IR 05000400/1985001
| ML18003B058 | |
| Person / Time | |
|---|---|
| Site: | Harris  |
| Issue date: | 02/15/1985 |
| From: | Blake J, Hallstrom G NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML18003B057 | List: |
| References | |
| 50-400-85-01, 50-400-85-1, NUDOCS 8503060105 | |
| Download: ML18003B058 (18) | |
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UNITED STATES NUCLEAR REGULATORY COMMISSION I,
REGION II
101 MARIETTASTREET, N.W.
ATLANTA,GEORGIA 30323 Report No.:
'0-400/85-01'icensee:
Carolina Power and Light Company
,411 Fayetteville" Street Ralgigh,"
NC 27602 Docket No.:
50-400, Facility Name:
Harris
License No.:
CPPR-158
Inspection Conducted:
January 15-18, 1984 Inspector:
G. A.
H lstrom Approved by:
J J.
Blake, Secti on Chi ef ng'ering Branch ivision of Reactor Safety SUMMARY 2-)f-s Date Signed p
]5 sd" Date Signed Scope:
This routine, unannounced inspection entailed 32 inspector-hours in the areas of licensee action on previous enforcement matters, construction progress, safety-related structures, safety-related piping and licensee identified items (50.55(e)).
Results:
No violations or deviations were identified.
I QCK 05000400 0g05 850220 Poa
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REPORT DETAILS Licensee Employees Contacted
- R. M. Parsons, Project General Man'ager, Completion Assurance
- N. J. Chiangi, Manager QA/QC Harris Plant
- G. L. Forehand, Director of QA/QC
- E. J.
Wagner, Engineering General Manager
"C.
S.
Bohanan, Director of Regulatory Compliance
"R. Hanford, Manager, Welding
"H.
W. Bowles, Director, ONS
"D. A. McGaw, Superintendent, QA
- E.
M. Steudel, Manager Technical Support
"M. D. Vernon, Superintendent, QC
- D. C. Whitehead, QA Supervisor - Surveillance
"C.
R.
Osman, Principal QA/OC Specialist NDE
"M. G. Wallace, Construction S'pecialist
"F. Strehle, Jr., Project QA Engineering
- G. 0. White, Project Engineer, Hangers Other licensee employees contacted included construction craftsmen, engineers, technicians and office personnel.
NRC Resident Inspectors G.
F. Maxwell
- R. L. Prevatte
- Attended exit interview Exit Interview The inspection scope and findings were summarized on January 18, 1985, with those persons indicated in paragraph 1 above.
The inspector described the areas inspected and discussed in detail the inspection findings listed below.
No dissenting comments were received from the licensee.
'(Open)
Unresolved Item 400/85-01>,-01,
"Adequacy of procedure qualification for weldments requiring notch toughness paragraph 6.c.(1)."
The licensee did not identify as proprietary any of the materials provided to or reviewed by the inspector during this inspectio Licensee Action on Previous Enforcement Matters (Closed)
Unresolved Item 400/84-19-02,
"Adequacy of AWS Dl. 1 Visual Inspection Procedure".
This item concerned the adequacy of CP&L procedure CAR-2165-A-003, Revision 5, for visual examination of weldments to the AWS D1. 1 st'ructural welding code, 1975 revision.
Region II concerns were identified and discussed with the licensee on July 10, 1984, and on August 2, 1984.
Major concerns centered on adequate technical bases to assure necessary weld strength and the preclusion of crack initiation for the limits of discontinui-ties to be allowed.
These concerns were accentuated by the proposed application of the procedure to full penetration groove welds and all possible material combinations under AWS Dl.l.
Other concerns centered on clarification of wording within the procedure to assure uniform and adequate application of the criteria involved.
The licensee agreed to incorporate changes within CAR-2165-A-003 clarifying ambiguities and restricting its application to fillet and partial penetration groove welds and certain group I
and group II materials of AWS Dl. 1.
The licensee further agreed to conduct additional engineering tests and analyses in resolution of the concerns involved.
The inspector reviewed the pertinent engineering test reports and held discussions with cognizant licensee personnel to ensure supporting justi-fication for criteria based on longitudinal versus transverse shear and preclusion of crack propagation for the allowable lack of fusion and under-cut.
The inspector also reviewed revisions 6 thru 10 of the procedure to ensure that the basic acceptance limits involved have not changed.
