IR 05000400/1982001
| ML20052B962 | |
| Person / Time | |
|---|---|
| Site: | Harris  |
| Issue date: | 02/22/1982 |
| From: | Coley J, Herdt A, York J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML20052B949 | List: |
| References | |
| 50-400-82-01, 50-400-82-1, 50-401-82-01, 50-401-82-1, NUDOCS 8205040200 | |
| Download: ML20052B962 (10) | |
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UNITED STATES
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' NUCLEAR REGULATORY COMMISSION h
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REGION 11 101 MARIETTA ST., N.W., SulTE 3100 o
s ATLANTA, GEoRotA 30303
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s Report Nos. 50-400/82-01 and 50-401/82-01 Licensee:
Carolina Power and Light Company 411 Fayetteville Street Raleigh, NC 27602 Facility Name:
Shearon Harris Docket Nos. 50-400 and 50-401 License Nos. CPPR-158 and CPPR-159 Inspection at Shearon Harris site near Raleigh, NC Inspectors:
% 7, Nu O-22-81 J. L. Cole}
g Date Signed
%1 hA 0 ~< U - 8 k J. W. Yor
~[J Date Signed Approved by:
cbM - N A. R. Herdt, Section Chief Date Signed Engineering Inspection Branch Engineering and Technical Inspection Division fijMMARY Inspection on January 19-22, 1982 Areas Inspected This routine, unannounced inspection involved 60 inspector-hours on site in'the areas of reactor coolant loop piping (Unit 1), steel structures and supports (Unit 1), other safety-related piping (Unit-1) followup on regional request (Unit 1), and independent inspection effort (Units 1 and 2).
Results Of the five areas inspected, no violations or deviations were identified in three areas; two violations were found in two areas (Violation - Failure to Follow Parameters of Welding Procedure, paragraph 6.c and Violation - Failure to Follow Procedures / Instructions - for. Visual Examination of Welds and Reporting of Discrepancies - Paragraph 9.a, b & c).
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REPORT DETAILS
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Persons Contacted
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i Licensee Employees
- R. M. Parsons, Site Manager i
- N. J. Chiangi, Manager, Engineering and CQA
- G. L. Forehand, Director QA/QC
- R. Hanford, Principal ~ Engineer - Welding
"D. C. Whitehead, Senior QA Specialist - Material Control
- G. M. Simpson, Principal Construction Specialist
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- E.. E. Willett, Resident Engineer - Mechanical
- A. M. Lucas, Senior Resident Engineer
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- C. R. Osman, Principal QA/QC Specialist - NDE
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Other licensee employees contacted included construction craftsmen and technicians.
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i Other Organizations
- W. D. Goodman, Project Manager, Daniel Construction Company (DCC)
NRC Resident Inspector
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- G. F. Maxwell t
- Attended exit interview 2.
Exit-Interview The inspection scope and findings were summarized on January 22, 1982, with
.those persons indicated in paragraph I above. The inspectors described the
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areas inspected and discussed i n. detail the inspection findings listed-below:
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Violation- - 400/82-01-01; " Failure to Follow Parameters of Welding Proce-dure" ~- Paragraph 6.c.
Violation - 400/82-01-03; " Failure to Follow Procedures / Instructions for
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Visual Examination of-Welds and Reporting of Discrepancies -1 paragraph 9.a,
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b & c.
. Inspector-Followup Item - ' 400/82-01-02; " Welder Instructions Needed for Reading Gas Flow Meters" paragraph 6.d.
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Unresolved Item 400/82-01-04; " Visual. Inspection of Vendor Welds" - para-graph 5.c.
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Inspector Followup _ Item - 400/82-01-05; " Inspection of Pipe Welds" -
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_ paragraph 9.d.
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3.
Licensee Action on Previous Inspection Findings
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Not inspected.
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4.
Unresolved Items
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Unresolved items are matters about which more information is required to determine whether they are acceptable or may involve violations or devia-
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tions. New unresolved items identified during this inspection are discussed in paragraph 5.c.
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Independent Inspection Effort (Unit 1)
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a.
Construction Progress The inspectors conducted a general inspection of the reactor building, l
auxiliary building, pipe fabrication shop and outdoor component storage
yard, to observe construction progress and construction activities ~ such as welding material handling and control, housekeeping and storage.
b.
