ML19317D290
| ML19317D290 | |
| Person / Time | |
|---|---|
| Site: | Oconee  |
| Issue date: | 06/22/1971 |
| From: | Brownlee V, Cochran B, Long F US ATOMIC ENERGY COMMISSION (AEC) |
| To: | |
| Shared Package | |
| ML19317D288 | List: |
| References | |
| 50-270-71-03, 50-270-71-3, 50-287-71-43, NUDOCS 7911270332 | |
| Download: ML19317D290 (31) | |
Text
D-r U. S. ATOMIC ENERGY COFDfISSION REGION 11 DIVISION OF COMPLIANCE Report of Construction Inspection C0 Report Nos. 50-270/71-3 50-287/71-3 Licensee:
Duke Power Company Oconee 2 and 3 License Nes. CPPR-34 and 35 Category A Date of Inspection:
May 3-7, 1971 Date of Previous Inspection:
March 11-12, 1971 Inspected By: I h WM C h 21.
/
V. L. Brownlee, Reactor Inspector Date (In Cha J&bn 4227/
. [ Cochran, Reactor Inspector
/ Dat(
Reviewed By:
4,,/7/
/
F. J. Long', Senior R6 tor Inspector
/ atd D
Proprietary Information:
None SCOPE An announced inspection was performed at the two 2,563 Mwt pressurized water reactors under cons truction near Seneca, South Carolina, kncwn as Oconee 2 and 3.
Inspection efforts were directed tcward a review of progress of construction
. (Brownlee), Attachment F - Reactor Coolant Pressure Boundar/- Piping (Brownlee),
Attachment G - Other Class I Piping (High Pressure Injection, Core Flced)
(Brownlee), Attachment J - Reactor Vessel (Cochran), Attachment L - Ccepenents (Steam' Generators, Core Flood Tank - Cechran) (Primary Pumps, Main S team Safe ty Valves - Brownlee).
79112 N J
00 Ppt. Nos. 50-270/71-3
- 50-287/71-3
.s SLMIARY Safety Items - None Ncn:cnformance Items - 51x items of ncnconformance were observed.
They are as follcws:
1.
Removal of arc s trikes en critical components without authorized repair procedures.
(See Section F. 3 and Exhibit A, Pho to Nos.1-5.)
2.
Lack of a techanism to assure "QA H,1d" work s tatus on Class I vessels.
(See Section F.3.)
3.
'4 eld procedure qualifications did not meet present code requirements.
(S(e Section E.a.)
4.
Lack of weld rod material control.
(See Section E.4 and Exhibit A, Pho to Nos. 8-10.)
5.
Ins tallation o f maj or components without detailed installation and QC procedures as required by ins tallation specificatien.
(See Section F.3.)
6.
Equipment recei eing requirenents of the purchase documents and the receiving reports do not contain referances or cenfirmation that the special requiremen:s of the applicable specifications have been met.
(See Section F.3.)
Unusual Occurrences - Ncne Status of P re naus iv Repo rted P roblems -
1.
D cument Crn:rol (CDN dated April 7 1971)
Revision 2, " Duke Power Cc=pany (Duke) Procedure for Drawing Centrol,"
was issued :c :he fleid for corrent only.
The precedure has not been implemented.
Cc:pliance will perf orm f ollewup.
2.
Oraanizatiop (C0 Reoort No.30-270, 237/71-2, Other Sienificant Items, Nc. 2) w Organiza:::nal realignment has contenced to man constructica of the
'!:Guire f acility.
Possible pr:blem is dilution of technicial competency and experience a: :he 01: nee units.
This is an area of concern and will be monitored ;;c sely by Cetpliance.
(See Sectica E.)
CO Rpt. Nus 30-270/ 71-3.
50-267 71-3 3.
- eri:.:oti:n ct Su. lear Valves to Desien Specifications (Inspection and En t o : :.e me n t L:
.st, Apr;l 12, 1971)
L t.sni er n;:llied.
Licensee comments that no Darling Valve Cc pany (Da r tin g) valves are being utilized in the primary coolant boundary.
A search and ierifica icn tor Crane Cetpany ca l.'e s is being pe r f o rmed by th e licensee.
C ):pliance will ic il:w up.
Other Significant c as -
Pragtess of C:ns t ruction a.
Unit Sc. : to estimated to be 7A% cc= piece.
P ressure boundary pipe e re c tica is 50% ccep le te.
All main c;31 ant pump casings are installed.
Cantainmen- ;1:e rnal suppt r e and s truc ture work continues.
Re f ueling cavi ty i;n+r plate erect :n is 50% sc=ple:e.
b.
Unit No. 3 13 estimated to be 42% complete.
Contain=eit liner is at
- he ten:h u;ursg con:aincent ccncrete is at the seventh lift.
Inte rnal s truc tures and support work ccatinues -
Management :nrerview - The inspectors met with R: ge rs, Beam and Hunnicutt.
Ihc scepe :t the taspection was outlined and tne inepector's co: cents were discussed.
Icess.: discussten were as feilews:
1.
O rg an i z a ".i c t lhe inspeutc r ;c amen ted that the organizaticnal/ f unctional realignment of the Occree site pe r s e r.ncl t a man tne McG ui c e facility would be monitored u !; s e ly by C: mp.l on e.
