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U.S. NUCLEAR REGULATORY COMMISSIONOFFICE OF INSPECTION AND ENFORCEMENT

REGION III

Report No. 50-373/80-19; 50-374/80-12

Docket No. 50-373; 50-374 License No. CPPR 99; CPPR-100

Licensee: Commonwealth Edison CompanyP.O. Box 767Chicago, IL 60690

Facility Name: LaSalle County Station, Units 1 and 2

Inspection At: LaSalle Site, Marseilles, Illinois

Inspection Conducted: April 1-3 and 15-17, 1980(j $ N W

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Approved By: C. C. Williams, Chief, _[[7MOProjects Section 2

Inspection Summary

Inspection on April 1-3, and 15-17, 1980 (Report No. 50-373/80-19; 50-374/80-12)Areas Inspected: Shop fabrication travelers and nonconformance reports, receiptinspection, rework procedures, location and traceability cf certified mill test

: reports, and toured material storage. Reviewed inspector qualifications, weldrod storage, preheating requirements prior to welding, and Commonwealth EdisonCompany audits of the Heating Ventilating and Air Conditioning (HVAC) contractor.Results: No items of noncompliance or deviations were identified.

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*DETAILS

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Persons Contacted

Principal' Licensee Employees

First-Visit, April 1-3, 1980

*L. J. Burke, Site' Project Superintendent*L.'T. Tapella, QA Engineer'*G. E. Groth, Engineer, Station Construction

Second Visit, April 15-17, 1980

*L. . J. Burke,- Site Project Superintendent*L. T. Tapella, QA Engineer*J. D. Dierbeck, Engineer, Station Construction

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*J. W. Gieseker, Engineer, Station Construction*T. Quaka ,- QA Supervisor

Other Personnel, Both Visits.

*C.: Baumgarten,.Zack,' Company, Site SuperintendentE. A. Thompson, Zack Company, QA ManagerT. Campbell, Zack Company, QC Inspector

Licensee Action on Previously identified Items

(Closed) Unresolved Item (373/74-41-01) was previously identified as un-resolved item-(373/79-13-15) and was closed and assigned a new numberincluding additional information. The original number was documented inIE Report No. 50-373/79-13 and No. 50-374/79-10 performed on March 22-23,and April 3-6, 1979. During the period April 27, 1979 to April 1, 1980,Ceco had ~ performed nine audits of Zack Company, either shop or field or acombination of both.

Presently, deficiencies from three of the audits have not been completelyresolved. A total of 99 questions were contained in the nine audits.These questions resulted in 25 deficiencies. The audits covered signifi-

' cant phases. of the QA /QC program such as QA program, QC procedures,i

personnel qualifications, procurement, document and procedure control,i

nonconformances, repair' procedures, quality control inspections,welding procedures, training, experience, etc. This item will remain,-

open pending additional hanger repair.and inspection..

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*Program or Functional Areas Inspected

1. Rework Procedures'

a. Rework of Shop Furnished Equipment

The Zack Company (Zack) representative informed the inspectorthat the company does not have rework procedures preparedor approved for use at the LaSalle site. Zack's basis is thatthe equipment (heating, ventilating, and air conditioningmaterial, ventilation ducts and hangers) is fabricated in theirChicago shop. Those pieces that are improperly dimensioned ordamaged in shipment are discarded and new sections fabricatedin the shop. The licensee concurred on this statement. Also,the inspector observed a number of reject assemblies in isolatedstorage,

b. Repair Work to Correct Nonconformances

During the'lienesee's audit of Zack Company on April 27 andMay 9, 1979, Audit Report No. 1-79-27, five deficiencies were |

reported. Deficiency No. 4 concerned the audit of Procedure QCP-9-Repair Procedure. The deficiency stated that contrary to ProcedureQCP-9, paragraph 6.7, Zack did not receive CECO approval for repairwork performed on NCR3 and NCR4, on CECO furnished equipment. Zacknow repairs all NCR's by approved procedure.

The licensee's response to file dated July 5, 1979, statesthat the rework required on Zack Company's NCR3 and NCR4 per 1

Station Construction Directives, has been completed and thework is acceptable. The other four deficiencies were cleared

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and the last one approved on December 12, 1979. I

2. Receipt Inspection

The inspector was informed by the licensee and Zack Company thatreceiving inspection had been audited, the results reviewed by bothcompanies and earlier problems had been resolved. Zack Company ,

employees perform the receiving inspection and compare equipment I'received against the traveler and truck load number.

