IR 05000354/1982006

IE Insp Rept 50-354/82-06 on 820503-31.No Noncompliance Noted.Major Areas Inspected:Svc Water Intake Structure Foundation Const,Structural Steel Erection & Pipe & Hanger Installation

ML20054H573
Person / Time
Site:	Hope Creek
Issue date:	06/07/1982
From:	Bateman W, Lester Tripp, Varela A NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I)
To:
Shared Package
ML20054H565	List: IR 05000354/1982006 ML20054H564
References
50-354-82-06, 50-354-82-6, NUDOCS 8206240213
Download: ML20054H573 (13)

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U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND EllFORCEMENT .

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Region I Report No. 50-35U32-06__

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Docket No. 50-354 License No. CPPR-120 Priority --

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Category A Licensee: Publjc_ Service Electric and Gas Company 80 Park Plaza - 17C Newark, New Jersey 07101 Facility Name: H_ ope Creek Generating Station,_U}it f 1 f nspection at: Hancocks Bridge, New Jersey f nspection conducted: May 3 - 31, 1982 Inspectors: _ ._ Q

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, Ba man, n'or Resident Inspector i t f

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bdate signed A. A. Varela, Reactor Inspector date signed Approved by: /.[. Chief, Projects section 2A h 72-da'te signed

. E. Tri Inspection Summary:

Unit 1 Inspection of May 3-31, 1982 (Report No. 50-354/82-06):

Areas Inspected: Routine unannounced safety inspection by the resident inspector (87 hours0.00101 days <br />0.0242 hours <br />1.438492e-4 weeks <br />3.31035e-5 months <br />)

and one regional based specialist inspector (38 hours4.398148e-4 days <br />0.0106 hours <br />6.283069e-5 weeks <br />1.4459e-5 months <br />) of work in progress including

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l reactor pressure vessel internals installation, service water intake structure (SWIS)

foundation construction, structural steel erection, pipe and hanger installation, maintenance and storage of equipment and materials in and adjacent to the power block, cable tray support installation, HVAC ductwork and support installation, handling and rigging of diesel generator, electrical penetration installation, and concrete pre-

placement activities. The inspectors also made tours of the site, reviewed licensee

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action on construction deficiency reports, inspected the welder qualification program, evaluated qualification records of a sampling of site QC personnel, and reviewed QC records of heave / settlement monitoring, bioshield high density concrete placement, and and SWIS tremie placement and corin Results: No items of noncompliance were identifie Region 1 Form 12 (Rev April 77) 8206240213 820610 PDR ADOCK 05000354 0 PDR I

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DETAILS 1. Persons Contacted Public Service Electric and Gas Company (PSE&G)

A. Barnabei, Site QA Engineer R. Bravo, Principal Construction Engineer G. Dalton, Senior Construction Engineer A. E. Giardino, Project QA Engineer P. Kudless, Project Construction Manager G. Owen, Principal Construction Engineer j,

Bechtel Power Corporation (Bechtel)

B. Bain, Lead Welding Engineer J. Benner, Contract Administration A. J. Bryan, Assistant Project QC Engineer C. Colletto, Assistant Lead QCE - Civil W. Dorman, Assistant Project Field Engineer M. Drucker, Lead Site QA Engineer R. Hanks, Project QC Engineer M. Henry, Project Field Engineer D. Long, Project Superintendent R. Mackey, Resident Project Engineer J. R. McCoy, Lead Contracts QC Engineer K. Mills, Lead QCE Mechanical G. Moulton, Project QA Engineer D. Sakers, Assistant Project QC Engineer J. Serafin, Assistant Project Field Engineer D. Stover, Project Superintendent, Contract Administration S. Vezendy, Lead Welding QC Engineer General Electric Installation and Services Engineering (GEI&SE)

R. Burke, Site-Project Manager M. Hart, Site QC-Supervisor General Electric Nuclear Energy Business Operations (GENEB0)

J. Cockrof t, Site Engineer C. Brinson, Site QA Engineer J. Rich Steers (JRS)

J. Gagliano, Field Engineer T. Hughes, Site Project Superintendent M. Russell, Site QC Supervisor J. Saums, Sponser Engineer

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W-H Constructors (W-H)

