ML19317G052
| ML19317G052 | |
| Person / Time | |
|---|---|
| Site: | Rancho Seco |
| Issue date: | 02/23/1971 |
| From: | Crews J, Dodds R, Spencer G US ATOMIC ENERGY COMMISSION (AEC) |
| To: | |
| Shared Package | |
| ML19317G049 | List: |
| References | |
| 50-312-71-01, 50-312-71-1, NUDOCS 8002210751 | |
| Download: ML19317G052 (29) | |
Text
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1 V
U. S. ATOMIC ENERGY COMMISSION DIVISION OF COMPLIANCE 9
REGION V Report of Inspection CO Report No. 50-312/71-1 Licensee:
Sacramento Fbnicipal Utility District License No. CPPR-56 Category A Date of Inspection:
January 26-28, 1971 Date of Previous Inspection:
November 16-18, 1971 Inspected by:
23 ko R. T. Dodds (Principal)
Date Rea t r Inspector C) unow
% i J. jII.' C( ews Dpte i
Reactor inspector (Prepared Sections D & E)
Reviewed by:
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G. S. Speycer Date Senior Reactor Insp*<:ror Proprietary Information:
None SCOPE Type of racility:
Pressurized Water Reactor Power Level:
2452 Mac Location:
Sac: amento County, California Type of Inspection:
Construction Inspection I
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Accompanvine Personnel:
None 6002 slo 75,/
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SUMMARY
Construction Deficiencies - No significant deficiencies were identified during the inspection.
Status of Previous 1v Reno-ted Problems - No problems were listed as being outstanding following the last inspection.
Other Sirnificant Items 4
.1.
Overall project construction status was estimated to be on schedule with 30% completion as of January 28, 1971. All but 20 feet of the concrete for the vertical wall of the containment building has been placed. Field fabrication (laydown work only) of the dome liner has been started. The cor.tainment building (including inside shield walls) was estimated to be 55% complete. About two-thirds of the concrete for the second natural draft cooling tower has been placed.
The dam for. the 160 acre lake on the site has been completed and the lake was approximately half full of water.
(Section L.)
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2.
No significant deficiencies were identified during the annual
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review of the QA program which was performed in accordance with PI-4000/1 (Draft).
(Section C.)
3.
SMUD's vendor audit of Velan Engineering (Valves) and B&W Canada (pumps) disclosed significant deficiencies in the QA programs at these facilities. SFUD suspended all work on their products until the QA programs comply with the requirements of the respective contracts.- (Section C.6.)
4 The QC program for pipe welding is to be re-evaluated by SMUD and Bechtel with particular attention to the control of essential variables during welding.
(Section D.2.)
5.
The standard Bechtel QC program for electrical systems is not intended to provide independent assurance that cable installations are in.accordance with the design criteria for separation, cable tray loading, etc. The QC system is designed to insure that the installation is in accordance with the detailed routing design generated by a computer program.
Bechtel personnel stated that special quality plans are to be prepared for reactor control and engineered safeguards cable systems. These plans-will provide independent verification of conformance to.the design criteria during installation, according to the Bechtel representatives.
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U 6.
Sections F.,
G., H. and I. list the status of the Operating Organization, Safety Committees, training, and preparation of procedures and manuals. Personnel hiring and training (including proposed training) appears adequate for the status of the project.
Manacement Interview - The results of the inspection were discussed with Messrs.
Mattimoe, Jackson, Raasch, Rodriguez, McMahon, Vander Knyff, Demon, Binghan and Steen. The following items were included in the discussion:
?
1.
The need to activiste the Management and Plant Safety Review Committees at'an early date was emphasized by the inspectors.
This will be done as soon as practical according to Mr. Mattimoe.
He pointed out that the members of the Conunf ttees were active as individuals in their respective fields in the design and construction of the plant and in the formation of operating i
standards.
2.
The desirability of corrective action logs for items requested for consideration by SMUD's design review engineers will be i
investigated.
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3.
Mr. Vander Knyff stated that the Bechtel QA program for the field welding of piping systems would be re-evaluated with particular attention to the extent to which the program provides assurance of conformance to essential variables during welding operations.
4 Inspection plans will be reviewed to ensure that tests required by the addenda to_the specifications have been incorporated into the plan, according to Mr. McMahon.
5.
Mr. McMahon stated that special QA programs are to be prepared fori electrical installations which are to be a part of reactor control i and engineered safeguard systems. These spe:ial programs are to be designed to provide independene assurance that cable installations conform to the design criteria for cable separation, cable tray loading, etc.
j DETAILS A.
Persons Contacted The following persons were contacted during the inspection.
J F
s !.51R Assistant Chief Engineer J. Mattimoe D. Raasch Project Engineer J. Jackson Quality Assurance Director W. Friedrich Quality Assurance Engineer R. Rodriguez Plant Superintendent R. Oubre'
' Assistant Superintendent Nuclear Plant Operations J.-Kirby Shift Supervisor L. Kielman Mechanical Engineer R. Wilson Nuclear Engineer Bechtel Corporation - (Engineering and Construction Management)
V. McMahon Chief Quality Assurance Engineer Quality Assurance EnF neer (Source Inspection)
R. Hunter.
i W. Taylor Quality Assurance Engineer (Mechsnical)
W. Chapla Quality Assurance Engineer (Piping & Welding)
D. Martz Quality Assurance Engineer (Electrical & Instrumentation)
R..Denom Chief Inspector W.-Bingham Nuclear Engineering Group Supervisor Bechtel Corooration - (Construction)
J. Vander Knyff-Project Superintendent B. Ayers Project Field Engineer B. Boyd Welding Supervisor D. Wilson Welding Engineer Leave 11'-Dravo W. Steen' Project Manager B.