The licensee performed an audit,- No. 1-79-2, on February 1, 1979,concerning Zack's QA Manual, Revision 4, dated October 4, 1977,Sections 2, 10, 16 and 19 and QCP's 2, 8, 13, and 14. A total ofseven deficiencies were reported. The first deficiency concernedthe receipt of E6011 welding electrodes without a copy of the openended Purchase Order on site to verify conformance. Zack agreedto maintain a copy of the original Purchase Order on site to, permitthe QC inspectors to verify future orders as conforming to theoriginal P.O. ''

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* The six other deficiencies were cleared and approved by March 30, 1979,.by the licnesee's QA Department.

3. Storage

The inspector toured the storage laydown area to the extent possible.Spring rains.left some of the area covered with water or extremelymuddy. Stored material in the yard appeared to meet storage require-ments. The material, ductwork, sheetmetal and hangers were stored ondunnage. A few pieces of sheet metal had blown from the various stockpiles, but were restored to the proper storage areas when the area wasobserved the following day.

4. Weld Rod Control

Until recently, the only weld rod used on site by Zack welders wasE6011. Now they have extended their welding capabilities to useE-7018 welding electrodes. . Qualification welding procedures and

-welder qualifications have been developed and approved for theuse of.the E7018 electrode.

The E 7018 electrodes are received in hermetically sealed cans andare accompanied by the manufacturer's certification and a certifiedmill' test report. The weld rod is remov?d from the shipping containersand stored in a holding oven at 275 F. The oven was calibrated inMarch 1980. The rod is issued to individual welders who store itin portable rod containers, i.e., rod caddies. These carriers areplugged in at the job site and maintain rod temperature at approxi ,mately 250'F. Any unused rod remaining after four hours is returned torod storage and a new supply is issued to the welder.

Zack Company had the holding oven locked and located in one room ofthe trailer together with unopened rod cans.

The other welding electrodes (E6011) were stored in the opposite endof the trailer in a different room. Each type of rod was issued atits storage location.

5. Travelers

Travelers are used for tracing items through fabrication, shipping,and receiving. The inspector selected five hangers in place in thefield and then traced them back through documentation to the certifiedmill test report.

If a .new section is shipped to the field to replace a damaged (dis-regarded) section, a new traveler is sent'with the replacement item.

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6. Receipt Inspection

No unusual problems were observed regarding Receipt Inspection. Theincoming material is checked against the traveler as it in unloaded.All documentation required for the load is to accompany the shi.pment.

7. Material Certs

Material'Certs accompany the shipment and since they are deliveredwith the truck shipment, they are filed on site. In the instancesverified, the documentation was traceable.

8. Installation of Dampers, Vanes, Etc.

Turning vanes are installed in the ventilation duct prior to delivery.Repairs in the event of damage, is done in accordance with the proce-dures for handling nonconforming items.

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A review of the fire dampers indicated there were 15 Ruskin FireDampers on site. None are Model NIBD-23. All are gravity drop,Model IBD-2. These dampers are rated for three hours and have a160 F fusible link. The inspector observed one damper that wastested to show its operation. There are four of the 15 dampersthat are safety related.

9. Prehaating

In reviewing drawings, etc. it was observed that none of the embedswere heavy enough to require preheat. However, it was discoveredthat several welds have been made to structural steel. In someinstances, this material is greater than 3/4" thick and preheatingwould be required. Presently, it is not known which attachments aresafety related. NCR No. 420 has been written to document this Un-resolved Item (373/80-19-01). The licensee is reviewing thestructural drawings to identify those areas with structural steelgreater than 3/4" thick. The NCR has been sent to SNED for engi-neering resolution.

10. HVAC Inspection of Erection

The status of final inspection of HVAC work at LaSalle is essentiallyas documented in IE Inspection Report No. 50-373/79-41 and No. 374/79-27. As documented previously in this report the erection of the HVAC,

-specifically welding,. remains an open item (373/79-41-01).

Unresolved Matters

Unresolved matters are matters about which more information is required inorder to ascertain whether they are acceptable items, items of nongompliance,or deviations. An unresolved item disclosed during this inspection is' dis-cussed in Details, Section 9. Also, a previously reported unresolved itemis discussed in Section 10 of this report.

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* Exit Interview-

~ The inspector met with licensee representatives (denoted under PersonsContactedt on April._3 and 17, 1980. The inspector summarized the scopeand findings of the inspection.~ The licensee acknowledged the findings.as reported.

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