IR 05000223/2003022

Insp Repts 50-424/85-09 & 50-425/85-09 on 850223-0322. Violation Noted:Failure to Follow Procedure to Prevent Dissimilar Metallic Matls from Coming in Direct Contact W/One Another

ML20127F724
Person / Time
Site:	Vogtle, University of Lowell
Issue date:	04/16/1985
From:	Rogge J, Sanders W, Sinkule M NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
To:
Shared Package
ML20127F705	List: IR 05000223/2003022 ML20127F702 ML20127F712
References
50-424-85-09, 50-424-85-9, 50-425-85-09, 50-425-85-9, IEB-84-03, IEB-84-3, NUDOCS 8505200577
Download: ML20127F724 (13)

Text

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R8oo UNITEC STATES

- o, NUCLEAR REGULATORY COMMISSION

. o REGION il-5* $ .101 M ARIETTA STR E ET, o * ATLANTA, GEORGIA 30303

%*****/ APR 181985 Report Nos.: 50-424/85-09 and 50-425/85-09-Licensee: Georgia Power Company P. O. Box 4545 Atlanta, GA 30302 Docket Nos.: 50-424 and 50-425 License Nos.: CPPR-108 and CPPR-109 Facility Name: Vogtle 1 and 2

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Inspection Conducted: February 23, 1985 - March 22, 1985 Inspectors: M M l%19 FG K W. F. Sanders, Senior Resident Inspector, Construction Date Signed

& "0-0 U l2,1986 Oste Signed p J. F. Rogge, Senior Resident Inspector, Operations Accompanying Peronnel: J. Schepens, Resident Inspector, Construction

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Approved by: 2r , k /fD M.-V.iSinkule, Section Chief .Dafe Signed'

Division of Reactor Projects SUMMARY Scope: This routine, unannounced inspection entailed 352 resident inspector hours on site (40 hours4.62963e-4 days <br />0.0111 hours <br />6.613757e-5 weeks <br />1.522e-5 months <br /> were on backshifts) _ inspecting: quality assurance, ~

refueling cavity seal ring installation, refueling canal welding, containment

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dome reinforcing steel and tendon sheathing, cavity liner plate welding, containment post tensioning, reactor coolant system primary loop piping

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installation'and welding, safety-related piping installation and welding, reactor-vessel internals fit-up and invessel storage activities, and storage and protection of safety-related equipmen Results: One violation was identified (Failure to Follow Procedure to Prevent Dissimilar Metallic Materials from Coming in Direct Contact with One Another -

paragraph 14).

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8505200577 850418 PDR ADOCK 05000424 G PDR

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APR 181985 REPORT DETAILS

. Persons Contacted Licensee Employees

- D. O. Foster, Vice President and Project General Manager P. D. Rice, Vice President and General Manager, Quality Assurance W. T. Nickerson, Deputy Project General Manager W. C. Ramsey, Readiness Review Manager H. H. Gregory III, General Manager Nuclear Construction

• M. H. Googe, Project Construction Manager G. Bockhold,'Jr., General Manager Nuclear Operations 0. Batum, General Manager Engineering and Licensing C. W. Hayes, Vogtle Quality Assurance Manager C. E. Belflower, Quality Assurance Site Manager - Construction

• E. D. Groover, Quality Assurance Site Manager - Construction

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S. D. Haltom, Quality Assurance Engineering Support Supervisor W. E. Mundy,- Quality Assurance Audit Supervisor J. E. Sanders, Project Construction Manager - Unit 1 D. M. Fiquett, Project Construction Manager - Unit 2 B. C. Harbin, Manager Quality Control

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• J. L. Blocker, Assistant. Quality Control Manager T. L. Weatherspoon, Assistant Quality Control Manager

• G. A. P,cCarley, Project Compliance Coordinator W. C. Gabbard, Assistant Project Compliance Coordinator

• J. O. Dorough, Administrative Manager

• L. N. Brooks, Civil Manager

• Stone, Engineering Supervisor Other licensee employees contacted included craftsmen, technicians, supervision, engineers, and office personne Other Organizations F. B. Marsh, Project Engineering Manager - Bechte!

