IR 05000438/1986007
| ML20212F492 | |
| Person / Time | |
|---|---|
| Site: | Bellefonte  |
| Issue date: | 12/15/1986 |
| From: | Bearden W, Ignationis A, York J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML20212F461 | List: |
| References | |
| 50-438-86-07, 50-438-86-7, 50-439-86-07, 50-439-86-7, NUDOCS 8701120030 | |
| Download: ML20212F492 (8) | |
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Report Nos.: '50-438/86-07 and 50-439/86-07 Licensee: Tennessee Valley Authority 6N38 A Lookout 1101 Market Street Chattanooga, TN 37402-2801
' Docket Nos.: 50-438 and 50-439 License Nos.: CPPR-122 and CPPR-123 Facility Name: Bellefonte 1 and 2 Inspection Conducted: October 1, 1986 - November 30, 1986 .
Inspectors: d dn M/ N J. W. York (/ (f D' ate S~igned J
ld W. C. Bear $n un wb $n UOste//Signed 8 [,
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Approved by: fi0 A. J.'
hcar$O 45ection Chief
/Y) 5lY(3 Datfe' Si@ned Ightonii,trojects Division of TVA SUMMARY Scope: This routine announced inspection v.:s performed in the areas of
- safety-related pipe supports and restraints, instrumentation, structural steel welding, review of quality assurance for extended construction delay, and licensee identified item Results: One violation was identified in one area: Failure to Follow Procedure for Documenting Condition Adverse to Qualit ,
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8701120030 861229 PDR ADOCK 05000438
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REPORT DETAILS Persons Contacted Licensee Employees
- Darling, Site Director
- L. Cox, Construction Project Manager
- S. Johnson, Site Quality Manager
- J. Blackburn, QA Manager
- D. Bridges, QE&C Manager
- D. Smith, Assistant Construction Engineer
- D. Hager, QA Specialist s
- Kent, QA Specialist
- K. Turner, Engineering Associate
- T. West, Engineering Aid
- Gandy, Mechanical Engineer Gther licensee employees contacted included construction craftsmen, technicians, and office personne ,
- Attended exit interview Exit Interview The inspection scope and findings were summarized on October 1,1986, with-those persons indicated by an asterisk in paragraph one above. The licensee acknowledged the inspection findings with no dissenting comments. The licensee did not identify as proprietary any of the materials provided to or reviewed by the inspectors during this inspection. At no time during the inspection period did the inspectors provide written material to the license . Licensee Action on Previous Enforcement Matters (92702)
This subject was not addressed in the inspectio . Safety Related Pipe Supports and Restraints - Units 1 and 2 (50090C)
The inspectors observed the following supports / restraints (hangers) in various stages of fabrication:
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Hanger No. 2KE-MPHG-0801 Sheet 1 R8 Class of Hanger - ASME Sec. III, Subsec. NF, C13 Welder - FBDQ Detailed Welding Procedure - SM 11-B-9 R4 Filler Metal Heat No. - 77061 (E 7018 electrode)
Other documents - Sequence Control Chart (SCC)
No. 2KE-H 4465, Field Change Request (FCR)
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No. C - 3240, and Inspection Rejection Notice (IRN) No. 10-6-86-RBl. Welder adding to shear lugs (weld numbers d,f and h) to correct distance between lugs and pipe clamp. Also, observed hanger QC reinspecting hange Hanger No. - 2KE-MPHG-1019 sheet 2 R901 Class of Hanger - ASME Sec. III, Subsec. NF, Cl3 Welder - FAHF Detailed Welding Procedure - GT-88-01 R6 Filler Metal Heat No. - C4611 (308L)
Observed welder adding filler metal to shear lug Hanger No. ORF - 0739 Class of Hanger - SCAT 1 Welder - FCIY Detailed Welding Procedure - SM-P-1 R9 Filler Metal Heat No. - 77061 (7018 electrode)
Observed Welding
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Hanger No. 2KE-MPHG-3216 R901 Class of Hanger - AMSE Sec. III, Subsec. NF, Cl3 Welder -FBOS Detailed Welding Procedure - SM-11-B-3A R1 Filler Metal Heat No. - 77061 (E 7018 electrode)
Observed hanger WQC inspection of fit u Parts rejected because tack weld metal caused parts to distort out of tolerance (weld nos, e,f,g,and h).
