IR 05000285/1990016
| ML20012E103 | |
| Person / Time | |
|---|---|
| Site: | Fort Calhoun  |
| Issue date: | 03/20/1990 |
| From: | Barnes I, Gilbert L NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20012E101 | List: |
| References | |
| 50-285-90-16, NUDOCS 9003300073 | |
| Download: ML20012E103 (6) | |
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APPENDIX
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U.S. NUCLEAR REGULATORY COMMISSION
REGION IV
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NRC Inspection Report: 50-285/90-16 Operating License: DRP-40-L Docket: 50-285 Licensee:.'OmahaPublicPower. District (OPPD)
1623 Harney Street Omaha, Nebraska 68102
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facility Name: FortCalhounStation(FCS)
l Inspection At: FCS, Blair, Nebraska
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Inspection Conducted: March 5-9, 1990
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8-3 -2o-Y o Inspector: [ L. D. Gilbert, Reactor Inspector, Materials Date and Quality.'rograms Section, Division of Reactor Safety I
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r Approved:
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.s-ao-9o I. Barnes, Chief. Materials and Quality
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Date-Programs Section, Division of Reactor Safety
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t Inspection Summary i
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Inspection Conducted March 5-9. 1990 (Report 50-285/90-16)
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Areas Inspected: Routine, unannounced inspection of control of special
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processes.
Results: The licensee through its Standing Order, Welding Manual, and Quality Control Manual provides, for the most part, comprehensive instructions for'the e
control of special processes. However,twonon-citedviolations(paragraph 2.1)
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were identified for failure to provide adequate instructions for controlling l
heat input within the range qualified and failure to qualify the full range of
- material thickness specified in the WPS. Also, as a welding program enhancement,
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the licensee committed to correlating the settings on the welding machines to actual welding amperage before making safety-related welds.
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9003300073'900322'
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AGOCK 05000285 PDR T
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i DETAILS j
1.
PERSONS CONTACTED
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- R. L. Andrews, Division Manager, Quality-& Environmental Affairs
- G. R..Peterson, Manager, FCS i
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- D. J. Matthews, Supervisor Station Licensing
- C, F. Simmons, Station Licensing Engineer
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- R.,W. Short, Supervisor Special Services Engineering l
- C. N. Bloyd, Special Services Engineering
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- D. W. Dale Supervisor QC e
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'*J. E. Lechner, Lead Engineer
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- P. E. Hamer, ISI Programs
- R. Acker QA Auditor
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- C. Huang, Supervisor Health Physics
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- T. J. McIvor, Manager Nuclear Projects
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'R. L. Jaworski, Manager, Station Engineering
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- J. L. Skiles Supervisor Nuclear Projects
- T. G. Therkildsen, Supervisor, Nuclear Licensing
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- S. L. Linquist, Licensing Engineer E. Lundstrom. Weld Test Administrator
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P. Ferrone, QC Welding Coordinator C. Eckhardt, QC. Inspection Coordinator i
R. Ruhge,'QC Level III Inspector
G.:Reardon, Welding Specialist J. Kyle, Welding Specialist
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- T. Reis, Resident Inspector
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- C.-E.. Johnson, Reactor Inspector The inspector also interviewed other licensee employees during the inspection.
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- Denotes attendance at exit interview conducted on March 5-9, 1990.
2.
CONTROL OF SPECIAL PROCESSES
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The purpose of this inspection was to verify that the licensee had established measures to assure that welding and radiographic examinations are controlled and
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are accomplished by qualified personnel, using qualified procedures, in accordance with applicable codes, standards, specifications, criteria, and other special
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requirements.
