.
There are two Class I welds, for each
vessel nozzle to safe end and safe end to safe end extension associated
with this modification. Twelve radiographs for the following welds were
examined and found to be acceptable:
Weld No.
Description
Size
Materials
N4 AIR 4
Nozzle-safe end
15"xl 1/8"
C. Steel-C. Steel
Sect III 1971.S1973
N4BIRI
Nozzle-safe end
15"x1 1/8"
C. Steel-C. Steel
Sect III 1971.S1973
N4D1
Nozzle-safe end
15"x1 1/8"
C. Steel-C. Steel
Sect III 1971.S1973
N4Cl
Nozzle-safe end
15"xl 1/8"
C. Steel-C. Steel
Sect III 1971.S1973
Safe end - ext
12"xl'
Inconel-Inconel
Sect III 1971.S1973
Safe end - ext
12"x1'
Inconel-Inconel
Sect III 1971.S1973
Safe end - ext
12"xl'
Inconel-Inconel
Sect III 1971.S1973
Weld procedure qualification record PQR-3 indicating both GTAW and SMAW
processes were used for the above welds was in the files, NDE personnel
were qualified to procedure VT 2R2 for visual examination, IR2 for
Penetrant Test and 3R1 for the radiographic examination.
Radiographic results were available and accepted by CG&E so this item is
closed.
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Section I
Prepared by C. M. Erb
Reviewed by D. H. Danielson, Chief
Engineering Support
Section 2
1.
Quality Record Review - ITT Hammel Dahl Flow Control Valve
The ITT Hammel Dahl Flow Control Valve, MPL B33F060, S/N 00/2000/002A,
a Class 1 valve was selected for review. Material certifications
and Deviation Requests applicable to the following items were
examined.
Material
Shop Inspection
Part
Specification
Manufacturer
Certificate
Body
SA351/CF8M
Quaker Alloy
Lumberman's Mutual
20" Seat ring
CF3A, #6 Stel.i.te
Quaker Alloy
Lumberman's Mutual
Plug
CG3A, #6 Stellite
Quaker Alloy
Lumberman's Mutual
Bonlet
SA351/CF8M
Quaker Alloy
Lumberman's Mutual
This valve was built to the requirements of ASME Section III, 1971 Edition,
and the body was cast by Quaker Alloy to ASME Section III, 1971 Edition,
Summer 1972 Addenda.
The stainless body and valve plug were solution annealed at 2020 F
to 2040 F and water quenched. Autographic records of this heat
treatment were in the quality files. Visual examination of welds
indicated acceptable conditions for preservice examination.
Quality records for an 18" globe check valve in the Feedwater
System and a 20" Darling discharge motor operated valve in the
Recirculation System were also examined.
No items of noncompliance or deviations were identified.
2.
Observation of Work and Quality Record Review
Welds on the Low Pressure Core Spray (LPCS) and High Pressure Core
Spray (HPCS) pump casings were examined and found to be well prepared for
pre- and in-service inspection.
These pumps were manufactured by Ingersoll
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and are made of carbon steel to GE Specification 21A9243. Revision
O.
The LPCS pump is MPLIE21COOIA and the HPCS is MPLIE22C001,
SN/0872-133. A PQC check list was in the record which indicated
certain tests had been witnessed by GECo in the vendor's plant.
Certifications for materials, welds. NDE and personnel were included
in the files as were nonconformances.
No items of noncompliance or deviations were identified.
3.
Suppression Pool, Safety Relief Valve Quenchers
Quenchers for the Safety Relief Valves (SRV) are on order from
Sargent Company.
There will be extensive reinforcement for the SRV
piping, but the complete design was not available. No particulars
were available for further reinforcement of the downcomers to the
suppression pool.
4.
Records Storage
When securing the radiographs for examination, the inspector observed
a large number of X-ray film packages stacked on the floor inside
the records room.
This is an undesirable condition and the licensee agreed to correct
the matter. This matter is unresolved and will be reviewed at a
subsequent inspection.
(35S/79-01-01)
5.
Observation of Installed Pumps, Piping and the Installation Area
Piping welds to the Residual Heat Removal System (RHR) pumps, the
LPCS pumps and the HPCS pumps were examined and found to be in
the ground condition and suitable for preservice and inservice
inspection.
A number of electrode stubs and unused electrode E7018 and E6012
were found at the 475' and 508' level. This condiiton is a noncom-
pliance with Kaiser procedures which have been accepted by CGLE
as controlling welding at their site. This is item of noncompliance
No. 2 in Appendix A.
