ML20040B315
| ML20040B315 | |
| Person / Time | |
|---|---|
| Site: | Millstone  |
| Issue date: | 01/06/1982 |
| From: | Elsasser T, Mattia J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML20040B311 | List: |
| References | |
| 50-423-81-14, NUDOCS 8201250386 | |
| Download: ML20040B315 (12) | |
See also: IR 05000423/1981014
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U.S. NUCLEAR REGULATORY COMMISSION
OFFICE OF INSPECTION AND ENFORCEMENT
Region I
Report No. 50-423/81-14
Docket No. 50-423
License No.
CPPR-113
Priority
Category
A
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Licensee:
Northeast Nuclear Energy Company
P. O. Bcx 270
Hartford, Connecticut 06101
Facility Name:
Millstone Nuclear Power Station, Unit 3
Inspection at:
Waterford, Connecticut
Inspection conducted:
October 30, 1981 - November 30, 1981
Inspectors:
\\ C A%
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'd. C. Mattia, Senior Resident Inspector
date signed
date signed
date signed
Approved by:
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T. ElsaM er, Chief, Reactor Projects
date signed
Section IB, DRPI
Inspection Summary:
Unit J Inspection on October 30, 1981 - November 30, 1981
Report No. 50-423/81-14
Areas Inspected: Routine inspection by the Resident Inspector of work activities
associated with pipe erection, electrical cable tray erection, receipt inspection,
cadwelding, storage and maintenance of equipment and material. The inspector also
perfonned plant inspection tours and reviewed licensee action on previously identified
items. The inspection involved 124 inspection hours, including 3 off-shift hours by
one NRC inspector.
Resul ts: Of the six areas inspected, two items of noncompliance were identified in the
following areas: Failure to properly maintain and store safety related equipment, and
failure to promptly correct nonconformances associated with the storage of safety re-
lated equipment.
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Region I Form 12
(Rev. April 77)
8201250386 820108
PDR ADOCK 05000423
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DETAILS
1.
Persons Contacted
Northeast Utilities Service Company (NUSCO)
B. Carlson, Assistant Project Engineer (Berlin)
A. Cooper, Construction Project Specialist
D. Diedrick, Quality Assurance Manager
K. Gray, Construction QA Supervisor
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S. Orefice, New Site Construction Superintendent
J. Powers, Licensing Engineer (Berlin)
T. Sullivan, Resident Engineer - New Site Construction
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S. Toth, System Superintendent Generation Construction
R. Vaccaro, QA Construction Technician
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Stone and Webster Corporation (S&W)
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R. Bernard, Assistant Manager - Field QC (Boston)
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J. Carty, Head Site Extension Engineering Officer
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J. G. Kappas, Superintendent of Construction
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W. MacKay, Resident Manager
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G. Marsh, Senior Engineer, Welding /NDE
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M. R. Matthews, Assistant Superintendent Field QC
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J. Hims, Receiving and Material Controls Technician
R. Reams, Materials Supervisor
W. Towne, Receiving and Material Controls Technician
G. G. Turner, Superintendent, Field QC
W. Viau, Materials Control Technician
W. Voss, Field QC Engineer
R. White, Supervisor - Preventative Maintenance
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Tne inspector also conferred with other licensee and contractor personnel
during the course of the inspection.
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2.
Licensee Action on Previous Inspection Findings
a.
(Closed) Unresolved item (423/81-03-01):
During a previous inspection
the west sedimentation basin was observed to be unstabilized, with
material eroding in basin walls and sediment flowing to the adjacent
marsh. The basin was inspected and was found to be in satisfactory
condition. The sedimentation basin walls were reinforced with concrete
to stabilize the walls.
The inspector also noted that the weirs were
recently replaced with new hay.
This item is considered resolved.
b.
