ML19276H308
| ML19276H308 | |
| Person / Time | |
|---|---|
| Site: | Crane  |
| Issue date: | 09/25/1970 |
| From: | Howard E, Hunnicutt D, Tillou J US ATOMIC ENERGY COMMISSION (AEC) |
| To: | |
| Shared Package | |
| ML19276H275 | List: |
| References | |
| 50-289-70-06, 50-289-70-6, NUDOCS 7910160650 | |
| Download: ML19276H308 (9) | |
Text
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U. S. ATOMIC ENERCY CGOilSSION REGION I DIVISION OF COMPLIANCE Report of Inspection CO Report No. 289/70-6 Licensee:
Metropolitan Edison Ccmpany (Met Ed)
(Three Mile Island Unit No. 1)
License No. CPPR-40 Category A Date of Inspection:
August 26, 27, 28, 1970 Date of Previous Inspection:
June 18, 1970 Inspected by:
M
- 4. vuni.alb J,5/7p D. M. Hunnicutt, Reactor Inspector (Principal)
Dati h
nm 0mY Yb h 0 u
J. H. Tillou, Reactor Inspector (Construction) tate Reviewed by:
k w/of f/M/70 0
A4, E. M. Howard, Senior Reactor Inspector
'Date' Proprietary Information:
None O
SCOPE A routine announced inspection was made_of Unit No.,1, one of the two
~
2535 MWt pressurized water reactors (B&W) under construction on Ihree Mile Island near Middletown, Pennsylvania.
The inspection effort was directed toward an appraisal of the performance of the licensee-contractor ef fort of various items listed in PI 3800/2 and included an inspection of Attachment F
" Reactor Coolant Pressure Boundry Pipin3" (4800 and 5000), Attachment G "Other Class I Piping" (4800 and 5000), Attachment I " Electrical" (5200) and Attachment J " Reactor Vessel" (4900 and 5500).
SUMMARY
Sa fety Items - None O
Noncenfermtnce Items - CONAM Laboratory, contractor to UE6C for all NDr of pipe welding at site, has not met the requirements of FSAR, Section 6.1.2.4 and USAS B 31.7, Appendix B-110.1, in that the CCNAM NDT procedures for in-spection of the make-up, purification and decay heat systems are not qualified as required by the above references.
(Section E) 7910160 SO
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. Unosual Occurrences - None OtFer Stanificant Items 1.
The reactor vessel arrived at the construction site an August 22, 1970.
This sessel is to be stored on a concrete pad near the equipment access Concrete pouring and possibly other work will be performed op er.
1 abov
<his storage area inteniittentily until the vessel is moved ins.de the containment vessel about December, 1970.
Overhead prctection for the reactor vessel has not been included la the stcrage plans.
(Section H)
~
Z.
The decay heat coolers have been removed and returned to the manufacturer for rework.
The stainless steel tubes in these coolers were cleaned in a chlorinated solvent.
(Section C.5) 3.
The field weld identification system for all piping installatien was changed from a numerical sequence system to a new system thn allows any erection drawing to be used as a weld map and the weid identifica-G tion numbers can be pre-determined and are readily located.
(Section D) 4.
Several possible problems and/or problem areas cencerning electrical safety related systems were discussed with Met Ed and UE&C.
(Section G.3)
Status of Previousiv Reported Problems 1.
Results of radiographic interpretation for Grinnel Corporation pipe following repairs. This item is considered resolved.
(Section C.1) 2.
Status of four inch valves from A11oyco.
These valves have been replaced.
A11oyco did not disclose the cause(s) of cracks in the rejected valves.
This item is censidered resolved.
(Section C.2) 3.
Weld history records.
The areas of high stress stampings en the river water secondary system heat exchangers have been grcund out and re-stamped with low stress stamps. This item is considered resolved.
(Section C.3) 4.
Deficiencies on PDM bleed tanks due to unacceptable welder qualificatten records. The records and tanks have been inspected and meet the pre-scribed requirements.
This item is considered resolved.
(Section C.4) 3.
CB&I NDI' qualifica! ion procedures meet the requirements stated in ASME Bari Code,Section III.
This item is considered resolved.
(S e c-tien C.7) 1419 177 I
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- M ea gment Im erview An exit interview was held with Messrs. Hreczuch, Allen and Kopp on Aagt.st 28, 1970.
The following items were discusseU:
Ihe inspector stated that all outstanding items, with one e.Eception had been resolved.
Mr. Hreczuch stated that it was Met Ed policy to ecmplete identi-fled items at the earliest date possible and to up-date the status of out-standing items periodically.
