ML20128L129

Insp Repts 50-424/85-17 & 50-425/85-17 on 850429-0503. Violation Noted:Asme Class 1 Piping Matl Accepted W/O Ultrasonic Insp

ML20128L129
Person / Time
Site:	Vogtle
Issue date:	06/03/1985
From:	Jackson L, Upright C, Wright R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
To:
Shared Package
ML20128L103	List: ML20128L100 ML20128L107 ML20128L129
References
50-424-85-17, 50-425-85-17, NUDOCS 8507110252
Download: ML20128L129 (9)

See also: IR 05000424/1985017

Text

. .

jp Ct!g UNITED STATES

4 fo NUCLEAR REGULATORY COMMISSION

[~ , REGloN il

g j 101 MARIETTA STREET.N.W.

• 's ATLAN TA, GEORGI A 30323

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Report Nos.: 50-424/85-17 and 50-425/85-17

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

Inspection Condu t pril 29 - May 3, 1985

Inspectors: d-8 N

L. H. J son Date Signed

• l( d - 3 - S *$

R. W. Wright ( Date Signed

'

Approved by: M i

M d~

C.M. Upright /)Iectjh' Chief lYate(Signed

Division of R(acto (/ Safety

SUMMARY

Scope: This routine, unannounced inspection entailed 74 inspector-hours on site

in the areas of procurement, receiving, and storage; in-depth QA inspection of

performance; licensee actions on previous enforcement matters; and followup on

previously identified items.

Results: One violation was identified - ASME Class 1 Piping Material Accepted

Without Ultrasonic Inspection.

8507110252 850610

PDR

0 ADOCK 05000424

PDR

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REPORT DETAILS

1. Persons Contacted

R. M. Beaver, Jr. , Material Procurement

• C. M. Burke, Senior Quality Assurance (QA) Field Representative

D. Dalenberg, Senior Civil Quality Control (QC) Inspector

R. L. Davis, Senior QA Engineer

• D. M. Fiquett, Unit 2 Field Manager

• M. H. Googe, Project Construction Manager

• E. D. Groover, QA Site Supervisor

• B. C. Harbin, Manager of QC

• C. W. Hayes, Vogtle QA Manager

• G. A. McCarley, Project Compliance Coordinator

• D. R. Murphy, Construction Engineer

E. Peek, Consultant for GPC - VSL Contract

• S. Pietrzyk, Assistant Project Engineer

• P. D. Rice, Vice President and General Manager, QA

Other liecnsee employees contacted included engineers, technicians, and

office personnel.

Other Organizations

J. Bond, Superintendent, Vorspan System Logsinger (VSL)

D. Wright, Assistant Superintendent, VSL

T. Pahapill, QA Manager,'VSL

NRC Resident Inspector

• R. J. Schepens

• Attended exit interview

2. Exit Interview

The inspection scope and findings were summarized on May 3,1985, with those

persons indicated in paragraph 1 above. The inspector described the areas

inspected and discussed in detail the inspection findings listed below.

Violation - ASME Class 1 Piping Material Accepted Without Ultrasonic

Examination, paragraph 4.e.

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

to or reviewed by the inspector during this inspection.

. .

2

3. Licensee Action on Previous Enforcement Matters

a. (Closed) Severity Level IV Violation (424, 425/84-14-01): Three Audits

Not Documented, Issued, or Followed-Up in Accordance With ANSI N45.2.12

The licensee responses dated August 24, 1984, and December 3,1984,

were considered acceptable by Region II. The licensee's December 3,

1984 response identified one additional audit (MD05/M006-82/11,

Richmond Engineering Company) that was conducted on January 2,1982,

but was not issued. GPC's QA Engineering / Support Manager and the

original QA auditors conducted a detailed review of these four audit

reports to assure that each question that was originally raised was

properly addressed and resolved. The inspector examined the resolution

effort which consisted of four volumes (one per audit) and supporting

documentation. Each concern appears to have been adequately addressed.

Although a few corrective actions (File No. X7BG01, Correspondence No:

QA-3778) have not been fully completed, agreement on these items had

been concurred on and a monthly report on the status of each is

prepared for the Vice President and General Manager QA.

The inspector concluded that the licensee had determined the full

extent of the violation, taken action to correct current conditions,

and developed corrective actions needed to preclude recurrence of

similar problems. Corrective actions stated in the licensee response

have been implemented.

b. (Closed) Severity Level IV Violation (424, 425/84-14-02): Incomplete

Corrective Action for Closure of Audit Findings

The licensee responses dated August 24, 1984, and December 3, 1984,

were considered acceptable by Region II. The inspector examined the

volume prepared to resolve the outstanding concerns identified in the

unpublished audit CD06-81/80, Coatings, and related audit finding

report (AFR) numbers 235 and 236. Each concern appears to have been

addressed and resolved. In a few cases, action items were assigned to

fully resolve the concerns, such as specification changes and FSAR

'

updates. These action items are being closely followed by GPC

management.

