ML20137X293
| ML20137X293 | |
| Person / Time | |
|---|---|
| Site: | Vogtle  |
| Issue date: | 09/23/1985 |
| From: | Rogge J, Schepens R, Sinkule M NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML20137X266 | List: |
| References | |
| 50-424-85-37, 50-425-85-29, NUDOCS 8510040498 | |
| Download: ML20137X293 (20) | |
See also: IR 05000424/1985037
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UNITED STATES
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NUCLEAR HEGULATORY COMMISSION
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REGION ll
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101 MARIETTA STREET, N.W.
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ATLANTA, GEORGI A 30323
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Report Nos.: 50-424/85-37 and 50-425/85-29
Licensee: Georgia Power Company
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P.O. Box 4545
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i Atlanta, GA 30302
Docket Nos.: 50-424 and 50-425
License Nos.
CPPR-108 and CPPR-109
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Facility Name: Vogtle 1 and 2
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Inspection Conducted: July 22 - August 30, 1985
Inspectors: W . T h
9/28/85
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J. F. Rogge, Senior Resident Inspector, Operations
Date Signed
@.M.
9/2.0/85
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R. J. Schep9 s, Resident Inspector, Construction
Date Si ned
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Approved By:
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M. V. SinEufe, Section Chief
DWte Sligned
Division of Reactor Projects
SUMMARY
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Scope:
This routine, unannounced inspection entailed 212 Resident inspector-
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hou'rs on site (32 hours3.703704e-4 days <br />0.00889 hours <br />5.291005e-5 weeks <br />1.2176e-5 months <br /> were on backshifts) inspecting: containment and safety
related structures, piping systems and supports, safety related components,
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auxiliary systems, : electrical equipment- and cables, quality programs and
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administrative controls af fecting ouality, and follow-up on previous inspection
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identified items.
The inspectors also participated in a corporate management
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meeting and an ACRS hearing.
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Results:
Two violations were identified
" Failure to Prescribe Appropriate
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Procedures to Control Area Cleanliness" - Paragraph 15, and " Failure to Establish
Appropriate Acceptance Criteria to Verify Pump Internal Cleanliness" - Para-
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graph 15.
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8510040498 850924
>PDR
ADOCK 05000424
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REPORT DETAILS
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1.
Persons Contacted
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Licensee Employees
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D. O. Foster, Vice President and Project General Manager
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P. D. Rice, Vice President and General Manager, Q.A.
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W. T. Nickerson, Deputy Project General Manager
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W. C. Ramsey, Readiness Review Manager
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H. H. Gregory III, General Manager Nuclear Construction
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M. H. Googe, Project Construction Manager
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G. Bockhold, Jr., General Manager Nuclear Operations
0. Batum, General Manager Engineering and Licensing
- C. W. Hayes, Vogtle Quality Assurance Manager
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- 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
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W. E. Mundy, Quality Assurance Audit Supervisor
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J. E. Sanders, Project Construction Manager - Unit 1
D. M. Fiquett, Project Construction Manager - Unit 2
- B. C. Harbin, Manager Quality Control
- C. R. Brewer, Assistant Quality Control Manager
T. L. Weatherspoon, Assistant Quality Control Manager
G. A. McCarley, Project Compliance Coordinator
W. C. Gabbard, Assistant Project Compliance Coordinator
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J. O. Dorough, Administrative Manager
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- W. F. Kitchens, Operations Superintendent
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- J. L. Blocker, Mechanical Engineer Supervisor
"M. S. Hairston, Regulator Compliance Associate Engineer
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- A. L. Mosbaugh, Superintendent Engineering Liaison
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- C. H. Williams, Jr., Operations Supervisor
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M. Stone, Engineering Supervisor
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T. Dannemiller, Senior QA Engineer
J. Rowland, Coordinator
J. B. Beasley, Startup Support Superintendent
Other licensee employees contacted included craftsmen, technicians, super-
visors, engineers, inspectors, and office personnel.
Other Organizations
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- D. R. Ellsworth, Surveillance Specialist - Bechtel
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- R. K. Watson, Assistant QA Manager - Pullman Power
L. Fields, QA Manager - Chicago Bridge and Iron (CBI)
C. Petterson, Flushing Engineer - Westinghouse
M. L. Bagale, Surveillance Specialist - Bechtel
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I. Jamison, NSSS Flushing Supervisor - Bechtel
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J. Foley, Lead Engineer Startup Support Group - Bechtel
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2.
Exit Interview (30703C)
The inspection scope and findings were summarized on August 30, 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 licensee.
(0 pen) Violation,
50-424/85-37-01 " Failure to Prescribe Appropriate
Procedures to Control Area Cleanliness" - Paragraph 15.