The principle area of concern is that the Oconee s ite d:es cet s a f e r a dilution ci te chnical competency and experience.
(See Se. tion 3.
Beam and Hunnt.utt defended the Duke pcs::1:n.
2.
Deficie7 ries The inspe:t.ars Acentified and notified the representatives that Ccapliance will cake excepttan ;c the follcwing nontcnformence items:
i a.
Retr.21 et are s t rikes on critical ;c.npanents without authorized repair p eccedures.
(See Section F.3 and Exhibit A, Photo Sas 1-3.)
b.
La;k et a mechanisa to assu:e "QA Ecl1" wc :k s tatus on Class I vessels.
(See Sc
- n F. 3.)
L.
C0 Rpt. Nos 50-270/71-3.
50-286/71-3 Weld pro;edute qualifications do not meet present coda requirements.
c.
(See Se v.n. E,a.;
d.
Lack ci wsid material control-(See Exhibit A, Pheto Nos. 8-10, and Sect 1:n E.
e.
Ins taliaci r. c i major compenents without detailed installation and QC prcc4dar(s as required by the installation specification.
(See Se ction F. 3 7 f.
Babcock anc Wilcox Company (B&W)/ Duke receiving requirements of the purchase a;.uten ts and the receiving reports do not contain references or centi:13t-.m that the special requirements of the applicable specifica-tions have b-:en me t.
(See Section F. 3. )
The representati.es acknowledged the legitimacy of le=s a, b, e and d.
Items e and t generated discussion relating to how Duke has typically operated in the pas:.
Ihe conclusion was that Duke cons truction, in many areas, is centr:11cd in verbal form with little written instructione or do cumen t a ticn.
DETAILS A.
. Persons C;ntar ed Dume Power Ccepany (Duke)
J. C. Ro ge rs - Project Engineer, Oconee and McGuire Nuclear Station D. L. Beam -
Assie: ant P roj ect Engineer, Oconee Nuclear Station G. L. Hunnicutt - Prinicpal Field Engineer R. E. Blaisdell - Field Engineer (Welding NDT)
A.
R. Hollins - Assis tant Field Engineer (Welding - NDT)
S. Woo d - Gene ral Welding Fo ren:,
J. E. Evatt - Welding Inspectct !Tabrication Shop, Core Flood)
C. G. Freeman - Weiding Inspector (Reactcr Coolant Lcep)
F. S. Bulgin - Weiding Inspector (Fleid Welding, HPCI)
M. M. Williams - Welding Inspector H. 3. Jones - Welding Inspector G. W. Greer - Field Engineer (NDT, Assigned to McGuire)
D. L. Freeze - Field Engineer, Civil M. Curtis - Design Engineering, Mechanical W. Owens - V1,e President, Engineering (T+1 econ)
Babcock and Wil:cx Cocoanv (36W)
W. Faase j
C0 Rpt. N:s. 50-2 70/ 71-3
- 50-287/71-3 B.
Organizattor The lolicw;ag changes have been made in the site quality control and te;bni.al s upport group to man the McGuire f acility.
T. E. Touchs tone (released to McGuire), Field Engineer, Civil, has been replaced by D. L. Freeze.
Freeze's p revious po itisn was Field Engineer (of fice, records).
Ihe inspector cues tioned Eunnicutt during the inspection regarding the choice of men selected.
Hunnicutt defended his positicn.
The inspector cautioned Hunnicutt regarding personnel reassignment and the ef fect or dilution of technical competency and experience.
M. W.
Fos te r, Assis tant Field Engineer, Civil, has replaced Freeze as Field Engineer.
G. W. Greet, Field Engineer, NDI. has been released to McG ui re.
The field engineer, NDI, positico and associate field engineer, welding, positica has been combined.
The newly assigned Field Engineer, Welding - NDI, is Blaisdeli, the previcus Associate Field Engineer, Welding.
Blaisdell is being prepared for release to McGuire in the future.
A.
R. Hollins is assigned Assistant Field Engineer to Blaisdell.
The associa ta field engineer pcsitions, piping and equipment, have been combined ;nto the field engineer, mechanical, position.
Sibley, previous field engineer, piping, has been assigned as the Field Engineer Mechanical, with Martin, previous field engineer, equipment, assigned as Associate Field Engineer to Sibley.
Sibley is schedul-:d to McGuire at a future
- date, i
<l Corporate level precotions:
1.
C. Horn - President 2.
B. B. Parker - Executive Vice President and General Manager 3.
W. S. Lee - Senior Vtte President of Censtruction and Engineering 4.
W. H. Owens - Vice President oi Engineering 5.
C. E. Watkins - Vice President of Cons truction C.
Main S team Safe ty Valves T.e QC record file fer the Crosby-Ashten main steam safety valves for Unit 2 were reviewed.
The document file contained Dake Purchase Order T-20090, Specification OS-254, Addendus 2, revised ibrch 1,1971, enginee ring change notices, till tes t repor ts for body, bonnet, nozzle and insert, PT, CT, MI, RT tests and hydro.
The re;ord file did not have cer tificacica of capacity as required by Section III, Article 9 of the ASME Boiler and Pressure Vessel Code (B&PV).
Curtis will follow up.
l l
\\
CO Rpt. Nos. 30-270/71-3.