R. Garvey, Site Project Manager S. Herschman, Corporate QA Manager M. Wita, Site QC Manager Site Tour Routine inspections were made to observe the status of work and construction activities in progress. The inspector noted the presence of and interviewed QC and construction personnel. Inspection personnel were observed performing required inspections and those interviewed were knowledgeable in their work activities. Work items were examined for obvious defects or noncompliance with regulatory requirements or license conditions. Areas inspected included structural steel erection, maintenance and storage of equipment and materials in and adjacent to the power block, cable tray and support installation, HVAC ductwork and support installation, housekeeping and fire protection, and con-crete preplacement preparation No items of noncompliance were identifie . Review of Nonroutine Events Reported by the Licensee On April 7,1982, the licensee reported a potential significant con-struction deficiency in accordance with the requirements of 10 CFR 50.55(e) involving deflected main steam line bellows assemblies. These bellows form the containment pressure boundary where the steam lines pass out of containment. On May 6, 1982, the licensee notified the NRC that their evaluation of the deflection of the bellows indicated that the problem was not reportable and withdrew the ite The deflection of three bellows resulted from deflection of the process pipes to which one end of each bellows was attached. The deflection of I two process pipes was caused by improper installation of pipe support steel. The deflection of a third bellows resulted from moving the pro-cess pipe while the bellows was independently supported. The problem was identified by comparison of survey readings taken at different times

to ensure the correct location of the process pipes. The bellows, de-

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signed and manufactured by Zallea Brothers, Inc., were limited in the amount of deflection they could withstand without jeopardizing their integrity, i

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Because the limit on the amount of bellows deflection was not known with any certainty at the time the problem was identified, the licensee reported it as a potential construction deficiency. Subsequent evalua-tion of the bellows deflection limit was performed by Zallea Brothers, Bechtel, and the licensee and the results indicated that the Hope Creek bellows were not deflected beyond design limits and that the problem, had it gone undetected would not have jeopardized the safe operation of the plant. As a result the licensee withdrew the potentially reportable ite The inspector observed the deflected bellows and portions of the activities to restore them to the correct configuration and reviewed the correspon-dence addressing this problem. The inspector concurs with the licensee's withdrawa (354/82-00-01) On July 17, 1981, the licensee reported a significant construction defi-ciency in accordance with the requirements of 10 CFR 50.55(e) involving Varglass tie wrap slippage and unraveling that could result in hindering safety related relay operation in GE supplied motor control centers. In a licensee letter dated 8/17/81, it was stated that a silicone sealer would be applied at the tie wrap knot and also between the knot and the cable to prevent unraveling and slippag The inspector's efforts to close out this item disclosed that a fix different from that described in the licensee's letter was in proces The new fix involved replacing the Varglass tie wraps with Tefzel tie wraps. The inspector requested the licensee send a letter to the NRC

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noting the change in solution of the tie wrap problem. By letter dated _

5/21/82, the licensee informed the NRC of their revised plan This item remains open pending qualification of the Tefzel tie wrap and replacement of the Varglass tie wraps with Tefzel tie wrap . Reactor Vessel Internals - Observation of Work Activities and Review of Procedures During this inspection report period the shroud to shroud support weld was nearly completed. The post weld as-built condition of the shroud was satisfactory to GENE 80. Welding of the incore instrument housings to their stub tubes commenced. The weld processes used to accomplish this weld included initial root passes by GTAW and balance of passes by SMAW. Filler metal used was inconel. The inspector witnessed welding and inspection activities of the incore housing welding. Locating, bolting, and torquing of the core support plate also commenced during this report perio _ _ _ - _ _ _ _ - .

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1 The inspector reviewed the following documents relative to welding of the incore instrument housings:

-- ASME Section IX, 1974 Edition through Winter of 1974 Addenda

-- GEI&SE WPS HC40090, Rev. 1

-- GEI&SE PQR ISE-PQ-401, Rev. 1

-- GEI&SE Mockup Procedure 15 MU-1, Rev. 3, Incore to Vessel Mockup Requirements

-- gel &SE SDDR #43

-- GENEB0 FDDR #KT1-114, Rev. O

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-- GEI&SE Traveler HCI-14-T, Installation of the Incore Housings

-- GEI&SE JPCS's HCI-14-J-XXYY (XXYY corresponds to incore housing i position - there are 55 housings)

