ML20050N440
| ML20050N440 | |
| Person / Time | |
|---|---|
| Site: | Rancho Seco |
| Issue date: | 03/26/1982 |
| From: | Eckhardt J, Hernandez G NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V) |
| To: | |
| Shared Package | |
| ML20050M903 | List: |
| References | |
| 50-312-82-02, 50-312-82-2, NUDOCS 8204140340 | |
| Download: ML20050N440 (6) | |
See also: IR 05000312/1982002
Text
..
-
__
.
U. S. NUCLEAR REGULATORY COMMISSION
REGION V
Report No. 50-312/82-02
Docket No. 50-312 (C0N)
License No.
Safegurads Group
Licensee:
Sacramento Municipal Utility District
!
l
P. O. Box 15830
Sacramento, California 95812
Facility Name:
Rancho Seco
Inspection at:
Herald, California
(Rancho Seco site)
(
Inspection conducted: January 12-15, 1982
Inspectors: M.
mM
3/J.6/8&
pHernandez, Reactor (,JAspector
Date Signed
~
!
-
[
8/J4/82
Approved by:
_
,
J./H. Eckhardt, Acting Chief, Reactor Projects
IIate Signed
Section 1, Reactor Construction Projects Branch
Summary:
Inspection on January 12-15, 1982 (Report No. 50-312/82-02)
!
Areas Inspected: Routine unannounced inspection by a regional based inspector
of licensee activities related to' plant modifications including:
review of
construction and quality implementing procedures; observation of work activities;
handling and storage of material; and drawing control activities.
The inspection involved 32 inspector-hours onsite by one NRC inspector.
Results: Of the six areas examined, three items of noncompliance were
identified (these items are identified in paragraphs 4, 5, and 7).
!
i
l
!
8204140340 82O329
PDR ADOCK 05000312
O
l
l
r
. _ _
_
_ _ ,
.
. . . .
. - _ _
-.
-
=
_
'
.
.
DETAILS
1.
Persons Contacted
a.
Sacramento Municipal Utility District (SMUD)
- R. Columbo, Technical Assistant
- V. C. Lewis, Resident Engineer
- J. Jewett, Senior Engineer-Quality Assurance
- T. E. Perry, Site Supervisor-Quality Assurance
- J. Paman, Generation Engineering Quality Control Supervisor
S. Crunk, Nuclear Operations
b.
Bechtel Power Corporation
.
C. Letellier, Quality Control Coordinator
H. Davis, Civil Inspector
E. Conley, Mechanical / Welding Inspector
c.
SMF Corporation
,
T. Twomey, Job Superintendent
H. Keltner, Engineer
- Denotes those attending the exit interview.on January 15, 1982.
Also, in attendance were the Senior Resident and Resident NRC
inspectors.
2.
Site Tour
Upon arrival at the site, the. inspector. toured the facility modifications
to observe in-process and completed work activities and to ascertain
general compliance with regulatory requirements, codes, standards, and
site procedures.
During the tour the inspector observed that on the east side of the
Nuclear Service Electrical Building (NSEB) high strength ASTM A-325
bolting material for use in the erection of the building structural
steel was not protected, stored, and controlled within the requirements
of ANSI N45.2.2, " Packing, Shipping, Receiving, Storage, and Handling
of Items for Nuclear Power Plants," and Regulatory Guide 1.38.
(These items are detailed in paragraph 7.)
3.
Licensee Action on Previously Identified Insoection Items
a.
(0 pen) Follow-up Item (50-312/81-24/03):
Storage of material in
laydown area not in compliance with the requirements of ANSI
N45.2.2Property "ANSI code" (as page type) with input value "ANSI</br></br>N45.2.2" contains invalid characters or is incomplete and therefore can cause unexpected results during a query or annotation process..
The licensee has recently taken measures to insure that the
laydown area will comply with the ANSI standard.
However, this is
l
being done on a piecemeal basis by the maintenance contractor
I
(H. P. Foley Company) as time and his work schedule allows.
-
-
-
. - -
..
.
._.
_
.-
.
- _ _ _ .
'
.
.
,
-2-
-
.
At the exit interview the licensee stated that a plan will
be formulated to accelerate the process of bringing the laydown
area in compliance with the ANSI standard. This item will remain
open pending a future inspection to verify the results of the
licensee's actions.