D.
Primat5 Cec ian t Pamps The 1:.spects dit;ussed with Curtis and Gwens the use of Bingham Pump Cc=pany (Bingham) as primary coolant pump supplier.
The inspector was provided the ici'.: wing background in forma tion.
Duke did participate in the original selection of bidder.
Byron Jacksen Pumps, Inc. (BJ),
Wes tingho us e Electric Ccrporation (W) and Bingham were active bidders.
Owens c:tcented that W was reje ted because ;f pump problems at that time.
B6W and Duke agreed to accept Bingham provided full pressure /
te=pe ratuce/ tl.w locp tes ts could be peric cred.
Contracting time permitted approximate 1y one year buf fer.
nitial operationa] tests identified undersized bearing and shaf t p r ob lems.
>Hnor moctr1 cations did not sols e the design problem.
Binghan did produce a new design but scheduitng did not permit the time and B&W/ Duke elected to utilize the W pumps on Unit 1.
The new 3ingham design pump has cecpleted all tes ts of the eriginal specification according to twens.
A 500-hour and 100-hour tess at f ull tempe rature/ pressure have been successfully completed with an additt;nal 500 hour0.00579 days <br />0.139 hours <br />8.267196e-4 weeks <br />1.9025e-4 months <br /> run scheduled.
All tes ts have been per-fe rmed with no seal problets.
The pump casing has no*. been modified since ti.e original design with the exception or minor modifications tb the double volute which is not a pressure boundary p t.
Owens assured the.inspec tor that B6'i and Duke's cwn engineers and QA personnel have f clicwed this problem closely.
The inspector made arrangements to review the pump QC file at a subsequent inspection.
E.
Primary C2c. ant and Other Class I Pipe 1
Field Weldtn2 Control and Documentati.n With the excep tt:,n or the 22 field welds of the reactor coolant 1:aps, Duke utillaes an IBM punch card I?r centrol and documentation of field welding.
Ihe weld card pregras encocpasses USAS B31.7 pipe plus USAS B31.1.0 design with addi-1:nal seistic requirements.
Duke maintains a separate rtle for each at the reactor coolant loop welds.
See Exhibits :
a.
B, Main Coolant Joint Identificaticn Numbers.
b.
C, IBM Punch Card (Field Weld Che ckor f Lis t).
c.
D, System Isocetric.
Field welding control is as follcws :'
Isemet rics are d rawn irc= Duke drewings.
(See Exhibit D.)
a.
b-The welding engineer places welding informatica on the iscretric.
(See Exhibit D.)
CO Rpt. Nes 50-270/71-3.
c.
IBM ca:d3 are p nthed with weld ideatiticatica inrormation, (See Exhiatt C.)
d.
.lBM cards and iscmet ri are dist::t uted tc the field welding
.inspe tors ror process, e.
At:cr c;mpletica of weld, the cara: are returned to the incetplete
- lle.
t.
Printout of incomplete welds (NDIf is pe rf o rme d,
g.
NDI is performed and signed cif.
h.
Cards returned to cc plete file.
2.
Weld Pr cr.adures, Procedure and Welder Q>alifications Duke maint ains a weld procedures manual.
Each welding insp:ctcr is prcvid;d a c:py Ihe manual is composed of two sections, s tructural s tee l weld:tg p rocedures and pipe welding p ro. edures.
Pipe weld pro-
-e da c c: and weldors are required to be quall led in accordance with Sect 1.n IX of the ASME B&PV Code.
Weldar qualification contrcl is by IBM card printout.
Use uf process by the weldor is checked at J0-day tr.ter /als agains t the printout.
The printout defines weldor, proced;re, thickness qualitied, and position.
Weldor proficiency teedback is monitored by IBM printout noting - weldor, joints welded, radi..g:aphs reject or accept.
Foilawup is per f orced oy the field
. welding engineer.
3.
S DI Pr cedate and T6that 2ans Duke has rece ntly implemented NDI (MI, PI, RI) and welding inspector tr aining :ourses ons tte.
Duke has qualitied/ certified pe rsonnel in MI and PT enly.
Othe r training and certification has been acccaplished by the Erec ticn Department ei the B&W, Barber cn, Ohio.
NDI personnel are certified in accordance with SNI-!C-1A recuirenents.
Ccurse out-lines are as rollcws:
a.
Mag.eti; P.ticle (MT) Course Irav.img The ceia,e cens ts ts or 16 hours1.851852e-4 days <br />0.00444 hours <br />2.645503e-5 weeks <br />6.088e-6 months <br /> s;.heduled classrac instruction.
(1)
Principles or magnets and cagnetic fields.
(2) Magnet. cation by = cans 01 elemtric current.
(3)
P rinciples c f demagnitizatien.
(4) MT tes t eq uipmen t.
(5)
Types c f dtscontinuities 1ccated by MT testing.
(6)
MI test indi cations and interp retation.
(7)
Duke procedure fer MT examination, Specification MI-1.
(81 Ccde requirements (a)
ASME ShPV,Section VII', Acceptance Standards.
i
~_
CC kot. Nas. 50-270: 11-1
-d-50-287/7. ;
(c.
