IR 05000321/1970002
| ML19322D343 | |
| Person / Time | |
|---|---|
| Site: | Hatch  |
| Issue date: | 04/10/1970 |
| From: | Varela J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| Shared Package | |
| ML19322D327 | List: |
| References | |
| FOIA-79-416 NUDOCS 8002110532 | |
| Download: ML19322D343 (15) | |
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,,t g - . .. . . l j - - i... , -- . g . . b '! I' - . Reactor InsPcetor ' ' ' ' ' l ' ', Region II, Division of Cmpliance . ' )* LICENSE NO. CPPR-65, DOCKET NO. 50-321INSECmR'S EVALUA - i l - This memorandum refers to CD Report No. 50-321/70-2.
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s... ~ { Coorgia Power Co:pany (CPC) has a greater nu=Ler of quality control - i personnel at the Hatch site than most licensecs and appear to have g a working system or recordkceping; however, the qualifications of the fic1d inspectors are quastionable as demonstrated by leading . ., - ,. ' . questions submitted by the inspector to the Hatch inspectors end
their. supervision. A case in point is the code requirement for machining or grinding after thermal cutting in order to perform a - * - , N meaningful dye penetrant. or magnetic particle examination. This is , , Q\\ a standard requirement witli. boilermakers on Section VIII work, but .. . _ g Q is disregarded by many.tinee it does slow up produdtion.
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" ( Staffa and Miles attempted to " brush this item off" and Benagas,
' lh Bohanan and the PIL insPcctor were unauare of the above requirement.
, ~ .: . ' ! The inspector atter:pted to ' catch CB&I in this violation on the L i suppression chamber and vasi advised by Benagas and one of the "' 'I
weldors that an oxy-acetylene cut on cam No.10 wod1d bh welded . f
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on the next operations however, the visit was terminated before O.
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. . t l sis wcld was accocplished.
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Th-inspector witnessed no mag particle or dye penetrant examination.
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Discrepancies observed were alleged t'o be " pickup" points, even an , inexcusable one in which a veldor on the torus velded over stub of
t . Mt which was ic: mediately adjacent to the main horizontal _ joint.
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This is a code violation.
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QA and QO managemcnt at Hatch has failed to review with the fi6ld -
! inspectors the salient requirecents of ASME Section VIII.
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. . - Staffa, CPC's QA Directer, continually defends anything in the ,i.
, i** Uq .- nature' of a discrepancy instead of calmly assesing the. discrepancy. - , - ., .
l in relation to the applicable codes.- ' .' . %. It is this attitude that prohibited CPC fro'm. advising Region II ' - ~ l p,, ! of a, serious incident and, where 3::'not for clie secidental discovert . - by Rc5:fon II. the S20,000 iniurv to the knuckle section of the con- ,
tainment would have been incorrectly repaired as evidenced by the '
CPC and CB&I reports of the incident and incorrect repair procedures.
The ques ion remains, how many other similar incidents in the past '
have been overlooked? '
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. ! J. H. Varcia
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, -, . e , , - . .} . S 1rginia Polytechnic Ink;titute (ATFon'aut):" ~ " ' ' ~ ~ ~ ' ' h 1.icence no. n-W:, Occuct ho. 'n;.u-4 , %(
L ! \\ h, conducted a routinc incpection of the
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kfccilityonf.pril 16-17, 1970.
There ucrc' no items of I ^ 4 noncocpliance or cafcty cignificcnce.. The facility is g % Q now being operated on a core regular ba is and the gb inspector reports a cignificant inprovencnt in nannsc- ...% -- t ment and supervicion.
Considerable unrest c=ong ~
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students and other demonstrators was obscrved at,the - ' D g time of the inspection.
Houcver, the reactor super-G]t D. visor, Dr. A. Robc:on, indicated that no risk to the. u! ...,., facility is involved.
- . i U ' ~. -c i X .a IIIO UATER REACTORS EIDTS CONSTRI'CTIO?t - - - - = - - c b . . , g Ccorgia Forcr Co:ncny (b.' I. Ihtch Ho.1)-
. . Licenco ico. ci rn-ov, acehc c nc. po--rd.L - j i l 6 cnd J. H. Vcrcla conducted an cnnounced , insucetion on March 23-25, 1970. 6 and - - N~ l M continued the incocetion at the licenccc's - !' concral offices, Atlanta, on %:.r'ch 20 The 'incpection
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offorts'ucre directed at ccmpleting the requirements of y.7 %q PI 4600 k and PI 54(00 Concreting), Attachment C - PI 4800. fWelding) - - structures), Attachment F - PI 4000 (Uciding) N 3: b N.- 4 % k cnd PI 5000 pip ng), Attachment G - PI 4800 (Ueldin5) i 7hd $Nk and PI'5000 Piping), Attcchsent L - PI 4900 (Purps and ' Tv .- % Valses) to meet the requirencnta of PI 3800/2. h.
. ' bM \\ ( IScensee's cun11tv _o mtroncdom11tv ennb-M pynym 4 E.. ;.. ~ E; y flinctionintt ucll as an overal' nrne-nm however a CDN- ' 'l D k, will be 1:: sued for n' uca.'tness in the site cuality con-1. } \\ fvn1 nrortrcn in that c cajor relding repair was performed e J-N on the trciihition course (1 nuchlo section), uhich is a -- . J' strces relicved portion of the drywell struct,ure, prior ' % to approval of a "Specic.1 Repair Preccdure" and the con-
_ g currence of the code inspector.
