ML19263B881
| ML19263B881 | |
| Person / Time | |
|---|---|
| Site: | Comanche Peak  |
| Issue date: | 12/14/1978 |
| From: | Renee Taylor NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19263B872 | List: |
| References | |
| 50-445-78-20, 50-446-78-20, NUDOCS 7901250011 | |
| Download: ML19263B881 (10) | |
See also: IR 05000445/1978020
Text
4
U. S. NUCLEAR REGULATORY COMMISSION
OFFICE OF INSPECTION AND ENFORCEMENT
REGION IV
Report No. 50-445/78-20; 50-446/78-20
Docket No. 50-445; 50-446
Category A2
Licensee:
Texas Utilities Generating Company
2001 Bryan Tower
Dallas, Texas
75201
Facility Name:
Comanche Peak, Units 1 & 2
Inspection at:
Comanche Peak Steam Electric Station, Glen Rose, Texas
Inspection conducted:
November 1-30, 1978
/h
78
Inspector- _
x=
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r R. G. Taylor, Resident Inspector, Projects Section
Date'
Approved:
h
f 78
W. A. Crossman, Chief, Projects Section
Date
Inspection Summary:
Inspection on November 1-30, 1978_(Report No. 50-445/78-20; 50-446/78-20)
Areas Inspected:
Routine inspection by the IE Resident Inspector of safety
related cmstruction activities including follow up on licensee actions on
previous rindings; welding on reactor coolant boundary and other piping;
welding oj penetration assemblies; component storage and maintenance;
and concrete placements.
In addition, the IE Resident Inspector initiated
the programed mid-term QA inspection.
The inspection involved one-hundred
ten (110) inspector-hours by one NRC inspector.
Results:
Of the thirteen major activities inspected, one deviation from
commitments was identified (failure to achieve adequate radiographic
sensitivity - paragraph 6).
790125000
$
DETAILS
1.
Persons Contacted
Principal Licensee Employees
- J. B. George, TUSI, Project General Manager
- R. G. Tolson, TUGCO, Site QA Supervisor
- J. V. Hawkins, TUGC0/G&H Product Assurance Supervisor
R. V. Fleck, TUGC0/G&H Civil Inspection Supervisor
- D. E. Deviney, TUGCO, QA Technician
Other Personnel
- H. O. Kirkland, B&R, Project General f4 nager
B. C. Scott, B&R, QA Manager
J. P. Clarke, B&R, QC Manager
The IE Resident Inspector also interviewed a number of other
site construction craft and quality control employees during
the course of the inspection.
2.
Licensee Action on Previous Findings
(Closed) Unresolved Item (50-445/78-05; 50-446/78-05):
Unavail-
able Vendor Quality Documentation.
The licensee located the vendor
prepared radiographs for Valve Isolation Tanks, cpl-CTATVT-02 and
CP1-RHATVT-02, previously indicated as unavailable.
Discussions
with quality assurance records storage personnel indicated that
the radiographs had been misfiled.
The IE Resident Inspector
selectively reviewed the radiographs which are identified as
2277-2 and 2277-3 and correspond respectively to the above
component item numbers. Weld quality was found to be consistent
with the requirements of Subsection NC of ASME B&PV Code, Section
III, 1974, while radiographic quality was in accordance with ASME,
Section V, Article 2, same edition.
The engineer also issued
Design Change / Design Deviation Authorization No. 3097 to Project
Specification 2323-MS-69A to delete requirements for vendor work
process dacumentation on the basis of not being required as a job
site permanent record. The IE Resident Inspector had no further
questions regarding this matter.
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(Closed) Unresolved Item (50-445/78-13):
Documentation of Reactor
Coolant Pipe Quality.
The licensee obtained microfilmed documenta-
tion from Westinghouse which was reviewed by the IE Resident In-
spector. The documentation indicated that all components of the
primary reactor piping were assembled by Southwest Fabricators in
accordance with ASME B&PV Code,Section III, Subsection f;B.
The
materials utilized in the fabrication also appear to fully comply
with the Code.
The IE Resident Inspector had no further questions
on this matter.
(Closed) Deviation (50-445/78-07; 50-446/78-07):
Safety Related
Concrete Testing. The licensee has completed all actions contem-
plated by his letter dated June 5, 1978.
Brown & Root fionconfor-
mance Report C-1245 has been issued documenting that a total of
eleven (11) concrete placements in Category I structures were
made between March 22 and April 18, 1978, which were not tested
in accordance with commitments. The engineer has indicated the
placements are acceptable since the concrete design mix testing
program, in effect at the time, did provide data to substantiate
that the concrete met overall quality requirements.