M. Malcom, Deputy Project Engineering Manager - Bechtel

• D. L. Kinnsch, Project Field Engineering - Bechtel

• D.W . Stroham, Project Quality Assurance Engineer - Bechtel

• R. J. George,- Mechanical Discipline Manager - Bechtel

• G. H. Fredy, Project Field Engineer / APE - Bechtel

• G. Introcaso, Administration Manager - Pullman Power

• T. J. Pruitt, Field QA/QC Manager - NISCO

• D. R. Murphy, Construction Engineer - Oglethorpe Power Corporation

• Attended exit in+erview

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APR 181985

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' 2. . Exit Interview (30703C)

The inspection scope and findings were summarized on March 22,1985, with those persons indicated in paragraph 1 above. The inspector described .the areas inspected and discussed in detail the. inspection findings listed below.- No' dissenting comments were received from the license (0 pen) Violation 50-424/85-09-01: " Failure ' to follow. procedure to prevent dissimilar metallic materials from coming in direct contact with one another" - Paragraph-1 (0 pen) IE Bulletin No. _84-03: " Refueling Cavity Water Seal" Units 1 & 2 -

Paragraph 2 The licensee did not identify as proprietary any of the materials provided

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to.or; reviewed by the inspector during this inspectio .

, Licensee Action on Previous Enforcement Matters (92702)

Not inspecte c Unresolved Items (92701)

Unresolved items are matters -about which more information is require to

- determine ' whether they are acceptable or may involve violations or

~ deviations. Unresolved items were not identified during this inspectio . Construction Inspection - Units 1 & 2 (92706C)

Periodic inspections were made throughout this reporting period in the - form of. general type inspections in different areas of both facilitie The areas were selected on the basis of the scheduled activities and were varied to provide wide coverage. : Observations were made of activities in progress to note defective items or items of noncompliance with- the required codes and regulatory requirements. On these inspections, particular. note was made

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.of the presence of ~ quality control inspectors, supervisors, and quality control evidence in.the' form of available process sheets, drawings, material l identification, material protection, performance of tests, and housekeepin Interviews . were made with craft personnel, supervisors, coordinators, quality-control inspectors, and others as they were available in the work area Unitli -independent ' inspection encompassed but was not limited to the following areas:

I- (1) Refueling Cavity Seal Ring - Periodic inspections were conducted during the weld out of the seal ring to the reactor vessel seal c ledge and -the reactor cavity- line The purpose of these inspections were to determine that the requirements of applicable specifications, codes, standards, work performance procedures! and inspections (QC) procedures were being followed. This work was completed during this inspection perio ~ '

APR 181985

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(2) Refueling Canal - An inspection was conducted during the fit-up phase of. the bellows assembly. This was a replacement bellows being installed due to the first one being damaged after installation during the grinding operatio : to flat top the wel ' The weld prep configuration of the penetration pipe and new bellows was inspecte (3) Refueling Bridge Crane Rail Installation - An inspection was conducted of the preparation activities for the installation of the track Unit 2 independent inspection encompassed but was not limited to the following areas:

Cavity -liner plate welding - The inspector conducted a general inspection of the welding operation, i.e. , weld filler metal control and storage, fit up cleanliness requirements, slag removal and grindin No violations or deviations were identifie . Containment (Structural Concrete) - Unit 2 (47053C)

Periodic inspections were conducted of the containment dome reinforcing steel and tendon sheathing installation and the North and South walls around the steam generators to determine that the requirements of applicable specifications, codes, standards, work performance procedures and inspection (QC) procedures are being followe No violations or deviations were identifie . Containment (Prestressing) - Observation of Work Activities - Unit 1 (47063C) Procedure and Document Review The inspector reviewed and examined implementation portions of the following specification, procedure, and quality assurance manual pertaining to the installation of vertical tendons, to determine whether they comply with applicable codes, standards, NRC Regulatory Guides and licensee commitment ' Specification No. X2AF04, Revision 2, date of issue 7/24/84

" Technical Provisions for Containment Post-Tensioning System".