(0 pen) Violation, 50-424/85-37-02 " Failure to Establish Appropriate
Acceptance Criteria to Verify Pump Internal Cleanliness" - Paragraph 15.
(0 pen) Inspector Followup Item, 50-424/85-37-03 " Review Licensee Action on
QA Surveillance Report Finding No. 85-016-BJ" - Paragraph 11.
(0 pen) TI 2500/14, " Location of Unit I and 2 Manual Reactor Trip Circuits" -
Paragraph 24.
(Closed) Inspector Followup Item, 50-424/82-09-01 and 50-425/82-09-01
"Embedment Plate Threaded Bolts" - Paragraph 23.
The licensee did not identify as proprietary any of the materials provided
to or reviewed by the inspector during this inspection.
The following NRC exit interviews were attended during this inspection by a
resident inspector:
DATE
INSPECTORS
August 9
- L. Jackson, R. Wright
August 15
- R. Latta, A. Belisle
August 16
- J. Harris
August 30
- R. Newsome
3.
Licensee Action on Previous Enforcement Matters (92702)
Not inspected.
4.
Unresolved Items (92701)
Unresolved items are matters about which more information is required to
determine whether they are acceptable or which may involve violations or
deviations. Unresolved items were not identified during this inspection.
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5.
Construction Inspection - Units 1 & 2
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Periodic inspections were made throughout this reporting period in the form
of general type inspections in different areas of both facilities.
The
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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 of the presence of quality
control inspectors, supervisors, and quality control evidence in the form of
available process sheets, drawi ng s , material identification, material
protection, performanceof tests, and housekeeping.
Interviews were made with craft personnel, supervisors, coordinators,
quality control inspectors, and others as they were available in the work
areas.
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Independent inspection effort encompassed but was not limited to the
following areas:
VSL platform installation and load testing on Unit 1.
Walkdown of the Unit 2 main steam line tunnel to observe in process
hanger welding, small bore piping prepping, fit-up, welding, and to
ensure appropriate protection from the outside environment was being
provided during inclement weather.
No violations or deviations were identified.
6.
Fire Prevention / Protection and Housekeeping Measures - Units 1 & 2
(42051C)
The inspector observed fire prevention / protection measures throughout the
inspection period. Welders are using a welding permit with a fire watch and
extinguisher.
Post indicator valves were being maintained in the open
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position. Fire fighting equipment is in its designated areas throughout the
plant.
Periodic inspections conducted throughout the inspection period identified
weak housekeeping practices in the following areas.
The auxiliary
feed-water pump house containing the motor driven feedwater pumps was found
cluttered with tooling (such as welding cables, electrical cables, air
hoses, hand grinders, grinding shields, etc.), trash (such as wood cribbing,
paper cups, rags, etc.) and water on the floor creating a ccngested and
dirty work environment. Six cable trays, five in the Containment Building
and one in the cable spreading room, were found cluttered with tooling and
equipment (such as hand grinders, oxygen hoses, welding stingers and ground
cables, hanger tube steel, air hoses, grinding shields, wire brushes and
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flashlights) and trash (such as cigarette butts, tape, cloth, wood, metal
shavings, dirt and paint chips, and light bulbs).
These items were
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identified to the licensee and corrective action was taken.
The licensee
was informed that housekeeping will continue to be monitored closely
throughout the upcoming inspection period for evidence of improvement.
No violations or deviations were identified.
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7.
Containment (Structural Concrete) - Unit 2 (47053C)
a.
Procedure and Document Review
The inspector reviewed and examined implementation portions of the
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following procedures pertaining to the placement of concrete to
determine whether they comply with applicable codes, standards, NRC
Regulatory Guides and license commitments.
-CD-T-02, Rev. 15
Concrete Quality Control
-CD-T-06, Rev. 9
Rebar and Cadweld Quality Control
-CD-T-07, Rev 8
Embed Installation and Inspection
-CD-T-20, Rev. 6
Installation and Inspection of Trumpets,
Rigid Extensions, and Duct Sheathing
-2X2001A002, Rev. 11 Containment Concrete Forming and
Placing Plan and Section
-2X2007A001, Rev. 2
Diesel Generator Building Forming
Plan at El 220'-0"
-AX2008A121, Rev. 6
Auxiliary Buildirg Area 3 #2 Plan
at El . 240'-0" (Level 2)
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b.
Installation Activities
The inspector witnessed portions of concrete placement indicated below
to verify the following:
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(1) Forms, Embeds, and Reinforcing Steel Installation
- Forms were properly placed, secure, leak tight and clean.