UdA> 3;l 1.0, Ccde rc rcssura Piping Acceptance Standards
(->
USAS B;l
, J.>de :s r F ressure i ping Suc.ea: Power Piping A'_.e p t an ce stancard:
(d)
AW5 Di.0-6s, sp-ci:i ;& c t e n: tar Weided Highway and Railway Brldf..
t,.
i tquid Pmetrant Ccurse I t ait..n e s-te or 12 L.ucs hi juu d class reca las tr N tion.
N..t;: 3 e e
(1)
History et Pr Meth;c (2)
Pr p ec..w e s la g.
(;:
be.e..ti-n
- t PI te
- n a l (4)
Pr tert cq,tpment.
(3)
F r ind:.a t tens (6)
C;tg ac.. Inspt: :1.3 p:v;adures and s:ar.dards.
(a, Cu = pro.edurs :r liquic p :ne t r an t e x a:.i n a tic a, PI-1 (e)
A5 ME B s F i', 24;ti..11 ', a t :ep:an;e 5:andards t)
U5as 331,1.0,
..de ter Prassure Piptag, Pcwe r Piping Jr..eptance Standards LdAd B J 1. e., Lede Ist Pre-,uru r ip t o g,.,,i c;1 ear Icuer t.,
,d>
Piping Act4ptanme Standara,.
le)
D asc pt:Caddre It r leak testing using thE 11;uld p:natrant cc n 2, PI-2 (ti asME 54;ti:n /I:1, Appendix Li, Metheda tar Liquid Per.c. t t an t Examina: ton (3)
Ab.ga d ;
.3..oJ-03,
..cthJds I'4.id penetta5L inspEcrion.
g,
.i s d.. g c a ; t' e : Iraining C-u: 5a c.
l '.. t : u.:. ; r. g suria 13 used as 1:022t 12.
".ructi,n Laterial IOr 1:.d'.vidcal= being tr2104a a3 r ad.. g: ag he r - and rad:'grapher's
.s s : 1:, t a n. - JLder the C;r.t;ructi;i Us p 2 r t set.; 'Oyp rO duc t Caldrid1 1;;sn c.
In additivn rb-.;Oplet. r 11 thd Course, 30 individual 1.s t ha /d thr,e monthe va r.e-j.o t r a:a ng with the Ccnstructicn r3diagrapher's a521s'Snr priv! t0 h61ag r6c0CDEndad Departcent as a as 9 rJd: Jfraph;r and inri6 LCGth5 J; Lf.-thc-j0D training as a rid;;grapher's h61pdf p!. !
te;n4 (di.G 6hdsd as a rad;O4rdDht!'s asilstant Dr thu E q ul's a.: n ; tt3.I.nf and formal Instruct!CS, the
$ b r i t titi cr.d, r s liail examinat1On app:cVnd di..dus.
3'.2 : pasa by the stat: health phy.-iciet, d
L 3;>; :n-p :t.: Irsin:ra C..
c
' f. e T I il:11G f ;v a.' o n 1 almi r.l s id f e d Dj tne Field Welding NDI E.adineer, Bla.sdell.
Instr':t:,c.casists ci the fv11cwing:
t
l CX) Rpt. Nos. 50-270/71-3,, -
50-287/71-3 (c) Qualification for thickness range from 1/16-inch through 1-3/4-inch wall thickness cilizin3 8 inches I.D.
with.875 wall pipe with a preheat temperature range of 300*F, interpass temperature range of 500*F and postheat treatment at 1200*F - one hour.
(d) Weld procedures lacked definitive guidance relative to defect 1 repair and verification of defect removal.
(e) Joint design figure indicates use of backing strip while actual qualification was made without backing strip.
(f)
Weldor performance qualification tests were not per-formed cs required by the weld procedure.
Some weldor qualifications were being performed in accordance with the Summer 1970 Addenda utilizing the 6G position, ten-inch pipe and radiographic the weld for acceptance.
(2). Welding electrodes were found exposed to the elements for
. undetermined periods of time without being discarded.
Loose electrodes were found in the vanes of one primary pump casing, one container of 7018 electrodes was found open and exposed to the weather, and a number of individual (small bunches) of electrodes were found on welding machines and working areas.
No further discrepancies were noted in the recordkeeping, retrievability, personnel performance or program deviations.
b.
4800 - Welding 4805.03 - Implementation of QA Program Confirmed.
See comments of E.1 above.
4805.04 - Review of QC Sys tem a.1, 2, 3 and 4 - Qualifications See. comments of E.2 and 3 'above.
Discrepancies for Items a.1 and 2 are noted in Section 4.a. (1).
b.1, 2, 3, 4 5, and 6 - Identification of Weld Location, Weldor
~ Weld Procedures, NDT Technician, NDT procedures, NDT Results See comments of Section E.1 and Exhibits B,. C, and D and Section E.3.
,~.
CO Rp t. Nos. 50-270/71-3
- 50-287/71-3 The radiography log and control system identifies the weld number, NDT technician and NDT results.
c.1, 2. 3, 4, 5 and 6 - Visual Inspectica (See Exhibit C.)
Fain loop joint recordkeeping system requires additional, fitup measurements, preheat reading, weld material control, postheat treat, etc., requirements to be maintained.
d.1, 2, 3, and 4 - Preheat, Interpass Temperature, Pos tweld Heat Treat (See Exhibit C.)