-- GEI&SE WPS HC5001W, Rev. 5

-- gel &SE PQR ISE-PQ-504

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GEI&SE PQR ISE-PQ-418 f --

GENEB0 Dwg. 197R628, Rev. 12

-- GENEB0 Welding Specification 22A4202

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The work and inspection status of each of the 55 incore housings is coor-i dinated through a single traveler and 55 associated Joint Process Control l Sheets (JPCS's). The inspector noted that this system was being effectively implemented to maintain a current inspection status of all the incore housing welds. Review of the balance of the documentation disclosed the following two problems:

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(1) WPS HC40090, Rev. I was the weld procedure specification (WPS)

for the incore housing welds. This WPS referenced procedure qualification record (PQR) ISE-PQ-401. Review of this PQR in-dicated that it was not sufficient to qualify the WPS. The dis-crepancy involved GTAW maximum thickness qualified. The WPS stated the GTAW process could be used to deposit up to k" of weld metal but the PQR only qualified the WPS up to 1/8" based on ASME IX rule When the inspector pointed this discrepancy out to GEI&SE, they identified PQR ISE-PQ-418 which qualified the GTAW process to beyond 2" thickness. The inspector stated that this PQR should be referenced on the WPS to qualify the WPS. The appropriate revision was made to WPS HC4009D prior to the end of this report period. The inspector had no further questions on this issu (2) GENEB0 Weld Specification 22A4202 required a mockup weld for the incore housings. This requirement was specified to be a site mockup not a welder qualification mockup. However, in GEI&SE procedure 15MU-1, Rev. 3, Incore to Vessel Mockup Requirements, paragraph 4.6 required each welder to complete one incore housing weld joint and the weld to pass liquid penetrant testing at three different stages of weld completion. The inspector reviewed the qualification records for each welder who had welded on the incore housings and detennined that one of the three welders was not qualified in accordance with paragraph 4.6 of 15MU-1. In particular the liquid penetrant testing had not been performed on his incore housing mockup wel The inspector pointed this discrepancy out to GEI&SE and the li-censee. In ensuing discussions, it was agreed that the need for individual welder qualification for these welds was not required by 22A4202 nor was it dictated by conditions of limited accessibilit Consequently,15MU-1 was revised to delete the requirement for in-dividual welder qualification. The inspector had no further questions on this issue.

No items of noncompliance were identifie . . . _ . - . - - . - _ - . _- - - _ . - .

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I Safety Related Components - Observation of Work and Work Activities During this inspection report period the first diesel generator (DG) arrived by barge. The unit was transported to the diesel generator building entrance and rigged from there into its cell on the 102' elevation. The inspector witnessed the various handling and rigging methods used to move the DG into its permanent plant location. The inspector also questioned involved crafts and supervision as to their knowledge of rigging techniques used. Additionally, the inspector inspected the DG for evidence of shipping or rigging damage and identified none. The rigging operation was accomplished in a professional manner with no major problem No items of noncompliance were identifie . Reactor Coolant Pressure Boundary Piping - Observation of Work and Work Activities

The inspector observed welding activities associated with the field connection of recirculation loop B piping to the reactor pressure vessel (RPV) safe-end

, nozzle. This was the second piping connection welded to the RPV. The pipe material was stainless steel, therefore, a purge was require Purge dam material was installed in two locations to form the purge boundarie In particular the inspector witnessed portions of the following activities:

-- Fitup and tack of spool to recirc pipe,

-- Installation of alignment blocks to prevent distortion of the weld groove due to shrinkage,

-- Establishment of purge,

! -- Weldout of root by TIG proces Weldout of joint by SMAW process,

-- QC inspection of welding activities,

-- Control of weld shrinkage at joint between one end of the spool I

to recirc piping to effect fitup of other end of spool to RPV safe-end, and

-- Weldout of joint between spool and safe-end.

