ML20032B446
| ML20032B446 | |
| Person / Time | |
|---|---|
| Site: | Hartsville  |
| Issue date: | 10/02/1981 |
| From: | Mills L TENNESSEE VALLEY AUTHORITY |
| To: | James O'Reilly NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| Shared Package | |
| ML20032B440 | List: |
| References | |
| NUDOCS 8111050551 | |
| Download: ML20032B446 (3) | |
Text
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UNITED STATES 8
NUCLEAR REGULATORY COMMISSION o
y a
REGION 11 101 MARIETT/,ST N.W., SUITE 3100 ATLt NTA, GEORGIA 30303 o
Report Nos. 50-518/81-12, 50-519/81-12, 50-520/81-12, and 50-521/81-12 Licensee: Tennessee Volley Authority 500A Chestnut Street Chattanooga, TN 37401 Fact!ity Name: Hartsvilb N:::: lear Plant Docket Nos.-50-518, 50-510, 50-520, and 50-521 License Nos. CPPR-150, CPPR-151, CPPR-152, and CPPR-153 Inspection at 1:artsville site near Hartsville, Tennessce Inspectors: /f /1.
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W. B. Swand Date Signed
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4 VI j'v.1. F. Schagker Date Signed Approved by:
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F. S. Cantrelli Section Chief, Division of Date Signed Resident and Reactor Project Inspection
SUMMARY
Inspection on July 1-31, 1981 Areas Inspected This routine inspection involved 92 inspector-hours on site in the areas of structural concrete, A-1 and A-2 steel containments, A-1 drywell wall, earthwork, open items, independent inspection effort and procedures controlling, handling of nonconformances, observation of nondestructive examination (Unit A1) safety-related pipe welding (Units Al and A2), safety-related structural welding and nondestructive examination (Unit Al and A2), review of NDE implementing procedures.
Results Of the twelve areas inspected, no violations or deviations were identified in eleven areas.
One violation was found in one area; (Failure to perfonn and interprete nondestructive examination as acceptable, paragraph 12.b).
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DETAILS 1.
Persons Contacted uns
- 41oyees
- J. J. Ritts, ENDES - Licensing, Knoxville (telecon)
- W. K. Anders, DEDC-QA
- R. E. Young, Assistant Construction Engineer, PE
- T. L. Carden, Assistant Supervisor QC Welding
- D. J. fioss, QAST-HTN
- J. O. flailey, QAST-HTN
- J. W. Henry, QCE-QC
- D. J. Ward, QA - Construction
- D. F. Jaquith, QA - Construction
- R. B. Stamps, QA - Construction
- K. H. Ramsey, QA - Construction
- K. H. Stewart, HTN - Construction
- S. R. Stout, EN-DES NEB-NLS
- R. T. Hathcote, Site Project flanager W. T. Quinn, Construction Engineer; Acting Project Manager J. T. Dorman, Assistant Construction Engineer, Quality Control
- H. S. Sheppard, Assistant Construction Engineer, Quality Control P. F. Gillespie, Supervisor, Technical Services B. F. Huffaker, Supervisor, Materias1 QC Unit R. C. Nixon, Supervisor, Document Control Unit F. E. Laurent, Unit Supervisor, STRIDE Mechanical Project Engineering G, A. Gonzalves, QA Unit Supervisor M. U. Rudolphi, Unit Supervisor, Project Engineering, Hangers and Supports R. E. ficClure, Unit Supervisor, flechanical Quality Control J. T. McGehee, Engineering,flanagement Assistant S. P. Stagnolia, Supervisor QC Welding G. M. Crawley, Welding Engineer QC Other licensee employees contacted included document control personnel, craftsmen, QC technicians, and project engineers.
- Attended exit interview 2.
Exit Interviews The inspection scope and findings were summarized with the Site Proje:t flanager on July 2. 13, 20 and 31, 1981.
3.
Licensee Action on Previous Inspection Findings (0 pen) Infraction 518, 519., 520, 521/80-18-01.
See paragraph 5 for status.
2 4.
Unresolved Items Unresolved items are matters about which more information is required to determine whether they are acceptable or may icvolve violations or deviations. New unresolved items identified during this inspections are discussed in paragraph 7.
5.
Independent Inspection Effort The inspector made surveillance tours during which the status of project work was noted and constraction activities were inspected on nuclear safety-related structures, systems and facilities. The inspection was concentrated on Plant A power block structures, but included outlying structures such as the Plant A essential service water pump stations, earthfill for the spray ponds, the intake pumping station, and circulating cooling water pump house.
Open Site Items Control: Newly issued Nonconformance Reports (NCRs),
significant Quality Control Inspection Reports (QCIRs) and QA Unit audit findings were reviewed for pertinence to the inspection program and for adequacy of corrective actions.
