ML20235V504

Insp Rept 50-425/87-36 on 870724-0914.Violation Noted.Major Areas Inspected:Fire Protection,Containment & safety-related Structures,Piping Sys & supports,safety-related Components, Electrical Equipment & Cables & Instrumentation

ML20235V504
Person / Time
Site:	Vogtle
Issue date:	09/25/1987
From:	Livermore H, Rogge J, Schepens R, Sinkule M NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
To:
Shared Package
ML20235V464	List: ML20235V461 ML20235V475 ML20235V504
References
50-425-87-36, NUDOCS 8710150200
Download: ML20235V504 (11)

See also: IR 05000425/1987036

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S UNITED STATES

/ Qboog]o NUCLEAR REGULATORY COMMisslON

REGION 11

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p/ j 101 MARIETTA STREET, N.W. j

g ATLANTA, GEORGI A 30323 I

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Report Nos.: -50-425/87-36

Licensee: Georgia' Power Company

P. O. Box 4545

Atlanta, GA 30302

Docket No.: 50-425 License No.: CPPR-109

Facility Name: Vogtle 2 .i

Inspection Conducted: July 24 - September 14, 1987

Inspectors: MM . bW(MuP<,c- 1 N bd a 34Ses ~

7/C87

H. H. Livermore, Senior Reisident Date Signed

Inspector, Construction

N kcge, hp .C <xIe 6[ %[ 87

J. F. Rogge, Senior Resident , Dath Sigtfed

Inspector Operations '

k.b,ke.b,epdM f C LLb N.,87

R. J. Schepens, Resident ) Date Signed

I pector Operations

Approved by:_  % 7[)C57

M. V. Sinkule, Section Chief Date Signe'd

Division of Reactor Projects

SUMMARY

Scope: This routine, unannounced inspection entailed Resident Inspection in

the following areas: fire protection, containment and safety related

structures, piping systems and supports, safety related components, electrical

equipment and cables, instrumentation, and preoperational test programs.

Results: One violation was identified involving " Failure to Follow Procedures

for Quality Control (QC) Inspection of Mechanical Equipment," Paragraph 11. j

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. REPORT DETAILS-

- 1. Persons Contacted-

Licensee Employees

• P. D.. Rice; Vice. President,.Vogtle Project Director )

~* R. H. Pinson, Vice President, Project. Construction  :

C. W. Whitney, General Manager, Project Support i

R. M. Bellamy, Quality Assurance Manager, Corporate ,

C. W. Hayes, Vogtle Quality Assurance Site Manager.- Construction

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• D. M. Fiquett, Project Construction Manager -' Unit 2

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2*G. A. .McCarley, Project Compliance Coordinator.

C.L.'Coursey,McintenanceSuperintendent(Startup) i

M. P. Craven, Nuclear Security Manager

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• H. M.:Handfinger, Project Start-up Support Manager

F. D. Kuester, Project Field. Engineering 8

J.-A. Bailey, Project Licensing Manager

A. :W. Harrelson, Construction Electrical Manager .:

C.-W. Rau, Construction Mechanical Manager

L. N. Brooks, Construction. Civil Manager  ;

L. B.' Gleen, Quality Control Manager. l

• R. C. Soomerfield, Readiness Review i

• J. J. Gilmartin, Engineering Supervisor l'

'*S. M. Hall, S/V Procedures Support

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• M. Horton, Test Engineering Support  !

? '*R. W. McManus, Readiness Review Manager '

'J. E. Sanders, Assistant Project Manager  ;

.W. C..Ramsey,. Project Engineering Manager

L. D. Harless,: Manager, Quality Concerns

D. Janecki, Quality Concerns

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W. C. Lyon, Quality Concerns I

S. D. Haltom, Quality Assurance {

R. Folker, Quality Assurance Engineer '

Other licensee employees contacted included craftsmen, technicians,

engineers inspectors, and office personnel.