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Hanger Nos. 2KE-MPHG-1195 Class of Hanger - ASME Sec. III, Subsec. NF, Cl3 Detailed Welding Procedure - SM-11-B-3A R1 Filler Metal Heat No. - 77061 (7018 electrode)
Observed WQC checking fit up. Shim placed under pipe because pipe not supported by hanger. Suppor.ted then welded. Inspectors observed some of weldin Hanger No. - 2KE-MPHG-1155 R7 Class of Hanger - SCAT 1 Observed grouting of surface before placing hanger member on concrete anchors. Observed tightening of anchors so that plumpness was correct (plus or minus 2 degrees).
The inspectors checked the fabrication and welding operations for compliance with documentation, welder qualification (when applicable), and nondestruc-tive inspection requirement Within the areas inspected, no violations or deviations were identifie .
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3 Instrumentation - Components and Structures - Units 1 and 2 (52153C)
Before observing the installation of some instrument components, the inspectors reviewed portions of Quality Control Procedure (QCP) - 4.3, Re , Instrument Tubing Installation. Parts of the following installations were observed:
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Instrument Line No. 2IX-LLPA-0868-A Class of line - B 3 Tube Benders - No. 501 Observed installation of a section of tubing heat no. PSBN to termination point no. 2KE-IFT-959-A (HI) which is an instrument flow transmitter. Mechanical fittings were used for installing the tubin Hanger No.2-IRJ-0193-01 R1 Class of Hanger - ASME Sec. III, Subsec. NF, C13 Observed grouting of surface before placing hanger member on concrete anchors. Observed plumbing of vertical member Instrument and Control Forebay Water and Temperature Themocouple Well, Weld No. 22G00122 Class of Weld - Scat 1 Welder - FARK Detailed Welding Procedure - GT-88-01 R6 Filler Metal Heat No. - 35838 (308)
Observed WQC performing visual inspection.
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Weld Nos. - 2RK00166 B and C Class of Weld - ASME Sec. III. Subsec. NF, C1 3 Welder - PADX Detailed Weld Procedure - GT-88-01 R6 Filler Heat No. - 35838 (308)
Weld Map Change Request No. - 21899 Heat No. 90 Degree Elbow - 813F Instrument Tubing Heat No. PSBN Observed tack welding, fit up, and bending of tubing. Craft used tube bender Serial nos. 405557 and 406830. Benders were correctly color coded with red for use on stainless stee The inspectors checked the fabrication and welding operations for compliance with documentation, welder qualification (where applicable), and nondestruc-tive inspection requirements. Weld and base metal documentation was checked to determine applicable code acceptabilit Within the areas inspected, no violations or deviations were identifie . Structural Steel Welding - Unit 1 (55053C)
The inspectors observed the craft training session for training Module N TM-040, Structural Steel Fabrication and Installation.
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The inspector observed modification of the seismic qualified stairway in the Auxiliary Buildi -
at the Al and P line at elevation 697 fee The following were c.; m 2d for proper documentation and qualification:
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Welder - IAKC
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Detailed Welding Procedure - SM-P-1 R9
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Filler Metal Heat No. - 77061 (E7018)
A followup was performed on Inspection Rejection Notice (IRN) No. 10/17/86 DRS 1. This IRN was written by welding QC during a dye penetrant inspection of weld No. 0A4 1941 RI. This inspection and visual examination indicated a seam in the structural "I" beam. ASTM Section A6, Standard Specification for General Requirements For Rolled Steel Parts, Shapes, Sheet Piling, and Bar For Structural Use, contains the acceptance criteria for surface imperfections such as seam Five randomly chosen areas were ground to determine the depth of the seam, and all areas were less than 1/32 inch in depth. The ASTM A4 specification allows a surface imperfection to extend to 1/16 inch deph and still be acceptable for this thickness material (3/8 inch).
