IR 05000298/1989015
| ML20245J478 | |
| Person / Time | |
|---|---|
| Site: | Cooper  |
| Issue date: | 04/27/1989 |
| From: | Barnes I, Gilbert L NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20245J457 | List: |
| References | |
| 50-298-89-15, NUDOCS 8905040139 | |
| Download: ML20245J478 (4) | |
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APPENDIX B U.S. NUCLEAR REGULATORY COMMISSION
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REGION IV
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'NRC Inspection Report:
50-298/89-15 Operating License:
DRP-46 i
Docket:
50-298 Licensee: Nebraska Public Power District r
Facility Name: ' Cooper Nuclear Station
- Inspection At
Cooper Nuclear Station, Brownville, Nebraska Inspection Conducted: April 10-14, 1989
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Inspector:
//A 7/P7 L.' D.. Gilbert, Reactor Inspector, Materials
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and Quality Programs Section, Division of Reactor Safety Approved:
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C / F/ B(cnef, Chief, Materials and Quality
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t L Progratos Section, Division of Reactor Safety I'nspection' Summary Inspection Conducted April 10-14, 1989 (Report 50-298/89-15)
Areas Inspected: Routine, unannounced inspection of welding activities.
Results: A weakness was identified in the welding program, in that, the licensee did not have _an experienced welding engineer on staff to direct the welding program but assigns welding responsibility to a systems engineer as a collateral duty. Several examples of this weakness were identified and incorporated into a violation (paragraph 2) for failure to control welding activities.
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8905040139 890501 PJR ADOCK 05000298
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DETAILS.
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-Persons Contacted'
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.*G. R. Horni Division Manager'of Nuclear Operations-
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. E. M. Mace, Engineering Manager
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- G. E. Smith.. Quality'Assu'rance Manager,
- R. L.;Gardner, Maintenance Manager'
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- J.- R.( Flaherty, Plant Engineering Supervisor
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'*S.' S.: Freborg Assistant, Plant Engineering Supervisor
- B.1.9 Crow, Mechanical' Engineer (Welding)
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- J.'M. Meacham,: Senior Manager. Technical Support
- G. R. Smith,LLicensing Supervisor:
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- L. Bray, Regulatory Compliance, Specialist
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B. C. Toline, Quality Assurance Spec.ialist
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Power: Plan't Maintenance-3
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B.'0111s',[SiteSuperiAiendent M. French, Mechanical, Coordinator.
N. Leary, Welding Coordinator'
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I HartfordSteam'BoileNInspection'andInsuranceCompany
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J. Tetreault', Authorized Nuclear ' Inspector-
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'NRC,
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- W.'R. Bennett, Senior Resident-Inspector
The NRC inspector-also: interviewed other licensee employees during the
. inspectio'n; '
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- Denotes ~ attendance at exit interview conducted on April 13,'1989.
2.
Welding Activities (55050and55100)
Review of Welding Program and Procedures
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The NRC. inspector reviewed the licensee's program for controlling welding
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of safety-related activities to assure that welding is controlled and
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accomplished by qualified personnel 'ustna qualified procedures in accordance j
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with applicable codes, standards, specifications, criteria, and other
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special requirements. The following licensee documents were included in the review:
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CNS Procedure No. 0.30, "ASME Section XI Repair / Replacement,"
Revision 3
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o Maintenance Procedure No. 7.0.7, "Special Process Control Procedure,"
Revision 7 i
o Maintenance Procedure No. 7.7.1, " General Welding Requirements,"
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o Maintenance Procedure No. 7.7.2.1, " Welder Performance Qualification,"
Revision 1 o
Maintenance Procedure No. 7.7.3, " Weld Material Procurement and -
Control Procedure," Revision 0 o
Maintenance Procedure No. 7.7.3.2, "CNS-ECSC-2 Electrode Care, Storage, and Conditioning Procedure (E308, E309, and E7018),"
Revision 0 o
Maintenance Procedure No. 7.7.3.3, "CNS-RQA-1 Quality Assurance Specification for Welding Materials Certified to SFA Specification,"
Pevision 0 o
Maintenance Procedure No. 7.7.14.1, "CNS-GTAW-1 General Welding Procedure Specification for Gas Tungsten Arc Process," Revision 0 o
Maintenance Procedure No. 7.7.14.2, "CNS-SMAW-1 General Welding Procedure Specification for B31.1 (Piping) Shielded Metal Arc Process,"
Revision 0 o
Quality Assurance Plan QAP-2600, "Special Processes & Non-Repair Maintenance," Revision 1 o
Quality Assurance Instruction 0AI-12. " Guidelines for Audit Frequency
& Scheduling," Revision 18 o
Professional Service Industries (PSI) Procedure 81-102, " Methods for Radiographic Examination of Welded Joints," Revision 5 In addition to the above programmatic procedures, the following welding procedure specifications (WPSs) and their supporting PQRs were reviewed, o
Maintenance Procedure No. '7.7.15, "P1-BG Welding Procedure,"
Revision 0 o
Maintenance Procedure No. 7.7.16, "P1-STRUCT Welding Procedure,"
Revision 0
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-4-The NRC. inspector observed the qualification testing of a welder 'and inspected the completed weld test coupons and/or record of test for four other welders. The NRC inspector selected four additional welder performance qualification tests for review of the radiographs, PSI reader sheet, and NPPD QA surveillance ^ report. The NRC inspector also observed the weld and weld checklist documentation for a rigging attachment fabricated on Maintenance Work Request 89-1580 using WPS 7.7.16.
The control and
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storage of the welding electrode in the maintenance shop were inspected including that used for. welding the rigging attachment.. Three.QA surveillance reports on welding activities were reviewed; these i
surveillance had been performed as required by the audit program schedule.
The NRC inspector. identified the following discrepancies during inspection of the welding program and activities:
a.
Maintenance Procedure No. 7.7.15 does not control the heat input within the limits qualified as required by ASME Section IX 1983 Edition for welding materials requiring impact properties.
b.
The postweld heat treatment.specified in Maintenance Procedure No. 7.7.16 was not qualified by the supporting PQR as required by the ASME Code Section IX.:
c.
Radiographic examination reports, 173-?8061-2 and 173-98061-5, for double wall radiography of two welder performance qualification tests recorded that the penetrameters were placed source-side inside the pipe although the radiographic procedure specified placement of the penetrameters source-side and outside the pipe.
d.
Holding ovens containing E7018 electrodes were outside the temperature range specified in Maintenance Procedure No. 7.7.3.2 and the temperature was not being checked daily as required by the procedure.
e.
The temperature range of 150-200 F specified in Maintenance Procedure No. 7.7.3.2 for electrode holding ovens does not comply with AWS D1.1-85, which states that E7018 electrodes shall be heated to at least 250 F.
This is an apparent violation for failure to control welding activities.
(298/8915-01)
3.
Exit Interview An exit interview was conducted on April 13, 1989, with those personnel
denoted in paragraph 1.
At the exit interview, the NRC inspector informed
.the licensee that the failure to control welding activities would be an apparent violation. No information was presented to the NRC inspector
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that was identified by the licensee as proprietary.
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