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Other Organizations  ;

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D. W Smith, Support Nuclear Operations 01gethrope Power Corporation

C. Markham, Westinghouse Project Manager

D. L. Kinnsch, Project Engineering - Bechtel i

T. E. Richardson, Project Engineering Manager - Bechtel

B. Edwards, Site Manager, Pullman Power Products (PPP)

• J. E. Miller, Qut.lity Aassurance Manager, PPP

• Attended exit ~ interview

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2. Exit Interviews - Unit 2(30703C)

The inspection scope and-findings were summarized on September 14, 1987,

with those persons indicated in paragraph 1 above. The inspector

described the areas inspected and discussed in detail the inspection

findings. No dissenting comments were received from the licensee. The

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

or reviewed by the inspector during this inspection. Region based NRC

exit interviews 'were attended during the inspection period by a resident

inspector.

3. Licensee Action on Previons Enforcement Matters - Unit 2(92702)

Not inspected.

4. Unresolved Items - Unit 2

Unresolved Items are a matter about which more information is required to '

determine whether it is acceptable or may involve a violations or

deviations. No unresolved items were identified during this inspection

-period.

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5. General Construction Inspection - Unit 2(92706)

' Periodic random surveillance inspections were made throughout this

reporting period in the form of general type inspections in different area

of the facility. The areas were selected on the basis of the scheduled

activities and were varied to provide wide coverage. Observations were

made of activities in progress to note defective items or items of

noncompliance with the required codes and regulatory requirements. On-

these inspections, particular note was made of the presence of quality

control inspectors, supervisors, and quality control evidence in the form

of available process sheets, drawings, material identification, material

protection, performance of tests, and housekeeping. Interviews were

ccnducted with craft personnel, supervisors coordinators, quality control

inspectors, and others as they were available in the work areas. The

inspector reviewed numerous construction deviation reports to determine if

requirements were met in the areas of documentation, action to resolve,

justification, and approval signatures in accordance with Georgia Power

Company (GPC) Field Procedure No. GF-T-01. ,

No violations or deviations were identified.

6. Fire Prevention / Protection and Housekeeping Measures - Unit 2 (42051C)

The inspector observed fire prevention / protection measures throughout the

inspection period. Welders were using welding permits with fire watches

and extinguishers. Fire fighting couipment was in its designated areas

throughout the plant.

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The inspector reviewed and examined portions of procedures pertaining to

the fire prevention / protection measures and housekeeping measures to  !

determine whether they comply with applicable codes, standards, NRC

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Regulatory Guides, and licensee comitmeats.

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The inspector observed' fire prevention / protection measures in work areas

containing safety related equipment during the inspection period to verify

the following:

- Combustible waste material and rubbish was removed from the work  ;

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areas as rapidly as practicable to avoid unnecessary accumulation of

combustibles.

- Flammable -liquids were stored in appropriate containers and in

designated areas throughout the plant.

- Cutting and welding operations in progress have been authorized by an

appropriate permit, combustible have been moved away or safely

covered, and a fire watch and extinguisher was posted as required.

- Fire protection / suppression equipment was provided and controlled in

accordance with applicable requirements.

No violations or deviations were identified.

7. Structural Concrete - Unit 2 (47053C)

a. Procedure and Document Review

The inspector reviewed and examined portions of the following

procedures pertaining to the placement of concrete to determine

whether they comply with applicable codes, standards, NRC Regulatory

Guides, and licensee commitments.

-CD-T-02, Concrete Quality Control

-CD-T-06, Rebar and Cadweld Quality Control k

-CD-T-07, Embed Installation and Inspection l

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b. Inspector witnessed portiens of the concrete placement indicated J

below to verify the following:

(1) 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,

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 )

- Replacement inspection was completed and approved prior to

placement utilizing a Pour Card.

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- Construction joints were prepared as specified.

- Proper mix was specified and delivered.

- Temperature control of. the mix, mating surfaces, and 1

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- Consolidation was performed correctly.

- Testing at placement location was properly performed in

accordance with the acceptance criteria and recorded on a j

Concrete Placement Pour Log. l

- Adequate crew equipment, and techniques were utilized.

- Inspections during placements were conducted effectively by )

a_ sufficient number of qualified personnel.