Main loop joint records require additional recordkeeping for above lis ted itens.
Weld procedures define maxisus preheat, interpass and heat treat temperatures, e.1, 2, 3, 4, 5 and 6 - NDT See comments of Section E.3.
Duke has developed NDT procedures and specifies s tandards for acceptance.
f.2, 6 - Defect Re=7 val and Verificatica of Repair Defect removal is performed in accordance with weld procedure directions and verification is by NDT methods.
g.1, 2, 3, 4, and 5 - Weld Material Control Duke has a weld material control procedure. No deficiencies were identified.
4305.05 - Record Review a.1 - Visual Inspection The inspector reviewed the veld records for selected welds reviewed and found no deficiencies, a.2 - Heat Treatnent Records
. Heat treatment records for these welds inspected in the reactor coolant loop and no discrepancies were noted.
a.3 - NDI Records NDI records for those welds selected were reviewed and no dis crepancies noted.
?
C0 Rpt. Nos. 50-270/71-3.
~.
a.4 - Repair Records Reviewed and no discrepancies were noted, a.5 - Weld Material Control The inc,ector perforced a detailed review of stainless steel filler material and electrode control.
Duke orders material in accordance with MIL specification and receives actual chemical and physical certifications.
The certifications do contain trage ferrite content.
The inspector requested that Duke personnel plot ferrite content of several heat of material onsite utilizing the Schaef fler diagram and comparing this with the actual certifications supplied.
The inspector obtained heat numbers f rom the f abrication storage supplies, field s torage supplies and f rom weld cards.
The certifications were produced and Hollins plotted the equivalents.
The inspector with Duke personnel performed severa gage tests of several welds utilizing the respective heat number material.
The inspector's field findings were within approximately 2% points of Hollins plotted data and the plotted data agreed very closely with the supplied certification data.
Ferrite content of field welds checked within the core ficod and high pressure core inj ection system averaged 9 to 12%.
4805.00 - Work Observations a.1 - Use of Wald Procedures a.2 - Joint Preparation and Aliennent a.3 - Identificatica cf Weld, Waldor and Inspector a.4 - Acpearance of Partial and Canaleted Weld No discrepancies were noted ror thcsa Jelds selected for review.
- a. 5 - Con trc l o f Weld " ate ria _1 Discrepancy noted.
See Exhibit A, Photo Nos. 8-10.
F.
Reactor "essel and Steam Gener2t;rs This inspector effort was directed tcward inspection followup of the Unit No. 2 ins talled reacter pressure s.essel and s team generators plus review of the QA inspecticn and installation record 3
l CO Rpt. Nos. 50-270/71-3.
50-287/71-3
- y The inspection was pc formed in accordance with the requirements outlined in. Attachments J and L of ?I 3800/2.
1.
Summary-Unit No. 2.s teem generators. 2A and 2B were received at the Oconee site via railroad flat car February -1 and 22,1971.
The Unit No. 2 reactor pressure vessel arrived at the site on a special trailer transported from the barge dock near Augusta, Georgia, by Reliance Trucking Company on March 1, 1971.
Erection of the steam generators and reactor vessel was performed according to s chedule.
Installation of the primary coolant piping is progressing with the welding of 18 of 22 welds completed except for NDT and stress reliefing of the accepted welds.
The licensee informed the inspector that engineering has questioned the NDT rating of 90*F shown on the No. 2A core flood tank nameplate as being in error. There are indications that the value should be j
.115'F..This problem will be added to the Outstanding Items List and will be reviewed during a subsequent inspection.
Several areas of nonconformance were noted:
a.
. Installation of major components without proper procedures.
(Refer to Sections F.3, 4905.04.c.1, F.3, 4905.06.a.2, and F.4, 4905.04.
C.l.)
b.
Repair of construction damage to Class I components without repair procedures.
(Refer to Section F.3, 4905.04.c.3.)
Inability of the QA group to enforce a "stop order" on repair work.
c.
until proper engineering resolutien is received.
(Refer to Section F.3, 4905.04.c.3.)
d.
Numerous are strikes were observed en the reactor pressure vessel.
(Refer to Section F.3, 4905.04.c.1) e.
Equipment receiving. requirements of the purchase documents and the receiving reports do not contain references or confirmation that the special ~ requirements of the applicable' specifications have been met.
(Refer to Section F.3, 4905.04.b.6, F.3, 4905.05.a.2, F.4, 4905.04.b.2, b.6, c.3, and F.4, 4905.06.a.2.)
CO Rpt._Noo. 50-270/71-3 :
'50-287/71-3 m
- 2... Documents Reviewed
.B&W Specifications FS-lil-la Receipt, Inspection, Handling, Storage and Installation of the Reactor Pressure Vessel FS-lll-lb Receipt, Inspection, Handling, S torage and Ins tallation of the Reactor Vessel Closure Head FS-ill-2a Receipt, Inspection, Handling, Storage and Installatien of the Once-Through Co=mercial Steam Generator B&W and Duke reactor pressure vessel and steam generators receiving and
.. ins tallation reports.
(Rafer to Exhibits C and H.)
3.
Attachment J - Reactor Pressure Vessel - Unit 2 The B&W specification (FS-lll-la) uns reviewed to determine if the requirements for receiving, handling and installation of the reactor
. pressure vessel were adhered to.
