cl/wunited states nuclear regulatory commission÷rv • cl/wunited states nuclear regulatory...

÷rv • CL/wUNITED STATES

NUCLEAR REGULATORY COMMISSIONREGION 11

AIN TJ 230 PEACHTREE STREET, N.W. SUITE 1217J~jJ~~.-.ATLANTA, GEORGIA 30303

APR 1 4 1978In Reply Refer To:RII:EJV50-390/78-850-391/78-7

Tennessee Valley AuthorityAttn: Mr. N. B. Hughes

Manager of Power830 Power BuildingChattanooga, Tennessee 37401

Gentlemen:

This refers to the inspection conducted by Mr. E. J. Vallish of thisoffice on March 28-31, 1978, of activities authorized by NRC Construc-tion Permit Nos. CPPR-91 and CPPR-92 for the Watts Bar Nuclear PlantUnit 1 and 2 facilities, and to the discussion of our findings held withMr. T. B. Northern, Jr. at the conclusion of the inspection.

Areas examined during the inspection and our findings are discussed inthe enclosed inspection report. Within these areas, the Inspectionconsisted of selective examinations of procedures and representativerecords, interviews with personnel, and observations by the inspectors.

Within the scope of this inspection, no items of noncompliance weredisclosed.

One new unresolved item resulted from this inspection and is discussedin the enclosed report. This item will be examined during subsequentinspections.

In accordance with Section 2.790 of the NRC's "Rules of Practice",Part 2, Title 10, Code of Federal Regulations, a copy of this letterand the enclosed inspection report will be placed in the NRC's PublicDocument Room. If this report contains any information that you (oryour contractor) believe to be proprietary, it is necessary that youmake a written application within 20 days to this office to withholdsuch information from public disclosure. Any such application mustinclude a full statement of the reasons on the basis of which it isclaimed that the information is proprietary, and should be preparedso that proprietary information identified in the application iscontained in a separate part of the document. If we do not hearfrom you in this regard within the specified period, the reportwill be placed in the Public Document Room.

APR 1 4 1978

Tennessee Valley Authority -2-

Should you have any questions concerning this letter, we will be glad todiscuss them with you.

Sincerely,

C.E. MurpyChefReactor Construction and Engineering

Support Branch

Enclosure:RII Inspection Report Nos.

50-390/78-850-391/78-7

cc w/encl:Mr. J. E. GillelandAssistant Manager of Power830 Power BuildingChattanooga, Tennessee 37401

Mr. T. B. Northern, Jr., Project ManagerWatts Bar Nuclear PlantP. 0. Box 2000Spring City, Tennessee 37381

Mr. C. S. Walker400 Commerce StreetW9D199Knoxville, Tennessee 37902

I I

i. ..

UNITED STATES

NUCLEAR REGULATORY COMMISSIONREGION II

230 PEACHTREE STREET. N.W. SUITE 1217ATLANTA. GEORGIA 30303

Report Nos.:

Docket Nos.:

50-390/78-8 and 50-391/78-7

50-390 and 50-391

License Nos.: CPPR-91 and CPPR-92

Categories: A2 and A2

Licensee: Tennessee Valley Authority830 Power BuildingChattanooga, Tennessee 37401

Facility Name: Watts Bar Nuclear Plant, Units 1 and 2

Inspection at: Spring City, Tennessee

Inspection conducted: March 28-31, 1978

Inspectors: E. J. VallishN. Economos

Reviewed by: • /p..J. C ,ryant, ChefEn i eering Support Section No. 1Re :6tor Construction and Engineering Support Branch

Date

Inspection Summary

Inspection on March 28-31, 1978 (Report No. 50-390/78-8 and 50-391/78-7)Areas Inspected: Work and quality records of pressure boundary pipewelding and safety-related structures, installation of reactor pressurevessels and internals, installation of safety-related components andpipe support and restraint systems, progress of mechanical componentinstallation in reactor and auxiliary buildings. The inspectioninvolved 48 inspector-hours on site by two NRC inspectors.Results: Of the nine areas inspected no apparent items of noncomplianceor deviations were identified.