4.
Steel Structures and Supports - Welding Material Control
The inspector examined welding material, acceptance, storage and
handling activities associated with steel structures and supports to
determine conformance with the licensee / contractor's work and
Quality Assurance procedures and AWS Dl.1 Code requirements.
On exanining the contractor's (SMF Corporation) facilities for
control and issuance of weld filler material the inspector found
that:
(1) The weld rod holding oven's electrical supply had been
de-energized for an undetermined amount of time, such that the weld rod
~
was cold to the touch; (2) An uncalibrated thermometer was being
used to maintain the required oven temperature; and (3) Three full
containers of E7018 weld filler material were found open. Discussions
with the contractors personnel indicated that they were unaware that
the weld rod cans were hermeticaN sealed and that the cans had
been opened to facilitate reple
t of the weld rod oven.
(4)The
weld rod disbursement log did t
..uscate the time of issuance or
return of weld rod making it impossible to determine whether the
weld rod had been out longer than four hours.
SMF Cornoration Welding Filler Material Control Procedure
Specification (WFMCPS) states in part in paragraph 4.3.2(b) that,
" Low hydroaen type covered electrodes (EXX15 and EXX18) and
stainlesssteeltypecoveredefectrodesghallbestoredinvented
electrode holding ovens at 250 F and 350 F;" in paragraph 4.3.4 that
"When low hydrogen covered electrodes are to be used, they shall
be removed f6msealegcntiners nd stored in local storage
ovens at 250 F to 350 F for at least one hour prior to use;" and
in paragraph 5.2 that, "Whenever practical, a quantity of covered
electrodes sufficient for four hours of work shall be issued to the
welders at the beginning of shift. Unused electrodes shall be
returned to the issuing area at the end of the shift, after
completion of the weld, or destroyed."
Contract Specification C22.2 states in paragraph SC-12A(7),
" Calibration of Measurement and Test Equipment", that, "A system
of control will assure that all instruments, measuring equipment,
and test equipment are properly calibrated and perform accurately."
The failure to control and monitor weld filler material in accordance
with approved procedures and snecifications is considered an apparent
item of noncompliance with 10 CFR 50, Appendix B, Criterion V,
" Instructions, Procedures, and Drawings".
(50-312/82-02/01)
i
.
'
,.
,-
.
-3-
5.
Quality Assurance Audits
A review of SMUD Quality Assurance audits revealed that an audit
performed on October 27, 1981 on SMF's weld filler material control
program had identified a number of prograrunatic weaknesses. As a
result, a followup audit was scheduled on flovember 17,1981, this
audit not only verified the contractor's corrective action, but also
identified several new deficiences. A new audit was scheduled for
December 1981, however, this audit was never performed because of
licensee personnel changes.
The audit findings of October 27, 1981 and flovember 17, 1981 were
similar to the findings by the NRC inspector on January 13, 1982..
The failure to take appropriate measures to assure that the cause
of conditions adverse to quality are promptly identified and appropriate
corrective action taken to preclude repetition is considered an
apparent item of noncompliance with 10 CFR 50, Appendix B, Criterion XVI,
" Corrective Action".
(50-312/82-02/02)
6.
Review of Quality Records
The quality records associated with the acceptance, storage
and handling of welding filler material were examined to verify
compliance with the licensee's work and quality assurance procedures,
applicable codes and standards. This record review included receipt
inspection records, chemical and physical tests for the weld filler
material, and logs of weld filler material disbursement. Also
reviewed, were records of welder oualification. The record review
verified that the welders were qualified for the process being used,
and were using.the_ proper weld filler material.
flo items of noncomoliance or d'eviations were identified.
7.
Safety Related Structures (Structural Steel and Supnorts)
During the site tour on January 12, 1982 the insoector observed
that on the east side of the flSEB high strength bolting material
was not being_ stored, protected and controlled within the applicable
,
l
requirements of Regulatory Guide 1.38 and AflSI fl45.2.2-1972.
I
1
The licensee connitted to WASH document 1284, Guidance on QA
l
Requirements During the Operations Phase of Nuclear Power Plants,
in letter to the NRC/D0R of July 22, 1976 and September 23, 1976.