Status of Construction Site construction was estimated to be on schedule with 307. completion as of. January 28, 1971. Concrete for the reactor containment building has been placed to elevation +93.9 feet (120 of 140 feet of vertical wall). Field 4
-fabrication (laydown work) of;the dame liner has been started. The containment
- building (including'inside shielding walls) was estimated to be 557. complete.
About two-thirds of the concrete for the second natural draft cooling tower i
-has been placed. The dam for the 160 acre lake on the site has been completed and the' lake was-approximately half full of water.
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Periodic Inspection of Implementation of OA Program The annual periodic inspection of the implementation of the QA program was executed in accordance with the provisions of PI-4005.05 (Draft). The inspection included a detailed review of QA records to determine compliance with the AEC 18-point criteria and the Rancho Seco Project Quality Program manual. Personnel contacted during the review of the QA program included Messrs. Jackson, McMahon, Taylor, Hunter, Wilson and Keilman.
1.
SMUD - Bechtel Independent Audits The QA records documenting design review, manufacture and placement of concrete for the containment vessel were reviewed for conformance with SMUD's 20 point QA manual. A brief summary of items included in the review follows, a.
Design Review and Ouality Assurance Classification Design review and structure classification were completed in February, 1969 The design was independently reviewed by SMUD. Design review checklists sere utilized by both SMUD and Bechtel to assure attention to ; artinent requirements, b.
Procurement Document Control All procurement has been through vendors that have been
' qualified by QA. Contract purchase orders have been reviewed by the QA engineer and SMUD engineer prior to release for procurement.
c.
Sunolier Quality Assurance An " Evaluation of Suppliers Quality Assurance Program" has been performed by Bechtel source inspectors as part of the
'" Source Inspection Data Report" for all suppliers of materials for the concrete used at Rancho Seco prior to the awarding of the procurement contracts. Vendor inspections were being performed by source inspectors in accordance with approved QA Inspection Plans in accordance with the Supplier Quality Assurance Procedure.
-d.
Inspection Planning Concrete and Testing Inspection Plans have been prepared and followed for the manufacture and testing of materials for and the concrete used at R.ancho Seco. Separate sus were prepared O
and implemented for source, receiving and coutruction inspection
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and testing.
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6-e.
Confinuration Control Configuration control documents were being maintained in accordance with the QA Manual to assure proper review and approval and to maint.ain control of the containment building configuration. Each Configuration Change Document provides a record of who prepared the change, description of change, reason for change, remarks and approval signatures (Bechtel l
Engineering, SMUD Engineering,-Quality Assurance and Bechtel Construction Management - for information).
f.
Identification and Control of Material. Parts and Components A system of material identification and control to assure that materials and components used in the construction of the containment vessel were of proper configuration, free of defects and traceable to quality documentation has been included as part of the Receiving Inspec': ion Plant, g.
Centrol of Soecial Processes The control of special processes as such is not considered by SMUD to be applicable to the manufacture and placement of con-crete.
J h.
Receiving Inspection Receiving inspections are being performed as required in accordance with Receiving Inspection Plans for the materials used in the manufacture of concrete for the containment vessel wall.
1.
Construction Inspection Construction inspections are being performed as required in accordance with the Concrete Batching, Mixing and Placement-i Inspection Plan (QCI No. 104 - latest revision effective September 30, 1970).
-j.
Startuo Test Inspection Not considered by SMUD to be applicable to the manufacture and placement of concrete.
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Calibration of Measurement and Test Equipment Test equipment and scales used in the manufacture and testing of concrete and materials for concrete are being calibrated periodically in accordance with a schedule set by the test equipment inspection plan.
1.
Handline. Shioping. Storage and Preservation The handling shipping and storage of materials for the manufacture of concrete are being performed in accordance with purchase specifications, m.
Inspection. Tests and Operating Status A system using logs that require an inspector's stamp of approval is being utilized to define the quality status of material and work operations for the manufacture and placement of concrete.
n.
Nonconforming Material Control Nonconforming Material Reports are being initiated and processed
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whenever actual conditions are not in accordance with the applicable specifications. Nonconforming material is being segregated from acceptable material and documented on noncon-forming reports for disposition by proper aathority. Rejec' ed material (example: improper size of aggregate) is being promptly segregated by moving the item to a quarantined salvage area.
Records are being retained on all nonconforming material that indicate ultimate disposition of material. Nonconformances handled as " accept-as-is" or " repair" are being approved by the Engineering Review Board in accordance with the QA Manual.
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A log of all Nonconforming Reports is being maintained by QA in the QA Document Control Center to assure control, receipt and completion of all Nonconforming Reports, o.
Document Control Center A document control center is maintained at the site for the storage of records that represent objective evidence of the
. quality status of the concrete (and all other quality items) at Rancho Seco.
A
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System Auditing Independent audits of the QA program are being performed frequently by Bechtel QA Engineers in accordance with a schedule for audits of quality system elements (84 audits had been conducted at the time of the inspection). Of the audits performed to date, about 707. deal with the construction of the containment vessel. Aside from this, Mr. Jackson (SMUD) made 24 system audits in the last year of which four were pure construction audits.
q.