- Visual Examination of Welds (Unit 1)
With regard to the above inspection, the inspectors accompanied by a representative of the licensee on January 20, 1982 noted an apparent misaligned socket weld joint on the bottom mounted incore instrumenta-tion tubing (weld joint no. 38-SW-4). Further investigation by visual inspection and a spot radiograph revealed that this joint is properly fitted-up. However the appearance that this joint is misaligned was caused by weld shinkage. Westinghouse welding engineers evaluated this offset and concluded that no excessive wear would occur over the.long term usage of this tube.
This is documented in SHM-0176 dated Ja.nuary 21, 1982.
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c.
Visual Inspection of Vendor Accepted Material (Unit 1)
l With regard to the above inspection, the inspectors accompanied by a
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representative of the licensee noted on January 20, 1982 arc strikes around a nozzle on 'the bottom level connection for the laundry and hot
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shower tank serial no._591-48. One arc strike had created a crater of F
approximately.040" depth. The inspector noted that recent NRC inspec-
-tion reports #'s-50-400,'401, 402, 403/81-22, 50-400, 401, 402, 403/
81-15 and 50-400, 401, 402, 403/81-21 have also reported vendor accepted material that had material or welding discrepancies.
Discussions were! held with the licensee's cognizant personnel who
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agreed to evaluate their methods of determining to what extent vendor
supplied material will be inspected during receiving inspection and if
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the attributes used are adequate. The inspectors also stated that the
. licensee's field welding activity monitoring checklist (Exhibit 4 of
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CQA-22) should be used to identify vendor material already installed l'
that could have visual material or welding discrepancies. The -licensee did not have any dissenting comments concerning the above. This item will be reported as unresolved item #50-400, 401/82-01-04, " Visual
Inspection of Vendor Welds."
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Within the areas inspected, no violations or deviations were identified.
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_ Reactor Coolant Pressure Boundary Piping (Unit 1)
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a.
Observation of Welding Activities
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The inspectors observed work performance and work inprocess to deter-
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mined whether field welding activities associated with reactor coolant
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pressure boundary piping are controlled and performed in accordance with applicable code and specifications. The applicable code for this
I work is the ASME Boiler and Pressure Vessel Code, Section. III, Subsec-
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tion NB,1974 Edition including, Addenda through Winter 1976.
The following weld joints were inspected during inprocess inspection:
WELD JOINT #
SYSTEM SIZE
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RC-1-FW-7 Reactor Coolant 31" X 2.48" j
RC-1-FW-6 Reactor Coolant 31" X 2.48" 35-FW-5 Incore Instrumentation 1" X
.300"
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The welding was examined to determine whether:
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(1) Work is conducted in accordance with a document which coordinates and sequences operations, references procedures, establishes hold points, and provides for production and inspection approval, j
(2) Weld identification and location are as specified.
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(3) Procedures, drawings, and other instructions are at the work-station and readily available.
(4) WPS assignment is in accordance with applicable code requirements.
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(5) Welding techniques and sequences are specified and adhered to.
(6) Welding filler materials are the specified type and traceable' to certification.
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.(7) Alignment of parts is as specified.
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(8) Preheat and_interpass. temperatures are in accordance with proce-
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dures.
(9) Electrodes are used in positions and with_ electrical character-
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istics specified.
(10) Shielding gas is in accordance with the welding procedures.
(11) Welding equipment is in good condition.
(12)
Interpass cleaning is in accordance with applicable procedures.
(13) Temporary attachments are removed in accordance with applicable procedures.
(14) Welding personnel are qualified.
(15) Weld History records are adequate.
b.
Welder Qualification
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The inspectors reviewed the welder qualification records for the' welds listed in a. above.
c.
The inspectors observed three welders welding the reactor coolant loop
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piping noted above. All three were questioned concerning the weld parameters they were using. The applicable welding procedure was WPS No. 882 which required that the gas cup size be 4-8.
All three welders-were using a size 10 gas cup. Failure to follow welding specifications
is in violation of 10 CFR 50, Appendix B, Criterion V as implemented by
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paragraph 1.8.5.5 of the PSAR. This violation is identified as item number 400/82-01-01, Failure to Follow Parameters of Welding Procedure.
j d.
