ML20044C475
| ML20044C475 | |
| Person / Time | |
|---|---|
| Site: | Brunswick  |
| Issue date: | 02/12/1973 |
| From: | Mcfarland C NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | Long F NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| Shared Package | |
| ML20044C467 | List: |
| References | |
| FOIA-92-569 NUDOCS 9303230094 | |
| Download: ML20044C475 (13) | |
See also: IR 05000324/1973002
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F. J. Imag, Chiaf, Facilities Construction Branch, Directorata of
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Regulatory Operations, Region II
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INSFECTION OUTLINE - CAROLINA POWER AND UGHT C(3(PANY, BRUNSWIQt STEAM
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ELECTRIC PIANT, UNITS 1 AND 2, DOCKET NOS. 50-324 AND 50-325, UCENSE
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NOS. CFFR-67 AND CPPR-68
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Previous Inspection: January 9-12, 1973
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Report Moe.: This outline refers to 10 Report Nos. 50-324/73-2 and
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'50-325/73-2.
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Dates of Inspection: February 21-23, 1973
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Inspection Personnel:
C. R. McFarland - Principal Inspector
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it. D. Kalley
- Reactor Inspector
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Priority of Effort
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Bond to review the QA program implanantation, QC systems and records and
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to observe work related to'the reactor coolant piping systems, reactor
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vessels, and other a r ts.
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Brown and Root annasensat.
Need to determina effectiveness of new
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Need to determine status of work on Inquiry l
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Raport No. 50-324/73-1
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of special processes -Q/CDR and 50-325/73-1Q/CDR - suspect lack of control,
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jet pump adaptor weld defects. Priority of work
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to Unit 2 first.
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C. R. McFarland.Section I and II of tbs Final Report
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Progress of construction
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QA/QC program activities
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F 5005.03, and .04'
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C 5105.04, 4805.04
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K 4905.04, b.9 e.4
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L 4905.34 Supplaamat 1
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Status of inquiry report and activities
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Status of outsem= Mag items
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.9303230094 930202
O 'PMEALI92-569 PDR
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F. J. Imag
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W. D. Es11ey.Section II of Final Report
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1.
Observation of work on Reactor Coolant Pressure Boundary Piping.
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F 5005.05, 5005.06
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Observation of work on other Cimes I Fiping
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C 5005.05, 5005.06, 4805.05
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Observation of work on Vessel Internals
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K 4905.06 a.2.4, b.1.2
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5505.06 a. and b.
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Observation of work on other Class I composants
L 4905.05, 4905.06
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Work on Unit 2 before Unit 1.
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C. R. McFarland, Ranctor Inspector
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Facilities Section, Facilities Construction
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Branch
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DATE > t.2 M M .......... 2l....l M
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Form AlC-318 (Rev.9 53) AECM 0240
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REGION II
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FEEDER INSPECTION RIPORT IDENTIFICATION SHEET
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REPORT NO.
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TO:
W. A. Crossman, Acting Senior Inspector, Facilities Section,
Facilities Construction Branch
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Licensee:
Carolina Power and Light Company
Inspect 3cn DatesFeb. 21-23, 1973 l
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Southport, North Carolina
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Brunswick 1 and 2
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Other Inspectors
W. D. Kelley, Engineering'Section
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Feeder Report Prepared By:
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C. R..McFarland, Facilities Section
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Inspector's Evaluation (continue on attached sheet,'. if necessary)
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No items of direct safety concern were identified. No unusual information
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items were identified. No information was identified that should be included
in the letter to the licensee of items other than those in the Summary of
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Findings.
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Currently Unit.1 is expected to be delayed six montlis; the same six months
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delay that Unit ~2' ha.s experienced (as reported in 50-325/73-1). Unit 2
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scheduletmay ' slip .some inore .due to management problems and a lack of, pro-
d,uctivity by the crafts. Unit I need not incur a day for day. slip of Unit'2, ,
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however, management for constructica'and for startup and test.will need to-
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be more diligent and efficient;than at present,to minimize"further del'ays.