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Bechtel Log No. AX2AF04-100-7, " Field Instruction Manual for Installation of VSLES-55 Post-Tensioning System Within Nuclear Containment Structures", Revision 4, dated 2/15/8 Bechtel Log No. AX2AF04-81-10, "VSL's Corporation Quality Control Program for Nuclear Power Projects", date of issue 1/19/8 .__

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APR 181995 4 Installation Activities The inspector witnessed portions of the installation activities indicated below to verify the following:

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The latest issue (revision) of applicable drawings or procedures is available to the installers and were being use Tendons were free of nicks, kinks, and corrosion; were installed in designated locations; and the installation sequence and technique was per specified requirement Installation crew was properly trained and qualifie QA inspection was properly performed by qualified personnel in accordance with applicable requirements.

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Adequate protective measures were.being taken to ensure mechanical and corrosion protection during storage, handling, installation, and post installatio The following tendons were observed:

Vertical Tendon N Length Seg. N Activity 24-88* 578.7' 3 Tendon Initial Installation 22-90 577.9' 2 Mopping Tendon Sheathing

• Surveillance Tendon No violations or deviations were identifie . Containment (Steel Structures and Supports) - Units 1 & 2 (48053C)

Periodic inspections were conducted to observe containment steel and support installation activities in progress to verify the following:

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Components were being properly ~ handled (including bending or straight-ening).

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Specified clearances were being maintaine Edge finishes and hole sizes were within tolerance Control, marking, protection and segregation were maintained during storag Fit-up/ alignment meets the tolerances in the specifications and drawing ._ .

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APR 181985

No violations or deviations were identifie . Safety-Related Structures (Structural Steel and Supports) - Units 1 & 2 (48063C)

Periodic inspections were conducted to observe construction activities of safety-related structures / equipment supports _for major equipment outside the containment to verify that:

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Materials and components are being properly handled to prevent damag Fit-up and alignment are within tolerances in specification and drawing requirement Specified clearances from adjacent components are being me No violations or deviations were identifie . Reactor Coolant Pressure Boundary Piping - Observation of Work and Work Activities - Unit 1 (49053C)

During the inspection period pipe run walkdowns were performed where piping installation is near completion to determine whether the piping run is installed as shown on approved drawings and in accordance with applicable construction specifications. Specific pipe run walkdowns of ASME B&PVC,Section III, Class 1 piping inspected is listed below:

ISO No./ Revision Pipe Run Inspected 1K4-1201-049-02, Rev. 08 RCS Loop "4" Line No. 1201-049-12" From Hot Leg to Valve HV 8702A (RHR Sys. Train B Suction Line)

1K4-1204-023-02,-Rev. 10 RHR Hot Leg Injection Crossover to 1K4-1204-023-03, Rev. 11 RCS Hot Leg Loop No. 1 IK4-1204-021-03, Rev. 08 RHR Hot Leg Injection Crossover to RCS Hot Leg Loop No. 4 Specific areas examined during the pipe run walkdown for compliance with the applicable isometric drawings and the Plant Design and Instrumentation Construction Specification No. X4AZ01, Revision 19 were as follows:

Vent and Drain Connection and Locations Instrumentation Connections and Locations Valve Installation and Orientation Line Size and Location Fittings Type and Location Pipe / Valve / Fitting End Connections Hanger Locations and Types No violations or deviations were identifie . .