Thuro is cone question p* % g of. =pecific coda requirencnt for thic uciding repair. ~'~~~~^ - ~l Q The licen:ce maintains that d re bruching of the repair N arca catistics' code.
A better practice is grinding . g rather than bntshing and the Region II conctruction -
- g~ inspector maintains that the code requires gridding.
g Thic catter of code requirencnt vill be referred to q% Regulatory Headquarters for rcoolution.- . - ND . g:;:T N. g 9.. a...p- _- 6 k;.O~ .. .
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. . ,. .., , ,. . . J ' 2i ' This assigment is for the purpose of evaluation the licensee's constmetion program i.,' ' . .{...
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' and perfomance as delineated in P13800/2;.specifically, Section IV, welding'.(4800) !. '5' ., .. .
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, e l [ 'Ihe BWR containment for Hatch is being fabricated into subassemblies (Exhibit A,g lM . g - l , .' r ..I l , Photos 3, 4, &l2). Fra the number of assemblies empleted it appears that l .
II . s . ,. I . l installation will be starting before the end of the year.. ..
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, . !- . . , is l Sinnificant Items - ' - i - _ -
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Refer to Details Section (04.b.(4)). Also see Exhibit D-2.
The inspection record:s. !.. .. . - P ' i
t%B1 6m 500 only requires the inspector's initial.. The recorti is filled out by f, ' ,. , I.
j s - Benegas a weldor and he refers::to' Douglas McCusker as the eerson who tested j . - . .a;
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' t.he weld. Who is the inspector? Also, the final status of the weldment, .: '
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according to the data noted is not conclusive.
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Refer to details, Section (04.e.(1)) and (05.3(b)). Only one man detemines!. l$ l l
- t acceptability of radiography. All deteminations to date were perfomed i .] -, , i , ll without concurrence of the licensee or his representative.
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.,. . . ' Defect rmoval verification 'is inconclusive arid do not follow the CBI - ' I . i ! _,. _ . . I . I (: < . .. - ~
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Refer;to,Section (05 3.(c)) ( iJ ~ ~
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. The Contaiment Vessel report (Fom 500) does not address itssif to plate l . , !
i j- . defects resulting frcza are strikes etc.
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' ' 5.'Refertosection(054(6))- E '.
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N @. Heat treat 2nent is conducted and inspoeted by the individual welders and is not
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6. Refer to Sections (05.5.a,b,&c) . i ':. , .. - ,, . . . -.., -,..... _...,.. . ....... - .. _... , -.-- i . tractor does' not'rccord infomation relative to welding material . h, .. Th . " '. control.
. . , - f ' 7. Refer to Section 4805 06 . - . , The contractor is not following his specification GWS 900B, paragraph 7.4.5,. -.- _.
-. . . . , . .. . . .. _ - on color coding examination status and 7.4.6 on repair of defects.
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Refer to Section (06.a.(4)) ,
h- . i . . - .. .,.. . -, . ... ~ Inspection of a 20ft. long weldsent that was canpleted, repaired and inspected . , k ~.~ j ,showed additional defects'. ^ " ' ~ ~ ' - - " ~ - , i .. Analysis of the licensee s QC Program -- Refer to Section (4805.06.b(3)) -
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i with the managenent and execution.of a progra:n that will assure him confor ! '. .
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. ?--- mance with the tems of the contract.
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- !l . - V ' ".' ... -. I (Licensee). (SeeExhibitE.)
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. - p%. * ~. -;L.O.6 Preheating for finet welds for both peman'ent and temporary - .- E* . - - ,d d , - .. ... ...
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', attachemnts shan be 200*F minimum without regard to ambient-a c.
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i.- .-' - - ... , j:t - i/ .', temperature when the plate thickness of the Dry Wen shen plate j_,j; - S:.~. . .. . y , ,... . .2.
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' .w , . ... .. surfaces within cix inches of the point dere weldin'g' is to b'e 'I ' ~ ' ' "
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. l, ' , Preheat for tacking, fitting and pick-up welding is not required .
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y> j , tcaperature is below 50*F, a preheat warm to the hand (100*F minimum)
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- is required.
. . 1.0.8 When tacking, fitting-up, or pick-up wblding is perfomed on Dry - , - G.,,, l q ,
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, - ' Well shell plates greater than 1-1/6" in thickness the plate material p.. g . . ' j ' .. . .. , ir the area where the weld is to be made shall be at a temperature
~ ,. ...v , . .' , , wam to the hand (LOO *F minimum) regardless of the ambient temperature .,
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a- ,._1 ,, , . s: before the weld is made.- - . . +. -- .. . rn ... - . p'.. . f,, E.
Wondestrut.ve Testirut ' ' , . g-e.
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- e.l. Radiograph-Quality ? ? ' ^
- ._ u - - S'-t* ...e P dN. . ~ ., U .3.w.. . %' @ This is a 'one man show' with Glen Honoway of CBLI in fun and only control.
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(,.. j.. Pafer T.(sog c4* 34 [or far er de s E',.. ' ! e.2. Evaluation of Weld Quality From Radiograph - .-
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s - , . :. ., . . . . . ~ . ;' A Same as' preceding . .
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.. ~; I - e.3. Magnetic Particle Examination..1 _ _ _..- .-. _._. _ _.. . . ' .. Both forms No. 500 and WID-21 indicate a documentation of this enmination.
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' s.: , - e.4.*Dve Penetrant Examination - .- . si " , - f.i ~ g . ._ , f-j ' C'onfimed on Toms WID-21 and No. 500 c..
