IR 05000302/1973001
| ML19319C908 | |
| Person / Time | |
|---|---|
| Site: | Crystal River  |
| Issue date: | 02/22/1973 |
| From: | Crossman W, Vallish E NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML19319C870 | List: |
| References | |
| 50-302-73-01, 50-302-73-1, NUDOCS 8003040858 | |
| Download: ML19319C908 (13) | |
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UNITED STATES i
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ATOM!C ENERGY COMMISSION
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DIRECTORATE OF REGULATCRY OPERATICNS
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REGION 16 - SulT E 618 230 R E Ac nr R E E ST RE ET, NOR T HeEST
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A T L. A N T A, G E C RG I A 30303 RO Inspection Report No. 50-302/73-1 with attached Inquiry Report No.
50-302/73-lQ/CDR
. Licensee: Florida Power Corporation 3201 34th Street, South P. O. Box 14042 St. Petersburg, Florida 33733 Facility Name: Crystal River 3 Docket No. : 50-302 License No.: CPPR-51 Category: A2 Location: Crystal River, Florida Type of License: B&W, PWR, 855 Mwe Type of Inspection: Routine, Unannounced Dates of Inspection: January 23-25, 1973 Dates of Previous Inspection:' November 20-21, 1972 Performing Inspector:
A. R. Herdt, Metallurgical Engineer Engineering Section, Facilities Construction Branch Accompanying Inspectors: None Other Accompanying Personnel: None Principal Inspector:
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.2-2/ - 73 E. J(/ Vallish, Reactor Inspector Date Facilities Section, Facilities Construction Branch Reviewed By:
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t/2 a [73 W. A. Crossman, Acting Senior Inspector Date O
Facilities Section, Facilities Construction Branch 8003040
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SUMHARY OF FINDINGS I.
Enforcement Action A.
Violations
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Certain items appear to be in noncompliance with 10 CFR 50, Appendix B, " Quality Assurance Criteria for Nuclear Power Plants," as indicated below:
73-1-Al Decay Heat and Makeup and Purification Systems Welding Contrary to Criterion IX of Appendix B to 10 CFR 50, welding performed on the makeup and purification system was not in accordance with.the qualified welding procedure, SS-1-TIG, in that larger diameter filler metal than that Prescribed was in use.
(Details I, paragraph 2.)
73-1-A2 Decay Heat and Makeup and Purification Systems Radiographs
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Contrary to Criterion IX of Appendix B to 10 CFR 50, V
radiography of welds on the decay heat removal system were not in accordance with the prescribed Pittsburgh Testing Laboratory Procedure (PTL Q-7, paragraph 4.6)
concerning placement of penetrameters.
(Details I, paragraph 3.)
B.
Safety Items None II.
Licensee Action on Previously Identified Enforcement Matters A.
Violations i
All previously identified enforcement matters have been closed.
B.
Safety Items There are no outstanding or unresolved safety items.
III.
New Unresolved Items 73-1/1 Missing Radiographs Radiographs for the final acceptance of weld 42-DH could not s_-
be located.
(Details I, paragraph 3.)
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73-1/2 Suspect Lack of Material Control - Weld Filler Material-1/
l The licensee has received notification from the Babcock and Wilcox Company that steam generators may contain unqualified weld filler
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material.
(Details I, paragraph 6.)
IV.
Status of Previously Reported Unresolved Items 72-5/2 Welding Procedure Qualification The licensee has requalified welding procedure No. CS-1-TIG-SMA and Regulatory Operations has no further questions at this time.
The licensee stated that welding procedure No. CS-2-TIG-SMA will not be used for material thicknesses greater than 3/4 inch.
This item is resolved.
(Details I, paragraph 4.)
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72-3/5 Procedures for Final Inspection of Piping l
There has been no change in status.
This item remains open.
71-5/5 Cleanliness Procedures In Piping and Components Some but not all of the procedures have been prepared.
This item remains open.
(Details I, paragraph 7.)
72-5/1 Radiographs / Code Case 72 Investigation of this item continues.
(Details I, paragraph 9.)
72-5/3 Valve Wall Thickness Requirements Verification of valve wall thickness has begun.
This item remains open.
(Details I, paragraph 8.)
