IR 05000395/1978016
| ML20062C894 | |
| Person / Time | |
|---|---|
| Site: | Summer  |
| Issue date: | 10/05/1978 |
| From: | Conlon T, Crowley B, Girard E NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML20062C875 | List: |
| References | |
| 50-395-78-16, NUDOCS 7811150067 | |
| Download: ML20062C894 (11) | |
Text
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"- L i.,, [ ATLANTA. GEORGI A 30303 ~ %...../ m:.. ' m e ' Report No.: 50-395/78-16 " h . Docket No.: 50-395 R: y + 'EQ License No.: CPPR-94
, Category: A3/B1 ' " .. Licensee: South Carolina Electric and Gas Company P. O. Box 764 Columbia, South Carolina 29202 - Facility Name: Virgil C. Summer Nuclear Station, Unit 1 Inspection at: Fairfield County, South Carolina - Inspection conducted: August 21-24, 1978 Inspectors: B. R. Crowley E. H. Girard - Reviewed byr& b e s.' Nk 7? e>p - T. E. Conlon, Chief ~ Date Engineering Support Section No. 2 Reactor Construction and Engineering Support Branch-1 ] Inspection Summary O Insrection on ^Ugust 21-24, 1978 (Report No. 50-395/78-16) Areas Inspected: Routine unannounced inspection of reactor coolant pressure boundary piping; safety-related piping; containment structural steel;
safety-related structures outside the containment: site housekeeping. The ? inspection involved 48 inspector-hours on site by 2 NRC inspectors.
! Results: Of the five areas inspected, no apparent items of noncompliance or deviations were identified in foiir areas, one item of noncompliance (Infraction - failure to follow inspection and welding procedures) was identified in one area.
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'. > '. ~ ' - * [f / 6 ' D' ' , ', - E B. R. Crowley, Metallurgical Engineer Date $/p Engineering Support Section No. 2 j }~2:/s Reactor Construction and Engineering k,- , Support Branch I-. , rc;jp Dates of Inspection: August 21-24, 1978 uw ..[)N Reviewed b f [.. _ _ [ w n [.f z - ~
- s 17 T. E. Conlon, Chief
' 'Date ' . ' eL Engineering Support Section No. 2 Reactor Construction and Engineering Support Branch ' - 1.
Persons Contacted a.
South Carolina Electric and Gas Company (SCE&G) ' .
- J. F. Algar, Nuclear Site Manager
- D. A. Nauman, QA Manager
- H. I. Donnelly, Jr., Site QA Coordinator-
- D. R. Moore, Senior QA Engineer J. L. Gypin, QA Surveillance Specialist T. A. McAlister, QA Surveillance Specialists S. E. Cash, QA Surveillance Specialist
.i b.
Contractor Organizations Daniel Construction Company (DCC) . ,
j '*J. M. Harvey, Construction Manager ] (])
- W. L. West, Project QC Manager G. R. Curtis, Mechanical QC Supervisor K. Heaton, QC Engineer j
J. Hanna, QC Training Coordinator in,.ddition to the above personnel, the inspector interviewed other licensee and contractor personnel.
- Denotes those present at the exit interview.
2.
Licensee Action on Prev _ious inspection Findings (Closed) Noncompliance (78-10-02): Failure to follow weld procedure . The inspector verified ret raining of welders as documented on Welker ~i to'Donnelly letter dated 8/18/78.
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16 l3 (Closed) Noncompliance (78-12-01): Failure to follow procedure for , documenting larger welding data: RII has reviewed licensee corrective . e 3:-f action and has no further questions.
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Unresolved Items
' ,,u No unresolved items were identified during this inspection.
'. ;y 4.
Independent Inspection Effort , s,. : ,.g The following areas of interest were examined by the inspector: - 3 ' a.
Walk-through Inspection li A general walk-through inspection of the reactor building and x.
auxiliary building was made.
General site cleanliness and overall , welding and inspection activities were observed.
' - b.
Reactor Coolant Pressure Boundary Pipe Welding Reactor coolant pressure boundary piping is being welded in accordance with ASME Boiler and Pressure Vessel Code, Section III, Subsection NB, 1971 Edition with addenda through the summer of 1973.
The inspector observed the following in process welds at the stages indicated: FW6, ISO DE-RC-06-C: " Hot Pass" Complete, no welding in process
FW7, ISO DE-RC-06-C: Root pass in process i FW22, ISO DE-RC-06-B: Welding intermediate layers with / automatic process h.