(358/78-01-02)
Except as noted, no items of noncompliance or deviations were
identified.
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Section 11
Prepared by P. Barrett
J. Hughes
Reviewed by D. W. Hayes, Chief
Engineering Support
Section 1
1.
Instrumentation - Observation Of Work Activities
a.
The RIII inspector observed work performed relative to instru-
mentation used for engineered safety features system and
primary containment atmosphere monitoring system (including
instruments identified as E31-N012A, E12-N022A, J12N010A,
E12-N015A, E22-N004, E21-N005, E12-N010C, E12-N015C, IPT-
CM010, ITRCM011, and ILIRCM009). Proper instruments had been
installed,
i.e.,
range, rating, material, etc., in conformance
with the General Electric applicable drawings. Plywood covers
protected the instruments from construction activities after
installation.
Instruments which had been calibrated were
identified with a calibration sticker.
No components had
been identified by the license as nonconforming.
b.
The RIII inspector selected cables associated with several of
the above instruments in order to verify proper termination,
i.e.,
correct lugs used, ninimum bending radius not exceeded,
cable identification tags installed, and separation criteria
maintained.
The following drawings, cables and instruments
were inspected:
Instrument
Cable
Drawings
'*E31-N012A
NB381
E2844 Rev. F
E12-N022A
RH109
E2844 Rev. B
E12-N010A
RH106
E2844 Rev. B
E12-N015A
RH712
E2844 Rev. E
E22-N004
HP710
E2857 Rev. E
E21-N005
LPO40
E2802 Rev. B
E21-5010C
RH355
E2847 Rev. D
RH387
E2847 Rev. E
E12-N015C
T4711
E2847 Rev. D
No items of noncompliance were identified.
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2.
Instrumentation - Review of Quality Records for Cable Termination
a.
The RIII inspector reviewed cable termination records for the
cables mentioned in Faragraph 2(b). The following was determined:
(1) Termination drawings were current revisions;
(2) Calibration records for crimping tools were up to date;
(3) Correct materials were being used.
b.
Termination inspection records (CIP) included provisions as
evidenced by KEI QA stamp, to verify that:
(1) Current drawing revisions are used;
(2) Component name and location;
(3) Cable number and number of conductors;
(4) Crimping tool calibrated and numbe of tool used;
(5)
Stripping of cable and correct lugs being used;
(6) Separation and bundles secured properly;
(7) Cable color codes current;
(8)
Inspector stamp and date of inspection.
c.
Records and other documents reviewed include:
(1) Cable Terminated (Cable Number)
RH106
RH387
NB381
_RH109
RH711
HP710
'RH355
RH712
LPO40
(2) Coastruction Inspection Plans
IH22P018
1H22P001
1H22P021
1H22P024
No items of noncompliance were identified.
3.
Instrumentation - Review of Quality Records for Calibration
The RIII inspector reviewed calibration data sheets for the instruments
mentioned in paragraph 1.a of this section. Results of this review
are as follows:
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a.
On January 24, 1979, in CG&E's calibration lab the inspector
observed the scale from test gauge TGA-024 being used as an aid,
i.e. pressure conversion, to calibrate IPT-CM010. TGA-024 was
schedaled for calibration 2 1/2 years previously and had a
sticker applied "D0 NOT USE UNTIL CALIBRATED." Use of TGA-024
would not effect calibration of IPT-CM010, however, the licensee
could not determine if TAG-024 had been used to calibrate
other Class IE instruments.
(NOTE: Procedure IM. SAD.01 to control nonqualified test equip-
ment had been approved on January 26, 1979.) This matter is
unresolved and will be reviewed during a subsequent inspection.
(358/79-01-03)
b.
Instrument calibration procedure IC-GCP-P101 was used while
calibrating IPT-CM010.
The procedure was not approved for use.
It was stamped "Information Only."
This condition is contrary to 10 CFR 50, Appendix B, Criterion XI;
Wm. H. Zimmer Nuclear Power Station, Unit 1, FSAR, Chapter 17,
Paragraph 17.2.11.
This is an item of noncompliance identified
in Appendix A of the report transmittal letter.
(358/79-01-04)
Instrument IE 22-N004 was calibrated January 8, 1979, using test
c.
instruments TGA-193 and TDV-054. Calibration sheet for IE 22-N004
indicated calibration for TGA-193 expired December, 1978; TDV-024
expired October, 1978. Actually, exp*_ ration dates were March
and May, 1979, respectively as indicated on TGA-193 and TDV-034
calibration records.