V.
Design Changes N'ne o
VI.
Unusual Occurrences
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None
.i 1_/ RO Inquiry Report No. 50-302/73-1Q/CDR, dated January 18, 1973.
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VII. Other Significant Findi g A.
Project Status
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As of December 26, 1972, the status of completion is approximately
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63.4%.
B.
Personnel or Organizational Changes R. B. Johnson, Engineer, is leaving Florida Power Corporation.
C.
Inquiry Reports l
Suspect Lack of Material Control - Weld Filler Material - RO Inquiry Report No. 50-302/73-1Q/CDR dated January 18, 1973.
VIII. Management Interview
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The results of this inspection were discussed with H. L. Bennett, Director, Generation Construction, C. E. Jackson, Construction i
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Superintendent, E. E. Froats, Supervisor, Quality and Standards, and other members of the plant staff.
A.
Enforcement Action
The items under Enforcement Action above were discussed in
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detail.
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B.
Radiographs The inspector stated that during his review of radiographs of welds on the decay heat removal system, the radiographs
for weld 42-DH could not be located.
The licensee agreed
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that these radiographs were required and not readily avail-
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able.
The licensee further stated that if they cannot be located, the weld will be raradiographed, evaluated and
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documented.
(Details I, paragraph 3.)
C.
Control of Welding i
The inspector stated that during his review of welding being performed on the decay heat close cycle, the field weld data sheet required one welding procedure while the attached welding procedure was another.
The licensee agreed and took immediate corrective action to resolve this deficiency.
(Details I, s
paragraph 5.)
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RO Report No. 50-302/73-1 I-1
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DETAILS I Prepared By:
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N // 7.3 A. R. Hardt
/Da'te Metallurgical Engineer Engineering Section
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Facilities Construction Branch
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Dates of Inspection: January 23-25, 1973
b J2/20/M ReviewedBy//C.Edfrht
Date Menior Inspector Engineering Section Facilities Construction Branch i
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Persons Contacted
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a.
Florida Power Corporation (FPC)
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H. L. Bennett - Director, Generation Construction C. E. Jackson - Construction Superintendent
E. E. Froats - Supervisor, Quality and Standards
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D. W. Pedrick - Quality Engineer J. C. Hobbs, Jr. - Superintendent, Mechanical and Electrical Systems R. S. Dorrie - Engineer R. B. Johnson - Engineer
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Contractor Organizations (1) J. A. Jones Construction Company (JAJ)
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J. R. Amundson - Site Quality Control Supervisor
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(2) Livsey and Company J. J. Weaver - Project Superintendent M. Brown - Welding Engineer (3) Pittsburgh Testing Laboratory (PTL)
G. B. Brown - Chief Inspector O
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l (4) Babcock and Wilcox Construction Company (B&W)
L. M. Watson - Site Manager (5) Gilbert Associates, Inc.
i S. R. Buckingham - Site Coordinator, QA 2.
Decay Heat (DH) and Makeup and Purification System (MU) Welding The inspector er==ined the welding documentation on completed welds in these systems.
I There were no discrepancies noted on the DH system.
The inspector j
found during his review of the MU system that the weldors were not
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adhering to qualified welding procedure, SS-1-TIG, which requires:
i No weld. filler metal at the root bead or layer, 1/16-inch diameter l
weld filler metal on the second bead or layer and 3/32-inch diameter
weld filler metal on the remaining cover beads or layers. There was also a note added to the welding procedure which permitted either no
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weld filler metal or 1/16-inch diameter weld filler metal on the root pass. However, this note was included after some of the welds were made.
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Documentation showed that the weldors used only 3/32-inch diameter weld filler metal for each pass. This was verified by the weld rod
control documentation associated with each weld.
Welds 72 MU and 73 MU are examples of this deficiency and several others were pointed j
out to the licensea.
It was further noted by the inspector that several
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weldors were not adhering to the procedure, not just one or two.
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The licensee agreed with the inspector that the welding procedure was
not adhered to as written, but there was no violation of an essential element requiring weld procedure requalification in accordance with ASME Section IX.
The licensee stated that further examination and corrective action into this problem would be performed and, furthermore, the quality of all the welds involved in this deficiency would be fully examined with the possible use of radiography even though only visual examination is required.