Containment Erection: The inspector inspected fit-up of the ninth steel ring of the A-1 containment cylinder wall ano the third ring of the A-2 wall. Joint tolerances were being assured by the steel strap inserts, and preheating was established for welding and weld repair.
The applicable code for the containment welding is the ASME Boiler and Pressure Vessel Code, Sectioq III, Subsection NE,1974 Edition, including Addenda through S74.
Preheat adequacy was being checked by Tempstiks.
In the areas inspected, no violations or deviations were identified.
Document Control: The matter of drawing and engineerir.g change control is being followed under Infraction 518, 519, 520, 521/80-18-01. The sita QA unit is continuing to follow up on this problem by Audit HT-G-81-14.
Improvements were reported by the Auditors in the timeliness of processing of Engineering Change Notices (ECNs) and Field Change Requests (FCRs). A satellite Document Control Unit station in the Control Services Building between Units A-1 and A-2 has been established and manned to expedite the handling and to improve the control of construction documents.
To improve the operations, changes to Construction Engineering Procedures C.E.P. 6.01 Drawing Control are being development by the site to implement procedural changes outlined in the memorandum dated April 27, 1981, from the site manager to the site QA audit supervisor. The inspector has inspected the new DCU field dispensing station and is monitoring document control.
No violations or deviations were identified within the areas inspected.
c
3 Plant A Construction Slowdown: TVA announced on July 24, 1981, plans for a three-year extension of the completion dates for Hartsville Units A-1 and A-2.
6.
Licensee Identified 50.55(e) Items - Previously Identified Items (Closed) (518/81-05-01) Unacceptable Welds Documented as Acceptable (HTRD-50-518/81-07 and NCR HNPA-062) The inspector has verified that corrective actions described in the licensee's letters of flay 4 and itay 29, 1981, have been taken. The licensee's corrective ations were judged to be acceptable.
(Closed) 518, 519, 520, 521/80-10-02 Design Deficiency of T-Head Section of Anchor / Darling Gate Valves (NCR 6) The inspector has verified that the descrepant valves have been removed from the site and returned to the vendor for replacement of deficient discs.
7.
Handling of Nonconformances The inspector noted in reviewing Nonconformance Reports (NCR's) that the G.E. Sita Manager had not provided written approval for the desposition of NCR-HNPA-138. Construction Engineering Procedure (C.E.P.) 15.01 and 15.03 requires that the disposition of STRIDE items have the approval of the G.E.
Site llanager. The repair specified by NCR-HNPA-138 was to correct for clearnace, the obstructions from leak detection channels behind the stain--
less steel liner in Unit A-2 shipping cnk pool.
The inspector determined as a result of discussions with the site construction Engineer and G. E.
Site flanager that verbal approval from the G.E. Site flanager had been obtain for the repair work.
The inspector was satisfied that the responsible parties did conceive in the the disposition of NCh-HNPA-138 and that written approval from G.E. Site Manager was obtained.
The inspector noted that a discrepancy exist between the requirements set forth in OEDC-Quality Assurance Manual (QAM) and CEP 15.01 Control of Qual:ty Control Investigation Reports. OEDC-QAti section 10.2, subsection 2.3.5 and Quality Administrative Instruction OEDC-QAI-4 (Determining, Reporting and Colrecting Conditions A6/erse to Quality) requires that r.anconforming conditions to be corrected by " repair" or "use as is" be concurred in by the design project organization unless waived in writting.
C.E.P. 15.01 made the concurrence of the design project organization optiona; and permits the construction engineer or authorized nuclear inspector to make a determination r egarding " repairs" or "use as is" for nonconforming items.
The discrepancy between the dispostion requirement of nonconforming item as j
described in the OEDC-QAM and those in C.E.P. 15.01 was identified by the site QA units in Audit No. HT-G-79-15 on November 15, 1979.
The inspector expressed his concern to the Site Project flanager regarding the above and the lack of timely corrective action. This matter is
4 identified as an unresolved item and will be examined at a future insgection (513,520/81-12-01).
8.
Status of Inspection and Enforcement Bulletins (Closed for Hartsville) 81-03 Flow Blockage of Cooling Water To Safety System Components by Corbicula Sp.
(Asiatic Clam) and Mytilus Sp.
(Mussel).
The licensee's response to this bulletin is dated July 8,1981, and has been reviewed by the inspector.
At Hartsville during the construction period, no fouling of cooling water system components by Corbicula ( Asiatic Clams) has been detected. Mytilus clams are not indigenous to the Cumberland River.