Quality Control Instructions Quality Control Instructions have been prepared and approved for concrete batching and mixing in accordance with the QA Manual.
r.
In-Service Inspection Not applicable to the manufacture and placement of concrete, h
s.
Documents Reviewed by Inspector The following documents tere included in the inspection of QA records for the procurement of materials, manufacture and placement of concrete:
i Bechtel Design Review Check List (Containment Building)
Quality Program Check List SMUD Design Review Concrete Testing and Inspection Plan Material Verifications Material Test Reports Finish Product Test Reports Darex Test Reports (WR Grace Co.)
Daratard Test Reports (WR Grace Co.)
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Silo Cement Test Reports (Kaiser and Calaveras Cement Cos.)
Silo Pozzlan Test Reports (Bassait Rock Co.)
Ice Qualification and Test Reports (West Ice Service)
Water Analysis (site deep well)
Purchase Specifications (ice, pozzlan and cement)
Configuration Change Documents (welding of polar crane brackets, tendon sheathing alignment, and reinforcement placing and alignment) y
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Receiving Inspection Plans Receiving Inspection Report (ice, pozzelan and cement)
Construction Inspection (concrete placement)
Equipment Calibration Log Inspector Stamp Control Log i
Nonconforming Reports Audit Reports Quality control Instructions 2
Effectiveness of Corrective Action System
.The corrective action system consists of two segments, 1) noncon-forming material control and 2) configuration control. About 125 Nonconforming Reports and several Configuration Change Documents were reviewed. Every two weeks a letter is issued by QA that lists all outstanding rework and repair items. Distribution includes the engineers that have nonconformance under considerations. It appeared that action has;been timely and all items are being dispositioned in accordance with the applicable QA procedures.
l 3
Vendor Insoections
. The inspections of vendors by Bechtel and SNUD for confornance to QA requirements contained 1Ln contract specifications were verified to be in accordance with the appropriate vendor Inspection Plan.
4 The project' Inspection Plans for Taylor Forge (stainless steel pipe fittings) and Allis-Chalmers (butterfly valves) were reviewed. The l'
pertinent inspection requirements.were extracted from the contract
. specifications and included in the Inspection Plans.- The QA program 1
was reviewed and approved by SMUD's QA Director, Mr. Jackson. The plans required the vendor inspector.to make.three complete inspections i
of all items'at least three times during the lif a of the contract,.
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otherwise the. inspectors will be sampling 15% (Taylor Forge) and 25% (A111s1Ch11mers) of each design classificatior.. Hold points for inspection have been established for vendors. Completed-Inspection Plans are being returned to QA for objective evidence.
I-4A engineers review the inspection.results for conformance with the Inspection Plan.. No discrepancies were identified by the AEC inspector during the review of vendor inspection reports (3 reviewed).
4 Independent Review of Design Design Review Process Sheets and Quality Program Check Lists are' being utilized by Bechtel/SHUD to provide assurance that components,
. equipment and systems.have been reviewed for adequacy of design, 3
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. applicable codes, standards and criteria. The completed check lists for approximately 100 items were reviewed and found to be complete. No discrepancies were identified.
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'SMUD's "Conunent Memos" (review files) by Messrs. Kellman (Mechanical Engineer) and Wilson (Nuclear Design Engineer) were also inspected.
The memos are documented by number and must be responded to by Bechtel prior to the release of design or procurement specifications.
Nr. Wilson maintains a systematic log to show the status and disposition of memos.
Mr. Keilman was not organized to the same extent but rather, preferred to work out of the file. The inspector verified that Keilman's and Wilson's comments for four separate systens had been, or were being, incorporated into the design specifications. Additional memos were reviewed for substance but were not checked to assure that the comments had indeed been incorporated into the specifications.
5.
Significant ChanRes in OA Prorram Two significant personnel changes have occurred recently. he.
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McMahon has been made Chief QA Engineer for Bechtel, Vernon Office
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but still remains at Rancho Seco as the acting Project Quality Assurance Engineer.
Mr. L. Stromberg has been transferred from Rancho Seco to Bechtel Vernon Office where he will be assigned as Project Quality Assurance Engineer for San Onofre 2-& 3.
The Bechtel QA organization currently consists of the following:
V. McMahon Project QA Engineer W. Taylor Civil and Mechanical W. Chapla
- Piping and Welding D. Martz Electrical R. Hunter Source and Receiving Inspection Planning F. Horvath Engineering Auditor (Stationed at Vernon)
R. Anderson Document Control A significant change in the QA program for Rancho Seco was the transfer last summer of the Bechtel field inspectors from the
-jurisdiction of the 2ield engireers to the jurisdiction of a Chief Inspector who reports to the Project Manager. This move eliminated the disposition of nonconformance by discussion with field engineers and has forced the inspectors to document nonconformance, allowing disposition only after appropriate review and approval.
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11-i Last summer Bechtel was awarded the mechanical and electrical construction contract.. In this capacity Bechtel will install the l
mechanical, - electrical a nd instrumentation equipment and will perform all QA activities associated with this effort. Bechtel has been authorized by_the_ ASM._ta p.erform_worLunder the., Jurisdiction of,the AS E _ code.s_and-is responsible for compliance to the code.