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Second shif t coristruction work. could be applied, to Brunswick 2 and 1.if
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'ad4qua'te canagementkwde avail'able, or overtime could be audorized 'to '
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expedit'e construction. The CP&L economics will push for early completion
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of Units 2 and 1; electric power demand will probably come earlier than
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planned. Scheduling of R0 inspections will need to be frequent in 1973
to monitor the effectiveness of the CP&L and B&R programs.
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The attached Feeder Inspection Documentation is transmitted in reviewed and
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approved form.
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Comments:
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Fr.cilitier Censtructica Dranch
Lates J nsmetion: Febntary 22 - 23, 107:
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APR 111973
22Vic'.zcd Ly:
,,U. i.. C w':ar.cno . i.ct2 r c' Funior
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Inn ccLer, l'ncilitier Ecction
racilitier Construction Er: inch
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7.11.1:.f or -tica in t'to 6::tnils nnplien ccually to Tre.r.cTd ci: 1 nna 2 c:: cent
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' c f rc :..n n r: .riec in itin' ified '.:ith a cr ecific reactor.
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C- -~: 1 ! : : T- &cr ::.#
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,er - P.Onident P:r,'incer
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F.. Ct..:.:t n - N C; c:11:.lic t
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E.c.m r.r' Pent, Tr:c. C '_ r." .). .
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I'r.o--i ; e.t Stre u..s
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71.2 re:. c .nt es pletic n of civil 7:nd nrel itectual engineering featurcs at
of 0:nuny ::,1973, tas reyorted to 1 e os ic11cr.:n:
Iten
Un.it 1
Unit 2
l'le16 CLnstn:ction
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Etr::r aral Tt : 21
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Con c.~: to
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P2.r t ; w n.cical
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RO Rpt. Nos. 50-325/73-2
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The site preparation is 86% complete; the excavational backfill is 97%
complete. Work is continuing in all activities.
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The percentages reflect the changes in schedule reported in the report
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of the previous visit (50-324/73-1 and 50-325/73-1).
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The initial commercial operation of Unit 2 is scheduled for December 1974,
and appIcximately one year later for Unit 1.
The CP&L electric power
systems need has not been deferred; hence, efforts may be expected to be
made to accelerate the schedules for either or both units.
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.The ~epair of the jet pump adaptors is scheduled to be completed about
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April 15, 1973, for Unit'2 and June 2 for Unit 1.
The effect of this
repair work on the project schedule has not been assessed to date.
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Other construction work in January included welding the biological shield
wall plates in No. I reactor; setting of acid and caustic storage tanks;
continued installation of service water pumps in the service water in-
take building; assembling the 125-ton Whiting crane for reactor building
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No. 23 continued installation of makeup water system equipment in the.
water treatment building; setting beams for No. 2 main transformer;
cleaning condenser tube sheets in Unit 1 condenser; and energizing of
unit substation 4L for permanent lighting of the office building.
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3.
Personnel or Organizational Changes
The project reorganization of the project staff for B&R reported in
50-324/73-1 and 50-325/73-1 has been put into effect.
A. M. Barnes,
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is the Project Manager and J. Dodd is the Assistant Project Manager.
W. L. West, Jr., the B&R QA Manager, has also reorganized the QA staff
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since the last inspection. Senior inspectors have been added for welding
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(F. Creamer) and for electrical (J. Hamilton) . Recruiting is_in progress
to replace recent terminations.
United Engineers and Constructors, Inc.,
(UE&C) , hac added a QA Specialist, T. Halocki.
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The onsite QA staff for the project has increased to 76 persons: CP&L - 8,
B&R - 42, UE&C - 2; Law Engineering - 21, D'Appolonia - 3.
4.
QA/QC Program Activities
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The QA/QC program activities of CP&L and B&R appear to be well documented.
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CP&L weekly reports of onsite activities as reported by R. Coburn to
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W. B. Kincaid, Vice. President, Power Plant Engineering and Construction,
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were reviewed for the periods of January 13 '.hrough February 16, 1973
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(No. 97 through No. 101). Numerous activities reported were discussed with
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R. Coburn and with W. West, B&R QA Manager. Backup information was
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readily made available and discussed. Onsite QA meetings are routinely
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conducted with CP&L, B&R QA, B&R Construction, G-E and UE&C on all open
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items and new problem areas.