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- Rebar and other embedment installation was installed in
accordance with construction specifications and drawings,
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secured, free of concrete and excessive rust, specified
distance from forms, proper on-site rebar bending (where
applicable) and clearances consistent with aggregate size.
(2) Delivery, Placement and Curing
- Preplacement inspection was completed and approved prior
'to placement utilizing a Pour Card (Exhibit CD-T-02*18).
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- Construction joints were prepared as specified.
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- Proper mix was specified and delivered.
--Temperature control of the mix, mating surfaces, and
ambient were monitored.
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- Testing at placement location was properly performed in
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accordance with the acceptance criteria and recorded on a
Concrete Placement Pour Log (Exhibit CD-T-02*20).
- Adequate crew, equipment and techniques were utilized.
- Inspections during the placement were conducted by quali-
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fied personnel.
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- Curing temperature was monitored.
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(3)
Installation of Trumpets, Tendon Sheaths and Anchorage
Components for Containment Pours Only
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-Trumpets, sheaths and anchorage components were oriented
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properly, installed within specified tolerances, clear and
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free of damage.
Pour No.
Location
Inspection Activity
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2-071-001C
Diesel Generator Building
Preplacement, Placement
Base Slab
and Curing
2-010-039
Containment Dome El 356'
Preplacement and Curing
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5-5/8" to 363' 1-1/4"
A-082-059, 064
Auxiliary Building Wall
Placement
No violations or deviations were identified.
8.
Containment (Prestressing) - Observation of Work Activities - Unit 1
(47063C)
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Procedure and Document Review
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The inspector reviewed the following VSL Procedures which were developed in
response to GPC QA AFR No's. 802-II, 803-II, 804-II, 806-II, 808-III to
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determine whether they comply with applicable codes, standards, NRC
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Regulatory Guides and licensee commitments.
VSL Procedure No.
Titles
In Response to AFR#
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PT-01, Rev. O
VSL Field Procedure
804-II
Development and Control
PT-02, Rev. O
Control of Measuring and
806-II
Test Equipment
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PT-03, Rev. O
Review & Control of QA
808-III
Documentation
PT-04, Rev. O
Document Control
804-II
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PT-05, Rev. O
Receipt Inspection Storage
803-11
and Handling
PT-06, Rev. O
Nonconformance Control
802-II
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No violations or deviations were identified.
9.
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 (included bending
or
straightening).
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Specified clearances were being maintained.
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Edge finishes and hole sizes were within tolerances.
Control, marking, protection and segregation were maintained during
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storage.
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Fit-uo/ alignment meets the tolerances in the specifications and
drawings.
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Welding Activity (Unit 2)
a.
Observation of Work
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The inspector observed in process welding activities of the personnel
airlock weld (No.100-A2) to the containment penetration as described
below to determine whether applicable code and procedure requirements
were being met.
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b.
Welding Procedure Specifications and Quality Assurance Procedures
(1) The following Welding Procedure Specification (WPS) applicable to
the weld joint noted above was reviewed along with a sample of the
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Procedure Qualification Records (PQR) which supported the WPS and
compared with the ASME Code.
The WPSs and their supporting PQRs
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were reviewed to ascertain whether essential, supplementary and/or
nonessential
variables,
including
thermal
treatment,
were
consistent with Code requirements; whether the WPSs was properly
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qualified and their supporting PQRs were accurate and retrievable;
whether the PQRs had been reviewed and certified by appropriate
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personnel.
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WPS E7018/74-2195/6, Rev. 2; 2-140'0 X 228'-9 Containment
Liner ASME Code Section III Summer 1975.
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PQR 3659, Rev. 0; PQR 2631, Rev. 0 (PWHT); and PQR 3638,
Rev. O.
The Penetration Assembly, material SA516 GR70, was being welded to
the Containment Liner, caterial SA516 GR70. The inspector noted
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that the procedure was qualified for welding P-1 G-1 to P-1 G-2,
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therefore any combination of P-1 to P-1 material could be welded
with this WPS. The WPS thickness range is 3/16" to 2-1/2" and the
actual material thickness was 1-3/8".
(2) The following Quality Assurance Procedures / Documents were reviewed
to determine whether they comply with with applicable codes,
standards, NRC Regulatory Guides and licensee commitments.
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General Welding Procedure Specification for the Shielded
Metal ARC Process; GWPS-SMAWX, Rev. 1
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Nuclear QA Manual for ASME Section III Products Section 8.0
Welding, Rev. 8 and Section 7.0 Process Control, Rev. 7
Personnel Airlock Weld No. 100-A2 Record Drawing Table and
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As-Built Drawing
Containment Liner Detailed Checklist
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Bechtel Dwg. No. 2X2001J018
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c.