4900 - Mechanical Components i
.4905.04 - Review of QC System b.2 - Receipt Inspection and Handling The reactor pressure vessel was shipped from the dock near Augusta, Georgia, via a special trailer by Reliance Trucking Company.
The
. vessel.was inspected by Stokes (B&W) and Martin (Duke) for shipping damage and confirmation that the nitrogen blanket was.in existence and.the humidity indicator indicated that the interior was dry.
The B&W and Duke QA reports confirm that the vessel was received in a
.satisf actory condition on March 1,1971.
b.6 - Special Handling and Storage Precautions
.The reactor pressure vessel was placed in storage on the shipping rig and trailer from March 11, 1971, until it was installed on April 12, 1971.
Thi records are not available to confirm that periodic checks of the nitrogen pressure and humidity indicators were made; however, B&W and Duke personnel confirm that daily inspections of the stored vessel were made.
c.$
C0 Rpt. Nos. 50-270/71-3 50-287/71-3
.m c.1 - Installation Specifications and Procedares Paragraphs 13. and 2.3.1 of B&W specificatica (FS-lll-la), " Receipt, Inspection, Handling, Storage and Installation of the Reactor Pressure Vessel," require the erecting contractor to provide detailed procedures to describe the cethod for lifting, setting and aligning the reactor pressure vessel and the cons tructor to provide detailed instructions for installation of the sole plate.
Af ter a review of existing procedures and conversations with B&W and Duke personnel, it was determined that the required procedures were not prepared and that the equipment was installed by technicians operating under verbal ins tructions.
These actions are in violation of the B&W specification and Criterion V of Appendix B of 10 CFR 50.
c.2 - Use of Expertise in Ins tallation The reactor pressure vessel was removed f rom the shipping rig, uprighted and placed in position by a rigging and hoisting crew furnished by Reliance Trucking Company.
This was the sate company that set the reactor vessel for Oconee Unit 1.
The settint of the reactor pressure vessel sole plates and leveling the reactor vessel was done by Duke Mill Power employees who also set the reactor vessel for Unit 1.
c.3 - Installation Inspection A visual inspection of the installed reactor pressure vessel was performed with the general appearance of the ina talled vessel as being satisf actory.
The installation inspection reports furnished by S&W provide the following info rmation.
a.
Head flange mating surf ace ins talled at elevation 816' + 5-3/16".
Specified eleva tion - S16 ' 6+1/4".
1.
The maximum out-cf-level reading across the diameter of the i
=ating surface is 0.007-inch as compared to a per=issible out-of-level tolerance of 0.001-inch / f t (0.015-inch).
c.
The W-Y axis of the vessel is parallel to the north-south building center line ithin 0.31 inch as compared to the specified tolerance of 0.010-inch /f t (0.150-inch).
C0 Rpt. Nos..50-270/71-3.50-287/71-3
,m The vessel has been aligned within the specified tolerances and accepted by B&W (Faasse) and Duke (Henry) representatives.
On arrivd at the Unit 2' site, the licensee advised the inspectors that sometime during the weekend several are strikes were made on one nozzle of the reactor vessel and QA had issued a stop-work order on all work on that nozzle until the are strike damege was reviewed by B&W and a repair procedure was approved.
.Further visual examination of welding the primary coolant piping to the reactor vessel revealed numerous are strikes against the vessel wall and nozzles.
(See Exhibit E.)
..On the inspectors second day at the site it was determined that repair had begun on the arc strikes without the written repair procedure and in violation to the QA stop-work order that has been initiated. The repair consisted of grinding out the damaged areas
.and. performing magnetic particle inspection of the area.
The repair of damages to Class I components without proper written procedures is in violation of Criteria XV and XVI of Appendix B of 10.CFR 50.
The B&W repair procedure (Exhibit F) was received at the site two days af ter the repair was initiated.
.4905.05 - Followup Record Review a.2 - Storage Inspections Prior to the installation of the reactor pressure vessel, the vessel was stored on the special transporting trailer in the shipping rig.
.The. vessel. internals were protected agains t the environment by a pressurized blanket of nitrogen.
According to the licensee, the condition of the stored vessel was checked each day by v!.aual
' inspection of the vessel surf aces and checking the humidity
.. indicators. No QA records were available to confirm that the inspections were performed.
Special metal covers are provided to keep construction debris from
.f alling into the vessel during the interim until clean room con-ditions are established. QC inspections of the installed vessel are not specified.
- a. 3 - Ins tallation Inspections QA inspections are performed on all welding of primary coolant piping to the reactor vessel.
.The QA engineer assured the' inspector that a QA technician will observe _the torqueing of the anchor bolts.when that job is performed, t-J
C0 Rpt. Nos. 50-270/71-3 50-287/71-3 7
4905.06 - Followup Observations pf Work a.2 - Installation Technicues Duke Construction Department enjoys a good reputation for the quality of ccastruction it has performed in the past.
The capability of erecting large ccuponents has been demonstrated by the work done on Oconee Unit 1 and the relative case that was experienced in the installation of the large components in Unit 2.
The installation techniques are adequate; however, the lack of QA documents to confirm that proper engineering measurements and good cons truction techniques were followed throughout the installation is.of great concern to the inspector.
l a.4 - Protection of Ins talled Vessel With the exception of steel covers over the vessel-there are no special. precautions presently exercised to protect tce vessel agains t the environment.