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- - e.5. Ultrasonic Examination
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ply, e.6. Correlation of Record to Specific Weld. _.,, - ~~. ' ,. :' l* . . . .. .;;.; ; t - -- " - ,,.... . .. c.
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h This operation is reflected on Fom WID-21 und' r colu:nns, Description of Weld to be ' e
V.i:.; . .....,. . - tuid , ' ' - - Exn=ined, Rreination and Report No Source of Require:nent.. . ...; . ... ., . _.
j . - . . P Repair of Defects . ! j.'. .
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..' ' f.2. 'Defeet Re:noval Verification . ,. " - . . , l ." ' The CBLI Procedure GWS-900B addresses itself,in paragraph 10 to weld . , l 4= tion and paragrak11 to Rep of Weld Defects and states "Docu:nentati 1.- '
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' , . - . , ! of repairs shall bein accordance with the applicable QA Progra:n. There is no ; j , l ... -... _....,.. ...,...,;..., , . . . . ,~ . positive approach to defect rc::: oval verification ordy that i defect is noted j ' , .l . ,. .! l and corrected. - - - + "f - + r ,-- A.
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. l The writer believes that scxncthing like a " punch list" should be posted daily or ,[
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'. .o + periodically and that the weldor responsible should be identified. Also, . ' T t l l . .. ~ . . . . '
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I progressive drawings should be mintained shoeing weld:sents, NDT, repairs, I J.
- . sG- . .- . - - follod.ng NDT and a final "all green" indicating final inspection and acceptance.
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- e .e CB&I procedure RTP-2B shows Fom GF4 indicate's seam and piece mark, location anii ?- j . .
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. . .. 4,; size of defect, type of defect, no.of inspections and reshot No. and the name l l,' - . .. . . r .' q .., J:,y , , %s ,- .,,, ' of the weldor; however, CBkI were not following this procedure to the letter..
-* .. i ) E- , ~~ j g,. .,9 1.6'. Acceptance of Repair - - ~?.N;- l .l '. . .
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this a'ct is noted on the Fom WID-21 and it requires the signature of the QC l . ,
' - - , . [ l Supervisor CB&I's welding QA procedure (unidentified) paragraph 7.4.6 states: l.
" g... m... _,. p.. l.. - . . , - ,.. l 4...a., gfg, g g, -. -- ., further evaluation are found, the defects are
' ' ' I marked with " Repair" or a red sticker " Repair ~ ... - , '
- !'* Required" and arrows or other means as necessary
- -l-
- . . I " - . . ' . i t i 1..
. ., - . . -# , I .. .. - . .. - s :- :. !
- $
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i % ' - - . , - -
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- Es.
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{- - .,a- ..~., c. ";;. ; ' ' ' "" . '. Te:S . . .,. - - " - . . :y _ 1*** :. * .-~'*9 s, '. J y;
- ....ey k);, *,s. <
S: .?7 1 :. Xu***W r- '.- ~ < * --. we. : ~, y . r , .15% - '. - ~ -- *
- %.,
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.- '% . . ,^ . 1 11
- + : <.... m ,.w 4 p.-c.+ . h k
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..., ~...-. - - . s.
.c - ,, ~' - .. ..g 6..:., - . .. ... n ,. . . ...;.. . . .- s - . .... ... ....,
- ,,n.
- ~. y.,...gi., r,0 .g . , ... . . .
- . ......;- -,.. .. .s _ , ... gc~. I 5 [ hh'(2h (, e.mx =., ,h 4,[[2fy . - n.
. .... ' ' fk O,l,'f --* .
... __.. - . . LJ tJ . . . .u,. . .. . . . - s *. . , . - . . . ,
-10-
. . i* '. to indicate extent of defects. Such defects will.
- ]
j( be shown on the " List of Repairs", r:,ferenced ,. , .
. g . r.'.' "1 in the report cohn of the " Field Ernmination ' p-I .. < ' Check List", and signed off when the' repair has '
- ,,.
,... . . . been c mpleted. Usig this system, exact location. - . p_ , l[,l.; * . ...m.. , . i.
i,. of nonconformities need be retained only until .~ . 1.
l :,".' .. ~{ - such time as the repair has been made or the - I ' . 1M .g /, ,' _.. ......,...,._ . .... q.... ~:. part replaced.- .. . - . . .. -.... . ..__..s .... . No such evidence was observed k who obs'erved over 100 defects.
' ' i 4805 05 Record Review . , . -
. !
! l Chicago Bridge and Iron vaadn the process of pre-fabrication of the contaib '* t . t , . . - l ' ment vessel. On.a supling basis the followl.ng records were reviewed cnd "
l ,,
' '
l . n i . the results are indicated.} .'f _
.- ' .
- !
l - l . l.
l, , l i .3.a.
Radiorraph Quality,,% ,u.. _., ..,.,,. _ , j l - ' .
l he inspector viewed 37 radiographs of the contaiment botta head. The
' , ' . - .i . ,.., .., a. .. ... g.c ..,%.., _,,, y.
j.
.y , .....; .,. ,
i , radiograph quality was as follows: The 2T penetrcmeter hole, the penetraeter
l g - .. .y.. .
- *.
outline and ident numbers were clearly visible. Using.a densitometer '. defirm*ned-th C. ;-.. . --s - . .# the inspector the film density to be approximately 2.0 of four films inspef.ted.
, ' l e
i . .- . . _ _, ,, i The specification RTP,2B range for density is 1.7 to 2 5.
The films were ;. . , - r, ,- - _.
.. , generally free fra 'chnical and mechanical defects. ' ~ - .. . ~. .... . - _,. . . .