Welding Filler Material Control
The inspector reviewed the CBI program for control of welding materials
to determine whether materials were being purchased, accepted, stored
and handled in accordance with QA procedures and applicable code
requirements.
The following specific areas were examined:
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Purchasing, receiving, storing, and distributing and handling
procedures, material identification; and inspection of welding
material issuing stations.
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Weld Material Authorization & Release Reports - Weld Filler Metal
Certification and Receipt Inspection Report Nos.:
26 - E7018 3/32" 500#
23 - Linde #81 WireFlux 3/32" 1300#
21 - E6010 1/8" 750#
16 - E309 - 15 1/8" 90#
No violations or deviations were identified.
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10. Safety-Related Structures (Structural Steel and Supports) - Units 1 & 2
(48063C)
Periodic inspections were conducted to observe construction activities of
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safety-related structures / equipment supports for major equipment outside the
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containment to verify that:
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Materials and components were being properly handled to prevent damage.
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Fit-up/ alignment were within tolerances in specifications and drawing
requirements.
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Specified clearances from adjacent components were being met.
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No violations or deviations were identified.
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
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B&PVC,Section III, Class II piping are listed below:
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ISO NO./ REVISION
PIPE RUN INSPECTED
1K5-1204-006-01, Rev. 8
RWST Safety Injection Suction
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Header Piping (1204-006-24") - Spool
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Nos. 006-S-20 and 006-S-24
IK3-1204-006-01, Rev. 12
RWST Safety Injection Suction Header
Piping
(1204-006-24")
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Spool
Nos.
006-S10, 11, 12, 13, 14, 15, 16, 17, 18,
22, & 19.
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IK3-1204-038-01, Rev. 13
RWST .. Safety Injection Suction Header
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Piping (1204-006-24")
Spool
Nos.
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006-S-09, 08, 07, 06, 05, 02 & 01.
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Specific areas examined during the pipe run walkdown for compliance with the
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applicable isometric drawings and the Plant Design and Instrumentation
Construction Specification No. X4AZ01, Revision 19 were as follows:
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Vent and Drain Connections and Locations
Instrumentation Connections and Locations
Valve Installation and Orientation
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Line Size and Location
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Fittings Type and Size
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Pipe / Valve / Fitting /End Connections
Hanger Locations and Types
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During the inspection period, a review of the following flush procedures was
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conducted:
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1-1B8-02, Rev. O
Reactor Coolant System Pressurizer Spray Line
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Flush
1-18B-09, Rev. O
Boron Injection and Hot Leg to Loops
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1-1BJ-01, Rev. O
Safety Injection (with CVCS and RHR (crosstie)
Chr Nos. 1,2,&3
Flush
1-1BJ-02, Rev. O
Safety Injection Pump Discharge Piping Flush
Chg No. 1
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1-1EF-02, Rev. O
Nuclear Service Cooling Water System Flush
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1-1EF-05, Rev. O
Nuclear Service Cooling Water Train B Flush
Chg Nos. 1,2,3,&4
1-1EG-01, Rev. O
Component Cooling Water Flush
Chg No. 1
The following flushes were observed during the inspection period:
1-1BJ-02, Flow Path 2.10 -
Flush of the Miniflow Recirc Line No. 003 -
1 1/2"
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- 1-1BJ-02, Flow Path 2.13 -
Flush of the WPS Reactor Coolant Drain Tank
Pump Line 005 2" to waste
NSCW Train B operation of circulating water from the basin thru the NSCW
tunnel supply header piping bypassing the ACCW and CCW heat exchangers back
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thru the NSCW tunnel return header piping and discharging out into the top
of the basin via a temporary strainer. The purpose of this flow path is to
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circulate the water in the basin thereby cleaning it and the supply and
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return header piping prior to starting the NSCW flush.
During the observation of the flush for flow path 2.13, a review of the
official flush procedure package was conducted. A representative of Georgia
Power Company's Quality Assurance Audit Organization was present performing
a surveillance and documented the below discrepancies on surveillance report
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finding number 85-016-BJ:
On page 6 of the procedure the sign-offs for steps 6.1.1 (temporary
a.
modifications complete) and 6.1.2 (temporary hoses flushed) relating to
flow path 2.13 were not initialed and dated as being complete and step
6.2 (valve lineup) was initialed and dated as being complete along with
the flush being in progress. A review of Attachment 10.3 Temporary
Flushing Modifications required for flow path 2.13 revealed that these
activities had been completed prior to starting the flusn anu were
signed-off as such but had not been signed-off on the spread sheet for
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paragraph 6.3 on page 6. The flushing engineer initialed and dated
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steps 6.1.1 and 6.1.2 as .being completed for flow path 2.13 once this
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was brought to his attention and after confirming that they had been
previously completed and signed-off in Attachment 10.3. An entry was
noted in the log to document the late entry and the above action taken
to correct the discrepancy.
b.
