U.S. NUCLEAR .5~ OF · 2020. 12. 6. · U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION ANO ENFORCEMENT Region I 5.5~ 5-388/78-13 License No.CPPR-101 CPPR-102 Prior ity Licensee:

U.S. NUCLEAR REGULATORY COMMISSIONOFFICE OF INSPECTION ANO ENFORCEMENT

Region I

5 .5~5

-388/78-13

License No.CPPR-101 CPPR-102 Prior ityLicensee: Penns lvania P wer and Li ht Com an

Category A

2 North Ninth Street

Allentown Penns lvania 18101

Facility Name: Sus uehanna Steam Electric Station, Units 1 and 2

Inspection at: Berwick, Pennsylvania

Inspection conducted: August 21-September 21, 1978

Inspector : . al. M. Gallo, 'i nt Reactor Inspector date signed

date signed

date signed

y/R. W. McGaughy, ef Projects Section, dat si neds gnedReactor Construction and Engineering SupportBranch

Ins ection Summar :Ins ections on Au ust 21-Se tember 21 1978 Re ort Nos. 50-387 78-15 and 50-388 78-13

Approved by:

Unit 1 and Common, Areas Ins ected: Routine inspection by the resident inspector of workactivities relative to: installation and welding of reactor coolant pressure boundary andother piping; installation of reactor vessel internals; storage of reactor vessel 8 internals; site calibration control; and Spray Pond concrete placements. The inspector alsoperformed plant tours and revierled licensee action on previously identified items. Theinspection involved 87 inspector-hours by the NRC resident inspector.Results: Of the six areas inspected, no items of noncompliance were identified in four ..areas; two apparent items of noncompliance were identified in two areas. (Infraction-fai 1ure to qualify welders for the welding process in use-Paragraph 7.c.(2); Infraction- fail-ure to use specified curing compound for Spray Pond-Paragraph 9.b.)Unit 2 Areas Ins ected: Routine inspection by the resident. inspector of work activities relative to: installation and welding of reactor coolant pressure boundary piping; handling

d storage of reactor, vessel internals;Rand storage of reactor vessel. The inspector al-performed plant tours and reviewed licensee action on previously identified items. The

nspection involved 28 inspector-hours by the NRC resident inspector.Results: No items of noncompliance were identified.1Feg>on 1 Form 12(Rev. April 77)

DETAILS

Persons Contacted

Penns lvania Power and Li ht Com an

L.R.E.J.H.R.A.

Ballard, Site QAEBeckley, Site QAECarroll,, Site QAEGreen, Resident NQA 1/2/3/4/5Harris, Protect Construction ManagerPrego, Site QAER. Sabol, Manager, Nuclear Quality Assurance

Bechtel Cor oration

Y.M.J.P.D.K.R.M.G.H.J.J.A.R.H.K.E.J.J.H.J.A.

Ananda, Civil QAEK. Boone, Lead. Welding EngineerA. Dahnert, QC Engineer-PipingR. Delorme, Welding EngineerDharia, Subcontracts EngineerDurland, QC Engineer-WeldingDrake, Superintendent-Night ShiftA. Drucker, Electrican QAE 2/3/4/5Gelinas, QC Lead Engineer Piping/MechanicalGoodvin, QC Engineer-CivilHoagland, Construction AssistantKhandar, Mechanical OAEKontura, Mechanical QAELamb, QC Assistant Lead Engineer-WeldingLilligh, Project QAE 1/3/5Stout, Assistant Project Field Quality Control Engineer 2/5Strzelecki, QC Lead Engineer InstrumentationVan Omen, Subcontractor Administrator 5Vidunas, QC Lead Engineer ReceivingOman,. Field Engineer Storage and MaintenanceO'ullivan, Assistant Project Field Engineer 3Spielhagen, Project Field Engineer 2

General Electric, Com an Nuclear Ener Division NED

E.T.R.