The inspector concluded that the licensee had determined the full

extent of the violation, taken action to correct current conditions,

and developed corrective actions needed to preclude recurrence of

similar problems. Corrective actions stated in the licensee response

have been implemented.

. , .

3

4. Procurement, Receiving, and Storage (35065)

a. Inspection Objectives

This inspection was conducted to determine whether material and equip-

ment procurement specifications include applicable quality assurance

(QA) and technical requirements identified in the Safety Analysis

Report (SAR) and whether receipt inspection and storage activities are

in compliance with the QA program.

b. References

(1) GPC-SAR Chapter 17, Quality Assurance Program

(2) GD-A-06 Reporting of Defects and Noncompliances to the Nuclear

Regulatory Commission, Revision 6

(3) GD-A-10 Contractor Purchase Authorization, Revision 8

(4) GD-A-24 On-Site Procurement Process, Revision 7

(5) GD-A-30 Receipt, Receipt Inspection, Storage, and Handling,

Revision 8

'

(6) GD-T-01 Nonconformance Control, Revision 11

(7) GD-T-09 Inspection and Maintenance of Items in Storage,

Revision 7

(8) GD-T-14 Receipt, Storage and Handling of Welding Materials,

Revision 7

(9) GD-T-17 Housekeeping, Revision 2

(10) QC-A-01 Qualification and Certification of Technical Inspectors,

Revision 3

(11) WH-A-01 Material Issue, Revision 5

(12) MD-A-03 Mechanical Section Field Procurement, Revision 3

(13) MD-T-12 Receiving, Inspection, and Storage Issue of Pipe, Piping

Components, and Weld Filler Material, Revision 7

(14) DC-A-06 Review and Control of QA Documentation, Revision 9

. .

4

c. Program Review

The inspector reviewed the licensee QA program for procurement,

receiving, and storage of material and equipment as described in

references (2) through (14) to verify that they met requirements of

reference (1), the accepted QA program, NRC Regulatory Guides, and ANSI

standards endorsed by the program.

The safety-related materials and equipment received at the site are

either NSSS supplied or GPC procured from specifications prepared by

Bechtel Power Corporation, the Architect Engineer (A-E) for Vogtle

Nuclear Plant. Site generated requisitions are primarily for

consumables, standard stock items, and replacement items. These items

are purchased from specifications which have been previously approved

and issued by the A-E.

Within this area, no violations or deviations were identified.

d. Site Procurement Activities and Records

GPC has assumed the procurement responsibility for all materials needed

by on-site contractors. The inspector selected procurement item

contracts to determine that the following elements have been included:

-

Applicable regulatory, technical, and quality assurance require-

ments

-

Procurement documentation adequately reviewed

-

Purchaser notification points, hold points, and access rights

incorporated in or provided for in the documentation where

necessary

-

10 CFR 21 reporting requirements appropriately addressed

-

Documentation to confirm acceptability of the item required to be

furnished

-

QA requirements applicable to subcontractors

Within this area, no violations or deviations were identified.

e. Independent Verification

The following procurement orders were selected to verify implementation

of requirements:

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1

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Purchase Order Change Notice Specifications Vendor

PAV 5721 86 X4AQ34,R10 Consolidated Pipe

and Supply

PAV 5721 90 X4AQ34,R10 Consolidated Pipe

and Supply

PAV 9795 1 X4AQ37,R5 Robvon Backing Ring

Co.

PAV 12457 4 X4AQ38,R6 A&G Engineering Co.,

Inc.

PAV 9113 30 X4AQ36,R9 Consolidated Pipe

and Supply

PAV 10523 10 X4AQ32 Hub Inc.

Within this area, one violation was found. During the review of the

above listed procurement documents, and records related to those

procurements, the Certified Material Test Report (CMTR) for the 1 -inch

by 3/4-inch ASME SA479, Flow Restrictor, procured from Consolidated

Pipe and Supply Company and manufactured by Stainless Products did not

contain evidence of ultrasonic inspection. Bechtel specification

X4AQ34 specifies examination of Nuclear Class 1 piping material in

accordance with ASME Code, Article NB-2000. Purchase order PAV-5721,

change notice 90, requires the material to be SA479 which is a speci-

fication for stainless and heat-resisting steel bars and shapes for use

in boilers and other pressure vessels. Therefore, ASME Code, Article

NB 2540, requires examination of bars by ultrasonic methods prescribed

in NB-2542. ASME Code, Article NA-3767.4, requires the CMTR to include

the results of all required chemical analyses, tests, examinations,

repairs, and heat treatments performed on the material. The CMTR from

the material manufacturer does not contain evidence of ultrasonic

inspection of the bar. This is violation 50-424, 425/85-17-01.

f. Receiving Inspection

The inspector examined the system established for conducting receiving

inspection to verify the following:

-

Facilities are adequate.

-

CMTRs were reviewed and approved by trained personnel.

-

Inspection staff is adequate.

-

Inspectors are trained.

-

Inspections are documented.

-

Records are reviewed and approved.