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Jet Pump Adaptors
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Deficiency Disposition Reports (DDR's) were written for the unac-
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ceptable welding of the jet pump adaptors to the shroud supports
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for both reactors. S. Kaiser from Huntington Alloy was used as an
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advisor for the original procedure (October 1972) as well as for
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,the evaluation of the replacement repair procedure. Materials
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samples have been cut from welds from each reactor and sent to
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G-E San Jose for analysis. CP&L and B&R have met with G-E and a
program has been developed to cut out all adaptors (20 in each of
the two reactors), machine out the original weld material, reweld
using a new procedure, and require more QA/QC activities.-
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B&R has contracted for a welding consultant, K. Spicer, to work
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on the jet pump adaptor welding problem and other welding problems.
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J. Ferrel, a B&R lielding Engineer, will work' with K. Spicer.
B. Coleman, B&R, Houston, will witness the replacement repair
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welding of the jet pump adaptors.
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The adaptors have been cut out of the reactors and the weld material
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is being removed from the shroud plates and the adaptors,
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Cadwell Program
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The B&R report of the data for the Cadweld program problems has been
sent to UE&C. The B&R report is a review of 28,990 Cadweld inspection
records dated from May 1970 thmugh July 1972. The report includes
data relative to concrete plac.c. ment checklists noting QA signoff,
concrete placement checklists with added Cadweld items signed
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off for engineering and for cone truc-tion, the QC procedures for the
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Cadweld inspection.and testing, the field procedure for rebar splicing,
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and the Cadweld record summary. The report categorizes the Cadweld
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data that has derived data, Category B, and that which does not nave
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complete or suitable inspection documentation, Category C.
The CP&L
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onsite gC specialist thinks the report adequately provides for the
concerns discussed at our January inspection (50-324/73-1 and 50-324/
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73-1).
CP&L expects the UE&C report to analyze the above data and to
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present an integrated report for CP&L transmitted to RO.
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DDR File
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2he file of open B&R DDR's issued since January 16, 1973 was re-
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viewed (No. 305, January 16, 1973, through No. 360, February 13, 1973).
B&R actions on these items and CP&L's monitoring of these items were
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discussed for representative, significant problems and no further
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. questions were deemed appropriate at this time. The status of the
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open DDR's is reported to CP&L Raleigh, and management interest is
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evident.
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d.
Torus Concrete Encasement
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The need to repair voids in the torus concrete encasements for both
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reactors was written as a DDR May 5,1971; however, the current
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actions indicate that in the near future, epoxy grouting is to be
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used to fill the voids in the concrete. B&R QA has inspected the
epoxy manufacturer.
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The CP&L QA surve.;illance memoranda issued since the last inspection
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(January 23 through February 19, 1973) were reviewed and no further
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questions were det.med appropriate at this time. The surveillance
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memorandum of January 23 notes that B&R has not performed a wa'.i-
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through inspection of the work since April 17, 1972. This was
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previously reported in a surveillance memorandum dated December 21,
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1972. Walk-through inspections are expected to be performed about
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once per month per paragraph 4.10 of B&R QCP-1 per information in
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the January 23, 1973, surveillance memorandum.
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B&R Houston Audit
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B&R, Houston, conducted quarterly audit No'.11 of the Brunswick
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facilities on January 33 and February 1, 1973. They audited tha
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shop fabricated piping, the isometric drawings, and various fiel;
areas were checked against the isometric. B&R will issue a formal
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report of the audit.
Subsequent audits are to be conducted every
four to six weeks.
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Deep Bed Demineralirer Tanks
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The supports for some of the deep bed demineralizer tanks made by
Graver have been repaired. The state boiler inspector reviewed the
procedures, the qualification of the personnel, and the work
accomplishe.i.
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RO Rpt..Nos. 50-325/73-2
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Status of Incuiry Report Jet Pump Adaptor Repair
CP&L will provide to RO by February 28 an interim report of their
assessment of the problems related to the welding of the jet pump
adaptors to the RPV shroud supports plates for Units 1 and 2 and their
corrective activities and work to date as required by 10 CFR 50.55(e).
CP&L informed RO:II of the deficiencies on January 29 and 30.
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Inquiry Report Nos. 50-324/73-1Q/CDR and 50-325/73-1Q/CDR was issued
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February 5 and reports the preliminary information. Work to date is
reported above in item 4.a.