APR 181985

11. Safety-Related Piping - Observation of Work and Work Activities - Unit 1 (49063C)

During the inspection period, pipe run walkdowns were performed where piping-installation is near completion to determine whether the piping run is installed as shown on current, approved drawings and in accordance with applicable construction specifications. Specific pipe run walkdowns of ASME B&PVC,Section III, Class II piping are listed below:

ISO No./ Revision Pipe Run Inspected 1K4-1205-001-03, Rev. 5 RHR Train A Suction Line From Valve 1K3-1205-003-02, Rev. 10 HV 8701A (Line Nos. 1205-001-12" &

1205-003-12") to Elev. 160'-0" Line No. 1205-003-14" 1K4-1205-002-01, Rev. 9 RHR Train B Suction Line From Valve HV8702A (Line Nos. 1205-002-12" &

1205-004-12" to Elev.161"-6" Line No. 1205-004-14" Specific areas examined during the pipe run walkdown for compliance with the applicable isometric drawings and the Plant Design and Instrumentation Construction Specification No. X4AZ01, Revision 19 were as follows:

Vent and Drain Connections and Locations Instrumentation Connections and Locations Valve Installation and Orientation Line Size and Location Fittings Type and Size Pipe / Valve / Fitting /End Connections Hanger Locations and Types No violations or deviations were identifie . Reactor Vessel Protection - Unit 2 (50053C)

The inspection consisted of examination of the Unit 2 Reactor Vessel installed in containment to determine that proper storage protection prectices were in place and that entry of foreign objects and debris was prevented. The inspector noted that protective covers were installed on the bottom mounted instrumentation-penetration No violations or deviations were identifie . Reactor Vessel Integrated Head Package - Unit 1 (50053C)

The inspection consisted of examination of the Unit 1 integrated head ,

package stored on the refueling floor in its designated laydown area to l determine that proper storage protection practices were in place, entry of foreign objects and debris was prevented, and that access was controlle No violations or deviations were identified. . . . _ ,

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APR 1- 8 1985 -

1 Reactor Vessel Internals - Unit 1(50063C)

Periodic-inspections were conducted during .the inspection period when the upper. - and lower ! internals were stored in the cavity in their designated .

storage area' to ' determine that proper storage protection' practices 'were in place, entry of foreign objects and debris was. prevented, and that access was-controlled. The inspection' also . included the fit-up operation, the

' installation of the . reactor vessel internals, and the integrated head pack-age. This activity consisted of the.following tasks:

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. Trail fit-up of~the core barrel to the Reactor vessel to record fit-up clearances, e.g... nozzle gap measurements between the CSB and RV (with Clevis inserts) and clearance dimensions of lower radial support key,

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.etc.

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Removal of the core barrel and storage in its designated area.

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Radial support clevis insert dowel pin reaming, installation of dowel pins, and locking bar Refit-up of core barrel to the Reactor Vessel.

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Installation of the hold-down spring.

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Trial fit-up of the upper internals to record fit-up clearance ~

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Installation of the Reactor Pressure Vessel integrated head onto the Reactor. Vessel flange seal .and trial fit-up of the stabilizer bracket The' inspector reviewed and examined implementation portions of the following procedures or drawings pertaining to the above Reactor Vessel internal . fit-up operation to determine whether they comply with applicable codes

standards,-NRC Regulatory Guides and licensee commitment X4AZ06-56-3, NISCO Engineering Specification No. 4028-Vogtle-17

Revision C; Reactor Vessel Internals Assembly

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AX4AZ06-15-4, NISCO Engineering Specification No. 67, Revision C; Cleanliness Requirements and Control

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AX4AZ06-69-1, NISCO Engineering Specification No. 69, Revision A; Control,- Usage and Storage of Consumables for Use on Nickel Based Corrosion Resistant Material AX4AZ06-16-2, NISCO Engineering Specification No. 4028-Vogtle-6, Revision B; General Handling Procedur .

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Process Control .No. 105-17, Revision A, Reactor Vessel Internals, Installation of the Lower Radial Support Clevis Insert IX6AB06-53-1, y Dwg. No. 6125EE14, Sht 2 of 3, Reactor Vessel Lower

Radial Support Clevis Insert Gaging and Assembl . _ _ . _ _ __ .

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APR 181985 s ,

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AX4AZ06-60-3, WPS'430-2-1, Revision D WPS.for Manual GTAW of inconel to Itself on-Plate, Pipe, Tube, etc.,.1/16" thru 1/4".