The code work to be performed by Bechtel will be accomplished in accordance with Bechtel's "QC Manual ASME Nuclear Conponents" and y
accepted supplements.
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There now exists three separate and distinct Bechtel groups at the i
site, 1) Project Nhnagement with project field engineering and j
inspection responsibilities, 2) Construction and 3) Quality Assurance.
Exhibits.1-1 and 1-2, appended to the report, show the functional i
responsibilities of the Bechtel Engineering and Management, and l
Construction Organizations.
6 Corporate Enanement Review of Overall OA Program i
Bechtel QA audits vendor and construction inspector performance in accordance with a periodic schedule. Bechtel QA audits conformance
'to each.QA procedure at least quarterly. In addition to the-Bechtel audits, SMUD also audits vendor and construction activities.
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Jackson or.his assistant performed 24 independent audits to assure conformance to the QA program. While.this was a " hit-and-miss" proposition, SHUD has now established an audit schedule to assure management review of the overall QA program.
Mr. Jackson's audits in December 1970 of B&W Canada and Velan Engineering Company, Montreal,' Canada disclosed that these companies were not meeting the QA commitments specified in their contracts.
In view of this
. experience, it left Mr. Jackson with a question as to the adequacy of other vendor evaluations that had been performed by Bechtel source inspectors rather than Bechtel's QA engineers. Therefore, QA has been requested to audit these other vendor plants (13 in all) i for QA conformance to contract specifications.
It was expected that these special vendor audits will be completed by March 1971 4
Deficiencies' identified by Mr. Jackson included the following:
Velan Eneineering 1)
Receiving inspection procedures were not being followed.
2)
Parts were not identified.
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. Gauges were not calibrated.
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No periodic audit program.
5)
Inspection points were bypassed on shop traveler card.
6)
Water used for hydrostatic tests was not checked for chlorides.
'B&W Canada 1)
Purchase order review requirements not being met.
2)
Instruments were not calibrated.
3)
Inspection planning and receiving inspection were not formalized.
4)
Control of sected items relative to objective evidence of quality was not formalized and was-lacking.
4 5)
Material control was not formalized in procedures.
6)
Nonconforming material control was not formalized.
7)
No system auditing had been established.
D.
Primary and Other Class I Pipina - OA/OC Program Review
_The erection of primary or other Class I' piping systems has not yet a
commenced at the site. The quality control program relating to this activity was reviewed during the current inspection. Quality Control plans and proce-dures were reviewed, and discussions were held with persons responsible for the preparation and implementation of the program. The following information and c' srvations resulted.
1.
Procedural Requirements - General The Rancho Seco QA manual specifies the procedural requirements
-which constitute the quality plan for power piping systems. These l
requirements include individual quality plans covering inspections of source (vendor), receiving, and installation activitiet. The quality plans.are prepared by the QA Engineering group within the-Bechtel Project Engineering and Management organization.
Mr. Chapla had been the principal author of these procedures. The Bechtel Engineering Department (Vernon) reviews the quality plans and concura f i-V w
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s in the appropriateness of their content prior to their issuance for use. In some instances Quality Control Instructions (QCI's) have j
been prepared to cover special handling or surveillance requirements.
2 Review of Ouality Plans (Procedures & Instructions) a.
Source Iespection Plans According to Mr. Chap 1a, individual source inspection plans
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have been prepared for each of the principal suppliers of Class I piping and piping components. Included among these are the pipe and fitting suppliers (Swepco, Cameron, U. S.
Steel, etc.) and the shop fabricators (Associated Piping and B&W)..
j A review of the source quality plans revealed that they L
contained requirements for review, verification and witnessing of tests and inspections to insure conformance to the levels of quality specified by purchase specifications. Inspection-verification and witness steps ate detailed in the quality plans, and provisions are included for the signature of the i
Bechtel source inspector at each step. The procedures require that a source inspection release be initiated prior to the shipment of components to the Rancho Seco site. Generally, this release takes the form of a TWX report initiated by the Bechtel source inspector.
The TWK report is followed by the source inspection report and fully executed source inspection
- plan, b.
Receivinn Inspection Plans Quality plans ~ for receiving inspections were observed to include specific checks and inspections for shipping damage. Review
'and verification of test reports and other quality documenta-J tion are also included. A specific' requirement of these
-quality plans is to verify receipt at the site of the Bechtel source inspection release (TWX) for the material and the quality documentation supplied by the vendor.
Handling and storage requirements are included in the quality plans for receiving inspections. According to Mr. Chapla, special QCI's'are to be prepared to' cover the handling and storage requirements for-special components-such as vessels, tanks. pumps and motors. These QCI's are to. provide specific f
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. rigging, handling and in-storage servicing instructions..The
. inspector reviewed QCI's which have been issued for the handling i
of the following mechanical components:
l' (1) Coolant Drain Tank V-600 i
(2) Diesel Oil Storage Tanks T-887 A & B.
(3) Piping and Hardware QCI 300, dated October 27, 1970, was observed to set forth the I
requirements for the storage of B31.7 Class 1 and class 2 pipe and pipe components. Included in this instruction was the requirement that these components be stored in areas that provide protection against weather conditions and physical damage. This instruction also contains the requirement that nuclear piping components be segregated in storage from non-nuclear components.