The inspector stated that during a tour of the cable storage yard numerous
" approved for use" tags were difficult to read and that some items could lose their identity.
Mr. Kopp stated that UE&C is aware of this problem and is attempting to solve it by use of a cloth type tag and ink that is not affected by weather.
The inspector stated that no procedure was available for qualification of electrical material upon receipt.
Mr. Kopp stated that manufacturers certifi-cations are used and that some samples have been taken, but bare not been tested.
9 The inspector stated that proposed plans to store the reactor vessel near the containment vessel where it is exposed to possible damage frcm falling concrete or other materials could result in a serious problem.
Mr. Ereczuch 3
stated that protection for the reactor vessel would be constructed.
The inspectcr stated that GAI Specification 5550 did not specify adequate crane testing.
Mr. Rreczuch stated that the subject would be evaluated and discussed with GAI.
UE&C Procedure MCP-4, " Testing Cranes, Etc.", does not include detailed re-quirements for testing and inspection of the polar crane for a 600 ton load (design tests, etc.) prior to lif ting the steam generators (570 tenr each) and the reactor vessel (400 tons).
Mr. Hreczuch stated that the subject would be evaluated and discussed with UESC.
'lhe i fector stated that B&W General Erection Specificatien (fcr the NSSS)
No. FS-II-2, " Cleanliness / Cleaning Procedures", was not available at the ccnstruction site.
Mr. Hreczuch stated the matter would be followed up.
The inspector stated that Attachment 2, B&W Procedure No. FS-III-1A, " Setting the Reactor Vessel", was not availabic for revicv.
Mr. Hreczuch stated that the procedure had not been prepared.
3't h,) \\f8 The inspecter stated that no evidence had been found that indicated the licensee had reviewed or approved B&W field specifications fcr NSS compon-9 ents.
Mr. hreezuch stated that Met Ed had not revicwed these documents, but intended to review them in the near future.
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. The inspec tor stated that there appeared to be no provisions or pro,.edt.res to cover temporary storage and surveillance cf the reactor vessel during storage.
Mr. Hreczuch stated that this item would be taken under advisement and evaluated by Met Ed and its centractors.
The inspector stated that GAI Specification No. 5544 required only 57. radi-ography cf the main steam system.
Mr. Hreczuch stated that this requirement may be re'tised to 1007. instead of 57..
All welds have been 1007. radiographed, to date, although the commitment is for 57. to be radiographed.
The inspector stated that the site records for a randomly selected liquid waste dispesal system (Class III) pipe spool, No. WDL-40, was unavailable fcr audit.
Mr. Hreczuch stated that this matter was under investigatien.
The inspectur stated that there appeared to be no procedure for, nor docu-mented evidence of any corrective action on items identified by UE&C site audits.
Mr. Hreczuch stated that Met Ed would discuss this observation with Mr. Fant when Mr. Fant returned to the construction site.
The inspector stated that CONAM Laboratory NDT procedure qualificaticn 1(tters do not appear to meet the requirements of Section III, paragraph N-321, of the ASME ESPV Code.
Mr. Hreczuch stated that appropriate corrective actions would be taken.
DETAILS A.
Persens Contacted l.
Met Ed Mr. Gene Hreczuch, Construction Engineer Mr. Earl Allen, Resident QA Supervisor Mr. Vern Stuebner, Resident ~ Engineer, Electrical 2.
UE&C Mr. J. E. Fant Site QC Manager Mr. George Dorn, Construction Superintendent Mr. David Lambert, QC Engineer (Cadwelding and Painting)
Mr. Cuy Kopp, QC Engineer (Electrical)
Mr. Dennis Snyder, QC Engineer (Electrical) 3.
B&W Mr. Jack Uhl, Ccnstruction Erection Consultant Mr. J.
(Andy) Anderson, Site Representative 1419 li 9
/Ji 7
. B.
Construcrien Status Mr. Hreczuch estimated that Unit No. I was approximately 30% ccmplete.
This estimate was based on manhours expended.
C.
Outstanding Items 1.
Stainless Steel Pipe, ASIM A-358. Class I and II by Grinnel Corcoration*
Mr. Hreczuch stated that Met Ed had performed inspections and read the radiographs on this nuclear grade piping.
All piping in this lot was rejected for nuclear service and has been replaced with piping acceptable under the provisions of ASTM A-358.
This outstanding item is considered resolved by the inspector.
2.
Cracked Stainless Steel valves (4") **
A four inch Alloyco manufactured valve was observed to be cracked in the machined weld prep area and two other similar valves were cracked 9
in the bodies. These valves have been replaced with valves that meet the purchase specifications.