(Closed) Significant deficiency (423/80-00-08):
On March 18, 1981, the
licensee informed f1RC in a final report that significant repairs are
required due to weld joint misalignment of containment flued head
penetrations. The repairs were accomplished to meet the requirements
of the ASME Section III Code; Subsections NB-4233 & NB-4426. The
inspector reviewed the following nonconformance repnrts (N&D) associated
with these repairs:
N&D Number
Date Verified Acceptable By QC
0698
4/27/81
0653
6/30/81
0635
7/28/81
0603
8/24/81
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0570
3/30/81
0538
3/27/81
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0526
5/5/81
0520
3/27/81
0428
12/4/81
0397
11/5/81
The inspector randomly selected five repaired penetration data packages out
of the 29 penetrations repaired.
The following are the specific data
packages reviewed:
Penetrations # 47, 5, 3, 92 and 23. The data was in compi'ance with
the S&W ASME QA Manual and Specification #2190.520 - 109 requirements.
(Note: NRC inspection of the actual repairs was performed during
inspection 423/81-05). No items of noncompliance were identified.
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3.
Plant Tours
The inspector observed work activities in progress, completed work and
construction status in several areas of the plant. The inspector
examined work for any obvious defects or noncompliance with regulatory
requirements or license condition.
Particular note was taken of the
presence of Quality Control Inspectors and Quality Control evidence
such as inspection records, material identification, nonconforming
material identification, housekeeping & equipment preservation.
fio items of noncompliance were identified.
4.
Safety Related Piping Erection
a.
The following weld joints, which were in various stages of welding,
located in the containment building were inspected to verify compliance
with welding and installation procedures and code requirements:
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(1) 3 MSS-030-95-2, Field Weld #3.
Final weld pass was completed
and grinding was in process prior to nondestructive examination.
The inspector observed the grinding and also reviewed the weld
history data card.
flo items of noncompliance were identified.
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(2) 3 MSS-030-93-2, Field Weld #8. This weld joint was approximately
three-quarters completed. The welding was in accordance with
S&W weld technique procedure W21M, Rev. O.
The inspector
observed the actual welding and verified that the critical
parameters of the weld procedure were followed. The weld data
card was also reviewed for compliance with the applicable QA
procedures.
No items of noncompliance were identified.
(3)
3RSS-012-22-2, Field Weld #7. This weld joint was undergoing
weld repairs. An area of weld was excavated down to the root
and was in the process of being welded.
The repair was due to
radiography finding an area lacking complete fusion. The
excavated area was liquid penetrant' examined and accepted. The
inspector observed some of the welding to ascertain that the
repairs were in accordance with requirements of S&W weld repair
procedure W12U, Rev. 2.
fio items of noncompliance were identified.
(4) 3RCS-031-3-1, Field Weld #5. This weld joint was approximately
one-quarter completed. The welding was in accordance with S&W
weld technique procedure W13B, Rev. 3.
The inspector observed
the actual welding and verified that the critical parameters of
the weld procedure were followed. The weld data card was also
reviewed for compliance with the applicable weld procedure. The
inspector also reviewed the monitoring results of weld shrinkage,
at the eight locations around the pipe circumference.
fio items
of noncompliance were identified.
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(5) 3CDS-010-56-2, Field Weld #3. This weld joint was just fitted in
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place with 4 tack welds holding it in the correct alignment for
welding.
The field QC inspector had completed his inspection and
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released it for welding. This particular joint was a modification
in accordance with S&W construction revision notice #CDS-514-001.
The inspector reviewed the weld data card and also inspected the
fit-up of the weld joint. tio items of noncompliance were
identified.
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Note:
For the above items (1) - (5), each weldor's performance
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qualifications were reviewed and verified that they were
properly qualified for the particular weld procedure used.
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b.
The following weld joints, which were in various stages of welding,
located in the ESF Building, were inspected to verify compliance with
welding and installation procedures and code requirements:
(1) 3FWA-003-39-3, Field Welds #4 and 5.
Both welds were almost
completed. The final pass was in process.
The welding was in
accordance with S&W weld technique procedure W21U, Rev. 2.
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inspector observed the actual welding and verified that the
critical parameters of the weld procedure were followed. The
weld data card was also reviewed for compliance with the applic-
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able QA procedures.
No items of noncompliance were identified.