,RII Rpt. Nos. 50-390/78-8 I-iand 50-391/78-7

DETAILS I Prepared by: __E.J. Vallj/sh, Meoianical Engineer Datengineering Support Section No. 1eactor Construction and Engineering

Support Branch

Dates of Inspection: March 28-31, 1978

Reviewed by: "I-,/V_JXC.-Bryan, Chief DateZgineering Support Section No. 1Reactor Construction and Engineering

Support Branch

1. Persons Contacted

Tennessee Valley Authority (TVA)

*T. B. Northern, Jr., Project Manager*J. M. Lamb, Mechanical Engineering SupervisorL. J. Johnson, Mechanical Engineering.Unit Group LeaderS. Booker, Engineering Aid

*A. W. Rogers, Site QA Supervisor*J. R. Inger, QA Unit Auditor*J. S. Colley, EN DES QA Engineer

*Denotes attendance at exit interview.

2. Licensee Actions on Previous Inspection Findings

Licensee actions on previous inspection findings were not reviewedduring this inspection.

3. Unresolved Items

Unresolved items are matters about which more information isrequired in order to ascertain whether they are acceptable items,items of noncompliance, or deviations. An unresolved item disclosedduring the inspection is discussed in paragraph 8.

RII Rpt. Nos. 50-390/78-8 1-2and 50-391/78-7

4. Independent Inspection Effort

Inspection was made of the progress of installation of mechanicalcomponents in the Units 1 and 2 reactor and auxiliary buildings.This included the hydrogen collection systems, control rod drivecoolers, reactor coolant pumps, RHR and containment spray heatexchangers and pumps, and the ice condenser bays. TVA Drawing48 N 404 R6, titled, "Containment Vessel Interior ElevationSheet 2" was reviewed and used to verify locations, orientationdetails and installation requirements of the hydrogen collectionsystems.

No noncompliances were identified.

5. Reactor Vessel Installation - Work Observation (Units 1 and 2)

The reactor vessels are installed in place and the openings wereobserved to be adequately protected from foreign object entry.


6. Reactor Vessel Internals - Work Observation (Units 1 and 2)

The protection of the stored vessel internals was inspected inUnits 1 and 2 reactor buildings. The internals are stored in metalcovered containers which are adequately supported and braced inthe refueling canals.


7. Safety-Related Components II - Work Observation (Units 1 and 2)

FSAR Sections 1.2, 3.9, 5 and 17 were reviewed prior to thisinspection to determine licensee commitments in this area.Steam Generator Nos. 1 and 4 were selected as representativecomponents within the reactor coolant pressure boundary.The following documents were reviewed and used to verify locations,

orientation details and installation requirements:

a. TVA Drawings - 47W304-1 R4, "Mechanical Reactor Coolant Piping."

48N412-R7, "Equipment Support SG&RC

RII Rpt. Nos. 50-390/78-8 1-3and 50-391/78-7

Pump Vertical Column."

40N413-RO, "Equipment Support Lower Steam

Generator & Pump Tie Rod Supports & Arrangements."

48N414-R4, "Equipment Support Lower SG Supports."

48N416-R3, "Equipment Support Upper Steam Generator

Support & Arrangement."

48N417-R-4, "Equipment Support Upper Steam

Generator Support."

b. WB Field Instruction M-ll, "Installation of Nuclear SteamSupply System Major Components."

The installation of the steam generators was inspected for handlingand protection, installation, protection after installation and fornonconforming activities.


8. Safety-Related Pipe Support and Restraint Systems (Unit 1)

WBNP-QCP 4.8 R5 titled, "Inspection and Documentation Requirementsfor Mechanical Supports" was reviewed. This document, along withthose referenced, provided adequate inspection and documentationrequirements for the installation of the subject systems.

The following work procedures and drawings were reviewed and usedto verify locations, orientation details and installation require-ments and progress:

a. TVA Drawings:

47A406, "Detailed Support Drawings,"

47W406-7R4, "Chemical and Volume Control System Piping,"

47W435-1 thru -16, "Mechanical Safety Injection System Piping,"

30W615-1 thru -5, "Mechanical Pipe Supports and Anchors,"

47B435-380, 381 and 382, "System N3-63-7A Anchor Loads: SISRHR & CTS Piping."

RII Rpt. Nos. 50-390/78-8 1-4and 50-391/78-7

b. "WBNP Support Fabrication and Installation Operation Sheets -System 63-1 SIS-R", indicating completion thru step, "Releasefor Storage/Installation."

The Pacific Scientific mechanical snubbers listed below byserial number and size, were examined in storage includingfunctionally stroking the unit. Those serial numbers markedwith an * were found to bind or "hang-up" and be noisy duringthe stroking operation. The reason for this type operationcompared to the smooth quiet functioning of the other units isan unresolved item (50-390-78-8-1). The licensee stated thathe will contact the vendor and get an engineering analysis ofthe noisy performance. This item remains open.