- ..
3.b.
Evaluation of Weld Quality Frm The Radiograph a .e , s.
l~' 'WL' M.
l n..;. - . . .. . . ...... . - The CO inspector took issue with on3y one interpretation. he revi' ewer . ; '.
, - 4! - - = . a... .., -: g .,..: _.
~ ~ N.l cinimad that Assy. 7 to 47, film 2 to 3, was scratched.. The CO ixxpcinspector n,
. l , . . . . ., .. - . ,, . 941
could not. find the scratch on the film which when projected showed a. I ' m.. , .. . , j
f' discontinuity. The CD inspector asked F. Dutton.of CB&I, S. Tucker and - . , . ~ - -. g , .'f.
.,,, .. - . others present to inspect the film and try to find the " scratch". No one --
- ,9
' I . . -- .. y ,. . . .. was =W able to do so and Dutton ordered a reshot of this area of weldment. -. 4.' ' , l . . , - e..
.. . _ . . - 3.e. -Magnetic Particle 2xa.nination - ., M ' .- - [ . .. . -4 - - ~
- g
, , . The contalment Yessel Fom500 (Exhihit D-2) and the Field Examination Check , ... , .o - ~ . .. List Fona WID-21 indicale "sme" recording of this method of examination. l . i. ". -
' - .e.
. .. . . ~. y y: 3.9.,3: 3..,., ;(,y.. 4..; my c_ - 3 w..y _ y: - - , c _ . . ...
.
.. ..m ..,. =..... - ... ,. .. \\-- .m.... . .,....:.....,.,, h, ....,..... a.:. ....,... ..y.. e,,........ w,. a.y --,.. ; . . . . . . q. t v *--. h - n --,..... - - .
- .
.. r e.
. ~. v. ( +, , v.
- e w~. ~ i. ;. -. 3* - . , - i:- . . . u J 6. v.
1,. )
- {
t.1.L,._ dL-r. {, ._ J.
1..i G,. 4' h :r G. - - ' j. :. g.'. $ ' ;' r. .'.... a.
t- .. . . . Ib .9.- . , F - r- . _ . " ' $ hhh h h h h h h h y }$(,h..l & f f
. _ __.
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- -
.
.~, . . . - .. -. . ..
.' t '..j
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-tir-y , , . c'Ji,. jr 8; 4.d.
Qualification of Welder - %.-.. "n . i The contractor maintaina a list of the weldors and their quaifications;the . ,l~ ' fTC.b4
- i.
. , i,5r - . ' fabrication reports do not state.whether the veldor is qualified or not .i, $-;;$ * ': je '._ p x j
- ,
' . and this inspector (CO) does not consider this to be a requirement.
l ' 5,~.,j
. .._... ' " ,- - , . . ,. 4.e.
Teat Treatment , . , . , , The fabricators records do not verify or address themselves to this ,-
, .. I h l process. Each weldor has a "Tempil Stick" and checks his own work piece for. J
. j temperature and no one records this infomAtion. The CB&I Spccification !
. h I i ~ . - , , t l GWS 9004 paragraj.h 0 4, Monitoring, states: . i - I . l . - " Joints requiring preheat will be checked before welding of L.
.
, ' , the joint is started to ascertzi2 that the minimumpreheat - - j temperature has been reached.
i p g -,... ... w.. c. .. , . ! N Periodic checks will be made while welding is in progress J ' j l to insure that the required minimum temperature is bsing . , ' , j maintained.
l .
i i ' _ i Temperature indicating crayons will nomally be used to l - '; e i detemine that the x joint is at the required mini-n j ' I " temperature or above.
% '. lj -
- ]
, ,- - 4.f.
Accepta'nce of Repair , , t , p, Remarks in 04.4 a & b apply to'this function !,* ' ,- . , . u 4... . c 1 %a., !. 50 Records of Welding Material Control
' . ,< .- ???f) i ! 5.a.
Issue Control Exhibit D-2 indicates that the electrode ., 7,' i l ovens were inspected at 8:30 a.m.,11:00 a.m.
' - 5.b.
Post Issue Control 1:30 p.m. and 3:30 p.m.
Records are lacking ' r- '. in the identification, issue and disposition, !,, . . j 5'. c. Disposition of unused Material of unused material.1 < ~ '
j480506 C. ' Observation of Work Performance
" ^ s..i l
- *
' .' Fabrication of contaiment subassemblies was 'in progress. Observations a ; , , .. , ,
t . I ar an'followsI .- l ,. .
i .
i a.1.
Availability and use of prescribed procedures for weld perfomance, ! i.
'
- . . ! l.]- . !.jc including identification of Weld Type and Material . . . w m; , s?. is. s i,. ... - - . . . - l , - ., g.;a
"- , : ,.
. , ik.* M.; * * ** "' ' ". ' -,y. T..~ :, . % ; Mi
- 7," '. ? '* 'M('~ 'G, s 2." ~ '." 7 ':
- wi . . . . . ....s . - .. ;2 .,. . '.
.. . - -. - ea u .<.i..=.. - ..... - .;; .. > .
. -
- =.. s ;.g,
v.
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_ _ _ _. _ ..e e
- y '..
. '. 'O L-s,,..
- - ~, .% , h,.. . . . . s ., ., ,. c ' wQ.
. .13
. -: - _ . .* - . lf, A CD&I does not confom to to paragraph 7.4.5 of their specification (unidenti- , ~ - - . t;n g .. - , . . .. . , M.. -
.. ,,,.. ,"r' ' - ! ,
e -
- .t
. . Wg*C fied) which stat'ss.4,:.d.. ~l"~..,1
- l y'l-
- ,. 4 W...!y q.. g.w g.^ f..,
" _ - *.