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(2)
3FWA-003-39-3, Field Weld #6. The consuming of the root weld
insert was in process. The inspector observed the consuming of
the insert and also the appearance of the welds at the ID and OD
of weld joint. The weld data records were also reviewed. No
items of noncompliance were identified.
(3) The inspector observed field modifications to three pipe spools,
identified as: 3CCP-018-556-3, 3CCP-024-245-3, and 3CCP-523-54-3A, to be
in accordance with S&W construction revision notice #CCP-524-002.
The modification consisted of cutting sections of pipe and
machining the end weld preps. No items of noncompliance were
identified.
(4) 3QSS-014-26-1, Field Weld #6. This weld joint was approximately
three-quarters completed.
The welding was in accordance with S&W
weld technique procedure W12F, Rev. 3.
This particular weld joint
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was a field modification in accordance with construction revision
notice #QSS-5-002.
Radiography of Field Weld Joint #1 revealed
that a block of wood was inside the pipe.
Since it was
inaccessible to retrieve the piece of wood, a pipe section had to
t;e cut. A review of welding and weld data card was performed.
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No items of noncompliance were identified.
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(5) 3FWA-003-45-3, Field Welds #5 and #6. The weld joint #5 had the
final weld pass completed, and weld joint #6 was three-quarters
completed. The welding was in accordance with S&W weld technique
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procedure W210, Rev. 2.
The inspector observed the welding and
reviewed the weld data card. No items of noncompliance were
identified.
c.
The following weld joints, which were in various stages of welding,
iccated in the auxiliary building, were inspected to verify compliance
with welding and installation procedures and code requirements:
(1) 3CHS-003-15-3, Field Weld #2. This weld joint had just been
released for welding by S&W quality control inspector. The fit
up condition was acceptable. The welding was in process and the
gas purge was functioning, with the oxygen content in the pipe at
the acceptable level. The inspector observed the consuming of
the weld insert and verified that the requirements of S&W weld
technique procedure W12F, Rev. 2, were complied with.
No items of noncompliance were identified.
(2) 3CHS-003-111-3, Field Welds #1 and #2. These two weld joints
were on a pipe spool section and the weld joints were being
aligned in accordance with the weld procedure W12K, Rev. 1 and
drawing requirements. The inspector observed the handling and
rigging of the spool piece to verify that undue stresses (cold pull)
were not applied by crafts to align the pipe ends. No items of
noncompliance were identified.
5.
Maintenance & Storage
The inspector inspected the indoor and outdoor storage areas to verify that
safety related equipment / materials were stored and maintained in accord-
ance with the S&W construction methods procedure (CMP) 1.3 entitled
" Material / Equipment Storage" and 1.12, entitled " Material / Equipment Mainten-
ance".
The following are the specific areas and results of the inspection:
a.
Northeast Pipe Yard
The inspector verified that pipe was stored off ground and on dunnage.
that end caps were on all safety related pipe.
The inspector noted two
items that required investigation by ti.e A/E, they are as follows:
(1) An electric cable reel, Kerite Reel No. 7013 was stored in the
pipe yard outside of the normal electric cable controlled area.
This particular cable reel had the S&W " Accepted for Category I"
label affixed to the reel.
Further investigation by S&W revealed
that the reel was surplus
material from the Unit 2 plant. The
licensee stated that a " Surplus" label will be attached to the
reel so that it will not be used for Millstone III safety related
areas.
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(2) The inspector noted that there was a large gouge on an elbow of
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an ASME safety class 2 pipe spool, which was received on material
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receiving report (MRR) 79P-0482 on 11/21/79. The licensee was
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informed that the inspector's concern was that the gouge was a
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stress riser and may also be encroaching on the minimum wall thick-
ness. This item is considered unresolved pending review of
licensee's evaluation (423/81-14-01).
b.
flortheast Storage Yard
The inspector inspected material / equipment stored in this area to determine
that the appropriate level of storage and maintenance as depicted in the
requirements are maintained. The following specific items were noted:
(1) At left and right of the gate, inside the controlled area, there
were three Category I items on each side of gate area which were
recently covered with protective covering, and they were not
plainly marked so that they are easily identified without excessive
handling or unnecessary uncovering.