NOTE: The test data sheet for IE 22-N004
had been reviewed and accepted by the I&C supervisor.
Failure to evaluate test results is contrary to 10 CFR 50,
Appendix B, Criterion XI; Wm. H. Zimmer Nuclear Power Station,
Unit 1, FSAR, Chapter 17, Paragraph 17.2.11.
This is an item
of noacompliance identified in Appendix A of the report trans-
mittal letter.
(358/79-01-05)
Except as noted, no other items of noncompliance were identified.
4.
Instrumentation - Record Review of Electrical Testing
The RIII inspector reviewed testing data sheets for 29 cables
including those identified in subparagraph 2.c, that had been
tested previously,
i.e.,
continuity and insulation resistance.
Records established that the testing had been accomplished in
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accordance with approved procedure No. EC-1, Revision 2, dated
December 7, 1976.
The inspector determined that' the results
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met requirements.
No items of noncompliance were identified.
5.
Design Change Control
The RIII inspector selected four Design Document Changes (Nos.
SLE-295 dated January 4, 1977, SLE-466 dated June 16, 1978,
SLS-322 dated October 30, 1978; and SLM-461 dated November 7,
1978) to verify implementation.
The DDCs were either posted on or
incorporated in the applicable drawings.
The change identified in SLE-295 was accomplished as indicated on
the appropriate record, during the initial insta11allan activities.
Thus, there was no need for rework or reinspection.
The changes identified on SLE-466 included jumper wires which were
to be removed from Panel IPL10JC.
SLE-466 had been incorporated
into S&L drawings E-3572, Revision F and E-3571, Revision A.
Electrical Construction Test Procedure EC-12 record indicated
requirements of SLE-466 had been accomplished.
The RIII inspector
checked 10 of the 27 jumpers.
The jumpers had been properly removed.
The activities required by SLS-322 and SLM-461 had not been accomp-
lished but were controlled.
The RIII inspector reviewed and discussed the measures established
to assure that all design changes would be accomplished.
The
Construction Coordination of System Turnover for Preoperation
Testing Procedure, No. Admin 2, Revision 1 identified design change
reviews (i.e., Design Document changes, drawings, specifications,
etc.) which would be performed to assure control of the implementation
and inspection activities necessitated by all design changes.
No items of noncompliance were identified.
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Section III
Prepared by H. M. Wescott
Reviewed by R. C. Knop, Chief
Projects Section
1.
Review of NDE Implementing Procedures
The inspector reviewed Kaiser Engineers, Incorporated, "Special
Process Procedure Manual" (SPPM),to ascertain that quality assurance
plans, instructions and procedures have been established, as follows:
a.
SPPM No. 4.0, dated January 25, 1973, Revision 0,
"Nondestructis e Examination - General."
b.
SPPM No. 4.1, dated June 10, 1974, Revision 1, " Procedure
Specification - Radiographic Examination."
c.
SPPM No. 4.2, dated June 10, 1974, Revision 1, " Procedure
Specification - Liquid Penetrant Examination."
d.
SPPM No. 4.3, dated June 10, 1974, Revision 1, " Ultrasonic
Examination."
e.
SPPM No. 4.4, dated June 10, 1974, Revision 1, " Magnetic
Particf.e Examination."
f.
SPPM No. 4.5, dated March 18, 1975, Revision " Nondestructive
Examination - Personnel Qualification."
g.
SPPM No. 4.6, dated May 23, 1978, Revision 3, " Visual Exam-
ination (Welding)."
No items of noncompliance or deviations were identified.
2.
Review of Safety Related Procedures and QA Records (Piping)
The inspector reviewed Kaiser Engineers, Inc. safety related
procedures and QA records for piping as follows:
a.
SPPM 5.0, dated October 17, 1977, Revision 2, " Heat Treatment
Document, Equipment Calibration and personnel responsibilities."
b.
SPPM 5.1, dated October 17, 1977, Revision 3, " General Code
Welding - Field Welding Post Weld-Heat Trestment."
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c.
SPPM 5.2, dated October 17, 1977, Revision 3. "Noclear - ASME
Section III Heat Treatment Field Welding Post Weld Heat Treat-
ment."
d.