This item is considered closed.
(Closed)
Violation 82-01-03, "Failure to Follow Procedures/Instructions for Visual Examination of Welds and Reporting of Discrepancies".
CP&L's letter of response dated March 25, 1982, has been reviewed and determined to be acceptable by Region II.
The inspector reviewed corrective actions as stated in the letter of response and discussed with responsible licensee personnel the survey completed to assure that the missing weld in box-frame hanger CC-H-469, was an isolated example.
The inspector reviewed verifica-tion of a random sample of several box-frame design hangers which had been inspected and found in compliance with FCR-H-564 requirements.
The inspector concluded, that CP&L had determined the full extent of the violation, performed the necessary survey and followup actions and developed the necessary corrective actions to prevent, recurrence of similar circum-stances.
The corrective actions identified in the letter of response have been implemented.
This item is considered closed.
Unresolved Items Unresolved items are matters about which more information is required to determine whether they are acceptable or may involve violations or devia-tions.
New unresolved items identified during thi s inspection are discussed in paragraph 6.c.(l).
5.
Independent Inspection (92706)
Construction Progress The inspector conducted a general inspection of the Unit 1 containment and reactor power block outside containment to observe construction progress and construction activities such as welding, material handling and control, housekeeping and storage.
Within the areas'xamined, no violations or deviations were identified.
6.
Safety-Related Structures (Unit 1)
The inspector observed welding activities for safety-related seismic 1 pipe hangers located in containment and the reactor auxiliary building as described below to determine whether applicable code and procedure require-ments were being met.
The applicable code is the AWS D1. 1 Structural Melding Code, 1975 revision.
Observation of Work within Containment (55153)
The inspector observed in-process welding activities of structural field welds inside of containment as described below to determine whether applicable code and procedure requirements were being met.
The following welds were examined in-process to determine work conducted in accordance with traveler; welding procedures available; welding technique 'nd sequence; weld geometry; fitup; electrical characteristics; and equipment condition:
SM-H-2635-FJ 1 SM"H-2635-FJ2 SM-H-2635-FJ3 SW-H-2635-FJ4 SM-H-2635-FJ5 SW-H-2635-FJ56 SM-H-2635-FJ57 SM-H-2635-FJ45 The following inspector qualification
. status records and
"QA/QC Inspector Qualification/Certification" records were reviewed relative to inspection of the weld joints listed in paragraph 6.b. l.
~Ins ector SC DF RD TM T
e Certification VT-II VT-II VT-II VT-II
Visual Inspection of Melds (55155)
The inspector visually examined completed welds as described below to determine whether applicable code and procedure requirements were being met.
(1)
The below listed welds were examined relative to the following:
location, length, size
.and shape; weld surface finish and appearance; transitions between different wall thicknesses; weld
'reinforcement height and appearance; joint configurations on permanent attachments and structural supports; removal of temporary attachments, arc stri kes and weld spatter; finish-grinding or machining of weld surface, surface finish and absence of wall thinning; surface defects, cracks, laps, lack of penetra-tion, lack of fashion, porosity, slag, oxide film and undercut exceeding prescribed limits.'
Seismic 1 Han ers Reactor Auxiliar Bui ldin Unit 1 Containment CH-H-479-FJ1 CH-H-479-FJ2 CH"H"479-FJ3 CH-H-479"FJ4 CH-H-479-FJ5 CH-H-479-FJ6 MS-H"164-FJ1 MS-H-164-FJ2 MS-H-164-FJ3 MS-H-164-FJ4 MS-H-164-FJ 5 S I-H-1344-FJ1 S I-H-1344-FJ2
- SI"H-1344-FJ3A S I-H-1344-FJ4
"SI-H-1344-FJS
.
SI-H-531-FJ1 SI-H-531-FJ2
"*SI-H-531-FJ3 SI-H-531-FJ4 S I-H-531-FJ 5 S I-H-531-FJ 6 S I-H-531-FJ7 SI-H-531" FJ8 SI-H-531-FJ9 S I-H-518-FJ 1 S I-H-518-FJ2 S I-H-518-FJ3 SI-H-518-FJ4
"Rejected by gC due to inadequate penetration and scheduled for repair.
- Rejected by gC due to undersize and scheduled for repair.