- -.
' e ., p y; . " Color' p y ? W, Q.,}. k
. n :.m.
' . , codes adhesive tape or other marking means (; ' i ~ -F . are to be used during each field eyeination, ex-i
- ,-
. .,.. 1.. ' ' ' cept 100% radiography,'to indicate inspection 4~ - l
- l...
-. ' l status of item, seam or ccuponent.' The'non-destruc-
tive x testing operatior will mark 'MT OK" orTT OK", ,!. - l an arrow at the start of the e_= inntion and a reversed p.. arrow at the conclusion of the examination. For the - c7mination of seams, a line shall mark stops and starts . l . , as follows:
' -
, .- , . i . ,. ... . ,
' . ,- j - - t .
.. _ .- . .. . - -- .. .. - .;. - .
- .
' < , II ~ [ . _ Small attachme arr-tRi signedm otf-' Mil " I' *
" ' ' ' ..- ' or "PT OK" thout arrows.
, -l it CBk1 does not conform to its proceduce paragraph.7.4.6 which states: . -- , , . . ' % "Whenever defects rcq. drink r'. pair or subsequent . ' -
further evaluation are found, the defects are marked . ' with " Repair" or a red sticker * Repair Required" -
- 'e
' . i
and arrows or other means as necessary to bl ' j indicate extent of defects. Such defects will - -
i n
be shown on the " List of Repairs", referenced 4 . ,. . in the report colu:ms of the " Field Examination - f '.. -
- '
,.fDGGE Check' ixzdp List', and x signed off when the repair has ^ ' . ,i been ccSpleted. Using this systs, exact location.. I_ ' -
of nonconfomities need be retained only until -'. . . ., - f .
.i such time as the repair has been made or the - .. '
?.,.,' - M,,,. 4- ~ ' ., - . .s. ~,.' CD&I does not ec tfom i with their procedure 7.xx para. 6.1.1 which - n . , I ~ states, "Each layer of welding shall be mooth and free of slag".
- , . , . , - _ . . . . Weldors were x observed attempting to " boil out, the slag rather than - .?_ .. .\\ . , - i . mech'anical.17 vmove the slag. Spec.GWS-900 6 pg.t I.O.2 states" All slaga ll .. - .-. . ' _ . . . ' weldiq prior tb dossiliq' Inspector % net.fbead.*~ ' '. Ves,oec dfre,, cat.h beado(hld ', ' ' , l . location. Weldor and - - f l a.3 ' Identification of w , ...., _.. . ... _. _ _...... _ . . g g*s ~ , ' y- . ' s' w'as satisfactorily demonstr#,ed.
'" - ' , _ r. '.
i -- .] ', .. l* . , , h.
l. . . ., . - , ., - ,v . - - - ...
, ' . . , . -- - - .. , . j - . - - . , S.'; ) ' , 7.' . [ c.
. ,, 7 E '.* * ; I'.' ;. ~ -c - ~ '1- .~ - .s,k' ll ' f j-t..'.[- - v. '
ld*N %, - . . t .;A, - -- ._ . . . - 7, q,. a - j g . <4 , , " <' ~:4 . ' ,,..
,, - - - - ' * ~. ,. . - - + . ,
. J a..;. y U .p.4.;,a...j ,, "W n.
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r -- ;-v.. I' -
g.,m. *,t-1.1 *.w ng.
. ..v-- -.. s;.., .s.---
- e
. ~.,g g.sg h :g.
. - ,, -. .., . : .y,4*, p= a.
..v. e... r.,- - iI - - . . .... . e ;.n . . . ;.. - . c . .z.
.-
nzg:i. . . . .D.. b.u. G *."i::':....[ - L ' y,3 'd.
.~ . . M YN$NO M Ws{LQ Mig.ffh%QyQ ' l
. - - - - - - - - - _ _ _ _ ___ ___ _ L.' L ,.- < o o - gi . .,, . - - . . .R - . a, . .. .~ .
- . : - ~
... , '. A^b - - g , , . .. . . a.C ~ PhysicaT A5pearance of Partially Completed and Ccanpleted Welds . - - . . .
( -thrus .There was no ev:Laence of ^uutu Lh4 a
,v-
~: - .t ' . .. - ..,;, ~.; y,- . , , % - (b)-Cracks: - A crack was observedyhich was overlooked and ohly partially
~3 ground cut on PcMk 302 - BR to 302 - D shown on sxhibit. Al . . .., 4- ' " " ' - ~ ' . i l s . N
70 pv4mity vzutobserved on finished and acceptable weldsents
- .
' (d)-Undercut: Under=t was observed on an accepted weldnent of the j supprcsion chamber shown on exhibit.4 f I ' ' i b ' ' ' l (e)-Weld'Profiie: - L' eld profile by weldorh was not"'acceptalbe acco
- -
,
- - - ~ " ?. _ - . , . , to AWS welding Inspection, page 88 in that the i , , ~ ' ~ wcldaent indicated'sp$tter and undercut resulting frcan - . % excessive high amperage _, , , ' m i ...
- .
l - (f) - Presence of Arc Strikes and wcld spatter on Adiacent R Surfaces N
N
f (See Photo No.10 - Repaired and inspected wolding cont'ained.
- j
,M ~ 'Vddr/ fag / unrepaired Y $ p~eeted are strikes.., ~ ' ' . w
[
_ ... -. w a.5.