- . Curing methods and temperature was monitored.

No violations or deviations were identified.

8. Safety Related Piping - Unit 2(49063C)

Periodic inspections were conducted to observe construction activities of

the Reactor Coolant Boundary and other safety-related piping installations

inside and outside Containments. Verifications included but were not {

limited to the following: 1

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- Material and components were being properly handled and stored in 1

order to prevent damage. J

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- Fit-ups and alignments were within tolerances per specifications arid j

drawings. {

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- Specified clearances from pipe to pipe and adjacent components were )

met. J

- Piping was installed and inspected in accordance with applicable

drawings, specifications, and procedures.

- Those people engaged in the activity are oualified to perform the

applicable function.

- Drawing and specification changes (revisions) are being handled and

used correctly.

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No violations or deviations were identified.

9. Safety Related Piping Welding - Unit 2(55083C)

Periodic inspections were conducted during daily plant surveillance on

safety-related pipe welding at various stages of weld completion. The

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purpose of the inspection was to determine whether the requirements of

applicable; specifications', codes, standards, work performance procedures,

.and Quality Control (QC) procedures are being met as follows:

i -- WorkJ was conducted. inTaccordance. with a process sheet which

identifies the weid' and >1ts location by system, references,

c . procedures, or instructions and which provides for production'and QC

signoffs. ,

- Welding procedures, detailed drawings, and. instructions were readily

availcble in the immediate work area and technically adequate for the,

welds being made.

- . Welding procedure specifications (WPS) were in accordance with the

applicable Code requirements and that, a Procedure Qualification-

Record (PQR) .is referenced and exists for the type' of weld being

made..

- Base' metals, welding filler materials, fluxes, gases, and insert - 1

materials' were of the specified type and grade, have been properly

inspected and . tested, and were . traceable to ' test reports or

certifications.

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Purge and/or shielding. gas flow and composition were as specified in

the welding pecedure specification, and protection was provided to

shield the welding operation from adverse environmental conditions.

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Weld joint geometry includirg pipe wall thickness was specified and 4

that surfaces to be welded have been prepared, cleared, and inspected 1

in accordance with applicable procedures or instructions, f

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A sufficient number of adequately qualified QA and QC inspection

personnel were present at the work site, commensurate with the work

in progress.

- The weld area cleanliness was maintained and that pipe alignment and

fit-up tolerances were within specified limits.

-- Weld filler material being used was in accordance with welding

specifications, unused filler material was separated from other types

+ of material and was stored properly, and weld rod stubs were properly I

removed form the work location.

- There were no evident signs of cracks, excessive heat input,

' sugaring, or excessive crown on welds.

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Welders were qualified to the applicable process and thickness, and

necessary controls and records were in place.

No violations or deviations were identified.

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10. Reactor Integrated Head Package and Internals - Unit 2 ,

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The inspection consisted of examinations of the Reactor Vessel installed

in containment, the Reactor Vessel head with the installed control rod

drive mechanisms that are located on the refueling floor, and the upper

internals in their designated laydown area. Inspections also determined

that proper storage protection practices were in place and that entry of

foreign objects and debris was prevented. During this inspection period,

the inspector also monitored a fit check installation of the reactor

vessel head and the reactor vessel.

No violations or deviations were identified.

11. Safety Related Components 'Jnit 2(50073C)

The inspection consisted of plant tours to observe storage, handling, and

protection; installation; and preventive maintenance of safety-related l

components to determine that work is being performed in accordance with j

applicable codes. NRC Regulatory Guides, and licensee commitments. l

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l The areas listed below were randomly inspected at various times during the l

inspecticn period to verify the following as applicable:

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- Storege, environment, and protection of components were in accordance .

with manufacturer's instructions and/or established procedures. l

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Implementation of special storage and maintenance requirements such

as: rotation of motors, pumps, lubrication, insulation testing

(electrical), cleanliness,etc.

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Performance of licensee / contractor surveillance activities and

documentation thereof was being accomplished. ,

- Installation requirements were met such as: proper location, i

placement, orientation, alignment, mounting (torquing of bolts and

expansion anchors), flow direction, tolerances, and expansion

clearance.