(2)
gual ity records for the above welds were examined relative to the following:
records covering visual and dimensional inspections indicate that the specified inspection were completed; the records reflect adequate weld quality; history records are adequat e Wel ding Procedure Speci ficati ons and Quality Assurance Procedures (55151)
Welding Procedure Specification (WPS)
applicable to the weld joints listed in paragraphs 6.a.
and 6.b.(1)
were selected for review and comparison with the ASME Code as follows:
WPS 1A1, Rev.
1A4, Rev.
1Bl, Rev.
1BAl, Rev.
1BA5, Rev.
1Fl, Rev.
1F2, Rev.
Process SMAW~
SMAW GTAlrP" GTAW/SMAW GTAW/SMAW FCAW""*
FCAW P(R 1,
28B 1, 66, 66A
1,
1, 5, 28B, 28C, 144 63, 63A 63, 131
"SMAW - Shielded Metal Arc Welding
- ~GTAW Gas Tungsten Arc Welding
""~FCAW - Flux Cored Arc Welding (2)
During the review, the inspector noted that WPS 1F1 was applicable to weldments requiring notch toughness and that the heat input/
weld metal volume requirements of ASME IX QW 409. 1 were an essential variable.
The requirements may be considered generic in that they apply to the shielded metal-arc, submerged arc, gas metal-arc, flux-cored-arc, gas tungsten-arc, and plasma-arc welding processes.
Also, that QW 200.2 requires the PQR form to list the actual variable used within the limits of a narrow range.
Review of PQRs
and 63A indicate need for clarification of the licensee's conformance to QW 409. 1 and QW 200.2 requirements.
Further, that the generic implications should be reviewed.
Pending further licensee clarification, this matter will be identified as Unresolved Item 400/85-01-01,
"Adequacy of procedure qualification for weldments requiring notch toughness."
The below listed documents were reviewed to ascertain whether the welding program for safety-related structures had been approved by the licensee and whether adequate plans and procedures had been established to assure that welding would be controlled and accomplished consistent with commitments and regulatory require-ments.
Documents No.
Title MP-01, Rev.
MP-02, Rev.
Qualification of Welding and Brazing Pr ocedures Qualification of Welders and Welding Operators
MP-03, Rev.
MP-04, Rev.
Welding Material Control Procedure for Post-Weld Heat Treatment MP-08, Rev.
MP-09, Rev.
General Welding Procedure for Structural Steel (Seismic, Non-seismic)
and Hangers Procedure for Welding Equipment Control MP-10, Rev.
Procedure for Repair of Base Material s and Weldment MP-ll, Rev.
WP-110, Rev.
WP-139, Rev.
WP-140, Rev.
Tra ini n g and Qual ifi cat ion of Metal 1 urgy/We 1 di ng Eng inee-ring and Support Personnel Installation of Q and Non-Q Pipe Hangers and Supports Seismic Pipe Hanger Work Package Preparation Field Engineering Review of.
Documentation of Seismic Pipe Hangers and Supports CQA-l, Rev.
CQA-2, Rev.
CQA-4, Rev.
CQA-5, Rev.
CQA-24, Rev.
CQC-1, Rev.
CQC-2, Rev.
CQC-18, Rev.
CQC-20, Rev.
QCI-18.2, Rev.
TP-04, Rev.
Personnel Training and Qualification QA Document Control QA Records Document Reviews Procurement Control Tool and Measuring Device Control Noncomformance Control Weld Control for Seismic Class 1 and Seismically Designed Structural (Reg.
Guide 1.29)
Weldments Post-Weld Heat Treatment Seismic Pipe Hanger Inspection Documentation System Calibration of Controlled Tools
P 0'
TP-17, Rev
~
TP-32, Rev.
SS No. 021, Rev.
SS No. 033, Rev.
SS No. 034, Rev.
CAR-2165-A-003, Rev.
d.
Welder Qualification (55157)
Construction Inspection Nonconformance Control Structural Steel Inspection Purchasing Welding Materials for Permanent Plant Construction Structural Welding for Permanent Plant Construction Nondestructive Examination, Visual Inspection and, Testing Requirements for Code Classes 1, 2, 3, MC, Seismic and Non-Seismic Structures for Permanent Plant Construction Weld Inspection Criteria The inspector reviewed the CP&L program for qualification of welders and welding operator for compliance with QA procedures and ASME Code requirements.
The following welder qualification status records and
"Records of Performance Qualification Test" were reviewed relative to the weld-joints-listed in paragraphs 6.a.
and 6.b.(1).