(The CP&1. interim report dated February 27
has been received.)
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DET&TTA II
Prepared by:
w. D. Kelley, menctor Inspector
Date
W-ring Section, Facilities
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constrootion Brand
""*** *""'******' '*****Yjl'i'dt273
gg 111973
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J. C. Bryant, Senior Inspector
Data
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Enf naaring Section, Facilities
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construction tren&
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All information in the details applies equally to arenavid 1 and 2 escept
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where information is identified with a spoeifie saaeter.
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Individuals contacted
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Carollma Pouer and Li6t Company (@aL)
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F. R. Coburn - QC Specialist
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W. W. Phillips - QC Smahmtetam
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contreeter oms-imm t-
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(1) asown and meet, Ime. (saR)
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J. Dodd - Assistant Psoject manager
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w. L. umst, Jr. - Pse$ect Qa manager
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A. E an=ma, Jr. - Melding Superintendent
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W. S. Oismi - 91 melding *--8
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(2) United angineers and constzweters, Ime. (craC)
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2.
corroetive Aetien mot completed om Welding Procedures
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B0 toport uns. 50-325/72-2, 50-325/72-4, and 50-324/72-4 disones BaR
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welding PW- which safesemoed and rolled spaa General Electric
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Company (0-B) welding desuments ser ones acceptability. This.was
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listed as a violaties alman the 0-E psocedere udght have beam & anged
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at any time without tar kaawledge or approval. This item was resolved
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whom BaR esmeral us1 ding Instruction SP-45 was writtaa to ampleos
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the 0-E welding document.
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on the serment inspection, it was found that welding was belag per-
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Bormed am safety systene. piping using the procedure attid zeferomeed
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the O-E document since SP-45 still has not roosived proper approval.
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Failure to marry out the specified corrective action prior to welding
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_ on sasety system piping is considered to be a violation of 10 CFR 50,
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appendia 3, Criterien IFI, " Corrective Action.'
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ED Ept. Nos. 50-325/73-2
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and 50-324/73-2
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3.
Mangers cui systees Piping
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During a previces inspection (ED moport No. 50-324/72-4), the
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inspector identified igroper bolts installed in the main steam
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piping hangers. CPEL e6esquently issued a surveillance memo-
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randen (SIO requiring sa to take oc_wwe actiemi. The
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ED inspector's am81t of the St revealed that it was' closed een
sat isoned a deviation disposition report (EDR) requirlag a QC
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inspection of all main steam piping hangere. The 0C inspection
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revealed that the hanger vendor had swplied the wrong clevis for
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one hanger and the installed clevis bolts in some cases were either
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undereimod, short or had the threaded portion loaded in ahear.
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seither CP&L nor B&R had Wted, onepletely, corrective
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action for all of their findings.
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Dua to the MmMags of the QC inspection en the main steam
piping hangers, CP&L issued another SM Esquiring that all
eafety system piping hangers engineered by maC be field checked .
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by BaR to determine that they were erected im soonedance with
the hanger drawings.
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The licemese. said that after the field docet of the safety
system piping hangers has been onopleted, an engineering
~ evalastian of the Mdv vill be unde and gn-Antieng
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will be ande, if necessary, of corrective action required to
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assure that the hangers are adequate for the servios. The
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evaluation will include the eccentric ph===nt of the eye
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bolt in the wide elevis and the clevis bolt thread problems
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in the main steam systas.
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b.
The hanger vendor shipped the spring hangers preloaded with-
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tegorary pins and bolts holding the springs in pleos. These
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tegorary pins and bolts had been identified with red paint
and had a warning tag attached stating that they were to be
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removed prior to the systens being placed in service. During
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erection, the warning tags were removed and the red paint was
covered over.
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The CP&L SM issued for the field dock of safety system hangers'.
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also required the fo11ering
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(1) The spring hanger temporary pins and bolts will be reidentified.
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(2) All L mory hangers will be identified in -a manner
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that een be readily detected from floor level and their
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zumcmal will be a checstpoint on the final systens checkout.
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no 3pt. mos. 50-325/73-2
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and 50-324/73-2
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coupletion of these actions will be verified on et W.t
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inspections,
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4.