The IE
Resident Inspector and, Regionally based IE inspectors have made
repeated observationsH that the licensee's cancrete testing pro-
gram has been functioning on a placement by placement basis in
accordance with FSAR commitments.
The IE Resident Inspector
had no further questions regarding this matter.
(Closed) Infraction (50-445/78-12):
Failure to Follow Welding
Procedure.
The IE Resident Inspector verified, by observations
and by review of records and welding procedures, that the li-
censee had fulfilled commitments made in his letter of Septem-
ber 21, 1978, as it pertains to this item.
By way of interviews
with welders, the IE Resident Inspector understands that the
welders were given to understand the importance of compliance
to weld parameter requirements.
CP-CPM 6.9, " General Piping and
Inspection Procedure," has been issued which makes clear that
weld parameters are to be monitored and documented, including
travel speed.
Several weld procedures, including 88025, have
been revised to allow a slower travel speed while remaining below
maximum heat input levels.
The IE Resident Inspector had no
further questions regarding this matter.
IfInspection Report 50-445/78-09; 50-446/78-09, paragraph 5
Inspection Report 50-445/78-13; 50-446/78-13, paragraph 12
Inspection Report 50-445/78-18; 50-446/78-18, paragraph 6
Inspection Report 50-445/78-16; 50-446/78-16, paragraph 5
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.
(Closed) Deficiency (50-445/78-16; 50-446/78-16):
Failure to
Promptly Report a Significant Deficiency.
The licensee's letter
of flovember 7,1978, stated that the licensee's procedures re-
garding review and reporting of 50.55(e) items would be revised
and that appropriate personnel would receive indoctrination.
The
licensee has issued procedure CP-QP-16.1 dated flovember 28, 1978,
"Significant Construction Deficiencies," which excludes a " Design /
Construction Significant Deficiency Analysis Report." The proce-
dure appears to adequately treat the requirements of 10 CFR 50.55(e).
The IE Resident Inspector established by interview that responsible
levels of QA/QC supervision have been made aware of the procedural
requirements.
The IE Resident Inspector had no further questions
relative to this item of noncompliance.
(Closed) Unresolved Item (50-445/78-16; 50-446/78-16):
Potential
Significant Construction Deficiency Regarding Design of Seismic
Restraints for Service Water Pumps.
The licensee's design engi-
neer and the service water pump vendor have concluded evaluation
of this matter and stated by letter dated flovember 10, 1978, that
the matter was not considered reportable.
The issue in question
was whether a system of lateral pump casing restraints also
provided cr. acceptable restraint to vertical motion of the casing.
The engineer calculated the vertical restraint forces in the
system design and the vendor has concluded that these forces
would have had no detrimental effect on the pump casings.
The
IE Resident Inspector had no further questions.
(Closed) Infraction (50-445/78-13; 50-446/78-13):
Failure to
Follow Concrete Testing Procedures.
The licensee's letter of
October 13, 1978, stated that inmediate corrective action took
place when the situation was informally reported by the IE
Resident Inspector and that a more formal training and surveil-
lance prcgram was instituted.
The IE Resident Inspector has
observed several Category I concrete placements during October
and flovember 1978.
The test laboratory perscnnel were found to
be consistently taking samples of fresh concrete in the manner
required by the project procedures. The IE Resident Inspector
had no further question regarding this item of noncompliance.
(Closed) Infraction (50-445/78-12):
Failure to Segregate and
Identify Defective Material. The IE Pesident Inspector has
established by observation that nonconforming fabrications are
being identified in accordance with project procedures.
Craft
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labor supervision has been provided additional instruction
regarding procedural requirements for segregation of noncon-
forming materials and fabrications.
The QA surveillance group
has performed audits monthly relati e to compliance with appli-
v
cable site procedures as evidencM by reports G-009 and G-016.
The IE Resident Inspector had % further questions relative to
this item of noncompliance.
3.
Construction Fire / Explosion
On flovember 26, 1978, the licensee reported to RIV that an explo-
sion had occurred in a field office in the common auxiliary building.
The IE Resident Inspector went to the room involved, during the
morning of flovember 27, to observe what damage had been done to the
structure.
The IE Resident Inspector did not observe any damage
caused by an explosion, but did observe that a fire had taken place
that destroyed some paperwork and furniture.
The exact cause of
the explosion and fire was not identified but probably was initiated
by a leaking propane tank valve in conjunction with some ignition
source, possibly a coffee pot.