FW16, ISO DE-RC-06-B: Weld approximately full with
l automatic process, no welding in process The inspector examined the weld appearance for the above listed welds.
Also, intermediate radiographs for FW15R2 and FWlb on ISO DE-RC-06-B were reviewed.
Welding Qualification Test Shop c.
The inspector observed in process welder qualification work in j the welding qualification shop.
Five (5) pipe welders were j observed in the process of welding their performance qualification test assemblies.
In all cases the welders had a technique sheet - j describing how the assemblies were to be welded.
The assemblies
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4 . RII Report No. 50-395/78-16 I-3 - , p 0; y " ' In the areas inspected, no items of noncompliance or deviations were 5., a identified.
5.
Safety-Related Piping (Welding) - Observation of Work and Work ' . M+ - . Activities 5:' 1 0 7 s ' The inspector observed the safety-related pipe welding activities described below to determine whether the requirements of the applicable
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/k code, specifications and procedures were being met.
The applicable code for the welding is the ASME Boiler and Pressure Vessel Code,
Section III, Subsections NC and ND, 1971 Edition with addenda through the summer of 1973 as required by DCC specification SP-220-044461-000, ' " Erection of Nuclear Piping, Virgil C. Summer Nuclear Station, Unit'1".
The following in process welds were observed at various stages of fabrication:
( FW-8: ISO SP-06 FW-3: ISO MS-06 FW-1: ISO MS-09 FW-13: ISO FW-11 FW-10: ISO MS-08 . FW-13Rl: ISO MS-09 FW-17: ISO MS-08 FW-17: ISO WG-13 FW-14: ISO FW-11 FW-1: ISO MS-09 FW-11: ISO WD-08 Weld identification, joint preparation and alignment, evidence of QC verification of fitup, use of specified weld procedures, weld appearance, , l welder qualification, use of specified preheat and interpass temperatures, use of specified weld material, and practice of grinding starts and O1 stops, as applicable to each weld, were examined.
l FW 10, ISO MS-08 and FW 13RI, ISO MS-09 were examined to determine if l surfaces were suitable for the required NDE and if the proper NDE was I being performed at the proper state of fabrication.
During observat. n of the above welding activities, the inspector paid special attention to preheat and interpass temperature controls and practices. Most of the welds observed were heavy wall carbon steel which required a minimum preheat of 200 F~. The preheat was not to be interrupted until the weld was 30% complete in all cases observed, these requirements were being met.
The preheat was being maintained d with electrical resistance heaters and blankets.
The only time a " rosebud" torch is used for preheating is for fitup and tack welding.
' Interviews with welders indicate that this practice of preheating is the only practice in use on safety-related piping.
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e* ..;; - . ) t [ RII Report No. 50-395/78-16 I-4 .en , ': Welding wire room Nos. 2 and 4 were examined for storage conditions, . /j - issue records, and handling of returned materials.
Welding areas werd ,' examined for the presence of uncontrolled welding materials.
' .# )[g1 ?)F:,j _ In the areas inspected, no items of noncompliance or deviations were identified.
7,a I;ff; 6.
Safety-Related Piping - Revies of Quality Records m ,, l% % ' 0'? J The inspector reviewed the safety-related pipe records described below ..u to determine whether these records reflected material characteristics . Dj and work activities consistent with applicable code, specifications and procedures. The piping components were procured to DCC specifica- . tion SP-544-044461-000, " Fabrication of Nuclear Piping - ASME III - ' Virgil C. Summer Nuclear Station - Unit 1".
See paragraph 5 above for ) the applicable fabrication code and specification.
.. Records relative to material test reports and certifications, vendor manufacturing, receiving inspection and installation were reviewed for the following pipe spools: , i.
1-CS-57-03 1-CS-57-09 l-SP-06-02 1-SP-06-05 1-SP-04-03 1-SI-04-02 - 1-SI-04-01 ,J 1-SI-03-06
1-SI-03-05
1-CC-24-05 t (< ~). The following records, as applicable to each of the above pipe spools, were reviewed: a.
" Receiving Inspection Report" Nos. 1806, 1424, 2145, 1894, 0970, 1576, 0273, 0256 and 1654.