The inspectors also observed a welder welding the incore instrumenta-tion tubing. This welder was also questioned concerning the parameters -
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of_ his welding specification.
This welder was knowledgeable of the correct welding parameters, however when the welders torch gas flow
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meter was examined it was found to be reading outside the parameters of the welding procedure. The welder was questiened torcerning where to read the ' float in the gas meter and it was determinea that he was reading the bottom of the float.
This was a Harris flow meter and Harris flow meters are read in the center of the float. Others welders were questioned and although they were not working outside the para--
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meters of their welding procedure they also stated that the bottom of the float would be.where they would read the flow meter. The_ licensee
determined that four different types of flow meters are used at Shearon
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l Harris, two are read by using the center of the float and the other two j
are read using the top of the float. All gages were:labled as to where
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to read the float. The licensee agreed to provide additional instruc-tion to the welders as to where to read the float. This item was l
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reported as Inspector Follow-up Item 400/82-01-02, Welder Instruction
'l Needed for Reading Gas Flow Meters.
l-Within the areas inspected, no violations, except as noted in paragraph
6.c, or deviations were identified.
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~7.
Safety Related Piping (Unit 1)
The inspectors examined welding activities described below relative to safety related piping to determine whether applicable codes and speciff-cations were being met. The applicable code for this work is - the ASME-Boiler and Pressure Vessel Code,Section III, Subsection NC,1974 Edition including Addenda through Winter 1976.
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_a.
Observation of Welding Activities The inspectors observed the filler passes on - the following inprocess weld:
WELD SYSTEM SIZE 1-CS-197-FW-297 Chemical & Volume Control 3.0" X.383" The welding was examined to determine whether:
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(1) Work is conducted in accordance with a document which coordinates and sequences operations, references procedures, establishes hold points, and provides for production and inspection approval.
(2) Weld identification and location are as specified.
l (3) Procedures, drawings, and other instructions are-_ at the work l
station and readily available.
(4) WPS assignment is in accordance with applicable code requirements.
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(5) Welding techniques and sequences are specified and adhered to.
I (6) -Welding filler materials are the specified type and traceable. to certification.
(7) Alignment of parts is as specified.
(8) Preheat and interpass temperatures are in accordance with proce-dures.
(9) Electrodes are used in positions and with electrical character-
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..istics specified.
l-l (10) Shielding gas 'is in accordance with the welding procedures.
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(11) Welding equipment is in good condition.
(12)
Interpass cleaning is in accordance with applicable procedures.
(13) Temporary attachments are removed in accordance with applicable procedures.
(14) Welding personnel are qualified.
(15) Weld History records are adequate.
b.
Welder Qualification The inspectors reviewed the welder qualification records for the weld listed in a. above.
Within the areas inspected, no violation or deviations were identified.
8.
Steel Structures and Supports (Unit 1)
The inspectors observed welding work activities for steel structures and supports as described below to determine whether applicable code and pro-cedure requirements were being met. The applicable code for the following components is AWS DI.1-75.
The following welds on the main steam restraint for loop 1-C steam generator and a main steam whip restraint were examined.
WELD NO.
WELO DESCRIPTION DRAWING NO.
FW-11 Hanger Stiffener CAR-2168-G-236501 PC #507G-2 to PC #514C1 Web of I-Beam CAR-2168-G-235501 PC #507G-1 to PC #513C2 Web of I-Beam CAR-2168-G-235501 a.
ine above welds were examined to determine if welding was conducted as follows:
(1) Work is conducted in accordance with a document which coordinates and sequences operations, references procedures, establishes hold points, and provides for production and inspection approval.
(2) Weld identification and location are as specified.
(3) Procedures, drawings, and other instructions are at the work stations and readily available.
(4) WPS assignment is in accordance with applicable code requirements.
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(5) Welding technique and sequence are specified and adhered to.
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(6) Welding filler materials were specified type and traceable to certification.
(7) Weld joint geometry is in accordance with applicable procedure and inspected.
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(8) Alignment of parts is as specified.
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(9) Preheat and interpass temperatures are in accordance.with proce-
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dures.
(10) Electrodes are used in positions and with electrical characteris-tics specified.
(11) Welding equipment is in good condition.
(12)
Interpass cleaning is in accordance with applicable procedures.
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(13) Temporary attachments are removed in accordance with applicable procedures.