A. Gustafson, Site Manager 2M. LeVasseur, QC Representative 2/5M. Pulsifier, Mechanical Engineer

Installation and Service En ineerin IPSE -Reactor Internals

F. Forsythe, Si te ManagerD. Hess, QC EngineerT. Sartain, Welding Engineer

Dick Cor oration

J. Borst, FQC ManagerR. Hudak, QC Inspector

Peabod Testin Com an

M. Whalen, NDE Supervisor

l. / denotes those present at Exit Interview August 25, 19782. / denotes those present at Exit Interview September 1, 19783. / denotes those present at Exit Interview September 8, 19784. / denotes those present at Exit Interview September 15, 19785; / denotes those, present at'xit Interview September 21, 1978',The inspector also interviewed other PPSL employees as well asemployees of Bechtel, Dick Corporation, Peabody Testing Company,and General Electric Company.

Plant Tour

The inspector observed work activities in-progress, completed workand plant status in several areas of'he plant during generalinspection of'he plant. The inspector examined work for anyobvious defects or noncompliance with- regulatory requirements orlicense conditions. Particular note was taken of presence ofquality control inspectors and quality control evidence such asinspection records, material identification, nonconforming materialidentification, housekeeping and equipment preservation. Theinspector interviewed craft. personnel, supervision, and qualityinspection personnel, as such personnel were available in the workareas.

No items of noncompliance were identified.

3. Licensee Action on Previous Ins ection Findin s

(Cl'osed) Unresolved Item (387(388(78-02-02): Improved maintenanceof items released from the warehouse but not yet installed.

The licensee had initiated Deficiency Report No. 0085 to documentspecific conditions previously observed by NRC inspectors.

Valves HBB-BF-15703R and GBB-'T-F010A and B were observed with endcaps in place. Final inspection of these valves for internalcleanliness is done prior. to closure in accordance with QCI P 1.10Revision II.The response to Deficiency Report 0085 states that the correctiveaction regarding this, matter included meetings with craft andsupervision to emphasize the importance of maintaining and re-placing end caps, assignment of craft personnel to replace end capsat the end of each shift, and a daily survey by Field Engineeringprior to the start of the day shift to verify that end caps arereplaced and to identify discrepant conditions. The inspectorverified by discussions with assigned individuals that FieldEngineering personnel are conducting the required surveys that QCpersonnel are monitoring this activity. Field Engineering and QCpersonnel stated that their surveys included observation of thecondition of all safety related equipment in temporary or in-placestorage. Nonconforming conditions noted are processed in accor-dance with Project Special Provisions Notice SF/PSP 8G-6.1 Revision0 or field inspection procedure G-3 as appropriate. The inspectorreviewed the following additional documentation regarding thismatter:

Nonconformance Report No. 2953

In Process Rework Notice Nos. 2540, 2543, 2544, 2545

PPSL: letter to. Bechtel PLB-8575

Bechtel letter to PP8L BLP 9374

QCIR 73.0-M 204-HBB-116-1 (1)

QCIR 49.0-M 204-GBB-115-1 (2)

The inspector had no fur ther questions on this matter at this time.

4. Reactor Coolant Pressure Boundar and Safet Related Pi in Weldin )

The following listed activities were examined and verified thatthey were being pei formed in accordance with the ASME Section IIIand IX codes, PSAR Appendix D, the Bechtel guality Assurance ManualSection III, Site Specification M 204, and drawings M-198 and M-199.

W~iN -U i

Fitup, alignment and welding of joint GBC-101-1 FW 14.

Welding of joint HRC-'2-4 FW 16.

Welding of joint SP-DCA-M 78-35-BW 8 R-2.

-Unit 2

Welding of joint DLA-201-1 FW 3.

The inspector verified selected detailed drawings, weldingprocedure, base and filler metal certifications, welderqualification, quality control documentation, weld appearance,welding variables such as gas flow and amperage, and non-destructive testi'ng activities as appropriate.

b. Non-Destructive Testin -Unit 1

Liquid Penetrant testing of weld joint Nos.SP-DCA-M 78-4-FW"8 (c) R-l.