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RO Report No. 50-302/73-1 I-3
3.
Decay Heat'and Makeup and Purification System Radiographs The inspector examined the nondestructive test documentation on completed welds in these systems. The inspector found during his review that some radiographs had water marks and marginally acceptable penetrameter sensitivity. Radiographs for weld 42-DH could not be located even though this weld had been completed and accepted. The licensee agreed that these radiographs were not readily available and said that a search had been started. He stated, also, that if the radiographs could not be located, the weld will be raradiographed and evaluated. He agreed that corrective action is required to ensure that radiographs and other documentation are readily available.
During his review, the inspector found that the radiographs for weld 39-DH were not in accordance with the PTL procedure for radiographic inspection, PTL Q-7, paragraph 4.6 (Penetrameter Placement). This paragraph states, in part, "Penetrameters shall be placed 1/8 to 3/4 incit away from the weld...." The penetrameter placement on the radiographs of weld 39-DH were approximately 1-1/2 to 1-3/4 inches N
away from the weld. Other radiographs of welds in these systems had a similar deficiency and were pointed out to the licensee.
The licensee agreed with the inspector that the PTL radiographic inspection procedure had been violated and said that corrective action would be implemented.
The inspector reviewed the licensee's action on MU-65, since during the last inspection a question concerning its acceptability had been raised.1/ The licensee has further evaluated this weld and finds it acceptable to the code requirements.
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Welding Procedure and Weld Rod Procedure Review The instv tor reviewed welding procedures SS-2 and CS-2 BR/SMA and no disce ancies were found.
During the last inspection, it was noted that the postweld heat treated weld procedure qualification data for welding procedures CS-1-TIG-SMA and CS-2-TIG-SMA had not been performed in accordance with USAS B31.7. 7 The licensee has performed the required procedure qualification tests
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for the postweld heat treated condition for welding procedure CS-1-l l
l 1/ See RO Inspection Report No. 72-5, Details III, paragraph 5.
2/ See RO Inspection Report No. 72-5, New Unresolved Item 72-5/2.
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.' RO Report N.o 50-302/73-1 I-4 TIG-SMA.
This data was reviewed and the inspector had no further questions.
The licensee stated that welding procedure CS-2-TIG-SMA will not be used for material thicknesses greater than 3/4 inch for
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USAS B31.7 welding. The inspector considers this item resolved.
The inspector reviewed the revision of FPC W-21, " Weld Rod Control Procedure," since during the last inspection a clarification was required. 1/ The inspector had no further questions at this time.
5.
Control of Welding While observing welding on weld 526-SW in the decay heat closed cycle, the inspector noticed that the field weld data sheet specified welding procedure CS-2-BR/SMA; however, weld procedure CS-1-TIG-SMA was attached to the date sheet. The licensee took immediate corrective action to attach the correct procedure. Furthermore, an additional quality control step has been included to prevent repetition of the discrepancy.
6.
Suspect Lack of Material control-Weld Filler Material O
The licensee has received written notification from B&W that certain steam generators contain some weld filler material which did not indicate sufficient tensile or impact properties.
The licensee notified the AEC, Region II, of the possibility that Crystal River 3 may have steam generators containing the suspected weld filler material.
The licensee is pursuing the subject with B&W.
7.
Cleaning Procedures Cleaning procedures for stainless pipe and valves are still an unresolved item.
The licensee stated that two procedures, FPC 67 and 68, have been prepared and are currently in review and comment cycle.
These procedures should be approved within three to four weeks.
8.
Valve Wall Thickness Requirements Verification of valve wall thickness to meet construction requirements is still an unresolved item. The licensee stated that procedure JAJ
9.1.3, approved December 7, 1972, has been developed and that ultrasonic inspection has started on four valves.
Ni 1/ See RO Inspection Report No. 72-5, Details III, paragraph 2.
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RO Report No. 50-302/73-1 I-4'
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Radiographs / Code Case 72
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Acceptability of this code case for the deviation in sensitivity and penetrameter requirements is still an unresolved item. The licensee stated that Code Case 1443-1, approved by Council August 10, 1970, was identical to code Case 72..The licensee stated he is within 10 CFR _50, paragraph 50.55(a) since the code case involved is prior to January 1, 1971, as is the construction permit and this allows use of these code cases. Further investigation is continuing.