- Appropriate stamps, tags, markings., etc. were in use to prevent

oversight of required inspections, completion of tests, acceptance,

and the prevention of inadvertent operation,

i Safety-Related piping, valves, pumps heat exchangers, and instrumentation

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were inspected on a random sampling basis throughout the plant.

On July 30, 1987, the inspector conducted a followup inspection of field .

process sheets 2-1208-P6-002 and 2-1208-P6-003 which documented the change '

out of the two piece balance drum locknut per FEC0 N-99-BF on the train

"A" and "B" centrifu The inspector reviewed Pullman

Power Products (PPP) gal charging pumps.

procedure IX-48, " Equipment Installation." Paragraph

7.1 of PPP procedure IX-48 states in part that QC is responsible for

verification of items that fall within the scope of ASME (I.E. NF bolting,

pressure boundary bolting, etc...). The field engineer is responsible for

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verification of other items, including cleanliness inspections (all codes)  !

during installation. A review of PPP procedure X-11, " Visual Inspection," l

was also conducted. Paragraph 3.1 of PPP procedure X-11 states in part I

that certification of all personnel performing general visual inspection i

shall be in accordance with ANSI N.45.2.6 and PPP QA procedure II-4, )

entitled " Inspection and Test Personnel." The inspector determined that a i

control inspector was not utilized to document inspections of the work

performed on the centrifugal charging pumps which are ASME safety-related ,

equipment and that the field engineer who signed-off the process sheets in '

the block (hold for PPP inspector) was neither a QC inspector nor was the

individual certified for performing visual inspections. This matter will

be identified as violation 50-425/87-36-01, " Failure to Follow

Procedures."

During the above inspection the inspector also identified the following

concerns: 1) PPP field process sheets contain one block for PPP

inspectors to sign for hold points. The above item has identified that

field engineers also sign-off in the block for their hold points. Since ,

there is only a check in the block for a hold point it is left up to 1

personnel in field to decide whether the check is for a quality control l

or held engineer hold point. These two types of check offs should be made

distinguishable. 2.) PPP procedure 1X-48, paragraph 7.1, states in part

that QC is responsible for verification of items that fall within the

scope of ASME (i.e. NF bolting, pressure boundary, etc.). PPP procedure

IX-5, " Bolting Procedure," paragraph 6.3.2, states in part that the field

engineer shall inspect the bolted connection prior to torquing to enture

flange alignment is acceptable and shall verify that the recommended ,

torquing sequence is followed and that the torque reached is in accordance i

with recommended values. Also, discussions with QC inspectors in the

field confirmed that they are not required to verify torquing of ASME

pressure boundary pipe. The above two PPP procedures appear to be in

conflict with one another regarding QC's function to inspect torquing of

ASME pressure boundary pipe. 3). QC and field engineering are both using

a single checklist for recording their inspection results or verifications

by initials in the same columns titled "PPP Inspection and date," making

it appear to a reviewer that QC had inspected each line item, whereas they

had not.

12. Safety Related Pipe Support and Restraint System - Unit 2(500900)

Periodic random inspections were conducted during the inspection period to

observe construction activities during installation of safety-related pipe

supports to determine that the following work was performed in accordance

with applicable codes, NRC Regulatory Guides, and licensee commitments:

- Spring hangers were provided with indicators to show the approximate

" hot" or "coldd position, as appropriate.

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- No deformation of forced bending was evident.

- Where pipe clamps are used to support vertical lines, shear lugs were

welded to the pipe (if required by Installation Drawings) to prevent

slippage.

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Sliding- or rolling supports were provided with material and/or

l. lubricants suitable for the environment and compatible with sliding

contact surfaces.

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-- Supports are located and installed as specified.

- The surface of welds meet applicable; code requirements and are free

from unacceptable grooves, abrupt ridges, valleys, undercuts, cracks, i4

. discontinuities, or other indications which can be observed on the  :

welded surface..

No ' violations or deviations were identified.