The inspector informed the
licensee that this is an ANSI N45.2.2 requirement.
It appears that
the original identification was covered over and an opening in the
new covering will be cut at the proper location, to show the
identification data of the equipment.
(2) The inspector noted that the preservative coating for the Category I
equipment identified as 3-LWS-EV-1 (Waste Evaporator) was not
fully protecting the item from rusting.
This was also identified by
S&W storage inspector on 7/14/81 and an unsatisfactory inspection
report #X100416 was issued at that time. This inspection report
also referenced another unsatisfactory report IR #X0000077 for
other items with similar conditions. The IR #X0000077 report
found the rusting condition on 3/31/80. The inspector also noted
that the chiller surge tank (3-CHS-TK-3) referenced in the 3/31/80
inspection report had not been corrected.
The inspector informed
the licensee that this failure to take prompt action to correct non-
conforming conditions is considered an item of noncompliance
(423/81-14-05).
c.
Lower Northeast Pipe Yard
The inspector inspected material / equipment stored in this area to determine
that the appropriate level of storage and maintenance as depicted in the
various procedures are maintained. The following specific items were noted:
(1) Pipe spool piece identified as 3RCS-504-7-1-1 had two small dents
that probably occurred during handling or in storage that will need
to be dispositioned. This item is considered unresolved (423/81-04-01).
(2)
Pipe spool piece identified as 3RCS-504-3-1-1 has deep circumferential
grooves on one end of the pipe that probably occurred during handling.
This item is considered unresolved pending review of S&W disposition
(423/81-04-01).
Note:
Items (1) & (2) above had QC Category I acceptance tags
attached to each of the spool pieces.
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(3) The inspector noted that there were two tanks with rust in several
areas; apparently the preservative coating was not protecting the
base metal.
The tanks were identified as 3-CCP-TK-2 (Reactor plant
component cooling chemical addition tank) and 3-LWS-TK-1B (High level
waste drain tank). S&W had also previously identified this condition
and reject tags were on the tanks. A review of. inspection report X7050133
and nonconformance report #6708 indicated that for the 3-CCP-TK-2 it had
been identified on 3/31/81 as having an unsatisfactory condition; and
for the 3-LWS-TK-1B tank, the rusting condition was identified on
4/29/77. The inspector informed the licensee that this was two more
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examples (See Item b (2)) where corrective action for storage and
maintenance was not accomplished in a reasonable time period.
(423/81-14-05)
d.
Northwest Pipe Storage Yard
The inspector verified that pipe was properly stored on dunnage and end
caps installeJ.
The inspector also noted the following conditions:
(1) The inspector noted a gouge on an elbow of a spool piece identified
as 3-MSS-42-54.
This spool piece also had a QC Category I acceptance-
tag. This item is considered unresolved pending review of licensee's
evaluation (423/81-14-01).
(2) The inspector noted that several pieces of stainless steel pipe on
racks had their end caps off. A QC reject tag was also found on this
rack of pipes. A review of inspection report #X1000079 associated with
this reject tag indicated that the S&W QC inspector had identified
this unsatisfactory condition on 2/13/81.
The inspector informed
the licensee that this was ano&.her example (see items above) where
the corrective action for deficieacies found during storage inspec-
tion was not taken (423/81-14-05).
(3) The inspector noted that just left of the gate on the fence there
was a sign stating " Scrap Material", yet there were items located
in close proximity to the sign that had QC Category I acceptance tags.
For example, the following ASME Class 2 and 3 pipe spools were
located near the sign:
3-GWS-9-6-2-3
3-GWS-6-4-2-3
3-CHS-29-1-2-2
The licensee stated that this area will be better defined and/or
segregated.
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Transmission Line Storace Area
Stored in this area was heating and ventilating _ items, reinforced steel,
and material left over from containmert fabrication.
No items of non-
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compliance were identified.