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PQR 801, . Revision.D PQR for. combination GTAW/SMAW of Inconel to itself ' 'l on 3/8" thick. plate in 3G positio l The inspector: witnessed ' portions of ' the above Reactor Vessel internals I fit-up operations to. verify the following:

- Lifting ~and handling are consistent with established requirements and precautions.

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Lifting ~ equipment is as specified and ' required testing has been completed prior to liftin Core barrier, upper internals, and integrated head package are placed in position within-. dimensional tolerances, proper axis orientation

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and levelnes Radial support clevis insert dowel pin and locking bar'insta11ation is-

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in accordance with applicable specification With regard to the above operations, the inspector noted a personnel basket had been lowered into the Reactor Vessel to allow personnel to clean the hot leg nozzle mating surfaces. . During this operation . the carbon steel personnel basket came in direct contact with the Reactor Vessel stainless .

steel cladding. The inspector questioned the licensee about this operation and observed immediate action taken to remove the personnel basket and t wrap A-cloth around it to prevent carbon steel contacting the reactor vessel cladding as required by Paragraph 5.3.8 of Engineering Specification No. ES-67, Revision C dated 5/31/84.

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' Failure to follow the above procedure is considered to be in violation of 10

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CFR Part 50,- Appendix B, Criterion V. This-item was identified as Violation 424/85-09-01 " Failure to Follow Procedure to Prevent Dissimilar Metallic Materials From Coming in Direct Contact With One Another."

15. Safety-Related Components - Units 1 & 2 (50073C)_

The ' inspection - consisted of plant tours to observe protection installed components to determine that adequate protection from dirt, debris, water, or adjacent construction activities were in plac Unit 1 equipment examined included:

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Residual Heat Removal (RHR) Pumps

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Diesel Generator

- - Boric Acid Storage Tank

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Containraent Spray (CS) Pumps

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Containment Penetration Encapsulation Vessel for Train A&B RHR and CS

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Auxiliary Feed Pumps _

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APR 181985

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Pressurizer

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Main Coolant Pump Casings

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Steam Generators

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Safety Injection Pumps

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Auxiliary Component Cooling Water (ACCW) Heat Exchangers

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Component Cooling Water Heat Exchangers

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ACCW Pumps

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Reactor Makeup Pumps

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Boron Injection Tank

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Cable Spreading Room Train A & B

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Integrated Reactor Pressure Vessel Head

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4160V Train A & B Switchgear (IAA02 & IBA03)

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13.8KV Reactor Coolant Pump Switchgear

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Reactor Vessel Lower Internals

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Reactor Vessel Upper Internals Unit 2 equipment examined included:

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Residual-Heat Removal (RHR) Pumps

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Containment Spray (CS) Pumps

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Containment Penetration Encapsulation Vessel for Train J4 & B RHR and CS

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Pressurizer

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Steam Generators

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Safety Injection Pumps

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Reactor Vessel No violations or deviations were identified.

n 16. Electrical (Components and Systems) - Units 1 & 2 (51053C)

Periodic inspections were conducted during the inspection period to observe safety-related electrical equipment to verify that the installation and storage were accomplished in accordance with applicable requirements. The following areas were examined during the inspections:

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Location and alignment

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Type and size of anchor bolts

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Identification

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Segregation and. identification of nonconforming items

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Equipment space heating

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Rotation of motor shafts

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Lubrication and fluid levels

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Protective coatings, preservations, desiccants, inert gas blanket, et No. violations or deviations were identifie . Electrical (Cables and Terminations) - unit 2 (51063C)

Periodic inspections were conducted during the inspection period to determine whether the raceway installation and protection of installed cable is in accordance with applicable codes, standards, and NRC Regulatory Guide .

APR 181985

In reference to the raceway installation, the following areas were inspected to verify compliance with the applicable requirements:

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Identification

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Alignment

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Bushings (Conduit)

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Grounding

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Supports and Anchorages In reference to the installed cable, the following areas were inspected to verify compliance'with the applicable requirements:

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Protection from adjacent construction activities (welding, etc.)