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2.1 Welding Prooram (55050 AND 55100)
The inspector was briefed on the welding program by the Nuclear Project Supervisor res)onsible for the welding procram. Production Engineering Division had tie responsibility for tl1e welding program with the exception of i
tlie filler metal storage and issue, which is still under QC, The
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responsibilities for the special processes are specified in Standing Order
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G-72, "Special Process Control," Revision 3, which was issued on December 21,
1989. The standing order references the following welding codes: ASME Section III, 1983 Edition Summer 1984 Addenda; ASME Section IX, Current
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Edition; and.AWS DI.1, 1986 Edition.
i The welding and postweld heat treatment requirements are specified in special
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processprocedures(SPPs)andincorporatedintotheWeldingManual. The filler metal controls and surveillance and monitoring of special processes are j
incorporated into the QC Manual as QC procedures (QCPs).
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The inspector selected various documents.from the welding manual and the QC manual for review of the procedures and instructions for welding, heat
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treating, and nondestructive examination to be used for safety-related applications. These documents are listed in Attachment 1.
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To assess the implementation of the welder qualification portion of the welding l
L program, the inspector toured the new welder qualification facility and r
witnessed the qualification of a welder. The inspector also verified that
qualifications for selected welders.. listed on the Monthly. Welder Roster issued on March 1, 1990, were supported by a documented welder qualification record.
The welders had maintained their qualifications by using the welding processes
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for which qualified. The qualification of welders was found to be consistent
with SPP-1 and the ASME and AWS codes referenced in Standing Order G-72.
A QC
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I surveillance of welder qualifications was performed in accordance with QCP-230 j~
and documented in QC Report No. 900365.
The assessment of the welding 1 iller metal control program was performed by-
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tou ing the filler metal storage area, verifying the traceability of materials,
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checking rod oven temperatures, and reviewing the procurement documents and receiving records for selected filler metals in the filler metal storage area.
Tho (.ontrol of filler metals was found to be consistent with QCP-366 and the
AStu and AWS codes referenced in Standing Order G-72. A QC surveillance of the
fiiler metal control program was performed in accordance with QCP-230 and a
do;umented on QC Report No. 900491.
i The Welding Manual documents reviewed, for the most part, provide comprehensive instructions for welding. However, two deficiencies were identified during the inspector's review of the welding procedure specifications (WPSs) and their e
supporting procedure qualification records (PQRs).
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The first deficiency was related to the welding of materials requiring notch toughness properties in WPS-101 and WPS-102. The instructions for heat input
, control in these procedures were considered inadequate by the inspector to assure compliance with the heat input qualified by the supporting PQRs. The welding instructions did not specify which method to use for control of heat input and the parameters permit welding above the heat input range cualified by
.j the PQRs. The licensee initiated action to revise the procedures and issued Corrective Action Report-(CAR) No.90-096 on March 9,1990, to address this j
procedural deficiency as it relates to other procedures and past work. This is an apparent violation for failure to provide adequate instructions to assure
that walding is performed in accordance with qualified procedures; however, the i
violation is not being cited because it meets the criteria in Section V.A. of the Enforcement Policy.
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The second deficiency was identified during review of the supporting PQRs for
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WPS-801.
In reviewing the thickness qualified for the gas tungsten arc welding
(GTAW) and shielded metal arc welding (SMAW) processes, the inspector noted j
that both processes were listed as qualified for thickness ranges from 1/16 to i
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8 inches. However, the range from 1/16 to 3/16 inches for the SMAW process was-J not qualified by the supporting PQRs. The licensee initiated action to revise the procedure and issued Corrective Action Report (CAR) No.90-095 on March 9, 1990, to address this procedural deficiency as it relates to other procedures and past work. This is an apparent violation for failure to qualify WPS-801 in accordance with ASME Section IX for all thickness ranges and processes permitted by the WPS; however, the violation is not being cited because it meets the criteria in Section V.A. of the Enforcement Policy.
Also, as a welding program enhancement, the licensee committed to correlating the settings on the welding machines to actual welding amperage, before making
- safety-related welds, in order to aid the welder in setting the welding machine.
within the welding parameters of the WPS. Since there were no safety-related
welding activities in progress for observation during this inspection, the subject welding enhancement will be considered an inspector followup item.' (285/9016-01)
The inspector discussed the surveillance of welding activities with the QC
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supervisor and his QC welding coordinator. The coordinator indicated that he
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had performed several surveillances of in-process welding activities in
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accordance with-QCP-230.