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-Material status identification, incorporating the use of colored tags, is also covered by. QCI 300, including the identification
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and segregation of discrepant material.
c.
Installation and Erection Ouality Plans The quality, plan covering the installation, inspection and testing of piping systens to the requirements of USAS B31.7 Class 1 and Class 2 was reviewed in detail, and discussions relating to this plan were held with Messrs. Chapla, Friedrich, j
Vander KnyCf, Ayers, Boyd and Wilson. The plan was observed to include inspection requirements relating to the following.
specificiareas:
(1) Cleanliness of pipe components I
(2) Location and orientation of instruments, drains, vents, valves and auxiliary connections.
4 (3) Flow direction of valves 1
(4) Field bending and cold spring of piping.
(5) Clearances of valve operators and positioners.for maintenance 4
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F (6) Pipe hanger location, size and type i'
(7) Installation and removal of startup strainers (8) Witnessing of hydrostatic tests
-(9) -Installation of insulation (10) Thickness and continuity of coatings on underground ii P P ng.
(11) Qualification of welding procedures and welding operators (12) Nondestructive testing, including repairs (13) Completion of code data forms According to Mr. Vander Knyff, the nondestructive testing of piping systems is to be performed by 'he X-Ray Engineering
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Company (K-Ray) of San Mateo, California. The X-Ray NDT
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technicians are to be qualified to the recommended procedure SNT-TC-1A of the American Society for Nondestructive Testing.
Additionally, Bechtel construction inspectors are to be
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qualified in accordance'with the SNT-TC-1A procedure, The Bechtel written procedure for the qualification of NDT s
technicians was-reviewed with Mr. Boyd, who has been designated Level III by Bechtel, and will administer the qualification program for Bechtel personnel. The procedure was observed to
.be consistent with recommended -practice SNT-TC-1A in terms of
. the experience, training and examination of NDT personnel.
At the time.of the current inspection, three Bechtel personnelz were enrolled in the qualification program,- according to Mr. Boyd. He anticipated that these' persons would be qualified to Level II for radiography within approximately 30 days.. A review of th'e biographical' data'on each of these persons (Messrs. Wilson, McConkey and Pangburn) revealed that their prior NDT experience ranged:from 3 to 7 years.
According to Nr. Boyd, a-total of 19 Bechtel welding pro-cedures have been qualified for pipe welding at the Rancho z Seco site.- _ A. review by the inspector revealed that only one of these procedures (No.. Pl-A-LH) had been approved by RSMUD.. The records revealed'that 11 pipefiteers, 3 ironworkers and 2 electricians had been qualified to welding procedure 4
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The latter-two crafts were qualified for plate welding only, whereas the pipefitters were qualified for pipe welding in accordance with ASNE,Section IX.
During the inspector's review of the quality plan for welding, particular attention was given to the subject of adherence to essential variables of welding procedures and to the extent to which objective evidence of such adherence is to be provided by the records which are to be maintained. During discussions on this subject Mr. Boyd stated that the quality plan did not provide for the explicit documentation of adherence to all of the essential variables listed in ASME,Section IX.
Both he and Mr. Vander Knyff expressed the opinion that the Bechtel plan was quite comparable to the " general industry practice" in this regard.
Mr. Boyd further expressed the opinion that changes to many of the essential variables, such as ommission of backing strips, omission or addition of consumable inserts, changes to the mixture or percentage of shielding gas, etc.
would be highly unlikely or readily obvious to supervision-
.since welding operators had little or no opportunity to change these. Other essential variables, such as preheat temperature, g
post veld heat treatment, base metal type and thickness, and
,j weld metal type are to be documented on a Bechtel standard form No. WR-5, Field Weldine Check List. This form is a part of the quality control plan. At the conclusion of the discussions on this subject, Mr. Vander Knyff stated that the pipe welding QA plan would be re-evaluated by Bechtel with particular consideration to the extent to which the plan provides'for the control and appropriate verification of conformance to essential variables during welding.
E.
Electrical Systems - OA/OC Program Review The installation of electrical systems for reactor control and engineered safeguards systems has not yet commenced at the Rancho Seco site. During the current inspection, a review was made of the quality assurance program relating to these electrical systems. The following information and observations resulted.
1.
Procedura1' Requirements - General The Rancho Seco QA manual establishes a requirement for the prepara-tion of individual quality' plans for source, receiving and installation, activities relating to electrical systems. The quality plans are prepared by the QA Engineering group within the Bechtel Project Engineering and Management. organization.
Mr. Ebrtz has been the principal author of these procedures. The Bechtel
'N Engineering Department (Vernon) reviews the quality plans and concurs
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in the appropriateness of their content prior to their issuance for use.
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Review of Quality Plans a.
Source Inspection Plans Each of the principal suppliers of wire, cables and electrical equipment are to be included in the Bechtel source inspection program. According to Mr. Martz, individual source inspection plans have been or are to be prepared for each supplier. The inspector selected for review the source inspection plans for the following components.
(1) Motor Control Center (MCC) 2A1 This MCC is a part of the plant emergency 480V power system.
(2) Power and Control (600V) Cables (3) -Boric Acid Pumo-(P705-A)
The source inspections plans specified the inspection require-ments for review, verification and witness points. Provisions
(
were made in the inspection plans for the signature of the j
Bechtel source inspector for each inspection point. For MCC 2A1, verification of seismic design calculations or test data was-included, in addition to verification and witness points for all production tests. In general, USA and NEMA standards and specifications were cited in the purchase specifications covering individual device tests and production tests for the MCC. These standards and specifications were included by reference in the source inspection plan.