GBB-109-2 FW l-l (Excavation).

GBB-109-2 FW 12 (Excavation).

VNB-B21-2 FW A15.

The inspector verified'surface preparation, qualification ofexaminers, and testing technique.


5. Reactor Coolant Pressure Boundar, and Safet Related Pi in

a. Piping System Activities.

The inspector examined work activities for the Main SteamSystem- Line B inside containment- and Main Steam Relief Linesfor Line B. The inspector verified that the activities exam-ined were in accordance with the ASME Code Section III, PSARAppendix D, FSAR Sections 5.4.9 and 10.3, the Bechtel gualityAssurance Manual Section III, GE Specification 22A 4628,Bechtel Specifications M-201, M-204 and drawings M-199, VNBB21-2, GBC 101-12-1 and GBC-101-30-1.

The inspector observed handling, installation, protection,initial alignment, and identification. The inspector reviewedassociated gC inspection records, verified material certifications,and reviewed gC Engineering certification records.

b. The inspector examined two partially completed piping runs andverified that they were installed in accordance with approveddrawings and specifications. Piping runs examined were:

(1) The 20" RHR piping. from containment penetration X-12 to.pipe spool DCA-108-1-3.

The inspector verified conformance to FSAR Section 5.4.7 anddrawings DCA-108-1 and M-151.

(2) The RHR Service Water System Spray Pond Network B-l.

The inspector verified conformance with FSAR Section 9.2.6 anddrawings HRC-2-4, HRC-2-11, M-80-1 and M-80-2.


6. Reactor Vessel Installation Units 1 and 2

The inspector examined protection of the installed reactor vesselsand stored closure heads'for compliance with site procedures andPSAR Appendix D commitments. The inspector reviewed the proceduralrequirements for vessel protection and verified that requiredinspections and preventive maintenance were being completed. Theinspector observed that openings were covered as required, workplatforms inside the Unit I vessel were nonflamable and that Unit I

access was controlled. The inspector also observed the conditionof a selected closure head stud hole to verify freedom from rustand condensation. Documentation reviewed by the inspector included

Field. Inspection Procedure 6-5, Revision 0.

Project Special Provisions Notice SF/PSP G-5.1, Revision 3.

Equipment Maintenance Requirement and Record Form forUnit 1 and 2 Reactor Vessels and for Reactor VesselClosure Heads.

No items of noncompl.iance were identified.

7. Reactor Vessel Internals

a. Protection of Stored Vessel Internals-Units 1 and 2

The inspector examined protection of the stored reactor vesselinternals for compliance with site. procedures and PSAR Appen-dix D commitments. The inspector reviewed the procedural require-ments for internals protection and verified that required inspec-tions were being completed. The inspector observed the in-plantstorage of the Unit 1 Steam Dryer and the shroud head and separator.The inspector also observed the movement and subsequent in-plant storage of the Unit 2 Steam Dryer and shroud head andseparator. The inspector noted that NCR was issued by gualityControl regarding the storage 'ondition of these components.The. inspector also noted that the equipment maintenance requirementsand record form for the aforementioned Unit 2 components hadnot been rewritten to reflect their movement to in-plantstorage. Documentation reviewed by the inspector included:

Field Inspection Procedure G-5, Revision 0.

Project Special Provisions Notice SF/PSP G-5..1, Revision 3.

Equipment Maintenance Requirements and Record Form forUnit 1 and 2 Steam Dryer and the Shroud Head and Separ-ator.