Identification, handling, and control of weld materials.7.1.
- .
. m 3.... , _.
.. , -~~~ This operation was found to be satisfactory.
. . . ' - . - ,.. - . b.1.
Weldrepairincluding(SeeExhibiEA. Photo 9) m g g h;,., _ ~ '
(a). - Method of Rmew& was.tound to b~e inccznplete.
'LIC n "' -.,
, r ) - Verification - Verificat ongnadequat..m,e L.ups" were super-fuc% ~. of Me de s as 2 =p
- .
' L-l ' ' g.
", f.;,'
b
-+ '*M mal---J '.:. ' ' ^ tavnb oaf' feavi c'e/uh wbid wcre dit ried .- t.? - %.
, _ __ ; _ ~+ a__ h_____+_.-C"'- . , derc + _ -- _. a__+ a_ d_ - ,,_ _ a (c) !- Confomance to Reveld Procedure (See Ekhibit A. Phcd.o No.'1
- "
.O.- '] . The CO inspec attention to inspectedweldentland'adjac " .. p-- - p.. - . . -.._.._. _ __............. a , _. - ._ _ _j _ _ _ _.
, _ . ,
_ l gouges, undercut and a crack on plate material where a tempor.ny .
- ~
' .
! ' - s .a .... -, . .. , . (- l . attachment was much M CC removed and only partially ground u , ' l j. 3 l
- ,out.
'_
.. ,. . ,.T v r. n -,, , , ! _ ... ,,. , . t .. i,. - - , ,
i , ' s'- I . - , .. - '. . - .... '-
. .. . , ' -,, ' ... D.&{ '; ~. ,Q Q-4[
hy [.l lIn - 'i l_ *,[ g
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- . ;.,.gn.. ;..
.;. - w.
, y . .. _._ . ' ~ 'y.{R.y p ,4* ;.w '. - ;,. e ' op,-. pp &',.'m ',-;*b,.,.;.; , -h,3*..-r'
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. . . . go.J
. - . .e . .g .. . -15- . . . -- - . - r . ..... .. .
- -.
g< ,; _ . . - . . ,. .. y,, b.2.
Availability and Use of Prescribed Procedures and Performance of .J , a r . . o..O , E.,. QC inspections for NDT . ~. L w...,. w.. g . , ... ~..; .
- -
,, ~ &. y n* .. e. g. ~ m -e.
- - . . !-l."
IP' CB&I specification No. 69-4153 for the Edwin I Hatch Nuclear Station . ! . , ~ , W.
v-n;.. . . - -s ' , ,.- includes Radiographic 7-inatien Procedure RTP-2B, Liquid Penetrant F=ini ..p L.q - t t , . . ' < tion Procedure PTP-2B and Magnetic Particle E=inntion Procedure MTP-5B.
, . . a.
. ' I E ' These procedures reference the following: ~ j
- ,,,.
. '.
- ' c-.
,- . . ADG Boiler and Pressure Vessel Code, Section III, Nuclear - j. ~ ' - .. .
- .
. .,. -
. . {,~ ~~ ~ ' Vessels Sub'section B,1968 Edition and Winter Addenda 1968 ~...f1 "
'
' ,
- y.,,
, ' .,. m..- . . ~ . ,. I ASME Boiler and Pressure Vessel Code, Section VIII, Pressure - -., ~
- [.I l
. , , ., .. . . .. _ ' ~. ~ -,. - ,
l - Vessels, Division 1,1968 Edition and Winter Addenda 1968 e *'N
' - , . ..,
., < . . u:o n - i ASE Boiler a.nd Pressure Vessel Code, Section II, Weldingi.u: : ., '.
w...,.:. .. .,..., - -,,,,, . , .... -, ,., I l, [ ' Qualifications, 1968 Editien md Winter Addenda 1968.
j . ' . t . . . .t.... , . .. ! O.3 CONTENT - ' ! I'~
' .' , i. : ; , .- m g .: ;. "- _ 1 t.
.. . . .. .,
- .
Included in this ;gg specification are the followings. .< i.,. . , _,.. - i Y*.
- .
. -
- s.
.. - . .. 'L s., - . <
- ~ -- -'. .. ' . General- - ...1'. _ .- - ,. . - ,. ...:........,. ..,n_ y - .....,;--- .. . .'. . ;Jf Attachment "A" g r of Welding Procedure Qualifications ;rm.
j, !~ '. List . y s.,.,., s... ..e . a.. a
- .
.<
- L; -
.- . - . . ._ . :-. 1, <. ... A. y . =9 ~. .n - ... Attachment "B"....Preh at Requirenent's , , 8.. ;' I .- % . . .... .,. * 7,. :,. ?. m ~..a.'..:r.: . d.,.. .c . - z.
m'. . l Part I Preheat.T Requirements for Dry W,11: '- fi,yJ;- ~,.. b.
- 77
.-. , Q:p.
, ,,t,,,,.m.,
- ,,
. - - , . .~ ca,m,, :6. p[c.:,.4. .,. 3 ' ,'q$', ! - ,a4. .,.;r, w =1 y e..;..c.w. - . .. Part II Preheat Requirements for Suppression ChambeF*,:3j ~f f ' 1,.e.. , -
w. : w: .. w.
v . ., ,~.,, ... u... ... . . Preheat Requirements for personnelIocks & Hatches S ('T,f , h
- Part III
- .: .