Attachment 10.7 " Test Equipment Calibration sign-off sheet" was not
properly completed
i.e., the test equipment number was the only item
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filled in.
The instrumentation location, equipment description and
verification initial and date columns had not been completed. The
question of why only one entry when more than one flow paths had been
flushed was raised in addition to why the required blanks had not been
filled out. and,
c.
Sum 16, Rev. 4 references Regulatory Guide 1.37 which endorses ANSI
N.45.2.1 - 1973 " Cleaning of Fluid Systems and Associated Components
During Construction Phase of Nuclear Power Plants".
All of these
documents require that the system (or in this case piping subsystems)
be flushed at its normal design velocity (or other velocity if
specified by procurement documents).
During the observation of flow
path 2.13, it was noted that the procedure did not specify a quantita-
tive value for the minimum design velocity of that flow path presently
being flushed nor did it for any of the other flow paths contained in
the flush procedure package. The inspector observed the GPC quality
,
control inspector inquire of the flushing engineer what exactly was the
design velocity for flow path 2.13.
The flushing engineer performing
the flush did not know the design velocity value for flow path 2.13.
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However, it was noted that the procedure did require that the obtained
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velocity during the flush be recorded.
The question was raised how
does one know if the minimum design velocity is being met or obtained
since a quantitative value is not specified for each flow path
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contained in the procedure.
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The inspector advised the licensee that, pending review of the licensee
action to resolve surveillance report finding number 85-016-BJ, this matter
will be identified as Inspector Followup Item 50-424/85-37-03, Review
Licensee Action on QA Surveillance Report Finding Number 85-016-BJ.
No violations or deviations were identified.
12.
Reactor Vessel Protection - Unit 1 & 2 (50053C)
The Unit No. 1 inspection consisted of examination of the Reactor Vessel
installed in Containment to determine that proper storage protection
practices were in place and that entry of foreign objects and debris was
prevented.
During the inspection period, the inspector noted that adequate
measures were established and maintained during the removal of flushing
equipment from the vessel, the filling of the Reactor Vessel with water, and
the installation of Combustion Engineering's ISI-2 positioning device, into
the vessel for performing the Reactor Vessel Pre-service Inspection.
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The Unit No. 2 inspection consisted of examination of the Reactor Vessel
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installed in containment to determine that proper storage protection
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practices were in place and that entry of foreign objects and debris was
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prevented.
No violations or deviations were identified.
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13.
Reactor Vessel Integrated Head Package - Unit 1 & 2 (50053C)
3
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The Unit No. 1 inspection consisted of examination of the integrated head
package stored on the refueling floor in its designated laydown area to
determine that proper storage protection practices were in place, entry of
i
foreign objects and debris was prevented, and that access was controlled.
The Unit No. 2 inspection consisted of examination of the Reactor Vessel
head with the installed control rod drive mechanisms as it was being
relocated and stored initially on the refueling floor and finally to its
,
designated laydown area on the refueling floor.
Proper storage protection
practices were observed to be in place and maintained during these critical
evolutions.
No violations or deviations were identified.
.
~
14.
Reactor Vessel Internals - Unit 1 (50063C)
1.
Periodic inspections were conducted during the inspection period when the
'
t
upper and lower internals were stored in the cavity in their designated
storage area to determine that proper storage protection practices were in
l
place, entry of foreign objects and debris was prevented and that access was
controlled.
No violations or deviations were identified.
15. Safety Related Components - Unit 1 (50073C)
!
The inspection consisted of plant tours to observe protection of installed
>
'
components to determine that adequate protection from dirt, dust, debris,
'
water, or adjacent construction activities were in place.
Unit 1 Equipment examined included:
,
j
- Residual Heat Removal (RHR) Pumps
- Diesel Generator Train B
l
- CVCS Centrifugal Charging Pumps and Positive Displacement
Pump
- Containment Spray (CS) Pumps
- Containment Penetration Encapsulation Vessel for
.
!
- Auxiliary Feedwater Motor Driven Pumps & 1-1817-U3-008 A&B
F
- NSCW Train B Pumps Including the Transfer and Spare
,
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- CVCS Volume Control Tank
'
- CVCS Letdown Heat Exchanger
- NSCW Pumps Train B
- Safety Injection Pumps
- Auxiliary Component Cooling Water (ACCW) Heat
Exchangers
- Component Cooling Water (CCW) Heat Exchangers
- Reactor Makeup Pumps
- Boron Injection Tank
- Cable Spreading Room Train A & B
,
- 18816 480 VAC Switchgear
i
- 1AAB MCC Train A, 120 VAC Vital Power, & Vital AC
Inverter
l
- Nuclear Grade Piping, Valves, & Fittings
- Spent Fuel Pool Heat Exchangers
- Pressurizer Relief Tank
4
- Accumulators Tanks
- Reactor Coolant Drain Tank Pumps
- CVCS Letdown Heat Exchanger
- Excess Letdown Heat Exchanger
4
- Reactor Coolant Drain Tank and Heat Exch' anger
,
!