The inspector stated that the disposition of NCR and therevised equipment maintenance requirements and record form forthe aforementioned Unit 2 components would be examined duringa future inspection. (388/78-13-01 )

b. Handlin of Internals-Units 1 and 2

The inspector observed,. lifting and handling of the Unit 2Steam Dryer and the shroud head and separator from temporarystorage silos to in-plant storage. The inspector also observedthe installation into the reactor pressure vessel of theUnit 1 shroud. The inspector verified that the lifting andhandling were consistent with established requirements, liftingequipment was as specified and testing completed prior tolifting, and placement and installation were in conformancewith requirements. Documentation reviewed by the inspectorincluded:

GE I8SE Procedures160 A71211 Revision 0,160 A71210 Revision 1,160 A81201 Revision l.Bechtel FCI-M-156, Revision 1 for dynamic„load testing ofcrane.


c ~ Installation of Internals-Unit 1

(1) The inspector observed completed work and work in progressrelative to the installation, of'elected reactor internalscomponents. Items inspected included: jet pump beambolt tensioning,. jet pump head beam bolt-tack welds, andjet pump riser to brace arm welds. Except as noted inParagraph (2) below the inspector determined that workprocedures were being followed; installation was inaccordance with specifications and gC inspection activ-ities were in accordance with established procedures. Theinspector reviewed selected documents relative to thiswork including:

FSAR Section 3.2

GE drawings 197F 633, Revision 8; 117C 4354, Revision8

GE Specification 22A 4273 Revision 2

GE I8SE Jet Pump Installation Travelers 11T

GE IPSE Jet Pump Head Bolt Tensioning Special BeamProcess Control Sheets No. 115-15.

GE IPSE Jet Pump Beam Bolt Tack Weld Joint ProcessControl Sheets 11J-21

Except as noted below, no items of noncompliance were identified.

(2) The inspector examined the completed jet pump riser tojet pump brace arm welds for jet pumps A,B,C,D,F,G, andH. The welds examined met the requirements of the followingGeneral Electric Drawings:

GE Drawing 117C 4354 Revision 8.

GE Drawing 197R 633 Revision 8

The welds required by these drawings are partial penetrationsingle bevel flush contour groove welds.

The inspector also reviewed records relative to thesewelds. The records included jet pump installation travelers,joint process control sheets, visual and liauid penetrantexamination. results, material certifications for weldelectrode, certificationof conformance for base material,welder qualification records, and welder mock-up testrecords. Documents examined were:

Jet Pump Installation Traveler llT

Joint Process Control Sheets 11J-12 and 13 for JetPumps A, B, C, D, F, G, and H-includes record ofvisual and PT examination

Material Certification for Weld Filler Metal-HeatNo. C3548 R308L

GE Cerfiticates of Conformance for Riser Brace Armand Jet Pump Risers PgC Nos.-SJ 3371, 01249, 01237

Record of Welder Performance Test in Accordance withWelder gualification ISE-Wg-31.

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Record of Mock-up Testing in Accordance with Mock-upTest ll NU-3GE IPSE Weld and NDE Information Spread Sheet 160-77E-D155 Revision 5

Detail Weld Procedure ISE-DWP-3004 Revision 1

Welder Qualification ISE-WQ-32 Revision 0-A

Welder Qualification ISE-WQ-31. Revision 0-A

During this review the inspector noted that Detail WeldingProcedure ISE-DWP-3004, a Gas Tungsten Arc Welding (GTAW)Process,. is specified for the jet pump riser to brace armweld by GE Weld identification diagram 160-77E-0154.This GE Weld identification diagram requires WelderQualification ISE-WQ-31 for this weld. However, DetailWelding Procedure ISE-DWP-3004 requires Welder Qualifi-cation ISE-WQ-32. ISE-WQ-31 specifies the use of aconsumablc insert, where as ISE-WQ-32 does not.

, Welders who had welded the jet pumpriser to jet pump brace arm, a weld with no consumableinsert or other backing, were qualified only in accord-ance with ISE-WQ-31. The ASME Boiler and Pressure VesselCode Section IX, 1974 Edition, QW-356.1 lists QW 404.22as an essential variable for the performance qualificationof Gas Tungsten Arc Welding. QW-404.22 states, "Theomission or. addition of preplaced consumable inserts.Qualification in a singled-welded butt joint, with orwithout consumable inserts, qualifies for fillet weldsand single-welded butt joints with backing."