Provisions have been made for co.itinous chlorination of essential cooling water systen.s during clam spawning season or when river water temperatures exceeds 60* F. and for periodic checking of water systems for flow reduction from blockages.
Construction of the water treatment plant and its supporting sodium hypo-chlorite generation plant is well advanced.
The results of the licensee's biological suppression measures during plant operating conditions, will not be known for approximately ten years.
Unit A-1 is expected to be operational by 1981.
(Closed for Hartsville) 80-21 Valve Yokes Supplied by Malcolm Foundary Company, Inc.
Final responses from valves vendors through General Electrical indicate that no safety-related valves puchased for Hartsville (for STRIDE or 80P Systems) have parts mad-by Malcolm Foundary Company, Inc.
TVA's letter of July 23, 1981, attests to the accuracy of this information.
9.
Status of IE Circulars (Closed) 81-09 Containment Effluent Water That Bypasses Radioactivity Mor. i tor. This circular is not applicable to a construction site.
(Closed) 81-10 Steam Voiding in the Reactor Coolant System During Decay Heat Removal Cooldown.
This circular is not applicable to a construction site.
(Closed) 81-11 Inadequate Decay Heat Removal During Reactor Shutdown. This circular is not applicable to a construction site.
(Closed) 81-12. Inadequate Periodic Test Procedure of PWR Protection System.
This circular was received and reviewed by TVA.
- 10. Seismic Category I Concrete Formir.g, installation' of rebar, positioning of embedments, placements and post placement curing were inspected as work progressed in the Plant A containments, fuel buildings, auxiliary buildings, control buildings, and essential service water pump houses.
Specific phcements' inspected included power AY-225, 226; pour A2F-200,'18C, 15C and A1A-16H. Additional 4
inspections were made of installations of rebar for the foundations and sump areas of the emergency diesel generator building (DG Div.1-1) at the south side of Unit A-1.
During inspection of activities for structural concrete in these areas, the conformance with the requirements of C. F. Braun Specification 300-01, Revision 8, " Concrete", TVA Construction Specification G-2, QCI C-201, Rev.
4 and CEP 9.02, Revision 5, was verified by the inspector.
In the areas inspected, no violatio".s or deviations were identified.
11.
Earthfill and Compac. ion For Plant A Spray Ponds t
Placement and Compaction of earth fill for the peripheral dikes around the spray ponds is controlled by Specification N6C-875 Earth and Rock Foun-dations and Fills. By surveillance inspections of earth fill operations, and by review of calculations for tests, the inspector verified compliance with Specification N6C-875 and with quality control procedure QCI C-102, Foundation and Fill, Earthfill Control Testing.
In the areas inspected, no violations or deviations were identified.
12.
Safety-Related Piping (Units Al and A2) a.
Observation of Welding Activities The inspector obse.ved welding activities for safety-related piping outside of the reactor coolant pressure boundary as. described below to determine whether applicable code and procedure requirements were being raet. The applicable code for safety-related piping is the ASME B&PV Code,Section III, Subsections NC and ND, Ic74 Edition with addenda through sumer 1974.
The welds listed below were examined in process to determine: whether work was conducted in accordance with travelers; welder identification and location; welding procedure; welding technique and sequence; materials identify; weld geometry; fit-up; temporary attachments; preheat; electrical characteristics; shielding gas; welding equipment condition; interpass temperature; interpass cleaning; process control systems; qualification of welders; qualification of inspection personnel; and weld history records.
1
Unit Weld Joint Nn.
WPS System Al A1ARH1271004 GT1101AR-6 Residual Heat Removal Al A1ARH042004 GT1101AR-6 A2 A2ARH90015 GT-SM-11-0-3B R-8 Al AlBMR00315*
GT1101AR-6 Fuel Pool Cleanup
- Base metal repair.
In addition to the above, the inspection performed an audit of the detailed weld procedure specifications (WPS) to the referenced Procedure Qualification Records (PQR) and applicable ASME B&PV Code,Section IX requirements.
b.
Observations of Nondestructive Examination (NDE)
The inspector observed NDE on the following weld seams outside of containment as described below to determine whether applicable codes and procedure requirements were being met.
Item Weld Seam Unit System NDE Method 1
A1ASC007003 Al Supression Liquid Pool Cleanup Penetrant 2
A1 ARC 0010R01 Al Reactor Core Liquid Insolation Penetration Cooling 3
A1ACN0030R01-R1 Al Condensate Radiography The inspector observed the liquid penetrant examination of the completed welds above and evaluated the examination results as l
determined by the NDE Level II inspectors. The applicable liquid penetrant procedure identified as QCI-N-101 Revision 4 was utilized.