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The inspector also reviewed the QCIR's for each joint and the filler metal issue slip No items of noncompliance were identifie . Safety Related Piping and Supports - Observation of Work and Work Activities The inspector observed work in progress and completed work of safety related pipe welds. The particular attributes checked were proper fitup, use of qualified welders for tacking and welding, any obvious weld defects such as undercut, overgrind, excessive reinforcement, and arc strikes; existence of an approved QCIR adjacent to the joint being welded; sequential signoff of QCIR as work completed; and presence of QC personnel in the work area It was also verified that the requirements stated on the QCIR's such as type of filler material, weld procedure, and NDE were being adhered t The inspector also observed work in progress and completed work on safety related pipe supports. The particular attributes inspected included weld quality, attachment point to safety related steel or concrete structure, blocks installed in spring hangers, correct size of threaded rod, support spacing, completeness of hanger assembly including full thread engagement of nuts and use of proper nut locking arrangements, application of ASME III Subsection NF Code stamp, shear lugs present where required, interference problems, and location of hanger clamps.on pipe to ensure field and shop'

welds not obstructe No items of noncompliance were identifie . Qualification of Inspection Personnel NRC inspection reports 80-20, 81-02, and 81-09 discussed qualification of QC personnel. These reports expressed concern for the potential of diluting the overall capability of the QC department that could result from stretching the related experience requirements when hiring new QC personnel.. Since

NRC Inspection Report 81-09 the Bechtel QC department has increased in size by approximately 25% and has experienced personnel turnover. Additionally, JRS and W-H started safety related activities that required quality control inspection. Based on augmentation and turnover in site QC personnel, the inspector performed a review of QC personnel qualification records for '

Bechtel and JRS QC inspector .

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Prior to commencement of the QC personnel qualification review, the in-spector compared the requirements for QC personnel qualification contained in the Bechtel Construction Quality Control Manual, Rev. 2 with those im-posed by NRC Generic Letter 81-01. Generic Letter'81-01 imposed Revision 1 to USNRC Regulatory Guide 1.58 which endorsed, with some qualifiers, the 1978 revision to ANSI Standard N45.2.6, Qualification of Inspection, Ex-cmination, and Testing Personnel for Construction., This comparison in-dicated that the written Bechtel program was consistent with the latest NRC requirements. The inspector proceeded to review the training /qualifi-

, cation records for thirteen Bechtel QC personnel whose records had not previously

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been reviewed by NRC inspectors. Individuals were selected at random from each of the major QC technical disciplines. -This review indicated that Bechtel is continuing its efforts to hire and train experienced personne The combination of a substantial amount of previously related experience and intensive onsite training in both jobsite practices and technical disci-plines, demonstrates that the Bechtel QC qualification program meets regula-tory requirement A similar review of JRS was conducted. It was evident from this review that JRS QC personnel were also qualified in accordance with regulatory require-ment No items of noncompliance were identifie . Service Water Intake Structure (SWIS) - Observation of Work and Work Activities and Review of Quality Records The inspector performed the .following activities during an inspection of JRS in process and completed construction work:

(1) Observation of Basemat Preparation The inspector observed these activities within the dewatered cofferdam and evaluated against criteria established in the PSAR, engineering specifications, applicable drawings, and. industry codes and standards:

-- control of water leakage between sheet piling

-- high pressure water-jet removal of laitence at top surface of tremie concrete .

-- concrete chipping of tremie mounds

-- level course concrete application

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-- reinforcing steel i'nstallation rr.:

-- fonnwork installation _

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-- quality controlfinspection and documentation of above y ,.

-- subcontract surveillance by Bechtel of above (2) Quality Control Record, Review of Tremie Ccncrete' and Preparations

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for Basemat g The inspector reviewed ,JRS's QC, records pertaining to prepara-tions, placement and post-placen,ent activities of the tremie concrete / cofferdam sea) and the, foundation shear key incorporated in the tremie. .The follcWing QC records were reviewed and evalu-ated for conformance to rejuirements contained in JRS QA manual and QC inspection procedures:.

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-- final soundings and approval of contour for shear key ,

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-- concrete b'atch plant onaterials and mix qualificatien batching, m,ixing, delivery, testing and placing c

-- surveillance of subc3ntract batch plant operations t

-- documentation [ot/ coberete volume, placement method, and concrete testing (durfng five days of c'ontinuous s operation) 3

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J s post-placement core drilling through the tremie atfive locations preservation of cores ,,

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clean-upandhighspotremovaloftremietopsurface} (".