The failure to qualify welders for the welding processused is'contrary. to the requirements of 10 CFR 50,'Appendix B, Criterion IX. (387/78-15-01)

By letter. dated 'August 31, 1978, to the Bechtel Field'onstruction Manager, the GE Installation and Service

Engineering Site Manager stated that the brace arm toriser welds are considered to be sound and will performtheir intended fuction based upon: (1) Welder quali-fication on a brace arm mock-up (11 MU-3) prior towelding the brace; (2) inspection of the sectioned mock-up -indicated that deposited welds were sound and had fullpenetration; (3) the'welders were qualified to a proce-dure similar to the one required; (4) welders'erform-ance on these and other welds has been excellent;

(5) the welds had liquid dye penetrant examination (PT)of the root and final pass and were found acceptable.

The inspector examined the sectioned mock-up and notedthat in addition to the requirements of the procedure usedin the production welding, one weld pass had been made fromthe opposite side of the weld. It did appear that adequatepenetration to meet the requirements of the design weldhad been achieved.

8. Control of Measurin and Test E ui ment

The inspector examined Bechtel's program and activities relative tothe control of measuring and test equipment. The inspector verifiedthat these activities were in accordance with commitments in thePSAR Appendix D; Field Inspection Procedure G-4, Revision 6; ProjectSpecial Provisions Notice SF/PSP G-4.1, Revision 2.

The inspector examined the following relative to the above:

Measuring and Equipment List, gC-G-4-1

Calibration Record Card File

Out of Calibration Notices for CT 676 and CT 538

Instrument Calibration Instruction 5, Revision 2

Calibration Test Report for CT 1243


9. S ra Pond Concrete Work

a. Concrete Activities

The inspector examined concrete work activities in progressfor Spray Pond placement S-60. The inspector verified, exceptas noted in b. below, that these activities were in accordancewith commitments in the PSAR Appendix D; FSAR Section 9.2.7;Bechtel Specification C-36 and Dick Corporation Procedures.

12

The inspector examined the following activities relative tothe above: placement preparation, delivery and placement,wire mesh installation, and curing. Documents reviewed by theinspector included:

Bechtel Drawings C-65 and C-66

Dick Drawings SK 1-2

Concrete mix test results truck 15 ticket 52322

Dick gC in process records including Pre-placement,Placement, Concrete Placement Release, ConcreteTesting Record, and Concrete Curing Record.

Except as noted below, no items of noncompliance were identified.

C~id dDuring the inspection, on September.6 and 7, 1978, of theconcrete acti vities in a. above the inspector noted that thecontractor, Dick Corporation, was using a c~ring compoundidentified as Horn Clear Seal 150. The inspector determinedthat this product was a Type 1 curing compound in accordancewith ASTM Specification C309. However, Bechtel specificationC-36 Paragraph 7.4.9 (b) states "Liquid membrane curing com-pound shall be Type 2 in accordance with ASTM C309-58."

On September 13, 1978, Bechtel approved Supplier DeviationDisposition Request No. 034 permitting the use of the Type 1curing compound.

On September 21, 1978, the inspector examined 40 completedconcrete slabs on the Spray Pond. slopes. Of these 40, 8 wereobserved to have one or two hairline cracks of varying length.Representatives of the licensee stated that the Spray Pondcracks had been noted previously and would be documented anddispositioned. The inspector stated that the failure to usethe curing compound required by Specification C-36 was contraryto the requirements of 10 CFR 50, Appendix B, Criterion V.(387/78-15-02; 388/78-13-02) d

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10. Exit Interviews

At periodic, intervals.- during the course of this inspection, meetingswere held with facil.ity management ('ates and attendees are denotedin Detail 1) to discuss inspection scope and findings.