- Reactor Cavity Sump Pumps
!
- Battery and Charger Rooms Train A, B, C, & D
I
During an inspection of the safety injection train B pump room on August 17,
1935, the inspector noted that the safety injection pump was completely
disassembled and that zone cleanliness requirements for the safety injection
train B pump room had not been established as required by ANSI N45.2.3 -
1973Property "ANSI code" (as page type) with input value "ANSI N45.2.3 -</br></br>1973" contains invalid characters or is incomplete and therefore can cause unexpected results during a query or annotation process., Housekeeping During the Construction Phase of Nuclear Power Plants. At
the time of this inspection GPC's Field Manual Procedure No. GD-T-17, Rev. 2
did not address the criteria for establishment of zone 1,2,3,4,& 5 areas.
The licensee was informed of this matter and the inspector observed the
,
licensee take immediate corrective action. A revision to the Field Manual
Procedure No. GD-T-17 was in managements review cycle at the time of this
finding and was subsequently issued on August 22, 1985.
The inspector
subsequently observed that the licensee had established the safety injection
train 8 pump room as a zone 2 cleanliness area for the remaining work on the
safety injection pump until it was reassembled.
The above cordition is an example of failure to prescribe appropriate
procedural to control area cleanliness when performing work where foreign
matter may have detrimental effects. This is considered to be in violation
of 10 CFR Part 50, Appendix B, Criterion V and will be identified as
violation 50-424/85-37-01 " Failure to Prescribe Appropriate Procedures to
'
Control ~ Area Cleanliness".
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The inspector conducted an inspection of the safety injection train B pump
disassembly, cleaning, and reassembly process on August 17, 1985. This work
was being performed by Pullman Power under their construction QA/QC program
to resolve deficiency report number PP-11317.
This deficiency report
addressed the concern of foreign matter being in the pump as a result of a
leaking pump isolation valve during the performance of the safety injection
discharge line flush. The inspector reviewed the following documents which
controlled the work being performed to resolve the deficiency report.
,
- Field Process Sheet No.1X6AG02-16 for Train B pump 1-1204-P6-004
- Piping Material Requisition No. 113753; Replacement Parts -
Gaskets "0" Rings.
- 1X6AG02-16-2; Safety Injection Pump Operation and Maintenance
Manual
- Document No. IX-48, Dated 3/25/85; Procedure for Equipment
Installation
- Document No. XIII-4, Dated 10/18/84; Cleaning Procedure (Field)
- Westinghouse Process Specification No. 292722, Rev.9; Cleaning and
Cleanliness Requirements of Equipment for use in Nuclear Steam
Supply System and Associated Components.
The Pullman Power field process sheet detailed the steps to disassemble,
verify pump cleanliness, and reassemble the pump. Each step referenced the
appropriate document which was to give the necessary instructions to the
individual performing the step. The step for verifying pump cleanliness
referenced the Pullman Power Field Cleaning Procedure Document No. XIII-4,
Dated 10/18/84. The cleanliness acceptance criteria contained in Document
No. XIII-4, dated 10/18/84 was reviewed against the criterion established in
Westinghouse Process Specification No. 292722, Rev. 9.
The inspector noted
that the Pullman Power Document No. XIII-4, dated 10/18/85 failed to specify
the appropriate acceptance criteria for the inspector to veri fy pump
internal cleanliness prior to reassembly.
The Westinghouse Process
Specification No. 292722, Rev.9 states that when the surfaces are
accessible, a wipe test of a representative area in accordance with ASTM
A-380 shall be used to evaluate tF3 cleanliness of the surface. The surface
shall not exceed the limits for chloride and flouride contamination as
specified for the cleanliness classification which you are trying to
achieve. 1his acceptance criteria was not contained in the Pullman Power
Document No. XIII-4, dated 10/18/84.
The above condition is an example of failure to establish appropriate
acceptance criteria for the quality control inspector to use in verifying
pump internal cleanliness. This is considered to be in violation of 10 CFR Part 50, Appendix B,
Criterion V and will be identified as violation
50-424/85-37-02 " Failure to Establish Appropriate Acceptance Criteria to
Verify Pump Internal Cleanliness".
