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U.S. NUCLEAR REGULATORY COMMISSIONOFFICE OF INSPECTION AND ENFORCEMENT

Region I

Report No. 90-161/7a-14

Docket No. 50-363

License No. CPPR-96 Priority -- Category A

Licensee: Jersey Central Power and Light Company

260 Cherry Hill Road

Parsippany, New Jersey 07054

Facility Name: Forked River Nuclear Station, Ilnit 1

Inspection at: Forked River, New Jersey

Inspection condu fed: Octo er 24-26, 1978

Inspectors: NrW d[[4A [ //L. Narrow, Reactor Inspector ddte signed

W W G/b,. A ..| ~u ev 3 191rW. F. Sanders, Reactor Inspector date' signed

date signed

Approved by: [g[F6 7,

R. W. McGaughhief, Construction date sfgnedProject Section, RC & ES Branch

Inspectivn Summary:Inspection on October 24-26, 1978 (Report No. 50-363/78-14)Areas Inspected: Routine, unannounced inspection by regional based inspectors of the QAprogram for fabrication and installation of the containment liner, and review of thestatus of outstanding items. The inspection involved 40 inspector-hours on site by twoNRC regional based inspectors.Resul ts: No items of noncompliance were identified.

79010302 [

Region I Form 12(Rev. April 77)

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3. Field Fabrication of Reactor Pit Liner

An inspection was made of the field fabrication area for the assem-bly of the Reactor Pit Liner. The component, when completed, willbe a conical structure 41' diameter, 13' 6" high and will bemoved and installed in the reactor cavity as a unit. The followingactivities in progress were inspected to the requirements of theapplicable drawings and specifications: handling, weld jointfit-ups, application of preheat and the welding to join the upperconical plates, inspection of completed welds andwelding in progress to weld the vertical tee bar stiffners to thecylindrical section of the liner. The inspector also observed thefit up of a back up plate 5B shown on drawing E5.

No items of noncompliance were identified.

4. N.D.E. Personnel Qualifications

The inspector reviewed the personnel Qualification records for thetwo people on site who have N.D.E. responsibilities. The recordswere examined to the requirements of P.D.M. written pract'ceQ.A.S.II and SNT-Tc-1A for evidence of Education, experiente train-ing, technical examination, grading and statement of certification.

No items of noncompliance were identified.

5. Welder Qualification

The inspector examined the qualification records for 3 weldersto the requirements of ASME Section IX. The records show thatthe 3 welders qualified to SMAW, Vertical, Horizontal and overheadusing procedures Vert. 65-2, Horiz. 68-4, and Ov. 68-2. The testplates were examined by radiography.

No items of noncompliance were identified.

6. Record and Procedure Review

The inspector reviewed the following documents for compliance tothe requirements of the P.S.A.R:

a. Engineering specification 2700-205 for the fabrication, instal-lation and testing of the containment liner and penetrations.

b. P.D.M. Qualtiy Assurance manual for Nuclear Power Plant compon-ents (Corporate Field) Revision 1, 7-8-76 with supplementand revisions to 8-22-78.

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. DETAILS

1. Persons Contacted

General Public Utilities Service Corporation (GPU)

*T. Corrie, QA EngineerJ. Davis, Resident Civil Engineer

*R. F. Fenti, Lead Site QA Auditor*W. T. Gunn, Project Site Manager*N. C. Kazanas, Manager of Qualtiy AssuranceS. Levin, Supervisor, Site EngineeringE. Staples, QC Engineer

*J. C. Thompson, Site QC Supervisor*R. L. Wayne, Construction QA Manager*J. E. Wright, Site QA Manager

Stone and Webster Engineering Corporation (S&W)

*K. J. Platte, Resident Engineer*R. L. Wagner, Superintendent of Construction

Pittsburgh - Des Moines Steel Company

J. Massengale, Site ManagerH. Steiger, Site QC Manager

* denotes those present at the exit interview.

The inspector also interviewed other licensee and contractor em-playees during the inspection.