The source inspection plan for 600V power and control cables included requirements for the review of test results for physical,' electrical and aging properties of insulation materials.
.The plan requires the source inspector to review all and witness portions of the vertical flame and flame integrity tests on finished cables. Marking, tagging, packing and shipping require-ments are also included as specific review and verification points in the source inspection plan.
In the case of the boric acid pump (P705-A), performance test requirements had been included by an amendment to the original purchase specifications. The Bechtel source inspection plan
-did not include-specific requirements for the review or verification of these tests. This observation was brought to the attention of the'Bechtel QA Engineer (Mr. Hunter), who
_i initiated a revision to the source inspection plan ta include U
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v a review of these testing results.
Mr. EkMahon stated that the source inspection plans for other components would be
. reviewed by QA Engineering to insure that _ appropriate revisions are made to the inspection plans as changes are made to the purchase specifications.
b.
Receivinz Inspection Plans 4
l The receiving inspection plan for 600V power and control cables was reviewed. This plan included inspections for evidence of physical damage during shipment, verification of material identification (cable and reel identification is required), and water-tight protection for the cable ends. A verification of the completeness and adequacy of the quality documentation supplied by the vendor is also required by the receiving inspection plan. The Bechtel QA Engineer must sign the inspection point relating to the acceptability of quality documentation.
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The receiving inspection plan did not include surveillance
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requirements for the storage of electrical wire and cable at the site. ~According to Mr. Martz, storage and handling requirements for electrical components are to be the subject i
of special Quality Control Instructions (QCI's). These QCI's I
will be issued for use prior to the arrival on-site of any components which are to be part of reactor control or engineered safeguards systems.
Nk. Martz did provide for the inspector's review QCI's covering the storage and surveillance requirements for electrical transformers and electrical penetrations which are currently in storage at the site.
c.
Installation Inspection Plan The quality plan for the installation of electrical cable and wire was reviewed in detail, and discussions relating to it were held with Messrs. McMahon and thrtz, Attached as Appendix A to this report is the check list which_is to be completed during installation of electrical cables.- Similar check lists have been prepared for the connection (terminations) and testing of cables after installation.
According to Mr. Nhrtz, computer programs are utilized in the detailed design for cable routing. A review of the QC program and discussions with Mr. Martz revealed that the QC program, as it presently exists, is intended to insure only-that ceble m_
s n
Ad installations are in accordance with the design (routing) generated by the computer. In response to the inspector's inquiry, Messrs. McNbhon'and Martz stated that special quality planning is to be prepared for those electrical systems which are to be a part of the reactor control and engineered safe-guards systems. This planning, according to Mr. Martz, is to include additional inspections aimed at verifying that the-electrical installations are consistent with the design criteria for separation, cable tray loading, etc. This subject was discusaed at the time of the management interview.
4 F.
Rancho Seco Operatinz Organization i
Status of the operating organization for Rancho Seco was discussed with Messrs. Rodriguez and Oubre'.
Positions filled and the proposed staff for the plant which follows was found to exceed the minimum requirements listed in Section 12.2 of the PSAR.
Plant Superintendent Ronald J. Rodriguez - Nuclear Navy Engineering Officer, 8 years service O
after graduation from Naval Academy.
Technical Assistant (Listed as Analyst in PSAR)
Ronald W. Colombo - Nuclear Engineer, 7% years with Union Carbide and Westinghouse as Assistant Supervisor of Operation, Test Engineer, Senior Engineer (Supervised physics testing at San Onofre Unit 1).
Assistant Superintendent Nuclear Plant Operations (Operations Supervisor)
R. Pierre Oubre' - Civil Engineer with 8 years nuclear experience'in the Nuclear Navy (6 years - training, Engineering Watch Officer and Asst.
Chief Engr.) and Gulf General Atomic (2 years Manager, Reactor Operator Training).
Assistant Superintendent Technical Support (Technical Supervisor)
John V. McColligan - Mechanical Engineer, Bk years nuclear experience at Shipping Port Atomic Power Station (Shif t Foreman, Reactor Engineer and Station Operating Engineer).
Shift Supervisors William E. Spencer - 23 years reactor operations experience at Hanford Reactors.
O m
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. Fred L. Spencer - 21 years reactor operations experience at Hanford Reactors.
Willis J. Ford -. Retired USN Electronics Chief, 9 years nuclear experience in the Navy and at LaCross.
Norman L. Hill - 16 years in reactor operations at Hanford and Elk River.
Dayle Gouker - 7 years experience in reactor operations at Humboldt Bay and Lacross (13 years total in power operations).
John Kirby - 9h years nuclear experience at Hallam.
Note - All of the above have held Shift Supervisor positions or equivalent positions for a period of 5 - 8 years with a minimum time as a reactor Shift Supervisor of three years. Four of these men held senior reactor operator licenses.
Senior Control Operators Five Senior Control Operators have been hired and are on board. All have had at least four years of nuclear experience and have been cleared
\\s_ /
by the AEC Operator Licensing Branch to.take a cold SRO examination.
Four of the ' operators are from the Nuclear Navy and one is from the General Electric Reactor Startup Organization.