The IE Resident Inspector examined
the floor, ceiling and walls of the small ruom af ter cleanup on
flovember 29 and found no evidence of structt al damage.
Three pipe
runs through the room and an electricai conc sit installation also
appeared to be damage free.
fio items of noncompliance or deviations were identified.
4.
Containment Structural Concrete Activities
The IE Resident Inspector observed a Unit 1 containment dome concrete
placement on fiovember 30, 1978.
The placement, identified as 101-
8805-001, was tha initial six foot lift above the springline.
The
formwork was
d to be generally tight with only occasional small
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grout leaks.
.ne fomwork clearance from the reinforcing steel
generally was in excess of two inches and nowhere was the required
clearance of 135 inches violated within the span of observation; i.e.,
about one-half of the placement circumference.
The concrete was
delivered to the placement via two pumps to a split ring header and
deposited through rubber hoses.
Lift height and vibrator operations
appeared to be consistent with project specification requirements.
Observations were also made of the activities of one concrete test
laboratory crew making the required air content, slump and temperature
tests of the fresh concrete.
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.
The IE Resident Inspector observed Cadweld splicing of several
vertical number 18 bars in the Unit 2 wall.
The splices observed,
being prepared and fired, were made by persons identified as
"T"
and "U."
The work was accomplished consistent with the practices
recommended by the supplier, Erico Products, and were inspected
by a qualified Brown & Root inspector shortly after casting.
The
QA records disclosed that the two splicers had been qualified and
tested in accordance with ASME,Section III, Division 2 require-
ments.
No helpers were observed to be involved in the work.
No items of noncompliance or deviations were identified.
5.
Mid Term Construction Permit Quality Assurance Inspection
a.
Licensee Quality Assurance Manual
The above captioned inspection was initiated by the IE Resident
Inspector, during the reporting period, since it appeared the
licensee has essentially completed a major reorganization of
the on-site quality assurance / quality control groups as well as
the construction management organization.
The reorganizations
which have taken place also caused significant changes in the
licensee's corporate and site quality assurance manuals and
in a substantial quantity of the implementing procedures.
The licensee submitted a revised SAR Chapter 17.1, " Quality
Assurance During Design and Construction," to NRR for review
initially on August 14, 1978.
Revisions to the initial sub-
mittal were made by letter dated September 22, 1978, and were
subsequently approved by a letter dated November 3, 1978.
The licensee's manual and procedures accurately reflect the
revised SAR description.
The IE Resident Inspector had no
further questions regarding this matter.
b.
Contractor Quality Assurance Manual-
The licenee's qualitj assurance / quality control manuals and
procedures incompass all site construction activities except:
(1)
Component fabrication and installation activities accom-
plished in accordance with ASME B&PV Code,Section III
and the Certificate of Authorization issued to Brown &
Root.
(2)
Fabrication and installation of the seismic Category I
heating, ventilation and air conditioning systems being
accomplished by Bahnson Service Company.
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(3) Fabrication and installation of the containment liners
(Unit 1 now complete) and fabrication of certain piping
system hangers being accomplished by Chicago Bridge &
Review of the Brown & Root Quality Assurance manual for the ASME
Code work reveals no inconsistencies with the SAR description
referred to above or with ASME,Section III, Subsection NA. The
Bahnson manual was selectively reviewed by the IE Resident Inspector
as indicated in Inspection Report 50-445/78-15.
The CB&I manual
likewise was not reviewed since it had been reviewed as part of the
IE inspection as described in 50-445/78-12.
The IE Resident Inspector had no further questions relative to this
area of inspection.
6.
Containment Process Pipe Penetrations
The IE Resident Inspector observed the installation and welding of
two process pipe Unit 1 containment penetration assemblies to their
respective liner nozzles.
The units involved were M1-7 and M1-12,
which are in the main feedwater and steam generator blowdown piping
systems, respectively.
The welding being performed on Ml-7 was
automatic gas tungsten arc process in accordance with procedure
99026. The welding on M1-12 was a shielded metal arc manual process
in accordance with procedure 11010.
The observations confirmed that
the welding procedure requirements were being fulfilled in each
instance.
Subsequent record reviews established that weld procedures,
welders and filler metals met requirements of ASME B&PV Code, Section
IX.
The IE Resident Inspector also selected three additional completed
penetrations for the purpose of examining the radiographs of the
connecting welds.
The welds are idencified as penetrations MIII-12,
MIII-11 and MIII-2.