- - - " .w.n; .. .. . ..., General Welding Procedure; E7018'.i:. Q.p 4.p;#23:y',.h. a G v'; < . T Supplement I - ' .: . - -.. - .,..w. 3 ++ ::. m.,, .. '}' . i;,,. . . _ _ . - . . l l-Supplement II , General Procedure for Welding Wide Gaps & f ...., _.. S' . . .. . _.-- m.._ c.a.. w. -._ - ,
- ,;.,,
- ',;c.,;,.
&l ;,.j.',h i ~ l- .- ,
- f5SEIs=IHtih '.correctedJZA6f69Ro edd.:Rar"FT-TD.+
l ' . -- e.- . > :.,. ~ :.. ;.. s.
-
- -
,,. .
. ....i.
. . . .... .7 _ %;, ~... e . .... .. . I , . . . ..,... ~... . .. .. .,... _,.e .- ,, . The writer considers the procedures adequate but considers the'perfomance ! y; l:t. r , , ., ;. ;. s., ...q.. g, - p g .. . I , of QC inspections inadequate. The performance is inadequate Se'i$ause, thei.e,es.y (a [ -
. ga. ef.t, f.,Q.. ~ .u_.r...:u %.'
- ,
... . . ...e.._.,.7., - . _.,. +.... . ,, i .-R:ap:W.y h Q Q; S, %,:x3 . . t.ig, ,,-:
- R.~l
- L. o.:.. ? -..:.-? <::'
%., ' c . 4..., ..r. . s n.c. w ,. . - . $
. .- m, ;b. y p.p. xLwc wytv:~.n ; y,. g - . ...- . . - .. .p. x y.
.. y.
u . u..,..,.,...g.--.
- ...i..;Vn
- w
.p p..> }y'.;q:&qim G.. e c.. ..:.,,.. . .~.. ., ,,. m.,.. ..... . q. Q'.... n >... y.. . ... . ,_ s.v.: &.. , - s p.. ;-p M ' 3 :. q L ;t. ; ; p'. p.
' .y-A t' '
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> : .":::.4. '):....' .. >j - .- - ...
- -
.,.. .s. -: .; ; .- ,.. .': :t......' .. _.
..-. m..,. p - , . ,., , _ , q, z.g.
_ j'y ~ l. * _, f.e.c. :9_.
g j g{ +.j. } g ,
l . ' - ' ) L-t_. , i ..- , .
- .
co o ~ , ..1 . ~ - .,. - . . - . ..,. n . ' = ... . W$'e' y ,j a-t %h*- s.of progressive. prorrs=ned controlled supervised inspec. -e t ' ,
116 ey de nc e - , . - , ., . c..,. ' - - ,. . ,' M,'y ' - - tions) 'Iho writer toured the contaiment pre-fab area in th's company of
- .l .. . l. C - Y ~; G - .;'i.'i' - ..J6 i W;' %.. a.a ..ag.
- - .CBkI cnd Georgia Power personnel on three occasions and spent considerable, . ] ].- gj.
' ? .. -.~ .-
- :,
,a ... . ,. ... , . r ..,(time looking at welding x.in progress, c_o=..plet.ed weldments and repaired _.,.. ~ -.
. . .,. ' . . . . . , L - , weldments cnd every time this inspector pointed to a weld defect that was
s. ' l . ~ - .- l not circled or in scre manner " flagged". he was told that the partienh i ,- . ' - - - . L i - _ , , , , l.
. u assemb(y had not k received final inspection. In scoe cases where
- ,
'. l " flagging (with crayon) was done, there were additional defects undetected y,[., . . and to cu=narize, there was little i evidence' that defects requiring'NDT ' ' ._ - . ' , ,. ' notafsins en '
i .-were inspected except for notretionoon the welding check-off list which did hot
s.
s . I /
[ . correinto with the weldsent 100% i.e., t.here were defects other than those ' . ~....,.. 4:,...n. .:... g. ,.. - - < .. ....,..,.. . ' ., ... . F - recorded ard so=e of the defects were not flagged for NDT.
- !
-
c . l _ . - , I . ._ l E.3. Analysis of the Licensee's QC Program ^ ~ I - ($ - - .
. 'PPcM.s g . ('.,J Frca the preceding observations it effp=re that Georgia Power is delegating . ~ . ~. . ..., - . .
, On the last day of the inspection the writer - !' f-t or buying quality control.. u . ... .
- .-
q - '. ' '[ asked Mr. Mil's, Frank Dutton and Compliance inspector Upright to step outside. e ..
- 3
.-
- ']
- .
.~
- ::
. ...._ ,_ . ,*. 0 of the CB&I inspection trailer for the purpose of a discussion on obser-- . '!- -...... ; ~ - D u
- -. ;;,. ;
.g.
- )
, - , . . %y' vations delineated in the foregoing report. The somewhat private atmos- ,e.
I._~' t ,
.: . . .3 ; ' ..::
' 6..
h.'.,$ l phere was desirable xx since th'ere ker's weldors and inspectors 1[, the".QL;. 99_.@,s y.
i ... . ,... .>..., ~...,.. e ' . -.. . . ,.. . .- . ... .. .,Q b" .... . . ! p:c trailer that might resent an eacpose' of their dayh.ativities as seen, . .3 L.... t; ?;~ .. ., -. . .,j,.p.
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- . . ? J - q- , j l I told.Mr. Hiles that I wanted to asce myself that I had the correct ' w J. :,.. . . .. m.
