IR 05000458/1985068: Difference between revisions

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{{Adams
#REDIRECT [[IR 05000354/1985054]]
| number = ML20136B865
| issue date = 11/01/1985
| title = Insp Rept 50-458/85-68 on 850930-1003.No Violation or Deviation Noted.Major Areas Inspected:Quality Concerns Program,Asme Certification Program & Followup on Previous Insp Findings
| author name = Jaudon J, Mcneill W, Taylor R
| author affiliation = NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
| addressee name =
| addressee affiliation =
| docket = 05000458
| license number =
| contact person =
| document report number = 50-458-85-68, NUDOCS 8511200303
| package number = ML20136B850
| document type = INSPECTION REPORT, NRC-GENERATED, INSPECTION REPORT, UTILITY, TEXT-INSPECTION & AUDIT & I&E CIRCULARS
| page count = 7
}}
 
{{IR-Nav| site = 05000458 | year = 1985 | report number = 068 }}
 
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APPENDIX U. S. NUCLEAR REGULATORY COMMISSION
 
==REGION IV==
NRC Inspection Report: 50-458/85-68  License: NPF-40 Docket: 50-458 Licensee: Gulf States Utilities (GSU)
P. O. Box 2951 Beaumont, Texas 77704 Facility Name: River Bend Station Inspection At: River Bend Station Inspection Conducted: September 30 through October 3,~1985 Inspectors: + f  /o/.7//gs-W. M. McNeill, Reactbr Inspector, Reactor  D&te '
Projects Branch B1/    /pl3llf[
R.' G. I lor, Reactor Inspector, Reactor  D#te/
Proje ts Branch
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J./P.[Jaudo, Chief,ProjectionSdctionA,  Date (Reactor rojectsBranch
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Approved: .
gu AA  ff fy J P. Jau , Chief, ' Pro' ject Section A, Reactor Date i-Pro ct Branch
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      -2-Inspection Summary Inspection Conducted September 30-October 3, 1985 (Report 50-458/85-68)
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Areas' Inspected:
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Routine, unannounced inspection of certain activities within the Quality Concerns program, the ASME Certification Program, and followup on
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  . previous ~ inspection finding '
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The-inspection involved 72 inspector-hours onsite by three NRC inspector , . Resultsi Within'the areas inspected, no violations or deviations were
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  -3-Details Persons Contacted J. Deddens, Vice President River Bend Nuclear Group R. B. Stafford, GSU, Director Quality Services R. L. Spence, Stone & Webster (S&W), Resident Quality Control Manager The NRC inspector also interviewed and interfaced with other GSU and S&W personnel as necessary to facilitate the inspectio . Action on Previous Inspection Finding (Closed) Violation (458/8519-01): An engineering review did not ensure the adequacy of incorporation of changes by Engineering and Design Coordination Reports (E&DCRs) into drawing As corrective action, a 100% review of E&DCRs and drawing changes during the time in question was performed. As preventative action, the personnel involved in this review process were reinstructed in light of the errors which were identified. These actions were documented on an interoffice correspondence dated June 24, 1985. The project procedure, RBP 12.0, has been revised (Revision 13, Change Notice 11) to require that EK, Eti and EM series CAT I drawings be revised to incorporate all E&DCRs by February 28, 1985, which is 6 months after fuel load. A sample of ten E&DCRs were inspected to verify their incorporation. With the exception of an isolated minor transposition error, the sample indicated that the E&DCRs have been properly incorporated into the affected drawings. This violation is close (Closed) Violation (458/8519-02): Annual evaluations of suppliers using external historical data did not meet specified requirement As corrective action, Hayward Tyler Pump and Transamerica Delaval have restriction memos (GSU VQS-85-098 and 191) issued which limited procure-ment activities. It was established that Guideline was-not used as a supplier; therefore, they were removed from the Qualified Suppliers List (QSL). Additional observations of the NRC inspector were also corrected in regards to Pyco, Crosby Valve and Brown Boveri purchase orders and certification records. As preventative action, the procedure QAI-2.4 was revised August 22,1985 (Revision 2) to more clearly define the require-ments to be applied during annual reviews of external historical dat A review of the current QSL dated August 5, 1985, found one vendor to-have been given an annual review based on external historical data which was Conax Corporation of Cheektowaga, N.Y. This evaluation had been performed by S&W for Nuclear Utilities Parts Associates (NUPA) for GS ~
 