Welder S mbol WPS J48 F70 F16 D81 SJ16 1BA5 1A4 1A4 1A4, 1B1 1A4 e.
Welding Filler Material Control (55152)
The inspector reviewed the CP5L program for control of welding materials to determine whether materials were being purchased, accepted, stored and handled in accordance with QA procedures and applicable code requirements.
The following specific areas were examined:
Purchasing, receiving, storing, distributing and handling proce-dures, material identification; and inspection of welding material issuing stations.
Welding material purchasing and receiving records for the following materials were reviewed for conformance with applicable procedures and code requirements:
TYPE SIZE HEAT LOT BATCH/NO.
E7018 E7018 3/32"
]/8 II 2H429AC02 27425 Within the areas examined, no violations or deviations were identified.
7.
Safety-Related Pi ping (Unit 1)
The inspector observed welding activities for safety-related piping as described below to determine whether applicable code and procedure require-ments were being met.
The applicable code for safety-related piping is the ASME BCPV Code,Section III, Subsections NC and ND, 1974 edition with Addenda through Winter 1976.
Non-nuclear safety-related high energy piping identified seismic category 1 is fabricated to ANSI B31. 1 (73S73)
and post-weld heat treated when required to ANSI B31.1 (77W77).
Weld Heat Treatment (55186)
By examination of records for selected main steam pipe welds listed below, the inspector review the post-weld activities to,. determine whether weld area is instrumented to provide time-temperature records for the duration of the entire heat treatment cycle; temperature monitoring instruments are properly calibrated; sufficient temperature measuring devices are used; post-weld heat treatment (PWHT) temperature and holding time is specified, is adhered to; maximum initial tempera-ture, heat-up and cool-down rates are specified and are adhered to; temperature records being generated reflect adherence to regulatory requirements.
Weld No.
'
1-MS-64-FW-258 1-MS-64-FW-259 1-MS-178-FW-303 1-MS-178-FW-256 1-MS-178-FW-257 1-MS-156-FW-246 1-MS-156-FW-247 1-MS-156" FW-248 1-MS-155-FW-235 1-MS-155-FW-236 1-MS-155-FW-237 1-MS-155-FW-238 1-MS-155-FW-239 1-MS-155-FW-240 Within the areas examined, no violation or deviations were identifie +r
8.
Licensee Identified Items (92700)
(Closed)
Item 400/CDR 82-72,
"Undersized Skewed Tee Fillet Welds on Seismic 1 Pipe Hangers" (10 CFR 50.55(e)).
e On February 24, 1982, the licensee notified Region II of a potential 50.55(e)
item concerning undersized skewed Tee fillet welds on Seismic 1 pipe hanger s.
Several additional generic weld deficiencies on Seismic 1 pipe hangers were subsequently identified and reported in 50.55(e)
items 400/CDR 82-95 and 400/CDR 82-96 as described below.
Region II was notified that this item was reportable under
CFR 50.55(e)
on November 5, 1982.
The final report was submitted on November 30, 1984.
The report has been reviewed and determined to be acceptable by Region II.
The inspector held discussions with responsi-ble licensee representatives, reviewed supporting documentation, and
= observed representative samples of work to verify that corrective actions identified in the report have been completed.
(Closed)
Item 400/CDR 82-95,
"Shop Welding Deficiencies in Seismic
Pipe Hangers Supplied by Bergin-Patterson" (10 CFR 50.55(e)).
On August 13, 1982, the licensee notified Region II of a 50.55(e)
item concerning several generic shop welding deficiencies on Seismic 1 pipe hangers supplied by Bergin-Patterson.
These deficiencies occurred on Seismic 1 hangers which were inspected at the source of fabrication prior to October 1,
1982.
Corrective actions required revision in Bergin-Patterson and EBASCO QA programs, initiation of 100% receipt inspection, warehouse inspection prior to hanger issuance to the field, inspection in the field of installed hangers not previously inspected by the licensee for shop weld deficiencies, and reinspection of pipe hangers installed or partially installed prior to the June 26, 1982, initiation of 100% receipt inspection.
The final report was submitted on November 30, 1984.
The report has been reviewed and determined to be acceptable by Region II.
The inspector held discussions with responsible licensee representatives, reviewed supporting documentation,'nd observed representative samples of work to verify that corrective actions identified in the report have been completed.