A clean area is scheduled to be set up when the temporary opening in the containment building is closed.
b.2 - Protection of Vessel in Storage
.There are no special precautions being taken to protect the vessel in storage at this time.
This item will remain open for future inspections.
5500 - Cleanliness The installed reactor pressure vessel has not been cleaned and the clean room s tatus es tablished.
Cleanliness of the installed vessel will be reviewed during subsequent inspections.
4 Attachment L - Steam Generators (2A and 23) 4900 - Mechanical Cocponents 4905.03 - Innlecentation of QA Program The Duke QA program for the Oconee facilities has been evaluated and determined that the program is adequate.
If the QA documents are
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50-287/71-3
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3 properly executed, they will provide ress:7 ible cssurance that the equipment has been ins talled withni the d:ransional r.clerances established by th+. de s i gn.
. 4905.04 - Review,f yC svseen b.2 - Receipt insoection and lil7:lir 7 The. steam generators wer e shipped to the Oconee site via rail car with s team generator 2A ra teived and inspected n Februa y 1,1971, and steam generator 23 received and inspected 'e February 22, 1971.
.'Dae B&W. inspect 1 >n and re ceivin g repc r ts (Exn; bits G and H) were
. signed by St:k== (36W) and Martin (Duke) and tcciira that the
. humidity.indicaters checked al:1gne and -here was no external shipping danage to althar vessel.
.The.B&W shipping and receiving inspactica precedu:e (FS-111-22)
. requires that ccnfi::ation of the nitr gea blanket be made, during the. receiving inspection, by esad cg the pressute gauge and
.cccentarily Opening the dis :harge valve.
Its ractiving repcrt does not indicate that this requiren=nt ws. :2;11 ed with.
a b.6 - Special Handling and 5 to: a ge Prs tautians
.Each of the s:cas generators vs:e sect-d at the rail head in their
. shipping rigs f or several weeks bei::a thsy acts ins talled.
During
.this time, a daily inspect:cn ei the stared carpatents was made; however, no record was made of :ns :nspe.::'n findings.
b. 7 - Q ua ran t i r.e, f N: n c n :: :mi-- ;
n;:nents
..The Duke QC p:cgra provides ist gaarr.:ning :: n;nconforming ccm-ponents ; hcwever, n: a: tion was required for steam generator equip-ment received en this ar der.
c.1 - Ins talla ti:n s = c::: car: as ;::d F: : dure s
.The.B&W ins tallaticn Spa ci fica ti:n F5-111-; A r equi res the crecting
. contractor to pr: eide the de te: led *:cctt.c p:s:edare and the
.. installing :catract:r ce preerde de calle : ins tallatica procedures.
.These requi:_ rents ware never net, and th= erect:: provided the rigging and set the vessels in pla.e w. heat the required procedures.
The installer 1 s:alled th= vess=1s without tne re;utred procedures.
. -.m CO Rpt. Nos. 50-270/71-3 50-287/71-3 c.2 - Use of Expertise in Installation
.lle Duke Cons truction Department is experienced in construction of
. power plants and the installation of heavy components. The same
.craf tsman frcm the Mill Power section that installed the steam generators in Unit 1 also installed the steam generators in Unit 2.
c.3 - Installation Inspections
.The ins tallation reports were reviewed and are appended to this report as Exhibits G and H.
.The, welding of the primary c:olant piping to the steam generators and the. final torqueing of the ancher bolts remain to be done before the installation is considered complete.
During a. review of the ins tallation procedures and records, it was
. determined that the steam generator nozzles had not been checked for
'.' free iron" using the B&W Specification 207 as. required by paragraph
..3.7.of the B&W Specification FS-111-2a.
Further investigation determined that the referenced specification (207) was not available in the B&W or Duke files.
Efforts were initiated to obtain copies of the required precedure.
4935.05 - Follewup Record Review a.2 - Storage Inspections
.The. steam generators are in the process of being installed; therefore, the stcrage requirements are not in effect at this time.
This requirement will be checked on subsequent inspections.
a.3 - Installation Ins 3e tions A review.of.the installed tolerances, vertically, and elevations was
.made.
The ins talled component inspection sheets are appended to this report as Exhibits G and H.
.The. installed dimensions were reviewed and approved by B&W Engineering Supervisor, R. E. Ham.
Completion of the installation by welding the primary coolant piping
. to the steam generators and final torqueing of the anchor bolts will be reviewed during subsequent inspections.
t
C0 Rpt. Nos. 50-210/71-3 50-287/71-3 b - Material ani F4brication Certificatior.s
.The.s team generaters manuf acturing inspectiers.racords and certifica-
. _tions were.not available at the site; however, a release order for shipment, certi:ying that all tha QC, ASME, and specification require-
.ments had been fulfilled, was signed by W. C. Buskay, B&W Manager of QC at the Mount Vernon facility.
4905.06 - Followuo Ocse rva tions of Work 6
a.2 - Installati:n Technicue
.. Duke Cons truction Department installed tne s essa generators with the same degree of quality workman 3 hip as they have demons trated in the
.p as t.