WASH document 1284 contains Regulatory Guide 1.38, Quality Assurance
Requirements for Packagina, Shipping, Receiving, Storage and
handling of Items for Water-Cooled Nuclear Power Plants, which
i
states in oart:
"The requirements and guidelines....that are
i
i
l
l
!
!
,
.
.
-
.-
._
'
.
..
,
-
, . .
,
'
-4-
included in ANSI N45.2.2-1972, Packaging, Shipping, Receiving,
Storage and Handling of Items for Nuclear Power Plants....are
generally acceptable and provide an adequate basis for complying
with the nertinent quality assurance requirements of Anpendix B to
10 CFR 50,...."
ANSI N45.2.2 in paragraph 6.1. states in part that, " Levels and methods
of storage are defined to minimize the possibility of damage or lowering
of quality due to corrosion, contamination, deterioration or physical
damage from the time an item is stored upon receipt until the time the
item is removed from storage and placed in its final location."
Contrary to the above, the inspector observed that the containers
of high strength bolting material did not conform to the ANSI
,
recuirements in that most of the containers were open, sitting on
the ground, and the bolting material corroded to such an extent
that most bolts and nuts could not be freely moved by hand. The
inspector also found, five of what appeared to be cadmium plated
ASTM A-325 bolts which were intermingled with the apparently acceptable
non-plated ASTM A-325 bolting material and five bolts which had
forging head bursts.
!
Discussions with the licensee indicated that during a recent
Bechtel Quality Control surveillance, three cadmium plated bolts
were discovered installed in the NSEB, the bolts had been promptly
!
removed, but apparently the contractor had neglected to remove
the discrepant bolts from the general work area.
The licensee
I
further stated that craft personnel would be advised of the
detrimental effects of forging bursts and to segregate any defective
bolts found.
i
The failure to store, protect and control high strenath bolting
material within the requirements of ANSI N45.2.2 is considered an
apparent item of noncompliance with 10 CFR 50, Appendix B, Criterion XV
(50-312/82-02/03).
8.
Review of Quality Records
The material certification records and receipt inspection records
associated with the ASTM A-325 bolting material noted above were
examined for compliance with the contract specifications and
procedures and applicable codes and standards.
No items of noncomoliance or deviations were identified.
l
l
I
<
1
'
. - - -
- -
- - . . - ,
- ,.
..-.- . - .
- - - - - - - -
- . - -
- ,
--
--
.. -
. .
- . - - -
. - _ -
_ - -
- . -
.
. -
.
.._-
- _
.
!
-
.,
'
,
-
'
.
.
5-
-
9.
Contractor Performance
Observations by the insnector of contractor performance indicated
a general lack of understanding and familiarity with standard
industry work practices. This unfamiliarity probably contributed to
i
j
the discrepancies identified during this inspection and with the
a
apparent communication problem encountered during review of SMF's
I
drawing control.
During review of SMF " pink" construction drawings the inspector found
that the M-922 series of mechanical prints were extremely illegible,
When ouestioned, SMF personnel stated that they had brought this
i
i
issue up with the licensee, but to date the licensee had not remedied
the situation. Discussion with the cognizant SMUD engineer indicated
l
that SMUD was aware of the problem and had reouested that a white
1
informational print be attached to each of the M-922 series prints
)
for clarity.
However, the cognizant SMF engineer stated that the
contract specification required that SMF perform work only to the
.
pink construction drawings, so he had discarded the white informational
prints.
At the exit interview the licensee stated that the M-922 series of
prints were in the process of being replaced by a new 896 series of
prints which would rectify the problem of the illegible prints.
a
10. Management Interview
At the exit interview on January 15, 1982 the inspector stressed
that because of the range of problems encountered durina this inspection
l
there apneared a real possibility that without vigorous implementation
of the SMUD Quality Assurance Program, the prime contractor or sub-
l
contractors might inadvertently use or install naterial or equipment
!
which might not perform as intended in service. The licensee
acknowledged the insoector's concerns and indicated that appropriate
action would be initiated.
,
k
1
!
,
- - ~
,
- - - - -
--
,
.-
wmw
,,
ev,e
,.
--n.
~
,mem
-m.,e--m
,,,.,-,-,,,n-
-.w,
- - - --.-- ,~-- -
, -