(14) Process control system has provision for weld repairs.
f (15) Welding and inspection personnel are qualified.
(16) Weld history records and adequate.
b.
Welder Qualification The inspector reviewed the welder qualification records for the welds listed in a. above.
i Within the areas inspected, no violations or deviations were identified.
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9.
Followup on Regional Request As part of an ongoing investigaticn, it was requested that certain pipe welds and a random sample of difficult access welds on seismic supports inspected by a certain welding inspector during a particular time frame be-reviewed by Region II welding inspection.
The following seismic Category I welds were re-examined by Region II
inspectors:
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COMPONENT ID/ WELD NO.
SYSTEM ITEM INSPECTED-
-CS-H-1790 Chemica~. & Volume Control Seismic Hanger CX-H-1623 Chilled Water Return Seismic Hanger CC-H-469 Component Cooling Seismic Hanger BD-H-144 Blow down Seismic Hanger BR-H-731 Boron Recycle Seismic Hanger CS-H-137 Chemical & Volume Control Seismic Hanger RM-H-366 Reactor Make-up Water Seismic Hanger SI-H-1018 Safety Injection Seismic Hanger
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SF-H-704 Spent Fuel Pool Cooling & Cleanup Seismic Hanger
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CC-H-800 Component Cooling Seismic Hanger.
CT-H-205 Containment Spray Seismic Hanger
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SW-H-2343 Service Water Seismic Hanger
- CC-H-342 Component Cooling Seismic Hanger
- NOTE:
This hanger was alleged to be unacceptable.
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t In addition to the above seismic hanger welds the inspectors also inspected-the following welds on the laundry and hot shower tank #591-48, that were alleged to be rejectable.
ISOMETRIC WELD JOINT SYSTEM
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i 1-WL-1095 FW-3708 Waste Liquid 1-WL-1092 FW-3702 Waste Liquid
1-WL-1090 FW-3697 Waste Liquid Discrepancies noted as a result of the NRC reinspection are as follows:
a.
The inside of the box frame windows for hanger CC-H-469 had not been welded. A review of the records for this hanger revealed that the weld'
inspector had mistakenly referenced a Field Change No. FCR/H-564 that -
would have deleted these welds if the hanger had been designed -for a twelve inch pipe or smaller. Hanger CC-H-469, however was designed for two 18 inch pipes.
b.
Field pipe welds FW-3708, FW-3702 and FW3697, located on the top of the
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laundry and hot shower tank, had small arc strikes on the base metal
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adjacent to the field welds. Carolina Power and Light Company (CP&L)
procedure NDEP-601, Visual Examination of Welds, paragraph 9.11 states that, " weld and adjacent base metal shall be free of visible. arc strikes, weld spatter and mishandling marks."
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In addition to the above pipe fiel'd welds, arc strikes and weld spatter c.
were noted on vendor welds between the above field welds and the tank.
The weld inspector had not reported this condition as required by Section 19, paragraph 19.9 of CP&L's -Quality Assurance Program for Radioactive Waste Management System.
The three examples noted above were reported as a violation of 10 CFR 50 Appendix B Criterion V and was assigned number 50-400/82-01-03, Failure to Follow Procedures /Irstructions for Visual Examination of-Welds and Reporting of Discrepancies.
d.
As a result of the reinspections the Region II inspectors concluded that the samples taken were. representative of the more difficu_lt
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inspections the inspector in question had made on seismic supports.
Although one item of noncompliance was found the NRC inspectors concluded' this to be an oversight by the welding inspector.
When reading the instructions, this inspector apparently failed to see that the field change had size limitations.
The NRC inspectors found inspection stickers with the individual in question's name on supports that were very high and difficult to reach.
This indicated that the weld inspector had made the inspections since all of the reinspected supports were examined during the period that the weld insrector 'was working alone. As for the reinspection of the three pipe welds that were examined by the inspector in question, two discrepancies were noted in this area and reported above. The Region II inspector con-cluded that a larger sample of. pipe welds; particularity NON-ASME welds inspected by this individual would need to be reinspected on a
subsequent inspection. This is inspector follow-up item 400/82-01-05, Inspection of Pipe Welds.
Within the areas examined no violations except as noted paragraph 9.a, b & c, or deviations were observed.-
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