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Warehouse #2 Weld Storage Area
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An inspection was conducted to deteniine that welding material was stored
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in accordance with the S&W construction procedure CMP 1.3-3.79.
No items
of noncompliance were identified, but the inspector noted that 3 hermeti-
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cally sealed cans were badly dented at the bottom of the sealed end.
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materials involved were E8018 and E7018 electrodes. Stone & Webster had
the cans tagged so that their condition can be evaluated.
g.
Warehouse #2 Level B Storage Area
(1) The inspector noted the storage condition for the Conax electrical
containment penetration assemblies (Purchase Order #247). The
inspector also reviewed the vendor's manual storage instructions
and the S&W equipment storage history cards for the penetrations
to verify that they were stored and maintained in accordance with
the requirements. No items of noncompliance were identified.
(2) The inspector inspected four 4160 volt GE clad switch gear panels
received on material receiving report #81-4195 on S/4/81 for
purchase order #010. The equipment was identified as NJS-US-6A;
-6B; -7A and -7B.
The inspector noted that these panels had strip
heaters installed but there was no wiring to connect them to a
power source. A rev_iew of the S&W equipment storage history cards
indicated that the panel heaters were inspected every three months
(7/10/81 & 10/9/81) as required. These cards incorrectly ir.dicated
that the heaters were energized. The licensee was informed that
this improper storage and maintenance of safety related equipment
constitutes an item of noncompliance (423/81-14-02).
(3) The inspector observed that one of the covers of the G.E. 4160 V.
circuit breakers received on MRR 80-1271 for purchase order #010
was missing. S&W took immediate corrective action and recovered
the circuit breaker,
h.
Warehouse #1 Level A Storage Area
The inspector inspected the following items in this area and also reviewed
the equipment storage history cards associated with the following equip-
ment:
3-CES-MCB-MBB (Main Control Board, section 8)
WestinghouseSPIN#NEU-NIELCA(NuclearInstrumentPowerRange)
Westinghouse SPIN #NEU-ELSELCC-01 (Rod Drive Control Cabinet)
Westinghouse SPIN #NEU-CPELRC-01 (Rod Control Power Cabinet)
No items of noncompliance were identified.
i. Warehouse #4 Level C Storage Area
The inspector inspected various Category I supports stored in this area
to verify that the storage requirements were complied with No items of
noncompliance were identified,
j. Warehouse #5
The inspector-inspected several Category I pipe hsngers, supports and
snubbers stored in this area. The inspector noted that the mechanical
snubbers manufactured by Pacific Scientific Inc. were stored out of
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containers on pallets. The vendors storage instructions PHD-7594-1
recommends that storage should be in original shipping containers, and
if not, the pivot pins on snubbers should be removed and placed in
plastic bags. S&W stated that the vendor concurs (verbally) with their
method of storage.
The inspector informed the licensee that this is
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unresolved pending review of vendor's written concurrence or revised
storage instructions (423/81-14-03).
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Warehouse #7
This area had primarily ASME items such as small bore piping, tubing,
fittings, valves, nuts and bolts. The control and storage of items was
exceptionally good. The required traceability of heat and code numbers
for ASME items was also inspected. No items of noncompliance were
identified.
1.
Warehouse #6
The inspector examined the following items and also their equipment
history cards to verify that the storage requirements were complied with:
- Hydraulic snubbers, manufactured by Paul Monroe Hydraulics and
received on MRR 81-5810 and for purchase order #127.
- Diesel generators units A & B, manufactured by Fairbanks Morse
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and received on MRR 81-6091 for purchase order #241.
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No items of noncompliance were identified.
6.
Cadwelding
The inspector observed cadwelding being conducted inside the containment and
verified compliance with the S&W construction methods procedure (CMP) 6.1,
specification #999 and quality standard 9.11.
The cadwelding being performed
was for the fuel cavity liner concrete walls. The inspector inspected several
of the completed production welds for voids and also a recently completed
" sister" splice. A review of the cadweldor's qualification report and his
production summary and production testing cycle records was also done. The
following S&W inspection reports for the cadwelds inspected on 11/19 and 20/81
were reviewed:
IR #S1005537 - Final cadweld inspection report, dated 11/20/81
IR #S1005538 - In-process inspection report, dated 11/19/81
Also, the test results for " sister" splice #T-20284 was reviewed.