. _ . - . -.

,

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-

Identified discrepancies are appropriately resolved.

Receiving inspection reports documenting acceptance of items discussed

in paragraph e above were reviewed to confirm implementation of

requirements.

Records of certification and training of receiving inspectors and

document reviewers identified during this review were confirmed to be

in compliance with commitments. The receiving inspections were

conducted in accordance with the QA program.

g. The inspector reviewed references (5), (6), (7), (8), (9), and (13) to

assure that these procedures were in compliance with applicable ANSI

standards.

The inspector toured warehouses, laydown areas, Unit 1 containment,

reactor building, and auxiliary building to determine the following:

-

Storage facilities for Class A equipment had an environmentally

control atmosphere and provisions to prevent animals from

entering.

-

Facilities for Class B, C, and D equipment storage were satisfie'd.

-

Protection from damage during storage was adequate.

-

Periodic inspection of storage facilities was made.

-

Stored items were identified.

-

Nonconforming items were segregated and/or controlled.

-

Items in storage received the required preventive maintenance.

-

Records of inspections were maintained.

-

Equipment in the power blocks was adequately protected. Equipment

received periodic rotation and electric heaters in motors were

energized.

Within this area, no violations or deviations were identified.

h. Audits

The inspector reviewed the following audits:

GD10-84/53 Procurement

GD10-83/99 Procurement

GD10-83/19 Procurement

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SP01-84/07 Procurement and Warehouse Practice Including

Receiving Inspection

SP01-84-81 Procurement and Warehouse Practice

The above audits were selected to _ verify that the licensee is imple-

menting a program to evaluate the adequacy of the Procurement,

Receiving and Storage Program against ANSI standards N45.2.2 and

N45.2.13. These audits identified deficiencies, and reaudits confirmed

implementation of corrective action.

Within this area, no violations or deviations were identified.

5. In-Depth QA Inspection of Performance - Tendon Greasing (35061)

This inspection was conducted to determine whether site work is being

performed in accordance with NRC requirements and SAR commitments, the QA/QC

program is functioning in a manner to assure requirements and commitments

are met and that prompt and effective action is taken to achieve permanent

corrective action on significant discrepa cies.

The inspector observed the Unit I work activities concerning the greasing

activities for VSL tendon identification number 26-86 (Bechtel No. 63) and

16-96 (Bechtel No. 53). These greasing activities were conducted in

accordance with VSL's Field Instruction Manual For Installation of VSL

E5-55, Post Tensioning System Within Nuclear Containment Structures, R8 and

Bechtel Construction Specification No. X2AF04, R2. The tendon greasing

activities were inspected and documented to the requirements specified in

Chapter VII (VSL Construction QC Records) of the subject manual.

GPC has hired a knowledgeable consultant to oversee the VSL tendon opera-

tions. In addition to the VSL QC inspection effort, GPC QC is performing

100 percent verification of the receipt, installation, stressing, and

greasing of each of the first 20 horizontal and the first 20 U-shaped

tendons. Verification activities thereafter will be performed as needed and

as directed by GPC QC supervision. The inspector interviewed VSL craftsmen,

foremen, QC inspectors, and GPC QC inspectors to determine if their

knowledge of tendon installation activities and their training in this area

were adequate to perform their respective duties. The inspector reviewed

the following QC documentation for Unit I tendon Nos. 18-94 and 10-102:

Material receipt reports

Mill certifications

Installation checklists and reports

GPC tendon activity audits CD08-84/23, CD08-85/25, and the most recently

conducted QA assessment of VSL, audit CP01-85/33 were examined by the

inspector. These audits were reviewed to determine if they were meaningful,

effective, reflect quality performance and whether corrective actions taken

as a result of audit findings were proper, timely and complete. The latest

e

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audit (CP01-85-33) identified a few VSL program weaknesses or omissions in

the area of receipt inspection, QC procedures, and document control which

are in the process of being corrected. The inspector notified the licensee

that the region would follow up on the effectiveness of the corrective action

taken to resolve the subject audit findings. This item was identified as

Inspector Followup Item 424, 425/85-17-02, Audit CP01-85/33 Followup.

Since the tendon program is essentially just beginning, licensee representa-

tives, GPC's tendon consultant, Bechtel engineers and VSL QA personnel meet

frequently to resolve contract problems and establish mare definitive

engineering, QA/QC requirements when and if such need arises. The inspector

attended one such meeting concerning wedge material acceptability and the

need for further clarification on acceptability for shim spacing and overlap

criteria. The licensee is very much aware of prior tendon problems of other

nuclear plants and appears to be making a concerted effort to assure

Vogtle's program is adequate and conforms to. specification requirements.

Within this area, no violations or deviations were identified.

6. Inspector Followup Item (IFI) (927018)

(Closed) IFI 50-424/83-13-06 and 50-425/83-13-04 Control of Shelf-Life Items

The inspector reviewed GPC procedure GD-T-30, R1, and confirmed that

requirements have been established and a shelf-life program is being

implemented.

(