PSA-1/4 PSA-1/2 PSA-I PSA-3 PSA-10

1110 1904* 964 898 10681609* 1115 906* 929 6721616* 968* 9231017 897* 8841614* 1406

366369

The following two installed snubbers were inspected for adequateinstallation and signs of damage or deterioration:

MK 63-1 SIS-R74 (PSA-1)MK 74-1 RHR-R6 (PSA-I)

Two installed spring hangers were inspected for support rodsize, hot and cold position settings and adequate installation.

These hangers were 72-ICS-V17 and MK70-ICC-R77.

Three fixed pipe supports MK63-lSIS-R72, MK70-1CC-R77 andMK70-1CC-R680 were inspected for adequate installation.

QA Audit No. WB-G-78-01, titled "Fabrication, Installation andInspection of Structural and Miscellaneous Steel and PipeSupports," conducted January 10, thru February 2, 1978, wasreviewed for scope and adequacy and timeliness of correctiveactions.


SRII Rpt. Nos. 50-390/78-8 1-5and 50-391/78-7

9. Exit Interview

A meeting was held with the licensee's representatives (denoted inparagraph 1) and others to discuss the results of this inspection.Items discussed included the Units 1 and 2 installation progress ofthe reactor vessels, steam generators, hydrogen collection systems,control rod drive coolers, reactor coolant pumps, RHR and containmentspray heat exchangers and pumps and ice condensers. Inspection ofthe safety-related pipe support and restraint systems in Unit 1resulted in one unresolved item concerning the mechanical snubbers.The licensee was informed that no noncompliances were identifiedduring this inspection.

"RII Rpt. Nos. 50-390/78-8and 50-391/78-7

II-i

DETAILS II Prepared by-/ ,znee 7SN. Economos, Metallurgical Engineer DateEngineering Support Section No. 2Reactor Construction and Engineering

Support Branch

Dates of Inspection: March 28-31, 1978

Reviewed _____-__-___-__-'-- -- -?T. E. Conlon, Chief ZDateEngineering Support Section No. 2Reactor Construction and Engineering

Support Branch

1. Persons Contacted

Tennessee Valley Authority (TVA)

*T.*J.*L.*B.*J.*A.

B.J.K.B.

Northern, Project ManagerE. Treadway, Construction SuperintendentC. Northard, Welding Engineering Unit SupervisorA. Nicholls, Civil Engineering Unit SupervisorM. Lamb, Mechanical Engineering Unit SupervisorW. Rogers, QA SupervisorG. Johnson, Civil EngineerA. Kerr, Mechanical EngineerA. Hastings, Welding EngineerBrown, Welding Instructor

*Denotes those present at the exit interview.

2. Licensee Actions on Previous Inspection Findings

Previously identified inspection findings were not reviewedduring this inspection.

3. Unresolved Items

No new unresolved items were identified during this inspection.

RII Rpt. Nos. 50-390/78-8 11-2and 50-391/78-7

4. Independent Inspection Effort

a. Weld Repair - Units 1 and 2

Installation, inspection and testing of pressure boundary pipingis controlled by Section III of the ASME Code, 1971 Edition thruWinter 1971 addenda. Several pressure boundary/safety-relatedfield welds where repair activity was in progress were inspected.The welds are identified as follows:

Weld No. ISO Size

2-068C-WO03-03 Loop 3 31" x 2.6"2-063B-D194-18 IC-194 6" x .719"1-087B-D042-06 IC-42 12" x 1. 25"2-063A-D125-03 IC-125 8" x .322"1-074B-D053-08 IC-53 14" x 1.25"1-074B-D055-21 IC-55 6" x .719"1-074B-D054-10 IC-54 8" x .906"2-068G-WOO-03 Loop 1 31" x 2.6"1-063B-DO92-11A IC-92 10" x 1.00"

The inspector reviewed supporting QC documents including fieldweld operation sheets, repair sheets and NDE reports for eachweld to ascertain whether these were consistent with code andprocedural requirements. Circumstances leading to the repairand the corrective action to be taken were discussed withappropriate personnel.

b. Plant Tour - Units 1 and 2

The inspector walked through various areas of the plants toobserve certain pipe handling, installation and welding

.activities in progress and to inspect the general state ofcleanliness, including control of unused weld electrodematerial near the work areas.