Alloyco did not disclose the cause(s) of cracks in the rejected valves.
This outstanding item is considered resolved by the inspector.
3.
Weld Historv Records ***
The plant records and discussion with Mr. Allen indicated that the areas of high stress stampings on the river water secondary system heat exchanger have been removed by grinding and weld deposit material buildup.
Proper marking with low stress stamps on several joints on the secondary system heat exchangers had been completed in accordance with an approved procedure.
This outstanding item is considered re-solved by the inspector.
4.
Reactor Bleed Tanks (RBT) ****
The inspector verf fied that the welds were identified on each of the three RBT and that the welders' performance qualification records were in accordance with the requirements of Section IX of the ASME Code.
This outstanding item is considered resolved by the inspector.
1419 180
- CG Report No. 289/70-2, Paragraph B.2, and CO Report No. 289/70-4, pa ragaph 9
- C0 Report No. 289/70-2, Paragraph C.2, and C0 Report No. 289/70-4, paragraph
- C0 Report No. 25 /70-4, Paragraph J.5
- C0 Report No. 289/70-4, Paragraph J.6
/t b$
. 5.
Decay Heat coolers
- Mr. Hreczuch stated that the coolers have been removec ano retcrned to the manufacturer.
The decay heat cooler tubes are ' stainless steet and had been cleaned in a chlorinated solvent.
The ma.ufacturer is to re-move the welds, reelean the tube sheets, reelean the tube, and reweld the tubes in the tube sheets.
These coolers will be inspected caring a future routine inspection.
6.
CB&I NDT Qualification Documents **
The inspector verifi that CB&I has qualified the NDT qualification pro-cedure under the requirements stated in ASME B&EV Code,Section III, paragraph N-321.
A copy of the NDT procedure qualification decaments was available at the construction site.
This outstanding item is con-sidered resolved by the inspector.
D.
Field Weld Identification System Changes On August 4, 1970, the weld identification numbers for piping systems at Three Mile Island No. I were changed from numerical sequence, irrespective of the piping system (which required that numerous weld maps be kept to show the loca-tien of each weld) to a method where the weld will be assigned the number of the pipe spoc1 piece.
This method of identifying field welds will follow the flow of the process, starting upstream of the first weld between a piece cf equipment or tank and tne first spool piece will be designated the identification number on, the pipe or other starting point.
The last weld between the last spool piece and the piece of equipment tank it is welded to will be an odd weld number which will also be given the identification number of the last piece of pipe; however, in this case, the letter "Q" will be added to the identification number.
E.
NDT Procedures The inspector found that the CONAM Laboratory NIyr procedures have not been qualified ace.>rding to USAS B31.7, Appendix B-110.1 as reqaired by FSAR, See-tion 6.1.2.4 NOTE:
CONAM Laboratories are a subcontractor to UE6C for all NDT of ';ipe welding at site, including the make-up, purification and decay heat system.
In a subsequent telephone conversation with Mr. B. Avers, the inspector was inforned that GFU is requiring CONAM Laborntury to qualify all NDT procedures ander the provtsions of NAVSHIPS 25.U0s NAVSHIPS 250-1500 reqcirements re-
% ire qualtfication to a more r:angent criteria tnan specified in USAS B31.7.
1
>,A 1i9 1 8 1 wp.gif Memoranduin N >. 289/ 70 A, same subject, dated April 16, 1970
- -to R.> pert No. 289/70-4, paragraph J.7
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. UE6C personnel stated that the fomer method of weld identification re-solted in a single copy of the weld map,and if lost or mispiaced,ait records were unavailable.
The newly adopted method, described abcve, ali;ws any raction drawing to become a weld map and allows designation numbers to be pre-determined and readily located at any time.
F.
Reactor Coolant Picing (Weldine)
The inspection effort consisted of a detailed review of the QC system as required by Attachment F, " Reactor Coolant Pressure Boundary Fiping", PI 3800/2, Item 4804.03 and 4804.04.a.1 through and including g.5, except for Items 4805.04.e.1 through and including 4805.04.c.6.
All items were found to be in accordance with approved procedures and FSAR commitments, execpt for the NDT procedures.
(Section E)
G, Reactor Coolant Pioing System (Piping)
The inspection effort consisted of a detailed review of procurement G
documents and procedures as required by Attachment F, " Reactor Coolant Pres-sure Boundary Piping", PI 3800/2 (5005.04.a.1 through and including 5005.04.
d.3 and e.1 and e.2).
This inspection indicated that the B&W Commerical Nuclear Components (B&W-CNC) purchase specification for the reactor ecolant piping met the applicant's FSAR commitment.