Within the areas inspected, no violations or deviations were identifie . Review of Quality Assurance for Extended Construction Delay - Unit 1 (92050)
The inspectors reviewed the following documentation for heating two portions of Spent Fuel Cooling and Cleaning System (NM System):
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Work Plan No. 763
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Sequence Control Chart No. INM-A001
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Long-Term System Layup Procedure, NM, Spent Fuel Cooling System
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Drawing No. 38WO454-NM-03 RA, Mechanical Spent Fuel Cooling System
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Drawing No. 3B0454-NM-04 RA, Mechanical Spent Fuel Cooling System
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Drawing No. WMINNAS R8, Master Weld Map Spent Fuel Cooling System Resistant heaters were placed on two portions of the NM system and in conjunction with air blowing thru the twelve inch diameter stainless steel pipe were to be used to remove water from approximately 200 feet of the piping. This was necessary because this section of pipe does not have any low point drains. Examination of one section of the pipe after the heating and removal of the moisture revealed that the pipe had distorted or bowe The pipe has moved into contact with a sleeve thru the "W" line wall and at elevation 623 feet and has moved 1 1/2 inches above nearest dead load suppor The two sections of pipe were instrumented with thermocouples and the two resultant temperature recording charts showed that the temperature of the pipe did not exceed 300 degrees F. The faint light gold color of the oxide on the pipe indicated very little heating of the pipe occurred substantiates the thermocouple readings were probably correct and that no local heating caused the pipe distortio .
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'A discussion with the licensee revealed that the distorted condition of the pipe was learned on November 4th or 5th and Corrective Action Report (CAR)
No. BLN-CAR-86-14 was not written until November 14. The Standard Practice
. BLA 16.1, Identification of Conditions Adverse to Quality and Corrective Actions, Par 1.0 ' states that, " Documentation of- conditions adverse to Quality should be made promptly; maximum of -three working days after identification by plant personnel". The excessive tiam used in reporting a suspected condition adverse to quality is a violation of 10 CFR 50 Appendix B, Criterion V and is identified as Violation 438/86-07-01, Failure' to follow procedure for documenting conditions adverse to qualit In addition, the inspectors intend to follow the steps and evaluations to be used in correcting the bowed pipe, and this item is identified as Inspector Followup Item No. 438/86-07-02, Distorted pipe in Spent Fuel Cooling Syste . Licensee Identified Items (LII) -- Units 1 and 2 (92700) (Closed) CDR No. 438/85-20, Diesel Generator Exhaust Silencers Improperly Anchore In final report dated November 29, 1985, the licensee stated the following:
In reference to NRC Information Notice 85-25, " Consideration o Thermal conditions in the Design and Installation of Supports for
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Diesel Generator Exhaust Silencers," and to 10 CFR 50.55(e)
nonconformance report (NCR) BLN 3615 (CDR/BLRD-50-438/84-55, BLRD-50-439/84-51), " Deficient Category I Components and Miscel-laneous - Steel," a reinspection of the Unit 1 Diesel Generator
!.- . Exhaust Silencers Foundations was conducted by TVA personnel. The j following conditions and drawing discrepancies were identified:
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' Hairline shrinkage cracks were noted along the concrete surface of the support foundation.
f Some of.the 1" diameter MK5 anchor bolts did not have the
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designated 4-1/2" projection above the concrete surface of i the support foundation. Therefore, the anchor bolt nuts do not have full thread engagement and/or a jam nut installed, as called for by design drawing (The cause of this
, deficiency was a failure of construction personnel to install i the items as referenced in design drawings.)
i The anchor bolt nuts should be loose to allow movement to accommodate thermal expansion but were found to be tightened.
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(The cause of this deficiency was due to construction i
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personnel not using the required mechanical drawing to set the equipment and to the lack of clear requirements on design drawings delineating the tightness of nuts.)