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  -4-After reviewing the report of this review, GSU issued a restriction memo on Conax which indicates adequate implementation of the above referenced procedure. This item is close (Closed) Violation (458/8540-01): An inspection of the " Job Inspection Torque" used to verify preload found significant failures. GSW and S&W performed an engineering evaluation of the inspection results. This evaluation considered the frequency of failures, errors in tension measurement, designed safety factors and the connection design. It was concluded that the safety of design was not compromised. A review by NRC regional personnel and the CAT consultant found no problems with this evaluation. This item is close e (Closed) Unresolved Item (50-458/84-36-04) Cable Spacing e (Closed)UnresolvedItem(50-458/84-36-06) Electrical Separation e (Closed) Open Item (50-458/83-21) Electrical Separation e (Closed)UnresolvedItem(50-458/84-17-04) Separation Between Cables The above items are considered closed based on NRR approval of FSAR Amendments 19 and 2 e (Closed) Open Item (50-458/85-10-03) Missing tags on small pipe supports: This item is considered closed based on the subsequent as-built inspection as documented in Inspection Report 50-458/85-3 e (Closed) Open Item (50-458/85-10-04) Approval of design changes prior to approval of supporting calculation: This item was replaced by the violation identified in Inspection Report 50-458/85-12, item 0 e (Closed) Violation (50-458/85-12-01): Field-generated' design calcu-lations not reviewed: The NRC inspector reviewed several calculations and found that they had been reviewed. The NRC inspector reviewed S&W procedures dealing with final reconciliation of all field-generated changes with original design and was satisfied that all field-generated calculations used to support the design changes are included in the change package which will provide the necessary review. Review Of Quality Concerns The objective of the inspection was to review licensee action on quality concern NRC Inspection Report 50-458/85-25 described the quality concern program. NRC Inspection Report 50-458/85-62 discussed a previous review of quality concerns. During this inspection, the NRC inspectors completed the review of all quality concerns identified prior to September 30, 1985, which had been closed by the licensee. The NRC
 
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  -5-inspectors also reviewed all quality concerns in the licensee's system which had not been closed as of September 30, 1985. The purpose of this review was to determine if there were any safety issues which could affect initial criticality. No such issues were identifie A detailed review was made of the licensee's followup on quality concerns developed as a result of the drug screening conducted under the fitness for duty program of contract personnel. The licensee had concluded that there had been no adverse impact on quality as a result of work perfonned by these individuals. From their review, the NRC inspectors found no reason to disagree with the licensee's conclusion. Moreover, the NRC inspectors did not identify any other safety issues resulting from the quality concerns which had not been addressed (closed quality concerns)
or were not being addressed (currently open quality concerns).
 
No violations or deviations were identifie . Review of ASME Certification Process The objective of this inspection was to review the ASME nuclear certification process as it relates to safety-related piping system This process, while more elaborately detailed in the ASME Section III Code, .is essentially an independent (of the licensee or any of his agents)
system of audits and inspections of the entire pipe process from manufacture of the pipe, fabrication, installation and acceptance testing of the finished system. As a general rule, the following categories of commercial activities are involved:
e Material manufacturers: Producers of bulk pipe and other fittings meeting specified chemical and physical requirement e Material suppliers: Distributors, often called " jobbers," that
, purchase pipe and/or fittings from the manufacturers in large quantities for resale to users such as fabricators and installer The supplier may perform certain Code requirements relating to the *
product when not part of the material specification applicable t the manufacture e Fabricators: ' Shops which specialize inTfabrication of pipe sectio ~ns into what are commonly referred to as " spools" which range from .
lengths of~ straight pipe _to complex configurations of pipe, elbows, tees and flanges. Fabrication processes are generally.by welding
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and occasionally by bendin '
Installers: Frequently referred to as the contractor, the installer
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e receives spools from the fabricator and; installs-them in the construc -
tion sit Installation process utilizes welding and bolting of
, spools and other components such as pumps and valves to achieve a functioning piping system. The' installer generally conducts the
_ Code-required final hydrostatic test of the syste ''
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t The ASME audits'all 6f the preceding activities and issues a Code authorization certific' ate generally every 3 years. There are provisions; F
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however, where. a higher tier activity can audit and certify a lower tier
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activity w'ith 'the higher tier taking.on all;the Code responsibilities of
;    his lower, tier a' gent. ' Fabricators and instal.lers generally have a third
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party inspector assignedjin.the shop and/or field to aud't and inspect
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activities'on a day-to-day basis. The third. party inspector, referred to
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,    J in . the': Code J as an Authorized Nuclear Inspector, is usually an employee of 6  ~
an insurance company but on. occasion,is an employee of a city or state.
 