During an inspection of the Train A,B,C,& D battery and charger rooms on
August 27, 1985, the inspector noted that access control was being defeated
in the following manner:
_ . - - . . - -_. - . - _ -
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14
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- Train A battery room door was found to be unlocked
- Train C battery room door was found opened
- Train C charger room door was found wedged opened
,
i
Workers in the general area were questioned to determine if they were
working in the above rooms and no one acknowledged that they had been or
were going to be doing any work in the above noted rooms.
The inspector
1
advised the licensee of this matter and the licensee took immediate action
to correct the situation and documented their findings on a QA Surveillance
Report. The licensee's policy in this area is to maintain these doors
!
locked for personnel safety reasons.
Since there is no requirement that
'
these doors be maintained locked no further action will be taken at this
.
l
time by the resident.
'
16. Safety Related Components - Unit 2-(50073C)
'
The inspection consisted of plant tours to observe protection of installed
components to determine that adequate protection from dirt, dust, debris,
water, or adjacent activities were in place.
Unit 2 Equipment Examined Included:
- Residual Heat Removal (RHR) Pumps
4
- Containment Spray (CS) Pumps
,
- CVCS Centrifugal Charging Pumps & Positive Displacement Pump
1
i
- Safety Injection Pumps
- Auxiliary Component Cooling Water (ACCW) Heat Exchangers
- Component Cooling Water (CCW) Heat Exchangers
l
- ACCW Surge Tanks
'
l
- CCW Surge Tank
- CCW Drain Tank
j
- Reactor Coolant Pump Casings
- Accumulator Tanks
- Pressurizer Relief Tank
- Diesel Generator Fuel Oil Tanks
During the inspection period, the inspector observed preventive maintenance
being performed to the CVCS centrifugal charging pumps in accordance with
the storage requirements specified on the EMSL card. This work was governed
"
by the EMSL program which is administered under the field procedure manual
number GD-T-09, Rev. 8 " Inspection and Maintenance of Items in Storage".
.
No viclations or deviations were identified.
.
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15
17.
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 at during the inspections:
- Location and alignment
- Type and size of anchor bolts
- Identification
- Segregation and identification of nonconforming items
- Equipment space heating
- Rotation of motor shafts
- Lubrication and fluid levels
- Protective coatings, preservations, descicants, inert gas
blanket, etc.
No violations or deviations were identified.
18.
Electrical (Cables and Terminations) - Unit 1 (51063C)
Periodic inspections were conducted during the inspection period to
cetermine whether the raceway installation and protection of installed cable
is in accordance with applicable codes, standards, and NRC Regulatory
Guides.
In reference to the raceway installation, the following areas were inspected
to verify compliance with the applicable requirements:
- Identification
- Alignment
- Bushings (Conduit)
- Grounding
- Supports and Anchorages
In reference to the installed cable, the following areas were inspected to
verify compliance with the applicable requirements:
- Protection from adjacent construction activities (welding, etc.)
- Coiled cable ends properly secured
- Unterminated cable ends taped
- Cable trays, junction boxes, etc., reasonably free of debris
- Conduit capped, if no cable installed
- Cable supported
,
No violations or deviations were identified.
.
.
16
19. 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 completion.
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:
-
Work was conducted in accordance with a process sheet which
identifies the weld and its location by system, references
procedures or instructions, and provides for production and QC
signoffs.
-
Welding procedures, detailed drawings and instructions, were
readily available and technically adequate for the welds being
made.
-
Welding procedure specification (WPS) were in accordance with the
applicable ASME Code requirements and that a Procedure Qualifica-
tion Record (PQR) is referenced and exists for the type of weld
being made.
-
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
certifications.
-
That the purge and/or shielding gas flow and composition were as
specified in the welding procedure specification and that
protection was provided to shield the welding operation from
adverse environmental conditions.
-
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
instructions.
-
That the pipe to be welded to the component was assembled and held
in place within specified s,ap and alignment tolerances allowed by
the ASME Code.
-
That a sufficient number of adequately qualified QA and QC
inspection personnel were present at the work site, commensurate
with the work in progress.
-
That disbursement of welding materials was controlled in
accordance with approved procedures.
No violations or deviations were identified.
,
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17
20.
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,
standards, work performance procedures and QC procedures are being met as
follows:
-
That the weld area cleanliness was maintained and that pipe
alignment and fit-up tolerances were within specified units.
.
-
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 from the work location.
-
That there were no evident signs of cracks, excessive heat input,
sugaring, or excessive crown.
Installation Activities
,
l
During the inspection period, welds at various stages were observed in the
following systems:
-
Residual Heat Removal System
,
-
Component Cooling Water System
'
-
Chemical & Volume Control System
-
Nuclear Service Cooling Water System
No violations or deviations were identified.