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MAR 2 1973 *
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ENCLOSURE
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' Docket No. 50-302
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Enforcement Action
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A.
Violations l
Certain items appear to be in noncompliance with 10 CFR 50,
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Appendix B, " Quality Assurance Criteria for Nuclear Power-
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Plants," as indicated below:
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73-1/A1 Decay Heat:and Makeup and Purification Systems Welding
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Contrary to Criterion IX of Appendix B to 10 CFR 50, welding performed on the makeup and purification systems was not in accordance with the qualified welding procedure, SS-1-TIG, in that larger diameter filler metal than that-prescribed was in use.
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73-1/A2 Decay Heat and Makeup and Purification Systems Radiographs
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Contrary to Criterion IX of Appendix B to 10 CFR 50,
radiography of welds on the decay heat removal system was not in accordance with the prescribed Pittsburgh Testing Laboratory procedure (PTL Q-7, paragraph 4.6)
concerning placement of penetrameters.
B.
Safety Items
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None
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II.
Licensee Action on Previously Identified Enforcement Matters
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A.
Violations.
All previously identified enforcement matters have been closed. *
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B.-
Safety Items
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There are no outstanding or unresolved safety items.
III. New Unresolved Items
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73-1/1 Missing Radiographs
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Radiographs for the final acceptance of weld 42-DR could not be located.
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73-1/2 Suspect Lack of Material Control - Weld Filler Materia _1_
The licensee has received notification from the Babcock and Wilcox Company that steam generators may contain unqualified weld filler material.
IV.
Status of Previously Reported Unresolved Items-72-5/2 Welding Procedure Qualification
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The licensee has requalified welding procedure No. CS-1-TIG-SMA and Regulatory Operations has no further questions at this time. The licensee stated that welding procedure No.
CS-2-TIG-SMA will not be used for material thicknesses greater than 3/4 inch.
This item is resolved.
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72-3/5 Procedures for Final Inspection. of Piping
a There has been no change in status.
This item remains ~open.
71-5/5 Cleanliness Procedures in Piping and Comoonents Some, but not a.~.1, of the procedures have been prepared. This j
item remains open.
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72-5/1 Radiographs / Code Case 72 Investigation of this item continues.
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72-5/3 Valve Wall Thickness Requirements
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Verification of valve wall thickness has begun. This item.
remains open.
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Ltr.to Florida Power Corporation
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dtd MAR 2 1973-
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cc w/ enc 1:
A J. B. Henderson, RO RO:HQ (h)
-Directorate of Licensing (h)
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DR Central Files l
- PDR
- Local PDR
- DTIE, OR'
" State
- To be dispatched with licensee response.
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U. S. ATOMIC ENERGY COMMISSION
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REGION II
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DIRECTORATE OF REGULATORY OPERATIONS RO Inquiry Report No.: 50-302/73-1Q/CDR Florida Power :.:orporation (FPC)
3201 34th St.aet South
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P. O. Box 14042
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St. Petersburg, Florida 33733 t
License No.: CPPR-51
Facility:
Crystal River Unit 3 Descriptive Title:
Sus ect Lack of Material Control - Weld Filler Material Prepared Ey:
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E. J.~4allish, Reactor Inspector Date Facilities Section, Facilities Construction Branch A'. Date and Manner AEC Was Informed:
LicenseerepresentativecontactedRegionIIIytelephoneon January 5, 1973.
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B.
Description of Particular Event or Circumstance:
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FPC had received a written notification from Babcock and Wilcox Company (B&W) stating that certain steam generators produced by B&W contained some weld filler material which~did not indicate I
sufficient tensile or impact properties. The discrepancy-was identified at the Barberton, Ohio, B&W shops during an audit per-formed by the B&W QC organization.
C.
Action By Licensee:
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FPC notified the AEC Region II of the possibility that' Crystal River 3 may have steam generators containing the subject weld filler material. FPC intends to pursue.the subject with B&W to determine their situation.
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The licensee stated that to the best of his knowledge, the above
information did not contain proprietary information.
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