;    These inspectors are trained and examined by the National Board of Pressure
  ,  Vessel Inspectors and certified by the state within which they will perform their work.. Manufactdrers and suppliers, with few exceptions, do not have
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third party' inspector ,
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    ' The NRC in'spector sel'ected,the Service Water System as reasonably
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representative of the larger safety-related systems subject to all of the-steps identified and discusssd above. The NRC inspector reviewed the j    engineer!s line list to identify the line' size make up of the overall it system.' ~It was found that 11. pipe sizes ranging from 3" to 30" had
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    !been utilized. The NRC~ inspector determined that a further selection
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    . division would be necessary and with the knowledge that all piping larger than 2-1/2"'was fabricated off-site and installed by the on-site b    ' constructor, it was decided tha.t 12" pipe would present a representative L'    picture of the entire ASME certification process.
 
s The NRC inspector briefly reviewed the 208-page N-5 certificate for the t
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Service Water System comprising in excess of.approximately 3,300
    - fabrication and installation items. Thirty-eight pages'of the 208 were
,    ' selected since they document all of the spools fabricated off-site. .These
,    pages list 'approximately' 600 individual spools, of which 54 relate to the selected 12" size. -Of the 54 spools,~10 were identified as being within i    the reactor containment building and were divided equally between safety
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class 2 and 3. Review'of the Authorized Nuclear Inspector certified
[    document packages for the 10 spools indicated the following:
    -e~ The:10. spools are comprise'd of!approximately 420 feet of pipe.
 
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e The material manufacturers were United States: Steel- (approximately-400' feet) and Jones and Laughlin: Steel:(approximately 20 feet).  .
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    'The New materia Jerse' suppliers were y J(approximately  260two1 feet) and companie located Pennsylvania resp. (ectively)in 160 feet
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    ;The New. Jersey company material was certified.as having_come from
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itwo heats of United States Steel pipe while.the Pennsylvania firm
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    ' supplied their material. from two heats of Unites States-Steel pipe
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and one of Jones and Laughlin..
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    : All'of the spools 1were fabricated 'bylB. F. Shaw, and each was individually. certified on Authorized Nuclear Inspecto .
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    -7-The NRC1 inspector also reviewed the documents pertaining to the remaining 44 spools, all of which are located outside the reactor containment building'and are all-safety class 3. The 44 spools are estimated to have in excess of 600 feet of pipe along with the usual elbows and tees. The material was all supplied by the Pennsylvania company and was largely manufactured by U.S. Stee All of the material certification, regardless of manufacturer, indicated the pipe met the chemical and physical properties of ASME material
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specification SA-106 for grade B seamless pipe. The steel described by
  'SA-106 for grade B pipe is essentially a very common type of highly weldable mild carbon steel used in several other types of pipe and in structural steel shapes. Rough calculations by the NRC inspector indicate that pipe involved in this inspection has a service condition hoop fiber stress equal to approximately 4% of the minimum yield strength of the materia It should be noted that this entire inspection has consisted of review of documents with essentially no attempt to examine installed pipe. The NRC inspector chose this course based on an interview with site quality control personnel and a knowledge of usual manufacturing mill and fabrication prac-tices. The mills typically mark each length of pipe .,ith a paint or ink stamping system providing full identity and traceability to the documen-tation. Upon receipt at the fabricator, the fabricator assigns a new and
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unique number.to the material to avoid the possibility that different manu-facturers could use the same heat identification number. This new number is permanently vibroetched or-stamped into the pipe and marked on the appropriate manufacturer documentation; after which, the pipe is grit or sandblasted to a near-white condition, which removes the mill marking, prior to application of a rust proofing coat of primer pain Thus, die identity of the manufacturer.and all other mill traceability provisions have been surrendered to the fabricator's control and ~
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documentation system which must be relied on.during all subsequent f  fabrication, installation and ' verification activitie *
"  Based on this inspection and.other'NRC inspections performed during the
  ' construction period, the NRC inspector has determined that the ASME .
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certification process has contributed significantly to the quality-and -
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safety of the: River Bend Statio '
:  Noviol'ationsordeviations;wereidentifiedduringthisinspection'.
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  , 5". Exit Interview'    '
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f  'A:brief exit interview was conducted with Mr.-J. C. Deddens, N
Vice President of the River Bend Nuclear Group, near the end of the
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inspection to discuss'the findings"of this inspectio .
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