Upon completion of the examination of Item 2, but prior to removal of the developer, the NRC inspector evaluated the test results and noted that a linear indication at the toe of the referenced weld approx-imately 1/2 inch in length was visible.
Since this indication exceeds the acceptance criteria of the referenced procedure requirements, the i
inspector queried the Level II NDE inspector as to the acceptability of I
the examination. The response was that the examination was acceptable.
Tne inspector then requested the NDE Supervisor to examine the test l
results, which was accomplished.
Subsequently, the examination was rejected and reexamined in the area where the linear indication had appeared.
The re-examination was acceptable. The original examination bleed out in the toe of the weld was obviously due to under-cleaning where the weld tied into the base material.
Although this was not a relevant l
l v
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i indication, it could not be determined without re-examination as required by the referenced procedure requirements.
This failure to follow site procedures violates the requirements of Criterion V of 10 CFR 50, Appendix B.
(518/81-12-01).
i The inspector reviewed radiographr for condensate piping weld number three and perfomed a visual examination of the same. The initial weld was rejected by the licensee for excessive porosity and repaired in accordance with procedure requirements. The subsequent repair weld was radiographed while the ir.spector was on site, was reviewed and accepted. The applicable procedure was TVA Quality Control Instruction N-301 Rev. 3 titled, " Radiographic Examination of Welds ASME."
Qualifications of radiographers and liquid penetrant inspectors to American Society for Nondestructive Testing SNT-TC-1A 1975 Edition recommended practice was reviewed as listed in SEction 8 of this report.
i 13.
Safety-Related Structures a.
Observation of Welding Activities The inspector observed welding preparation and repair weld to Unit A2 biological shield tier number one located in the iron workers shop A.
Weld procedure Specification SM-U-1 Revision 4 was utilized. This procedure is a prequalified (PQR) as specified in AWS D1.1 Structural Welding Code.
In addition, the inspector observed welding in progress to structural beam MK 76A located at the 11' level column HZ line B, in accordance with Drawing S-905 Revision 4 Detail -X in Plant Al control room. WPS SM-U-1 ~ Revision 4 was applicable.
The above welds were verified to be in compliance with AWS D.1.1 applicable weld procedures, detailed drawings and instructions, proper weld identification /locaticn, welders qualifications, use of specified weld material, weld sequence and joint restraint, preheat and interpass temperature, final weld size and weld profile.
The inspector also verified welding material issue, temperature control, segregration, cleanliness, container integrity, records, and handling of reterned materials, at the weld rod crib, to be in compliance with TVA Process Specification CEP-803 Revision 12. Weld material handling by the respective welders was verified for adequate segregation, cleanliness, temperature control, issue records for proper sign offs, identify material and withdrawer, dates of withdrawal and amount withdrawn.
l 1
8 b.
Observation of Nondestructive Examination The inspector observed Magnetic Particle Examination (MT) of weld preparation to structural beam referenced in paragraph 7.a.
The preparation was partially a base metal repair and completion of insufficient weld as described in TVA Quality Control Investigation Report (QCIR-28229). The HT was conducted to TVA Quality Control Instruction (QCI) N-202 Revision 5, titled " Magnetic Particle Exami-nation of AWS Welds Prod and Yoke Dry Powder Method." Compliance to procedure requirements was verified. NDE inspectar qualifications and calibration of equipment was current.
In the areas inspected, no violations or deviat. ions were identified.
14.
Review of NDE Implementing Procedures The inspector reviewed the TVA procedures listed below to the applMable Code requirements.
Title Identification Revision A_pplicable Code Liquid Penetrant QCI-N-101 4
ASME II 1974 Solvent ;amovable Edition with Method of ASME Welds Addenda Magnetic Particle QCI-N-202 5
AUS D1.1 79 Examination of AWS Welds Radiographic QCI N-301 3
ASME III Examination of 1974 Edition Welds - ASME with W75 Addenda In addition, the inspector reviewed material certifications for liquid penetrant materials and NDE inspectors qualifications to SNT-TC-1A as listed below:
Material Certifications Penetrant SKL/HF Lot 79H039 Cleaner SKC/NF Lot 79G062 Developer SKD/NF Lot 79H056 The above materials were certified to contain less than 1% sulfurs or halogens by weight in accordance with ASME Section V, Article 6 Paragraph T630 1974 Edition with W74 addenda.
j
9-NDE Personnel Qualification Reviewed Name NDE Hethod Level
.Yarborough, J. M.
Radiography II' Howser, B. G.
. Radiography I
Arms, L. E.
Magnetic Particle-II Graham, G.
Liquid Tenetrant.
II
-McMilliam, G. D.
Liquid Penetrant II Within the areas inspected,= no violations or deviations were identified.
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