The radiographs icdicated that the welding ful-
filled the requirements of ASME,Section III, Subsection NC with
radiograph quality meeting ASME,Section V, Article 2 requirements.
'
In addition to the above observations of direct field fabrication
effort, the IE Resident Inspector selected still another penetration
assembly (MIII-14) for the purpose of reviewing supplier documenta-
tion and radiographs.
Review of the certified material test reports
indicated that the stainless steel flued head forging and carbon
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steel transition section fulfilled the requirements of SA-182,
grade F-316 and SA 516, grade 70, respectively.
Examination of
the radiographs of the factory made weld between the forging
and the transition piece revealed that the radiographs did not
meet the 2-2T sensitivity requirements of ASME,Section V,
Article 2 as invoked by Section III, Subsection NC and Project
Speci fication 2323-MS-74.
The IE Resident Inspector informally
notified the licensee on November 17, 1978, of the finding which
would be considered a deviation from commitments contained in
paragraph 3.8.2.1 of the FSAR.
7.
Safety Related Component Storage and Maintenance
In the course of the extensive plant tours and during other obser-
vation activities, the IE Resident Inspector observed and noted
the in-place storage and maintenance of various installed safety
related components. All observed electric motors had their space
heaters energized as evidenced by an indicator light and being
slightly hand warm. Vessels, such as heat exchangers not yet
connected to piping systems, were under positive internal pressure.
The various installed pumps were adequately sealed and covered
to protect them from on-going construction activities.
The
reactor vessel remains well covered with unconnected nozzles
sealed.
Access control has been established due to the work
involved in inspecting and/or repairing weld root areas at
connections between the vessel and coolant piping. The reactor
vessel internals remain sealed and stored in warehouses.
No items of noncompliance or deviations were identified.
8.
Reactor Coolant System Welding
No welding took place in the reactor coolant system during November
due to circumstances outlined in Inspection Report 50-445/78-16,
paragraph 6.
The licensee did, however, initiate work aimed at a
controlled removal of the linear indications detected in the weld
root area of welds connecting the piping to various vessel and
pump nozzles.
This work, which consists of shallow grinding
followed by liquid penetrant inspection, has been successful in
removing the unacceptable indications in six joints as of Novem-
ber 30.
The IE Resident Inspector observed the grinding and
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liquid penetrant inspection activities on November 28 and 30
and had no further questions.
The licensee has authorized the
resumption of welding provided that only automatic tungsten inert
gas process is utilized. The IE Resident Inspector will continue
to follow this work activity clorely.
No items of noncompliance or deviations were identified.
9.
Safety Related Piping Installation and Welding
The IE Resident Inspector observed that the craft labor force
continues to follow the project procedures relative to handling
of piping components during installation and fit-up for welding.
These procedures include keeping component open ends sealed ex-
cept for actual fit-up operations, segregation of tools for use
on only one type of steel;
i.e., either stainless or carbon and
use of non-metallic slings and stands / supports prior to reaching
the permanent installation level. The IE Resident Inspector ob-
served a number of welds in progress during the period. Two welds
were selected for spe;ial attention since one involved the third
attempt to make the weld to acceptable standards and the other was
the first observed use of a consumable filler metal insert. The
welds were FN-17B in line 4-SI-045-1501-R2 of isometric SI-1-SB-14-5
and FW-3 in line 16-CT-1-003-151-R2 of isometric CT-1-SB-01-0, re-
spectively. Welder "AlD" performed the open root welding of FW-17B
with welder "AJE" accomplishing fill and cover passes.
Welder
"AFN" accomplished the root pass of weld FW-3 (no observation of
subsequentpasses).
All welders appeared to be performing in com-
pliance with the designated weld procedures.
A subsequent records
review established that the weld procedures and welders were
properly qualified to ASME,Section IX.
The IE Resident Inspector also reviewed randomly selected weld
radiographs during the inspection period.
Radiographs selected
were identified as those pertaining to FW-13 in line 18-FW-1-17-
1303-2 of isometric FW-1-RB-03 and FW-4 in line 8-RH-1-027-60lR-2
of isometric RH-1-SB-19. Weld quality and radiographic quality
were found in both instances to be consistent with the requirements
of ASME, Sections III and V.
No items of noncompliance or deviations were identified.
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10.
flanagement Interviews
The IE Resident Inspnctor met with licensee management on Novem-
ber 17, 20 and 30, 1978, to discuss findings and resolution of
open items. The IE Resident Inspector also attended the exit
interview of the regional office based inspectors on flovember 22,
1978.
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