Review of Post Weld Heat Treatment (PWHT ) strip charts for
main steam line field welds as follows:
(1) 43MS-1MS01CA36-33
(2) 44MS-1MS01CA36-34
(3) 45MS- 1MS01CA36-34-35
(4) 50MS-lMS01CA36-38
e.
Review of the manufacturers welding and QA records for the
Residual Heat Removal System (RHR) pipe spools as follows:
(1)
1RH- 10AB4-242
(2)
(3)
(4)
(5)
These records included certificate of Shop Inspection, Weld
History Records, Final Inspection, Radiograph Inspection
Reports, Code Data Reports, and Nameplate Rubbings.
f.
Review of Kaiser Engineers, Inc. Weld data sheets for field
welds as follows:
(1) RH 404A
(2) RH 404B
(3) RH 414
(4) RH 415
(5) RH 423
(6) RHK 29
Thesk records established the weld procedure to be used,
filler material type and sizes, heat treatment requirements,
hold points, and NDE requirements.
No items of noncompliance ar deviations were identified.
3.
Review of Nonconformance Report Records
The inspector reviewed the Kaiser Engineers, Inc., Nonconformance
Report Record dated January 19, 1979 and established that:
a.
3 NCR's remain open for 1976
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b.
22 NCR's remain open for 1977
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c.
289 NCR's remain open for 1978
d.
36 NCR's remain open for 1979
No items of noncompliance or deviations were identified.
4.
Review of Weld Material Controls
The inspector reviewed the KEI system for weld material control as
follows:
a.
Observation of weld material storage at the central receiving
and storage warehouse.
b.
Observation of weld material issue at the two issue points.
c.
Inspection of the weld rod hold ovens established that two (2)
of the eleven ovens were past due calibration, Oven No. W-11
by approximately four (4) months and W-51 approximately three
(3) months.
The two (2) ovens were calibrated prior to the termination of
this inspection.
This item is considered closed.
In addition the calibration stickers on oven Nos. W-12, W-49, and W-52
indicated that these ovens had been calibrated on September 20, 1978.
These ovens had no provisions for, and were not provided with thermo-
meters for direct temperature readout.
The licensee stated that they
did not have thermometers for directly measuring oven temperatures.
This condition is contrary to 10 CFR 50, Appendix B, Criterion XII
and the ZPS, Unit 1, FSAR Paragraph 17.1.12.2.
This is an item of
noncompliance identified in Appendix A of the transmittal letter.
(358/79-Of-06)
5.
Walkdown of The Residual Heat Removal (RHR) System
The inspector accompanied by a member of the sytems turnover
a.
group, started a walkdown of the RHR system. Due to the
number of open items (i.e., pipe hangers, supports, snubbera,
and restraints on the punch list this item of inspection was
terminated and will be inspected at a subsequent NRC inspection.
,
b.
During this walkdown the inspector observed many weld
electrode stubs and unused coated rods, 6010 and 7018 rod,
throughout the plant. See Appendix A, Item B.
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6.
Steam Jet Air Ejector (50.55(e))
During this inspection the inspector was made aware of an occurrence
that took place on January 19, 1979. While conducting a ' test to
demonstrate the flow rate through a HPCS syst3m orifice, a steam
jet air ejector condensor was over pressurized on the tube side of
the heat exhanger causing a portion of the tube sheet weld to fail
and crack completely through the shell.
A review by the licensee of the conditions causing the failure and
the systems affected is in progress to assure that no other condi-
tions adverse to quality has resulted.
This item will be further reviewed by the NRC inspector pending
further reports by the licensee.
7.
Containment Structural .'ntegrity Test (SIT)-Integrated Leak Rate Test
(ILRT)
The inspector was informed that the SIT and ILRT was presently scheduled
for June 15, 1979, with 150 hours0.00174 days <br />0.0417 hours <br />2.480159e-4 weeks <br />5.7075e-5 months <br /> between the SIT and ILRT.
Except as noted in items 4.d., and 5.b.
No items of noncompliance
were identified.
Unresolved Items
Unresolved items are matters about which more information is required
in order to ascertain whether they are acceptable items, items of noncom-
pliance or deviations. Unresolved items disclosed during the inspection
are discussed in Section I, Paragraph 4, and Section II, Paragraph 3.a.
Exit Interview
The inspection team met with Zimmer Management personnel (denoted under
Persons Contacted, Details Section) at the conclusion of the inspection
on January 26, 1979.
The inspectors summarized the purpose, scope and
results of the inspection which was acknowledged by Zimmer personnel.
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