The receiving reports included receiving inspection checklists, except report 0273, which was documented under an earlier revision of the receiving inspection procedure which did not require a check list.
! b.
Material test reports for chemical and physical characteristics.
c Southwest Fab isometric drawings.
d.
Southwest Fab NDE reports.
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SCE&G " Certificate of Inspection".
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" Controlled Weld Joint Record" for welds on each end of the pipe !? spools (reviewed only to verify installation, cleanliness and > .,r s , qualification of inspection personnel)".
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Personnel training and certification records for personnel involved ,
in receipt inspection and installation inspections of the pipe . , Pi spools.
4,, In the areas inspected, no items of noncompliance or deviations were ' " identified.
J 7.
Exit Interview The inspector met with the licensee representatives denoted in para-Oe graph 1 on August 23, 1978 and summarized the scope and findings of the inspection.
The licensee had no question's.
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E. H. Girard, Reactor Inspec' tor ( Date f.? Engineering Support Section No. 2 .? Reactor Construction and Engineering y
Support Branch ",
[ Dates of Inspection: August 21-24, 1978 Reviewed b f d l _ [[ g,,- ./ /t '
, . T. E. Conlon, Chief IIate ' - _ Engineering Support Section No. 2 ' Reactor Construction and Engineering Support Branch 1.
Persons Contacted O a.
South Carolina Electric & Gas (SCE&G)
- J. F. Algar, Nuclear Site Manager
- D. A. Nauman, QA Manager
- H. I. Donnelly, Jr., Sitc QA Coordinator A. A. Smith, Civil QA Supervisor S. E. Cash, QA Surveillance Specialist T. A. McAlister, QA Surveillance Specialist M. W. Eddings, Welding Superintendent b.
Contractor Organizations (1) Daniel Construction Company (DCC)
- J. M. Harvey, Construction Manager Q
- W. L. West, Project QA Manager (2)
Bahnson Service Co.
W. M. Crute, Project Quality Engineer
- Denotes those present at exit interview.
2.
Licensee Action on Previously_ identified Inspection Findin.gs This inspector did not review any licensee actions with respect to previous inspection findings.
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Unresolved Items ,s - -- ' i ^.t9
Unresolved items are matters about which more information is required " ic . in order to ascertain whether they are acceptable items, items of M noncompliance, or deviations. An unresolved item disclosed during the ' t inspection is discussed in Paragraph 4.b.
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Independent Inspection Effort ', a.
Plant Tour , A walk-through inspection of the containment and aexiliary buildings was conducted to observe construction status and work in progress.
b.
Reactor Coolant Pressure Boundary Piping - Observation of Welding and Review of Weld Records Welding and weld records were examined for a number of primary loop reactor coolant pressure boundary welds. This welding is required to comply with the ASME B&PV Code, Section III, Subsection NB (71 Ed., S73 Ad.). The welds examined included (1) 0.D.
surface of all reactor vessel (RV) to piping welds, (2) 0.D. of B-loop steam generator (SG) to piping hot leg weld (FW-16 on ISO DE-RC-06B), and I.D. of both B-loop RV to piping welds.
When last checked on 8/24/78, none of these welds were complete. Automatic welding was observed
! in progress on the B-loop SG to piping weld FW-16. Records at the work stations were checked for both B-loop hot leg welds (FW-15 ' and -16) to verify appropriate data entries (welding procedures, ' h filler metals, welders, inspection sign-offs, etc.). One record sheet was missing and unaccounted for, FW-15RI.
This is an unresolved item and is identified as item number URI-78-lb-02.
c.
Containment (Structural Steel Welding) - Examination of Cooling Unit Support Welds Completed welds attaching two beams to brackets on the containment for support of a cooling unit were examined for j compliance with the applicable drawings and procedures.
The ' beams are 4Bil and 488L on drawing IMS-02E-018-E2-4. The cooling unit to be supported is X4A-1A-All located at the 144 azimuth of the containment wall.
The weld details are depicted on drawing l E511-032 (details C and D).
The welding was specified to be in 'l '} d a Nk -. -...,..,, - -, ..- ... _ . -. - - ._. - . .- .
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- k accordance with AWS Dl.1-72 Rev. 2-74.