(Closed)
Item 400/CDR 82-96 "Seismic Pipe Hangers Previously Accepted by QC Welding Inspector" (10 CFR 50.55(e)).
On August 13, 1982, the licensee notified Region II of a 50.55(e)
item concerning deficient field welds on pipe hangers accepted by QC welding inspectors prior to July 29, 1982.
Corrective actions included expansion of the field inspections initiated in response to item 400/CDR 82-95 to include "on site" welds, initiation and conformance to a
pipe hanger inspection documentation instruction (QCI-18.2),
1 additional training and audit of gC weld inspection personnel, develop-ment of a system to aid gC supervision in resolution of technical inquiries, and development and conformance to site weld acceptance criteria for both field and shop welds (CAR-2165-A-003).
The final report was submitted on November 30, 1984.
The report has been reviewed and determined to be acceptable by Region II.
The inspector held discussions with responsible licensee representatives, reviewed supporting documentation, and observed representative samples of work to verify that the corrective actions identified in the report have been completed.
(Open)
Item 400/CDR 82-113,
"Boric Acid Transfer Pumps, Westinghouse Shop Order 205" (10 CFR 50.55(e)).
On May 16, 1983, the licensee notified Region II of a 50.55(e)
item concerning unidentified bolting material and undersize welds of the support plates of Units 1 and 2 Boric Acid Transfer Pumps.
The final report was submitted on September 1,
1983.
On review of corrective action, the inspector requested verification that the proper bolting material had been installed in the Unit
pump support structure and that the required supplemental fillet welds had been completed and inspected.
The licensee agreed to provide necessary documentation.
This item remains open.
(Open)
Item 400/CDR 83-127,
"Weld Deficiencies in Unit
and Chilled Mater Valve" (10 CFR 50 '5(e)).
On April 7, 1983, the licensee notified Region II of a 50.55(e)
item concerning vendor shop weld defects in a HVAC chilled water valve.
The final report was submitted on October 31, 1983.
On review of correc-tive action during a previous inspection (Report No. 50-400/84-35),
the inspector had requested verification of inspection of all valves on purchase order (P.O.)
NY-435176, as well as train A chilled water valves.
The inspector requested information on the status of this item and was informed that shop weld deficiencies had recently been identified on other three-way chilled water valves purchased under P.O.
NY-435176 and that investigation was continuing to determine the full scope of this problem.
Further, that the licensee had informed Region II on January 18, 1985, that this item was considered re-opened and supplemented by new 50.55(e)
item 400/CDR 85-199.
This item remains ope f.
(Closed)
Item 400/CDR 83-133,
"Safety Injection Valves" (10 CFR 50.55(e))
On May 24, 1983, the licensee notified Region II of a 50.55(e)
item concerning twelve 2" socket weld globe safety injection valves found to be made of carbon steel SA-105 material in lieu of required stainless steel SA-182, F-316 material.
The final report was submitted on June 22, 1983.
The inspector held discussions with responsible licensee representa-tives and reviewed supporting documentation to verify that this item was an isolated case and that corrective actions identified in the report have been completed.
g.
(Open)
Item 400/CDR 84-174,
"Stainless Steel Olets guestionable Starting Material" (10 CFR 50.55(e)).
On May 15, 1984, the licensee notified Region II of a 50.55(e)
item concerning vendor supplied stainless steel olets which had not been manufactured from starting material purchased to ASME NCA-3800 require-ments.
The final report was submitted on June 14, 1984.
On review of corrective action during a
pervious inspection (Report No. 50-400/
84-30),
the inspector had requested a
review of potential generic significance in light of item 400/CDR 84-178 as discussed below.
The inspector was informed that the licensee's review of potential generic significance was not complete.
This item remains open.
h.
(Open)
Item 400/CDR 84-178,
"Sockolets and Meldolets guestionable Starting Material" (10 CFR 50.55(e)).
On June 19, 1984, the license notified Region II of a 50.55(e)
item concerning vendor supplied stainless steel weldolets and sockolets which had not been manufactured from staring material purchased to ASME NCA-3800 requirements.
An interim report was submitted on July 16, 1983.
The manufacturer of the weldolets and sockolets also manufac-tured the deficient olets reported in CDR 84-174.
The licensee's review of potential generic significance is not complete.
This item remains ope ee
'