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6 Due to dirt, grout, and insulation, the physical conditions of the slotted connections appear to prevent the required sliding movement to accommodate thermal expansio (This deficiency was caused by a high level of construction activity in the area of the diesel generator exhaust silencers.)
All dirt, grout, and insulation were removed, and the nuts were loosened on the anchor bolts by TVA during preparation for an operational test of the diesel generator When these
" housekeeping" modifications were made, the sliding connection i functioned properly. The only other modifications performed were the tack welding of the nuts to the anchor bolts in the loosened position and an anchor bolt splice for extending the anchor bolts which did not have enough projection to provide full-thread engagement. The use of a jam nut will no longer be required--but is optional. TVA has revised drawing 40WO783-X1-2 to provide a splice detail for the short bolts and to include tightness requirements for the nut To prevent recurrence of this deficiency, the following actions were taken by TVA, corresponding to the conditions noted in the Description of Deficiency: The hairline shrinkage cracks on the surface of the support foundation were evaluated and considered not detrimental to the integrity of the foundation; therefore, action to prevent recurrence is not require . Quality Control and Engineering functions were separated in 1983, enabling more emphasis being given to quality installations through training programs and enhancement of Quality Control Procedures (QCPs). Additionally, QC units routinely perform self-audits of finished inspections to determine areas where more training emphasis is require Also, in August 1984, craft personnel began formalized training in QCP This training used a modular package concept for presentation and should improve the quality of craft installation . The investigation conducted concluded that this was an isolated instance; however, to prevent recurrence, Bellfonte Civil Design Group has been instructed to adhere to the following guideline in the future detailing of equipment anchorages: "If the anchorage details for electrical and mechanical equipment are not shown completely on the civil / structural drawings, the applicable electrical or mechanical drawings, showing the details, must be referenced on the civil drawings."
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7 Action to prevent recurrence is not required in relation to dirt, greut, and insulation on the silencer slotted connections, since this was due solely to a high level of construction activity in Bellefontes normal housekeeping and preventive maintenance procedures will preclude recurrence of this conditio The inspector reviewed the correspondence for the appropriate Nonconformance Report. NCR No. 4353, and found it adequate for the purpose of closing the item. The inspector examined the foundation and anchors associated with both Unit I diesel generators. All anchor nuts were modified as stated above. Construction activities are substantially complete in the area and no debris was noted that would interfere with movement within the slotted connections. The inspector verified that the associated drawing, 40WO783-XI-2, had been revised to include the requirement to back off the anchor bolt nut and tackweld the nut to prevent it from being tightened. There exists a series of hairline cracks in the concrete foundation (as stated in the original CDR). The cracks are more frequent and pronounced than on other similar foundations, raising the concern that the cracks might have resulted due to another cause. The licensee was not able to provide any documentation to indicate that the cracking in the foundation was properly addressed with respect to IE Notice 85-25 or that temperature of the concrete was monitored during continuous diesel generator operation. This item is identified as Inspector Followup Item, 438/86-07-03, Diesel Generator Exhaust Silencer Foundation Concrete Crack The inspector noted that a similar condition exists with the exhaust silencers being improperly anchored on both Unit 2 diesel generator The anchor bolt nuts were not loose and construction debris could interfere with sliding movement as reported in the CDR associated with Unit 1. This item was not reported for Unit However construction activities are not complete and work is not ongoing in this portion of Unit 2 due to the construction delay at the site. The licensee informed the inspector that quality control inspection of these unit 2 systems had not yet occurred and would resume when unit 2 construction resume This item is identified as Inspector Followup Item, 439/86-07-01, Diesel Generator Exhaust Silencer Anchor The inspectors reviewed the status of the following new LII's:
CDR N NCR No Title 438/86-11 BLN MEB Missing Internal Locknuts
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439/86-09 8622 on Anchor Darling Swing-Check Valves Within the areas inspected, no violations or deviations were identified.