In reviewing the surveillance reports, it was noted that the surveillance forms did not indicate whether the welding was safety-related _or nonsafety-related. The supervisor indicated that the surveillance program was developed to cover all controlled welding. Since the supervisor was responsible for the surveillance program as stipulated in QCP-230, he assured
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the. inspector that when safety-related welding activities were being worked, QC
would be aware of 'it and perform in-process surveillances. The supervisor. stated,
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that when safety-related welding was being performed, he planned to perform surveillances on a per shift basis. Also, he could see the need for developing
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l an overall schedule which would better define the frequency at which the various I
surveillances and monitoring activities specified in QCP.230 would be performed.
The supervisor was in the process of training three additional QC Level II
inspectors for performing these surveillance and monitoring activities.
2.2 Radiographic Examination program (57090)
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The licensee informed the inspector that radiographic examinations would be i
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performed by a contractor, and that Ebasco had been selected as the contractor.
}lowever, no safety-related radiography was being performed at this time. The
inspector discussed the licensee s control of the contractors radiographic
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examination program with the-licensee's QC supervisor. The inspector was
informed that the surveillance of the contractor would be accomplished in
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accordance with QCP-340 and the responsibility had been assigned to an
individual in QC, who was' certified for Level III activities in radiography.
The Level III for radiography also performs the technical review of the contractor's procedures for the QA a) proval of the procedures used by
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contractors. The Level III was in 11e process of performing the review of the Ebasco radiographic examination procedures.
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No violations or deviations were identified during this portion of the inspection.
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3.
EXIT INTERVIEW
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An exit interview was conducted on March 9, 1990, with those personnel denoted in paragraph 1 in which the inspection findings were summarized. No infonnation was presented to the inspector that was identified by the licensee as proprietary, t
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ATTACHMENT 1 I
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WELDING MANUAL DOCUMENTS
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GSS-1, " General Symbols Specification," Revision 0. Dated 2/89
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SPP-1, " Qualification of Welders," Revision 1, Dated 2/90 l
SPP-7, " Weld and Base Metal Repair," Revision 0. Dated 2/89 GWS-1, " General. Welding Specification for ASME and ANSI Welding," Revision 0, Dated 3/89 i
GWS-2, " General Welding Specification for AWS Structural Steel and Sheet Steel N
Welding," Revision 1. Dated 10/89
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WPS-101, " Welding Procedure Specification," Revision 4. Dated 5/89
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PQR No. 101-1, " Procedure Qualification Record," Revision 0. Dated 10/87
. PQR No.101-3, " Procedure Qualification Record," Revision 0. Dated 9/87 l
PQR No. 101-5, " Procedure Qualification Record," Revision 0, Dated 7/88 l
WPS-102, " Welding Procedure Specification," Revision 3, Dated 5/89 j
PQR No. 101-2, " Procedure Qualification Record," Revision 0. Dated 10/87 WPS-120 " Welding Procedure Specification," Revision 2, Dated 5/89 WPS-801, " Welding Procedure Specification," Revision 4, Dated 1/90 PQR No. 801-1, " Procedure Qualification Record," Revision 0, Dated 9/87
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,PQR No. 801-4, " Procedure Qualification Record," Revision 0, Dated 6/88 f
PQR No. Specification 3, " Procedure Qualification Record," Dated 11/73
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QUALITY CONTROL MANUAL DOCUMENTS i
QCP-230, " Surveillance and Monitoring of Special Processes," Revision 1, f
. Dated 2/12/90 i
QCP-300, " Visual and Weld Inspection," Revision 1 Dated 1/16/90
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QCP-340, " Radiographic Film Interpretation / Surveillance," Revision 0, i
Dated 11/10/89 QCP-366, " Filler Metal Control," Revision 0, Dated 9/14/89
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