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-- surveys for heave / settlement' of SWIS foundation

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-- documer.tationbyh.kS ofsand disposition ef NCR's by Bechtel *

on trcitie concretA I " t

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batch plant records / truck tickets of concNete mix' ingredient weights from each of two plants jN  ;

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-- laboratory concrete inspection data sheets

-- tremie concrete test cylinder 28 day compression tests

-- Bechtel surveillance of JRS's implementation of in-spection program and JRS's monitoring of their sub-contractor's QA/QC programs The inspector observed above records to be legible, readily re-trievable, properly reviewed and approved. Where test equipment was used, the instrument number and calibration status was identified and the ASNT-TC-1A level of technician give (3) Reinforcing Steel for Basemat- Record Review The inspector observed in his review of QC records that three shipments of reinforcing steel from Bethlehem Steel received by JRS at the site were properly identified and accompanied by Bethlehem Steel's certified reports and confirmatory tests of conformance to requirements of ASTM A-615-75 However, Bechtel Specification C-200,Section II requires a Bechtel supplier quality representative (SQR) at the supplier plant to witness and verify shipments for release. Reinforcing steel received by JRS at site on April 27, 28 and May 20 were not accompanied by a release and Bechtel and JRS's QC documentation records.were lacking in evidence that mill test reports were reviewed by Bechtel's SQR prior to shipment to the jobsite. Upon questioning this apparent discrepancy, the NRC inspector was shown a waiver granted JRS by Bechtel dated April 15, which permitted shipping the above reinforcing steel without a signed release. However, this waiver was not translated into a formal reruirement to review the mill test reports at some other tim Prior to the end of this inspection report period, SDDR #23 was written to fonnally identify the waiver and to require onsite inspection of the mill test report The inspector had no further questions based on the following rationale:

-- Prior to JRS's purchase from Bethlehem Steel, Bechtel had a SQR at Steelton for their own purchases. A portion of his responsibility was to witness tests, verify mill test reports, and sign releases. Historically, there have been few problem _ _ _ _ _ _ . - - _ _ _ _ _ _ _ _ _ _ - _ - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

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-- JRS fullfilled the requirement of their approved QA Manual which pennitted the option of source surveillance at supplier or audit of supplier QA program. JRS performed the audit and approved Bethlehem Reinforcing Steel QA program on April 19, 198 No items of noncompliance were identifie . Upper Biological Shield High Density Concrete Grout Placement - Review of Records The NRC inspector perfonned a detailed review of quality documentation and evaluated QC records generated prior to, during, and after placement of 170 cubic yards of high density grout by pressure pumping into the upper biological shield (bioshield).

Because of the c itical aspects of this placement, in particular the im-portance of complete fill for radiation protection, FCR-C-6912 was generated to implement special requirements for placing, forming, finishing, curing, and testing the high density concrete. This review included interviews with QC inspectors, construction and project engineers and laboratory technician The following QC records were included in the inspectofs review and evaluation of conformance to industry codes and standards, engineering specifications /

drawings, and FCR-C-6912:

-- Qualification of grout ingredients, including mix proportions and laboratory tests on trial batches

-- Preplanning and preparation per Specific Work Plan / Procedure SWP/P #C-5959: drawing references, equipment / manpower, pumping scheme, controls, and data sheets establishing responsibilities

-- QC sign-off on prerequisites, in-process inspection activities, l

curing, final inspection activities and review of supplementary records on curing, batch plant / truck delivery tickets and test laboratory reports l

-- The NRC inspector verified the above supplementary records to con-

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firm adequacy of QC sign-of No items of noncompliance were identified.

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1 1 Heave / Settlement Monitoring Program - Power Block Buildings - Review of Annual Reports

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The NRC inspector reviewed annual heave / settlement measurement reports.

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(Previous NRC Inspection Reports discussing the monitoring program are 80-01 for 1978 and '79 and 80-13 for the period up to March 1980.)

Update plots of observed load / settlements for five power block basemats up to February 1982 were reviewed. Comparison plots for the differential settlement between adjacent power block basemats have been evaluated by Bechtel and found acceptable. A review of the plots by the NRC inspector confirmed Bechtel evaluation that settlements are leveling of Bechtel concludes present settlements are within the limits of desig The inspector had no further question . The inspectors met with licensee and contractor personnel during this inspection report period at which time they summarized the scope and

findings of their inspection activities.

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