Shipping, receipt, storage, fessue and handling was adequately covered by procedures to assure proper supervision and inspection in the areas of marking, identification, cleanliness, protection and control of reactor coolant piping.
The reactor coolant piping is being supplied by B&W-CNC, Barberton, Ohio.
H.
Electrical 1.
AttachmentI-ElectricalICablesandTerminations-5200)
The inspection effort consisted of a detailed review of t he QC system as required by At tachment I, " Electrical", PI 3800/2, Items 5205.04.a through and including d.3 and e.1 and e.2.
All items were found to be in accordance with approved procedures and FSAR commitments.
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2.
Identifying Tags The inspector observei_ that several of the " approved fo other paper tags used for identification of electrical cat sotrage yard were fading and may soon become illegible. M stated that UE&C was aware of this deficiency and was scart a more satisfactory method of identification.
/(, tb
. 3.
Seneral Ihe inspector discussed the desirabtlity of UEiC, GAI and Met Ed assuring themselves of the following safety relat ed items:
a.
Redundant Circuits Messrs. Kopp and Stuebner stated that computer runs would h u.ted to design cables routes.
The inspector infcrmed Messcs. Kopp and Stuebner that this method has proved to be misleactng at other facilities and that important safety circuits were fouro te be non-redundant in several cases.
Mr. Kopp stated that additional study would be carried out.
The inspector stated that t".is iss 2e would be pursued during future inspections.
b.
Methods of Marking and Taggine Installed Cables GAI has prepared a procedure indicating that plastic or brass tags attached with fiberglass string will be used.
The inspector 9
stated that a method to assure that each cable is accurately labeled or marked is extremely important.
Mr. Stuebner stated that other possibilities are still being censidered, but this appears to be the best method proposed to date.
c.
De-Rating Mr. Kopp stated that the present plans are for one layer of cables in each tray and conceiveably with additional separation to assure adequate de-rating.
A specification stating the method of de-rating is being prepared.
d.
Cable Travs The inspector asked what precautions had been taken to assure adequate clearances between cable trays and components, walls and operating equipment.
Mr. Kopp stated that the matter would be investigated. No cable trays have been installed in the con-tainment vessel to date.
e.
Methods for Wire Pulling Mr. Kopp stated that each bend will be pulled and cff-sets checked.
Each cable will be laid and lashed to avlod cable piling on one site of a tray.
f.
Cable Handling 1.d?q tn-Mr. Kopp stated that each cabic will be inspected prior to' and during installation and workmen cautioned concerning cable handling.
/6/
9-g.
Lubricants Mr. Kopp stated that no wire pulling compound wculd be allowed withcut special permission from UE&C Engineering.
I.
Reactor Vessel The reactor vessel arrived by railroad car at the constructicn site on August 22, 1970.
UE&C is responsible for providing both construction and QC personnel to acccmplish receiving inspection, handling, storage and installaticn of the reactor vessel.
The FSAR states that these activities are to be acecmplished -
according to the UE&C Field QC Manual, supplemented by detailed pr:cccures and instructi;..a from B&W.
UE&C activities will be under surveillance by Met Ed and B&W repretentatives.
There was no evidence that the B&W QA program or the B&W field specif1-cations for site handling of NSSS components has been formally approved by Met Ed, the applicant.
The UE&C QC procedures appear to be adequate when supplemented by detailed B&W procedures.
However, B&W has not provided a procedure for outside storage of the reactor vessel ner a procedure for inspection, monitoring or auditing of the storage conditions related to the reactor vessel during the indefinite outside storage period.
d UE&C is preparing a special procedure for installation of the reactor vessel and the reactor vessel bead.
Also, UESC is preparing additional draw-ings to provide for a storage saddle and handling equipment and a handling sequence for the latteral travel of the reactor vessel from the railroad car to the temporary storage area.
These reported procedures were not available for the inspector's review.
The reactor vessel is to be stored on a concrete pad near the equipment access cpening.
Concrete pouring and possibly other work will be perfernd above this storage area intermittently until the reactor vessel is moved in-side the containment vessel about December, 1970.
Overhead pretectica for the reactor vessel had not been included in the storage plans.
The inspectors discussed tais apparent oversight with Met Ed management.
Mr. Hreczuch stated that overnead protection for the reactor vessel would be constructed.
The inspector telephoned Mr. Avers on August 28, 1970, to empha i th O
cencern that the reactor vessel storage proposal appeared to be 3ubstandard.
Mr. Avers st ated tnat adequate storage, sorveillance and overbead prctectic' structures would be provided to assure that the reactor vessel was not da:
or contaminated witile in cutside storage.
,