. . ' - . - --.- y, f - .. 3.;, . . . ',. interpretation of the relationship 'between the ' people' constructing-" - , .. . * n... .. '. l Hatch. After reviewing scue of the salient observations, I daid to Miles; E F,"4 -,
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ti' contairment". Without hesitation, Miles' state, 'To hired the best.
j' . c*.y . . .. ...,,. , - ..... ,.... . ~ -b-}- . . ' vessel manufacturcr in the country and'we are buying the:r quality control." *,' ' : l. $ 6.,D '.y.P - .b. . -.r.. m ~ u.- 4.kg'.W v - ,. --. - ~, ~ y ypy '$ l:,7 . Thie quote identifies a problem area' and. indicat;es the fai1 re in execution ~ ! *.C
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.u n. ~ ^ - l e.I wQ of the Georgia Power QA 'progra:n, and based upon'observntion inn other ~..i - p..:-p c' . - .. activli es, in particular the concrete operation which disclosed gross p f., - .. . . ,. C . j 1, < . . i negligence in the delivery of a a: 4 cubic yard mix which did not contain l.
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- , I l [. - .h ~ c$npounding the' violation, it is evid'ent that the GP rite QC -does not i
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understand its function. GP has all the tools of the " Trade" but one, and
- ,, - . , that is the most' essential, it has no experience in field construction ' I", '
' ' . ' .- _, .. . , .g . that demands virification assurance proof and a progrE:ned way of life - " ', ' h~ }"] . .., -, .4 K ,, J J .* <-,, ,. . T , - . . . .', . - for the site force..-
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n.,._ - - = - . H. 2, = .' - .. a . .. y ,,;. . U, The GPC site managment maintains a daily log but its reporting merely [g- !.. m :;.. ' ... . -
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. .. .7 The inspectors of GP, CBkI, Pittsburgh Testing and the Standard Construction. [.1 ' _ _ .g p w..
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5: - . ... . .. .. ... .O. ~:l . must be an inspection point program but so devised that " tunnel. vision"- T , .- m. -- ' y. - - . ., e r."
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r t : - ~ n.w. . ~ '..,; ';' D, j:n., .i not be a check list it must de:nand in depth observation igt including ,' % ' u p ,. ] ! . . m ;s .,,.:. ., !{ , i ' -[ r J-important conversations with other organizations involved. * An exampla 7 t ;, . . . . .. . . : , , .- . . . .
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j Fy. ' of 1 a la:itity is the problens which E. Gillcapie (GPC) was having 'witf.
..' . ' *- Nk ., . ._. ;.:.+.. . ,,9.. p . . , 7, l CB&I., Gillespie stated, "thht,CB&I supervision was giving him a hard. ,, i.,. b ~.y ' . l ..-- .%..;.. -,c ........ u ~
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.. i . .. .I I ' U 'instead of the continued disregard which resulted in Gillespie s feeling ' .. ~f i:% 'i
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k.,. -- i . .. ~~ ' @s t 'of helplessness.
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-1B- . ,G Pi'Ci /Dur PA.fr ... - THE UJC.tT22. O CSE2VCD UJELhtAIC iti PROGLEtr Ca'EL A / .r,& - Lwit H COWTA fMED A 3 Malt. AMo uNy DF SLAG. C& rec.es]Ce. or: 7HIS DesED/ATIO q.y -y f.y ,, * '"$5ToSAfkt".M'#iSWF4MrMd8"MstMd!#pnw" ' -- -- . ~ . . . ',yhi^ m ~ * '- " the-elag-ranovedAo-condi-bien-wae-.inver,tigated-and . e.- . ", ,- .. ...-j.y :yyp.,pg..g;, v,.5.- g.,,. : _, c.. - - + . . 4[- cn-a PTL report 89 dated Septaber 12; Itan #7 stated Wee wMers m, !f J.
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. . ....... - - .. w ~- -- erved not to clean the slag fzun_ their craters. prior to further depos n. ", . - ~ . . First of =11 GPC was not aware of this proble:n, secondly, crators should be' .,. > - -- c.rct W - ' avoloed by training the QUALIFIED weldor to withdraw the electrode slowly and
. ' . , - thus filling the crater with metal or by using' foot control on the welding , t '
, , ' machine current. '(See Welding Metallki$gy AWS page 235 on Crater Cracks . .
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- .. .. . . t . in Wgid Metal.). Compliance discovered the foregoing condition in a matter, j l ' , . , . . . ~ '
- of hourt, in contrast to the unawareness of the licensee of these and other i H
. " ' deficiencies which have existed throughout their residency. To return to . -..,% . e .,..... ..,, p.. , g.
. .,,, _ , i- .. . the progrreming of an inspector's activities-it is not enough to daily repcrt .. , \\ ., _ , \\
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- .- - - . ' ~. probic:n areas, they must be ' logged" in a manner to give UISIBILITT.
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, , .A . . .. ~ .. .. The writer used isometrics of piping . This can be done in axyx many ways".
., . a , - . .. l . .._ systems. They were displayed on the walla of the inspection office and .' . gifits. . :. . . .. ',. ' V - the ixxpx incocctor noted in detail the weld r cher m ' rwa the r ...,,. -. . ... f
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., j , , c ' cut shorts', cold spring, as-builts harigers, testing etc., in a progressive - ]g .. ~
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. l assigned inspect'or kept the visibility current andk hx*x his daily reports ., . , cAccl aj.pt in a Y" r 'sel" Mn folde!r (4/d4t*[e4ft*['llMel'd[ ~.' 'i dY %- t.- were'ke a ' aAs.cf s-e//w/' ~. - . ' ~ " l 4.
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- i The foregoing may be delegated i but the licensee must be fully , n. aware.
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~ - . . The ' quality Assurance Manual can be perfect fro:n the stand point of its - T." '- , , p.. l
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