Within the areas inspected, no items of noncompliance ordeviations were identified.

5. Safety-Related Structures - Observation of Work and WorkActivities - Unit 1

Installation of the auxiliary building pipe rupture restraintsin the northside mainsteam valve room of Unit I was in progress.Fabrication and erection of these seismic Category I structures

RII Rpt. Nos. 50-390/78-8 11-3and 50-391/78-7

is accomplished per the latest Edition of the American Instituteof Steel Construction (AISC) and the Code of Standard Practice.Welding is controlled by the AWS structural welding code D1.1-72and the TVA Construction Specification G-29. Site quality controlprocedures (QCP) are used to provide process control and verificationof activities performed as required.

Certain components, inside the north mainsteam valve room wereselected for observation of work in progress and/or completed inorder to determine whether applicable requirements were being met.Components selected were as follows:

Components Identification Drawing No.

Vertical Columns H-6, H-7 48W1708-07-8

Horizontal Beams B-3, B5, B13 48W1708-03R4

Embed Plates MKII - W6 48W707R4

For the above items the inspector verified that activities and/orend products were being met in the areas of erection, use ofspecified material, utilization of qualified NDE and QC inspectionpersonnel, recordkeeping and NDE examinations as applicable.

Within the areas inspected, no items of noncompliance or deviationswere identified.

6. Safety-Related Structures - Review of Quality Reports - Unit 1

Requirements controlling materials, erection and inspection ofstructural steel and supports are delineated on TVA design drawings,construction specification G-29 and site QCPs.

The components identified in paragraph 5 above were selected for areview of quality records to determine whether they were consistentwith procedural requirements and if they reflected work accomplish-ment consistent with NRC requirements and SAR commitments. Thereview included material certifications, receiving inspections,nonconformances, shop releases, installation/erection QC checkoff-lists, NDE reports, field weld documentation and inspection asapplicable.


RII Rpt. Nos. 50-390/78-8 11-4and 50-391/78-7

7. Reactor Coolant Pressure Boundary Piping - Observation of Workand Work Activities (Unit 1)

Activities controlling pressure boundary are governed by Section IIIof the ASME, Code 1971 Edition through Summer 1973 addenda, siteapproved QCP procedures, the OEDC QA Manual and the TVA ConstructionSpecification G-29M. Pipe sections in the residual heat removal(RHR), reactor coolant (RC) and the safety injection (SI) systemswere selected in order to audit such piping activities as handling,issue, installation, storage, NDE, and quality related inspections.The selection included the following items:

Item System/ISO Size

MK-74-RHR-64 RHR, IC-53 14" x Schedule 140NK-74-RHR-66 RHR, IC-53 14" x Schedule 140S/N 11503, 11504 Crossover Loop 1 31" x 2.60"S/N 10395, 10396 Safety Injection, 10" x Schedule 140

IC-92

For the above activities relative to these components the inspectorverified QC inspections performed, recordkeeping, material certifi-cations, qualification of inspection personnel, location and positionof components, performance of required NDE and qualification of NDEpersonnel and, component lifts as applicable.


8. Reactor Coolant Pressure Boundary Piping, Review of Quality RecordsUnit 1

Documents which control the requirements for obtaining and main-taining QA/QC records for pressure boundary piping/components werediscussed in paragraph 7 above. Quality records of randomly selectedcomponents inside the pressure boundary were reviewed to ascertainwhether applicable quality requirements were met. The componentsselected were as follows:

Component System Size

MK-74-RHR-64 Residual Heat 14" Schedule 140S/N 6794 & 6796 Removal

Cross Over Loop 1 Reactor Coolant 31" x 2.60"S/N 1503 & 1504

RII Rpt. Nos. 50-390/78-8 11-5and 50-391/78-7

MN-63-SI-181 Safety Injection 10" Schedule 140S/N 10395 & 10396

Check Valve Safety Injection 10"N.B. #Wlll19

For these components the records reviewed included, receivinginspection, shipping releases, material certifications, installationrecords, storage inspections, Westinghouse quality releases,nonconformance reports and process control lists as applicable.

Within the areas inspected no items of noncompliance or deviationswere identified.

9. Exit Interview

The inspector met with the licensee representatives (denoted inparagraph 1) at the conclusion of the inspection on March 31, 1978.The inspector summariied the scope and findings of the inspection.