13. Electrical and Instrumentation Components and Systems - Unit 2 (51053C)

(52153C)

Periodic inspections were conducted during the inspection period to

observe safety-related electrical equipment-in order to verify that the

storage, installation, and preventive maintenance was accomplished in

accordance with applicable codes, NRC Regulatory Guides, and licensee

commitments..

' During' the inspection period, inspections were performed on various. pieces

of electrical equipment during storage, installation, and cable

terminating phase in order to verify the following as applicable:

- Location and alignment

- Type and size of anchor bolts

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Identification

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Segregation and identification of nonconforming items

- Location, separation, and redundancy requirements

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- Condition of wire (not nicked, etc.), tightness of connection

- Bending radius not exceeded

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Cable entry to terminal point

- Separation

No violations or deviations were identified.

14. Electrical and Instrumentation Cables and Terminations - Unit 2 (51063C)

(52063C)

a. Raceway / Cable Installation

The inspector reviewed and examined portions of the following ,

procedures pertaining to raceway / cable installation to determine

whether they comply with applicable codes, NRC Regulatory Guides, and

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licensee commitments.

-ED-T-02, Raceway Installation

-ED-T-07, Cable Installation

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Periodic inspections were conducted to observe construction

activities of Safety Related Raceway /Cabic Installation.

In reference to the raceway installation, the following areas were

inspected to verify compliance with the applicable requirements:

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Identification

- Alignment

- Bushings (Condait)

- Grounding

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Supports and Anchorages

In reference to the cable installation the following areas were

inspected to verify compliance with the applicable requirements:

- Protection from adjacent construction activities (welding, etc.)

- Coiled cable ends properly secured

- Non-terminated cable ends taped

- Cable trays, junction boxes, etc., reasonably frees of debris

- Conduit capped, if no cable installed

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Cable supported

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Bend radius not exceeded

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Separation

b. Cable Terminations

The inspector reviewed and examined portions of the following

procedures pertaining to cable termination to determine whether they

comply with applicable' codes, NRC Regulatory Guides, and licensee

conr11tments .

-ED-T-08, Cable Termination

In reference to cable terminations the following areas were inspected

to verify compliance with the applicable requirements: l

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Cable identification

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Proper lugs used

- Condition of wire (not nicked, etc.) l

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Tightness of connection

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Bending radius not exceeded

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Cable entry to terminal point

- Separation

No violations or deviations were identified.

15. Containment and Other Safety Related Structural Steel Welding - Unit 2

(55053C0(55063C)

Periodic inspections were conducted during daily plant surveillance on

safety-related steel welding at various stages of weld completion. The

purpose of the inspection was to determine whether the requirements of

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applicable specifications, codes, standards, work performance procedures .

and QC procedures are being met as follows: l

- Work was conducted in accordance with a process sheet or drawings 4

which identified the weld and its location by system, references, j

procedures, or instructions and which provides for production and/or l

QC signoffs.  !

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. Welding procedures, detailed drawings, and instructions were readily

available in the immediate work area and technically adequate for the

welds being made.

- Welding procedure specifications (WPS) were in accordance with the I

applicable Code requirements and that a Procedure Qualification

Record (PQR) is referenced and exists for the type of weld being

made.

- Base metals and welding filler materials were of the specified type

and grade, were properly inspected, tested, and were traceable.

- Protection was provided to shield the welding operation from adverse

environmental conditions.

- Weld joint geometry including thickness was specified and that

surfaces to be welded were prepared, cleaned, and inspected in

accordance with applicable procedures or instructions.

- A sufficient number of adequately qualified QA and QC inspection l

personnel commensurate with the work in progress were present at the

work site.

- Weld are cleanliness was maintained and that alignment and fit-up

tolerances were within specified limits.  !

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- Weld filler material being used was in accordance with welding  !

specifications, unused filler material was separated from other types

of material and was stored and controlled properly, and stubs were 4

properly removed from the work location.

- There were not visual signs of cracks, excessive heat input, or

excessive crown on welds.

- Welders were qualified to the particular process and thickness, and

necessary controls and records were in place.

No violations or deviations were identified.

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