21.
Participation in ACRS Meeting - Units 1 & 2 (94700)
On August 9, 1985, the ACRS held a meeting in Washington, D. C. pursuant to
the operating license review.
Regional representation at this meeting was
i
performed by J. F. Rogge and M. V. Sinkule.
i
22. Second Corporate Management Meeting - Units 1 & 2 (30301B)
,
On August 27, 1985, a meeting was held onsite with the persons listed below
to discuss the change in emphasis from construction to the operations
phases. Topics discussed at the meeting included the status and handling of
construction and preoperational problems prior to unit licensing, the
regulatory process steps in obtaining a license recommendation from Region
II, the Regional Inspection activity with emphasis on the preoperational
program and special team inspections.
It is anticipated that subsequent
meetings may be held as necessary to discuss the Startup Test, Health
'
i
Physics and other NRC programs as appropriate.
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Attendees
GPC/SCS
D. O. Foster, Vice President and General Manager
1
!
G. Bockhold, Jr., General Manager, Nuclear Operations
R. M. Bellamy, Initial Test Manager
J. F. D' Amico, Superintendent, Regulatory Compliance
C. W. Hayes, Vogtle Quality Assurance Manager
C. E. Belflower, QA Site Manager, Operations
P. A. Herrmann, Senior Engineer-Nuclear Safety, Southern Company
Services (SCS)
J. A. Bailey, Project Licensing Manager, SCS
,
i
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1
V. L. Brownlee, Branch Chief, Division of Reactor Projects (DRP)
M. V. Sinkule, Section Chief, Projects Section 2D, DRP
F. Jape, Section Chief, Test Programs Section (TPS)
}
J. F. Rogge, Senior Resident Inspector
R. J. Schepens, Resident Inspector
G. A. Schnebli, Reactor Inspector, TPS
W. H. Rankin, Project Engineer, DRP
23.
Inspector Follow-up Items (IFI)-Units 1 & 2 (927018)
'
'
(Closed) IFI 50-424/82-09-01 and 50-425/82-09-01, Embed Plate Threaded
Bolts. This item was reviewed and found to be duplicative of a Constructive
Deficiency Report (COR).
CDR 82-21 was inspected and closed in reports
50-424/85-08 and 50-425/85-08.
I
24.
Follow-up On Headquarters Requests (25014) Units 1 & 2
TI2500/14 (0 pen) Solid State Protection System (SSPS) Manual Trip Circuit.
This inspection was perfermed to determine the electrical location of the
'
manual trip circuit in relation to output transistors Q3 and Q4.
A
'
short-circuit failure of the output transistors would prevent the automatic
tripping of the associated reactor trip breaker.
In this case, the manual trip would have to be utilized to trip the breaker. By design the manual
trip switches should be located between the transistors output and the
undervoltage trip device in the breaker. A recent NRC review indicated that
!
erroneous controlled schematics showing the manual trip switches before the
,
transistors could lead to possible wiring errors.
,
l
The inspector verified with Document Control the number and location of each
I
controlled document for the SSPS System (1X6AX01-466-1).
Each document
contains Figure 10-9 SSPS Schematic Diagram (1296H01) Sheet 13 showing the
correct location for the Manual Trip switch.
In order to determine that
4
field construction was being constructed properly, the inspector requested
the licensee to arrange a panel walkdown. This item will receive continued
follow-up.
4
. . .
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19
25. Management Meetings (307028)
On August 15, 1985, the resident inspector attended a meeting with the
Georgia Power Company Startup Support Superintendent to discuss the function
and role of the newly formed Startup Support organization at plant Vogtle.
The inspector was informed that the primary responsibility of this organiza-
tion is to provide craf t support to the flushing group for performing
flushing modifications and system restorations and to complete punchlist
items on ANSI B31.1 Power Piping Systems. In addition this group will be
perforn:Ing ASME Section XI work. This group will not be doing any ASME
Section III work on Pullman Power ASME Section III N-Stamp piping systems.
The administrative procedure detailing how this group is to function is
presently being - developed and will be issued as SUM 36.
Other key
procedures which this group will be utilizing are SUM 22, Maintenance Work
Orders and Administrative Procedure No. 00351-C ASME Section XI Repair /
Replacement Program. This group is starting with a work force of 80-90
crafts and is expected to peak at 200-250 crafts. Support functions such as
planning, coordination, engineering, and quality control will be provided by
within this organization.
On August 20, 1985, the resident inspectors attended a meeting with Georgia
Power Company in Region II. Georgia Power Company outlined for the staff the
progress they have made to date in implementing numerous action plans to
improve the electrical construction area.
!
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