Control Operators The required five Control Operators have been hired. Two have nuclear operator experience while the others have conventional plant experience.
Auxiliary Operators and Equipment Attendents Scheduled to hire five each in September 1971.
Chemical and Radiation Protection Engineer Roger Miller - MS in Radiation Biology plus 7 years radiochemistry
. experience.
Assistants'- 2 scheduled to be hired, j
i
' Plant Health' Phys'icist
~
l Donald NWrtin - MS 'io nealth Physics plus health physics technician and j
' supervisor experience s? Elk. River.
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5 Assistants - 2 scheduled to be hired.
Instruments and Controls Engineer Samuel Farrington - Instrument and Control Engineer for PG&E. On Moss-Landing startup.
Technicians - Five technicians have been hired. One has nuclear experience.
Their technician experience varies from 2 - 12 years.
- Nuclear Engineer Dan Whitman - MS in Nuclear Engineering. Previously an Air Force maintenance Officer.
i Mechanical Engineer
' George Coward - Engineer from SMUD's hydro units.
Electrical Engineer
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Parsons - Large refinery startup experience.
V Technicians - Two eg ioyed.
Electrical and Mechanical Crews 9 men scheduled to be hired.
Administrative Aid. Clerk Janitors and Guards 10 persons in all will be hired - some already employed.
Computer Engineer Several prospects have been interviewed. Expect to hire Computer Engineer by April 1971.
j 4
G.
Safety Committees Discussions were held with Messrs. Mattimoe and Rodriguez regarding the
'fctmation of the Plant and Management Safety Review. Committees. The Management Committee has been formed but has not yet established it's charter.
The' formation of the Plant Review Committee was still in the planning stage, i
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The Management Safety Review Committee will be constituted as follows:
J. ' Mattimoe Chairman, Assistant Chief Engineer R. Stinson Power Production Manager
'R.~Connelly Manager, Engineering Department D. Browning Operations Department Manager D. Raasch
- Rancho Seco Project Engineer R. Wilson Chief Nuclear Engineer R. Columbo Secretary, Technical Assistant, Rancho Seco H.
Training The review of the training schedule with Mr. Oubre' disclosed that personnel have been and will be receiving training in excess of that stated in Section 12.3 of the PSAR. The training scheduled has been reviewed with n
~the Operator Licensing Branch. Fifteen persons in all will receive the.12 N/
week B&W simulator training course. They will be tested by the Operator s
Licensing Branch at the conclusion of the course as a test of the quality of the course, according to'Mr. Dubre'.
The following areas have been included in the training program for operations personnel.
1.
Basic Reactor Physien and Engineering.
2.
Operating Experience at Nuclear Plant.
3 Operating Experience at Conventional Plant.
4.
Nuclear Steam Supply System Description Lectures.
5.
Nuclear _ Plant Operational Training.
6.
Startup Activities.
7.
Specialist Schools and Training.
(Instrument, Electrical, Computer and etc.)
4 -
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-Procedures and Preraration of Manuals According to Mr. Rodriguez the operating procedures will be prepared by the Plant Staff. The Staff will also prepare the preoperational and startup test _ procedures. The startup procedures will be prepared _after receipt of system test requirements and specifications. Bechtel will prepare a systems description manual. Plant personnel are also involved in preparing the FSAR and will be preparing the technical specifications, both of which have been scheduled to be transmitted to DRL by May,1971.
2 l
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- Exhibit 1-1 QUALITY ASS * ' NCE PROCEDURE NO.1 O
/
BECHTEL ENGINEERING AND MANAGEMENT ORGANIZATION FUNCTIONAL RESPONSIBILITIES i
FOR THE QUALITY PROGRAM SOURCE INSPECTION 1.
Perform supplier evaluations.
2.
Inspect materials and equipment in accordance with inspection planning.
j 3.
Assure that all inspection activity is properly documented.
QUALITY ASSURANCE ENGINEERING 1.
Perform all quality assurance activity associated with design review.
1 2.
Prepare inspection planning.
3.
Perform periodic audits of the quality program.
4.
Maintain the Documentation Control Center.
5.
Perform quality assurance training.
6.
Monitor special processes.
7.
Chairman, Nonconforming Material Engineering Review Board.
PROJECT INSPECTION 1.
Perform receiving inspecti,on in accordance with inspection planning.
2.
Inspect construction operations in accordance with inspection planning.
3.
Perform special process inspection.
4 Monitor calitration 5.
Assure that all inspection activity is properly documented.
l-7 l
1 i
(
Exhibit 1-1 QUALITY ASSUP"fCE FROCEDURE NO.1 O
kj PROJECT FIELD ENGINEERING 1.
Coordinate and obtain drawing and specification changes from Engineering.
2.
Perform coordination function with contractors on technical and administrative matters.
3.
Assist contractors in resolution of problems encountered in construction.
4.
Assist in the preparation of inspection planning.
5.
Recommend to and obtain disposition of non-conformances by Engineering Review Board.
6.
Perform all necessary coordination with contractor personnel to implement non-conforming material dispositions of rework, repair or reject.
7.
Assist in obtaining corrective action on non-conformances and audits.
ENGINEERING
.k 1.
Define configuration of Rancho Seco Plant in drawings and specifications.
2.
Perform design review.
3.
Determine quality assurance classifications.
4.
Perform evaluation of bidders.
5.