2. Plant Tour

The inspector made a tour of the construction site to observe workactivities in progress. The inspector examined work items for anyobvious defects or noncompliances with regulatory requirements andfor evidence of quality control of the work. Specific activitiesobserved by the inspector included material handling, weld seamfitup and welding of containment liner; set up for radiography of alongitudinal seam; field facilities for developing and viewing ofradiographic film; removal of defective concrete in north interiorwall of Engineering Safety Features Compartment; preparation forconcrete placement, Block No.112 of basemat; and concrete curing.

No items of noncompliance were identified.

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c. Material, receiving, and certifications for 54 pieces ofmaterial which included

1. Receipt Inspection Report, Form QA 746-1

2. Documentation Check List, Form QA 730-1

3. Materia. Test Reports

7. Removal of Defective Cadwelds

During the plant tour the inspector observed that a cadweld sleevehad been cut longitudinally and was being removed from the rebar.The inspector was informed that this method was used for the re-moval of rejected splices in locations having insufficient space topermit cutting out the entire rebar joint. The inspector wasinformed that three reject splices had been removed in this manner.He examined the applicable documentation including inspectionreports and an interoffice memorandum from the A-E which identifiedremoval of the cadweld sleeve as the preferred corrective action.The inspector discussed the need for a detailed procedure forperformance of this work with the licensee's representatives whoagreed that a procedure would be provided.

This item is unresolved pending review by an NRC inspector of anapproved procedure for replacement of reject cadweld joints by thismethod. (78-14-01.)

8. Licensee Action on Previous Inspection Findinos

(Closed) Unresolved Item (363/77-01-01): Recalculation of reactorcontainment design. Copies of the Forked RiverInterim Peak Contain-ment Pressure Evaluation have been submitted to NRC Division ofProject Management with additional information to be supplied inthe FSAR submittal. Detailed review of this question will be con-ducted during the FSAR review.

(Closed) Unresolved Item (363/78-04-02): QA procedures to supple-ment "QA Plan." The inspector examined a random selection of QAprocedures and observed thatthe QA plan is referenced where appli-cable and the procedures do control activities affecting quality asprescribed by the "QA Plan."

(Closed) Unresolved Item (363/78-04-03): Evaluation of originalequipment storage and maintenance program and conversion to newprogram. The inspector examined a list of equipment which identi-fies all items of equipment requiring preventive services on site.The equipment list provides a comparison of maintenance requirementsbetween the old and new programs and upgraded the program to con-form to the manufacturer's requirements.

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(Closed) Unresolved Item (363/78-11-01): Thermoccu ple calibrationchecklists stamped " Uncontrolled." The inspector discussed thereason for use of this stamp with the licensee's representative andwas informed that the calibration cata had been recorded on thischecklist with the understanding that it would be transcribed onpermanent records of the using organizations. The inspector observedthat the data had been recorded on permanent records.

9. Licensee Action on IE Bulletins and Circulars

The inspector examined records and interviewed licensee represen-tatives to verify that corrective action had been taken withrespect to IE Bulletins and Circulars as shown below:

Circular 78-15 (Closed): Installation of tilting disc checkvalves. This circular had been referred to the A-E. Theinspector examined B&R letter No.13 JC-8-6052 dated Octo-ber 16,1978, whigh identifies tilting disc check valvesinstalled in vertical lines and provided that the design beprepared accordingly.

10. Procurement of Safety Related Materials

The inspector discussed problems identified at other sites withprocurement of materials from Modern Suppliers and Manufacturers,Inc. No m aterials had been purchased to date from this vendor andthe inspector observed that this vendor was not listed on theVendor Rating List dated October 1,1978.

The inspector had no further questions concerning this matter.

11. General

GPU Corporate personnel were on site reviewing the QA/QC programfor structural work together with GPU, S&W, and M-K site personnel.The review is intended to identify deficiencies and establish aprogram for their rapid correction.

12. Unresolved Items

Unresolved items are matters about which more information is re-quired in order to ascertain whether they are acceptable items oritems of noncompliance. An unresolved item disclosed during thisinspection is discussed in paragraph 7.

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13. Exit Interview

At the conclusion of the inspection on October 26, 1978, a meetingwas held at the Forked River site with representatives of the licensee &contractor organization noted in Para 1.The inspector summarized theresults of the inspection as described in the report.

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