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Coiled cable ends properly secured

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Unterminated cable ends taped

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Cable trays, junction boxes, etc., reasonably free of debris

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Conduit capped, if no cable installed

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Cable supported No violations or deviations were identifie . Reactor Coolant Pressure Boundary (Welding) - Unit 2 (55073C)

Periodic inspections were conducted on Reactor Coolant System Primary Loop pipe ~ welds at various stages of weld completio The purpose of the inspection was to determine whether the requirements of applicable specifications, codes, standards, work performance' procedures and (QC)

procedures were being met as follows:

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Work was conducted in accordance with a process sheet which identified the weld and its location by system, references procedures or instructions, and provides for production and QC signoff Welding procedures, detailed drawings and instructions, were readily available and technically adequate for the welds being mad Welding procedure specification (WPS) were in accordance with the applicable ASME Code requirements and that a Procedure Qualification Record (PQR) is reference and exists'for the type of weld being mad That the base metals, welding filler materials, fluxes, gases and insert materials were of the specified type and grade, have been properly ' inspected, tested and were traceable to test reports or certification That the purge and/or sheilding gas flow and composition were as specified ~1n the welding procedure specification and that protection was provided to shield the welding operation form adverse environmental condition _ _

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APR 181985

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' That - the weld joint geometry including pipe . wall thickness was specified and that surfaces to be welded have been prepared, cleaned and inspected in accordance with applicable procedures or instruction That the pipe to be welded to the component were assembled and held in place within specified gap and alignment tolerances-allowed by the ASME Cod That a sufficient number of adequately qualified QA and QC inspection personnel were present at the work site, commensurate with the work in progres That disbursement of welding material was controlled in accordance with approved procedure Procedure / Drawing Review The following documents were reviewed:

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2X4D4A17, Rev. 7, Reactor Coolant Loops

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(W) 32-III/I-8-12, Rev. A, Procedure for tacking the inser III/I-8-K1-A1, Procedure for welding the reactor coolant system primary loop pipin Process Sheet No. 2X4D4A17 003-W-0 Process Sheet No. 2X404A17 002-W-0 Process Sheet No. 2X404A17 006-W-0 Process Sheet No. 2X404A17 007-W-0 Installation Activities The inspection observed the above criteria on the following Reactor Coolant System primary pipe welds at various stages of weld out during the inspection perio Weld N Weld Out Stuge Inspected 002-W-02 Fit-up 006-W-01 1/3 out 006-W-02 Weld prep 010-W-01 Welded out

~003-W-02 Welded out 007-W-01 Fit-up 007-W-02 Weld prep 011-W-01 1/3 out 011-W-01 1/3 out No violations or deviations were identified.

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APR 181985

1 Safety-Related Piping (Welding) - Unit 1 (55083C)

Periodic inspections were conducted on safety-related pipe welding at various stages of weld completion. The purpose of the inspection was to determine whether the requirements of applicable specifications, codes,_

~s tandards, work performance procedures and QA procedures are being met as follows:

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That the weld area cleanliness was maintained and that pipe alignment and fit-up tolerances were within specified unit That weld filler material being used was in accordance with welding specifications that unused filler material was separated from other types of material and was stored in heated cans, and stubs properly removed form the work locatio That there were no evident signs of cracks, excessive heat input, sugaring, or excessive crow Installation Activities

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During the inspection period, welds at various stages were observed in the following systems:

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Residual Heat Removal System

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Component Cooling Water System

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Chemical & Volume Control System

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Nuclear Service Cooling Water System No violations or deviations were identifie . IE Bulletins (IEB) - Units 1 & 2 (92703B)

(0 pen) IEB No. 84-03: " Refueling Cavity Water Seal", Units 1 & 2. The Resident Inspectors have reviewed Georgia Power Company's letter of March 7, 1985, File No. X7BC24, Log No. GN-543, in order to determine if the requested actions of the bulletin have been acceptably addressed. This item is also under review by the Division of Reactor Safety Test Programs Section and will be closed pending the completion of this revie . .