In examining the welds it 4:9 was noted that the welds for beam 4B8L were not identified with "9 the welder's number as required by the applicable contractor's . N; _ procedure (4.0 in DCC Procedure WE-II-03). This example of a e> failure to follow procedure together with another reported for these welds in Paragraph 5.a below are considered to be W(.,a noncompliance with Criterion V of 10 CFR 50 Appendix B, which the c,.E licensee implements through Paragraph 17.1.5 of his FSAR. This noncompliance is categorized as an infraction.and identified as ^
- _'
item number 78-16-01. No noncompliances, other 'han the item 78-
- -
16-01 described in 4.c above, were identified. No deviations were < found.
-l ~ 5.
Containment (Structural Steel Welding) - Review of Quality Records - O.
The quality records for' the cooling unit support welds described in 4.c above were reviewed to determine whether they were in conformance with the established procedures and whether they reflected work i accomplishment consistent with the applicable. requirements.
In addition, several licensee surveillance reports on similar safety-related structural support welding were reviewed to determine whether timely and adequate corrective action was being taken with respect to deviations identified.
The details of this inspector's review and findings for coolant unit support weld quality records and the - surveillance reports are as follows: Review of Quality Records for Cooling Unit XAA-1A-AH a.
Bracket to Beam Support Welds i .! Records were examined for the support beam to containment wall
Q bracket welds for beams 4B11 and 4B8L on drawing IMS-02E-018-E2-
4.
There are four welds for each beam to bracket attachment (8 welds total for the two beams).
Details of these welds are depicted on drawing E511-032 (details C and D). Licensee and contractor documents examined to establish work and record requirements included the two drawings noted above, SCE6G > Procedures 6.1.2 and 6.1.5, and Daniel Construction Co. Procedure - WE-II-03.
Specific record areas reviewed included visual and dimensional inspection, weld history data, magnetic particle test (MT) records, and welder and inspector qualifications.
q In reviewing the MT records for the welds it was found that only final weld MT's were performed. For the given weld sizes, which were all 5/8 inch, Paragraph 4.2.1 of the licensee's Procedure j 6.1.5 speci f ied MT f or root, each 1/4 inch and final weld.
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The absence of the intermediate MT's is a y failure to follow procedures for these welds - the first was ' .' A identified in 4.c above. These two examples of failure to follow procedures for these welds represent a noncompliance with - Criterion V of 10 CFR 50 Appendix B, which the licensee implements .,, through Paragraph 17.1.5 of his FSAR. This noncompliance has been Ag, categorized as an infraction and is identified for record as item
- C 78-16-01 (as already noted in 4.c above).
e r o- ..$ b.
Review of Surveillance Reports .< . ' The following related licensee surveillance reports were reviewed: (1) Surveillance report (electrical) 219El dated 7/17/78
(2) Surveillance report (mechanical) 7-21-78 M4 (3) QA Surveillance Report 228E2 dated 7/25/78 These surveillance reports describe checks of support welds for conduits and cable trays.
They note a number of examples of accepted welding which they found failed to meet specified requirements.
The licensee has requested corrective action with respect to these findings through his corrective action request
CAR #039. Documentation of initial responses to this request were noted in the licensee's file. Final responses were requested by 8/25/78.
The licensee's Site QA Coordinator, H. Dornelly, '} indicated that an addition would be made to CAR #039 to require
j corrective action with respect to the possibly related l j noncompliance described in 4.c and 5.a above.
~ in the surveillance above and their ! O The problems identified considered potentially important indications of resolution are
the adequacy of the licensee's QA program.
Because of this , , ! potential importance the inspection failings and corrective i ! action for these problems will be examined further in a future inspection.
This item is identified as inspector followup item IFl 78-16-03.
! l One noncompliance, item 78-16-01, was identified. No deviations were found.
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Safety-Related Structures Outside the Containment - Observation . T... of Work and Work Activities $, ' - Partially completed work and work in progress were observed for safety-A related duct work support being installed in the Diesel Generator
M Building. Drawings applicable to t :is work included E-936-510, E-512-M;'!, 117, E-937-90 and E-937-937. Additional requirements were reviewed in ,;. ' specification SP-221-044461-000 (2/5/75).
No deviations or noncompliances were identified for this work.
.,,.,, 7.
Exit Interview The scope and findings of the inspection were summarized and the l . noncompliance dese;ibed in 4.c and 5.a above was briefly discussed.
The unresolved item (URI-76-16-02) described in 4.b above was identified by telecon to Donnelly on September 13, 1978.
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