As. referenced in paragraph 4905.04.c.1 in Section ?, the craftsman perf ormed the ins tallation wi thout the required installation procedures.
a.4 - Protection cf Installed Compcnents During the interis that the priaary coolant piping is being welded to the.s team generators inlet nezzles, the cutlet nozzles are protected with a wire mesh hausing and steel caver plata, Af ter the ins talla 1cn is complete, the manways will be the only
. access to the vessel internals, and they will ts kept in place except fer periodic inspection.
The ccc.dition of the ins talled vessels will be checked periodically on suosequent inspecticns.
b.1 - Quarantine of Non:enfo rming Coroonents
.The steam generators were re:eived at the Occnes site and were found to be acceptable and approved for installation.
There wera no ccnforming ccmponents, b.2 - Protection of Cceponents in Stsrage The staan ganerators will be placed in the installad storage condition while awaiting the completion of the plant, There are no special storage requirements for these vessels.
I l
1
i C0 Rpt. Nos. 50-270/71-3.
50-287/71-3
-,.m 5900 - Cleanliness There will be no attempt to clean the steam generators until the system is comp le te.
This requirement will be reviewed at a later date.
Attachments:
Exhibits A - H (Exhibit A - C0:HQ copy only)
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Exhibit E Page 1 of 1 a
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P. O. Box 607
,. l8 Seneca, South Carolina 29678 wabCOCh&WilCOX nw cons:ac::c, ce=v May 6, 1971 Mr. R.
E.
Blaisdell Re:
NSS Oconee II
? told Engineer 12-E-51 Duko Power Company P. O. Box 1234 Seneca, South Carolina 29678 Subje Arc Strikos on Reactor 7essel
Dear Mr. Blaisdell:
Please use the following procedure for removing tho arc strikos recently made cn the Unit U2 reactor VOSs01.
1.
Blond grind arc strike.
2.
Etch :ho ground area to detcrmine if a11 heat
~
affccted zona has been ramsved.
(lar.monium-perculphate is recommended for etching.)
3 After otching, flush etched sur' faco with*c1can potable water.
4 MT the ground araa, using the AC,ycke.
5.
Docume== to verify Location, size, and depth.
The above procedure has boon obtaL=ed af ter consultation with* cur Nuclear C:=ponents Engineering Dcpartmont and our Mt. Vernc= ^uali ty Cont rol Manager.
The abovo procedure should be performed under the supervision of J.
R.
McGill.
Please arrange to furnish him with all copies of the documentatien.
6 Very ruly ~ours, BABCCCK & 'd!LCOX
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E&V Ccnstruction Compan Q WP:ck 1 b e.,
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Berger - B&'d Cconoc Site H.
C. Gransee - Houston G. 5. Kul'ynych - Lynchburg C.
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Thompson - Barberton M. P. Way - Atlanta Exhib t E Page ot 1
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NSS COMPONENT INSP5CTION REPORT 17 i c)'1
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E OF INSPECTICth RECE!VING IN STORAGE INSTALLATICN XX FINAL
--_m Comp./Syst. No.
55
- 1. EquipmentM.tcrerial Description s w m omn-estor 2A Vendcr/ Works
% *n c e d 6 Vil e r.x P.O. #
Custemer N m pcver cemnany NSS 4
Appliccble Field Procedures Ps-Irr-?a Appi;c;hl Specil.' cations (Instructions, Drawings, Codes);
- o. cs-3-33 b.
cs 5-95 Dwg. 1286265 c.
- 2. Celivering Carrict Siii of Lading n Octe Rec'd.
- 3. Descript;cn oilnspection Cate 2-20 rnd 2-27 '71
_ _ ' ~nspected steam Generator 2A for verzicality and contac with soloplates.
The location of the V, X,
Y, and Z centerlines on J 6" inlet nozzle as related to the same centerlines on the base is shown on attachcd Field sketch 27A, dated 2-24-71.
Contact betwoon the top of the seleplates and the bottc= cf the vessel was measured with feeLors frem be:h sides of the skirt support flange.
Attached Field sketch 28A dated 2-2h-71 shows the
___lecation and the amount of openings fcund.
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DOOD~nnittiu FUUR UHlUIR b
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L. ' c[ 4 c c - c a :cis u inspected By: EN.
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BABCOCX & WILCOX POWER GENERATION O! VISION BARBERTON. OHIO
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BABCOCK & WILCox POW:..n GEN v a. 1CN *1V1S103 3;.aeEaTCN. Chlo
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NSS COMPON EN T IN SPECTION R2 PORT
,3 T.YPN OF IN'iPECTICN: RECElVING IN STORAGE WSTALL AT:CN "X FW \\L Cer p./Sy:r. No.
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- 1. Equi;:.r.an:Noteric! Descripti:n stes., Generator 23 Vendor /.'!crks Babcock & Wilco::
P.C. '1 Cas:cmcr Duke Pouer Company N55 L
ecole r. !d Precedures.;, eo
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Tha attached Fiold Sketch 30A da tcd :' arch 5_.
1971 shows the locazion and zha amoun: of cpenings found.
Tho "V" and
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The "X" and "C"
or east and wen:. centerlines located on the jf" inia: no2:le.nro reperced tc be a ccro:ci...n t ely as 2" to the north of the same centerlines at the base of the vessel.
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