Participate in disposition of non-conforming material.
v) 1-8 t
QUALITY ASSURANCE PROCEDUR2 NO. 1
' Exhibit 1-2 Ci V
BECHTEL CONSTRUCTION ORGANIZATION FUNCTIONAL RESPONSIBILITIES FIELD PROCUREMENT & WAREHOJSING 1.
Procurement of materials and supplies.
2.
Perform receiving inspections.
3.
Maintain control and storage of material on site.
FIELD CONSTRUCTION 1.
Installation, erection and testing of mechanical and electrical equipment, piping and instrumentation.
l 2.
Supervision of crafts.
3.
Provide and maintain all temporary construction equipment and facilities.
4.
Provide training for welders.
5.
Conduct qualification tests for welders.
6.
Maintain records of welder performance.
CONSTRUCTION FIELD ENGINEERING AND INSPECTION 1.
Perform field engineering.
2.
Prepare isometric drawings for piping systems.
3.
Prepare Quality Control Instructions.
4.
Perform construction inspections and tests.
5.
Supervise all non-destructive testing.
ENGINEERING 1.
Define configuration of Rancho Seco Plant in drawings and
' specifications.
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2.
Perform design review.
s 1-9
QUALITY ASSURANCE PROCEDURE NO,1 Page 2
(
/
3.
Determine quality assurance classifications.
4.
Perform evaluation of bidders.
5.
Participate in disposition of non-conforming material.
6.
Review and approve vendor drawings.
QUALITY ASSURANCE ENGINEERING 1.
Assist Construction Field Engineering in preparation of Quality Control Instructions.
2.
Perform periodic audits of the quality program.
3.
Perform quality assurance training.
SOURCE INSPECTION 1.
Perform supplier evaluations.
2.
Inspect materials and equipment in accordance with inspection planning.
/
3.
Assure that all inspection activity is properly documented.
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Specific cioa/ Drawing No. ftl.1( 7N. 21)
Inspection Plane.X71 Da te 12/17/ 7C Co:poncat NamcInsta11ation of Electric Cable & Wire M1.1 Contractor Prepared by D. 3. Mart 7 Installer Paec 2 Method of Inspection: Review-3, Witness $, Manualg, ',isual-V, Inspector S tamp or Initial designa t:d.cslen for c.4. " m leted" ice, 5I M P/
JEH Ivr.M or
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INITIAL llen, Insp.
1 Record Drawing Number V 19 Cables installed in accordance with
" Cable Pulled Cards" and approved d rJLtLMs -
V2 Dra',ing approved by Engineer V 20 Incorrectly installed cables removec and 12 daeased, new cable installed.
3 Record Cable Number V 21 All wiring installed so the cc:npletc system shall be free of short-circut and ngn-ingention 1 2rou ism gig gs grggtggdy,Jgle SKV{&15KVarmoredcablesperdrawin 14 Verify cable tray installation V 22 g
acceptable.
V5 Eerify storage of electric V 23 Cable ' supports installed at verticTl runs & where required per drawing.
cable acceptable, V6 No cuts / abrasions in insulation V 24 Cable termination kits (stress cones or orotective covering or kinks installed per drawing.
in honductors.
V7 No splices in conductors, except V25 Cables marked and ta,7,;cd in accordar with circuit ' schedule and " Cable as shown on drawings, 3 U 4 Card."
M5 sufficient length lef t at the V26 Cab 1 s color ceded, whererequired, i ends of cables to make connectionk accordhnee with drawings and "Cabic to equipment.
l Pulled Card."
VS All cables installed in a straight V 27 Cables colored, where required, at and orderly arrangement without time they are pulled fron reel or vi interlacing.
training cables.
V10. Cables protected from absorption V 23 Cable installation protected durin;,
of moisture, betore anu atter
- construction; covered by asbestos c!
pulling.
to protect cabic f rom welding sparks V9 Cabic installation lef t in a clean 2
V11-Patented cable grips used for pulling cables. Q ) b p k y.;4hd y.
and tidy condition.
-u V12 Maximum pull tension not excecd-V 30 "As ins talled" inf ormation on "Caola ing manufacturer's recommendation Pulled ( ard*
- as measured with a tension dyno-meter.
, V13 An approved wire pulling compound V31 1 Copy of "Cablu Pulled C.ard" sta: aped used.
and attached to this CIDR.
V14 Cable rollers $nd, pulleys used in R32 "Cabic Pulled Card" returned to pulling heavy cables.
Engineer.
V15 Cables formed to avoid sharp.
33 Nonconforming Reports prepared and bends over edtes of conduit bush-submitted with ecpy attached to thit
[qds"EE"c!_SbE #
'N"E CIDR. Recerd NCR No.(s) on CIDR.
V16 Cables formed to avoid bearing 34 All cc:apleted items on CIDit stamped, against edges of trays or encl-initialed and dated.
_est.res and_supoorts.
V17 Cable neatly cabicd or clamped 35
. Completed CIDI, with all attschunt>
using nylon ty-raps.
returned to QAE for revicw and filia ND f$$[1..$
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i DIVISION OF COMPLIANCE MONTHLY REPORT FOR FEBRUARY 1971 t'
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Sacramento Munic'ipal Utility District u
(Rancho Seco) -
CO-in-spection was conducted on January 20 to review placement of 4
selectively-review records'.of the licensees vendor inspect
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program.
No significant problems were found, f
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