No items
of noncompliance were identified,
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7.
Cable Raceway Erection
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a) The inspector inspected Category I cable tray supports being erected in the
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control building, ESF and containment. The inspector verified that the
cable tray supports were welded in accordance with S&W weld procedure
technique W70G, Revision 4,and engineering specification E350 requirements.
No items of noncompliance were identified.
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b) During inspection of the welding of cable tray supports inside the contain-
ment, the inspector noticed that the containment liner may be bowed in a
localized area, beyond the containment erection specification #C-109
acceptance criteria.
The apprcximate location of this area is at,
Azimuth 2900-3000 and elevation 75-80 ft. The NRC inspector was informed
that the containment as-built dimensions have not been performed as yet,
and that this area will be measured when the as-builts measuring is in
process. This item is considered unresolved pending review of the as-built
dimensions of containment (423/81-14-04).
c) During an inspection of the welding of supports inside the control building,
the inspector noticed that locking devices were .iot used for the cable
tray vertical adjustable connector plates.
(Note:
used whenever there
is a slight change in elevation of trays from the horizontal position).
Since locking devices are used on other types of connections, the inspector
approached the S&W craft foreman with this concern.
The foreman directed
the inspector to S&W engineering and design coordination report (E&DCR)
- P-E-3429. This E&DCR gave the details for installing the T.J.Cepes
vertical adjustable connector plates (Q37-02CV), but did not detail the
locking devices (nuts & lock washers). The NRC inspector informed S&W
field QC of this condition.
S&W engineering superceded P-E-3429 and issued
E&DCR #F-E-6436 which now addresses the locking devices. The engineering
instructions now state that locking devices are at the option of the
construction organization. The inspector had no further questions at this
time.
8.
Receipt Inspection
The inspector observed the receipt inspection of four - 42" butterfly valves,
identified as: 3HVU-CTV-32A, -B and 33A & B.
The inspector verified that the
handling, identification, inspection and documentation was in accordance with
the S&W receipt inspection procedures CMP 1.2-12.77 & QS-7.1ML.
No items of
noncompliance were identified.
9.
Location of Embeds Spent Fuel Pad Plates
The inspector observed the locating of several of the Embed Spent Fuel Pad
Plates in the fuel building. The locations are critical and are depicted on
Drawings EV-3S-2 and EV-3A-4.
The individual plates are welded to structural
embeds. No items of noncompliance were identified.
10. Welding of Fuel Transfer Canal Liner
The inspector observed the welding on the fuel tran fer canal liner as a result
of modification, which was on S&W construction revision notice #CH-SFP-1-012.
The welding was in accordance with weld technique procedure W76C, Revision 1.
The inspector noticed several arc strikes on the " concrete" side of the liner plate.
The S&W erection specification #2214.730-952 does not address arc strikes on the
" concrete" side of the liner plate. A discussion was held with S&W field QC to
verify that all arc strikes will be removed prior to concreting. The inspector
was assured that they would, and removal had commenced during this inspection
period.
No iums of noncompliance were identified.
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11.
Seismic Welding of Electrical Motor Control Centers to Floor Embeds
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The inspector observed the welding of the following motor control center
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panels to the embeds in accordance with weld procedure technique W70T,
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Revision 1:
- R PCC Water Pump MCC (3CCP-PIC)
- R PCC Water Pump MCC (3CCP-1B)
- Safety Injection Pump MCC (3SIH-P18)
No items of nor. compliance were identified.
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12.
Management Meetings
At periodic intervals during the course of this inspection, meetings were
held with senior plant management to discuss the scope and findings of
this inspection.
13.
Unresolved Items
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Unresolved items are matters abcut which more information is required in
order to ascertain whether they are acceptable items, items of noncompliance,
or deviations. Unresolved items disclosed during the inspection are
discussed in paragraphs 5 & 7.
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