Welding Asieetion Rate and Weldor Tutmover
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The BAR weld rejection rate was reported as being 964 based on
rejection of a weld if any repair is sequired. BER felt'that
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their rejection rate was Imer if based on linear inches of welding
hoeuver, BER is condocting a odool for their welders in an
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attaapt to reduon the number of weld repaire.
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During 1972, asR emperienced a welder turnover rate of 1974.
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The inspector told CPsL that the high rejoction of welds and the .
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high turnover. of weldors could have a serious impact on the
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quality of the welding on safety syntess. The licensee stated
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that he is aware of the problem and that it is his belief that the .
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R&R welder's school and the addities of a welding consultant and
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welding +an*=ician to the B&R site staff would overcome these
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problems.-
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S.
valve Deseos During manating - nait 2
Duria, a previous inspection (no moport so. 50-324/72-6) , the
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inspector identified a bent drain nipple on am EER valve. CPEL
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steequently issued-am sh requiring corrective action. On the.
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current inspection, the inspector foemd that the EM had hama
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cleoed out by a SSR ISR moporting repair of the nipple, follewed
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by dye penetrant osamination of the nipple and welds whid
revealed no creeks. The ED inspector said that he had no further
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questions en this item. valve damage during ha=AH ag 33 v31933
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ano moved into the buildings sentinues to plages the project.
A QC E7-^ien by ast is acer required Ser and valve before
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installation.
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6.
Overgrinding of EER Systes Bett Wolds - Ikilt 2
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During a previous inspection (30 Report Mo. 50-324/72-4) , the
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inspector identified overgrinding of ERR system piping butt
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welds. CP&L issued an SN requiring corrective acticut. . On the
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current inspecties, the inspoetor found that the ites had been
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closed by a B&R ISR reporting that 'the overground welds had -
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been ====4==4 and sepair welded as required.- 'rhe IDR stated
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that the welds had received WDf and near meet the requirements
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of the applicable piping ande, 331.1.0.
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ED a t. Nos. 50-325/73-2
II-4
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and 50-324/73-2
An audit of the II)R by the inspector revealed that their was
no reference to the weld procedure used for the repair. This
was brought to the attention of B&R, who revised their IIDR require-
monts to provide traceability of repair data.
In addition to repair of the overgrond welds, BER has instructed
the piping formann that over=4=^fng is a violation of the piping
code. Special wor $tmen have now been trained in proper grinding
- dahues and have been ar, signed to grinding butt welds.
h inspector has no further questiens on this stject.
7.
Main Steam Piping Spacer Material - Unit 2
During a pzuvious inspection (E Neport No. 50-324/72-4) , BAR
was mable to looste material certification for the spacer
material used in the main steam piping. CPEL issued an SN seguiring
BER to prv*ie= material certification.
An audit of the SM on the current inspection revealed that BAR
had located the meterial certification. CPSL verified that the
spacer material met Asps P-1 material requirements, and closed
the SN.
h inspooter has no further questions on the spacer
material.
8.
Piping htation haview
During the previous inspection (M Beport No. 50-324/72-4) , it
was found that CP&L had identified discrepancies in piping
documentation and had issued SN's requiring BsR to take corrective
action. Bak corrective action required the revision of their
Field Procedure F-33, :"Cantrol of Welding and Associated Processes,"
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to require a complete check of all piping data. h procedure
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required BER QC to log, on a checklist, all data before the data.
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are placed in the permanent. document file.
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BAR is in the proosse of reviewing all piping documentation,
system by system, and correcting document errors. h inspector
audited BER piping document files that had been corrected and
fomo no discrepancies. h OsL EM will continue to be open
until all system dan ===tation is corrected.
9.
Welding Documentation Revier
Due to errors found by asL and the piping documentation review,
a new weld data card was developed and placed in use when B&R
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E 3pt. Mos. 50-325/73-2
II-5
and 50-324/73-2
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Field Psocedure F-33 was revised. The data formerly recorded
on other forms are now recorded on the new weld data cards. B&R
QC mow cheds and logs on a dedlist all weld data before the
data are placed in a permanent document file.
Use of the new weld data cards was audited by the inspector and
no discrepancies were found.
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no:II
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scaryant
4/11/73
4/ /73
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