IR 05000400/1985012

Insp Rept 50-400/85-12 on 850319-22.No Violation or Deviation Noted.Major Areas Inspected:Const Progress, safety-related Piping,Reactor Vessel Internals & 10CFR50.55(e) Items

ML18018B923
Person / Time
Site:	Harris
Issue date:	04/10/1985
From:	Blake J, Hallstrom G NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
To:
Shared Package
ML18018B922	List: IR 05000400/1985012 ML18018B921
References
50-400-85-12, NUDOCS 8505170528
Download: ML18018B923 (32)

Text

~8 REQIr (4 P0 UNITEDSTATES NUCLEAR REGULATORY COMMISSION

REGION II

101 MARIETTASTREET, N.W.

ATLANTA,GEORGIA 30323 Report No.:

50-400/85-12 Licensee:

Carolina Power and Light Company 411 Fayetteville Street Raleigh, NC 27602 Docket NoeI 50-400 facility Name:

Harris

Inspection Conduct

March 19-22, 1985 Inspector:

G.

Ha s trom Approved by:

J.

.

a e, ection ie Engineering Branch Division of Reactor Safety License No.:

CPPR-158 dO dP Date Signed q- (o-8'<

Date Signe SUMMARY Scope:

This routine, unannounced inspection entailed 40 inspector -hours on site in the areas of licensee action on previous enforcement matters, construction progress, safety-related piping, reactor vessel internals, and licensee identified items (50.55(e)).

Results:

No violations or deviations were identified.

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REPORT DETAIL Persons Contacted Licensee Employees

• R. M. Parsons, Project General Manager, Completion Assurance

• N. J. Chiangi, Manager of Quality Assurance/Quality Control (QA/QC)-

Harris Plant

• G. L. Forehand, Director of QA/QC

• R. Hanford Manager, Welding

• D. A. McGaw, Superintendent, QA

• D. C. Whitehead, QA Supervisor - Surveillance

• C. R.

Osman, Principal QA/QC Specialist - Non Destructive Examination (NDE)

• M. G. Wallace, Construction Specialist

• G. M. Simpson, Principal Construction Specialist

• R. L. Maurer, Pipe/Hanger Manager

"A. H. Rager, Manager - Construction Inspection (CI)

~P.

Cook, Senior QA/QC Specialist (Central Control)

E.

C. Mitchell, Resident Engineer - Second Shift J. Evatt, Welding Engineering Superintendent

- Second Shift E. Betz, QC Supervisor - NDE Other licensee employees contacted included construction craftsmen, engineers, technicians, and office personnel.

Other Organization 0.

F. Painter, Site Manager, Westinghouse Electric Corporation NRC Resident Inspector

• G. F. Maxwell

• Attended exit interview Exit Interview The inspection scope and findings were summarized on March 22, 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 400/85-12-01

"Adequacy of Corrective Action to Protect Permanent Plant Equipment" - paragraph 5.

(Open) Inspector Followup Item 400/85-12-02

"Arc Strikes on Refueling Cavity Liner Plate" - paragraph Iff MH W

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The licensee identified as proprietary some of the materials provided to/and reviewed by, the inspector during this inspection; however, details from these materials are not included in this report.

3.

Licensee Action on Previous Enforcement Matters (Closed)

Unresolved Items 400/84-09-01

"PQR/WPS Preheat Temperature".

This item concerned the adequacy of supporting procedure qualification-record (PQR)

No. 84 for welding procedure specification (WPS)

No.

1-3BA1 - Rev. l.

WPS No.

1-3BA1 is a multiple-pass combination gas tungsten-arc welding (GTAW)/shielded metal arc welding (SMAW)

procedure used for welding safety-related piping.

NRC concern regarding the adequacy of PQR-84 had been expressed due to the following:

ASME B&PV,Section IX, paragraph QW-406. 1 and Table QW-253 state that the WPS for shielded metal arc welding shall be requalified if there is a

decrease of more than 100'F in the preheat temperature from that qualified.

The minimum temperature for welding shall be specified in the WPS.

PQR 84 indicated that the minimum preheat temperature qualified was 400'F, (PQR 84 was identified as the applicable PQR for WPS 1-3BA-1 Rev. 1).

Carolina Power and Light (CPSL)

backup documentation for PQR

indicates that the preheat temperature for the first or root pass was 400'F and then the preheat temperature increased from 420'F to 600'F with only two of 24 readings recorded below 450'F.

WPS 1-3BA-1 Rev.

1 specifies a minimum preheat temperature of 300'F.

Therefore, the 400'F preheat temperature as reported on the PQR appears only applicable to the first pass and is not representative of the preheat temperature of the entire weldment where the preheat average temperature was 498'F Cognizant licensee personnel informed the inspector that WPS 1-3BAl-Rev.

and PQR-84 were considered technically adequate.

However, in response to NRC concerns PQR-84A was completed on February 22, 1985, to substantiate a

300'F minimum preheat temperature and a 340'F maximum inter pass temperature.

Further, Rev.

4 of WPS 1-3BA1 has been issued which was supported by PQR-84 and PQR-84A.

WPS 1-3BAl-Rev.

4 lists a preheat temperature range of 300'F to 500'F and a 500'F maximum interpass temperature.

After review of backup documentation, the inspector concluded that licensee actions were sufficient to satisfy NRC concerns.

This item is considered close FN

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(Closed)

Unresolved Item 400/85-01-01

"Adequacy of Procedure Qualification for Weldments Requiring Notch Toughness."

This item concerned the adequacy of supporting PQR's'o.

63 and 63A for WPS 1Fl, Rev. 8.

WPS 1Fl, Rev.

8 is a multiple-pass flux cored arc welding (FCAW)

procedure for welding safety-related structures and piping.

The WPS was considered applicable for weldments requiring notch toughness.

In this case, the heat input/weld metal volume requirements of ASME IX QW 409. 1 are 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, 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 indicated need for clarification of the licensee's conformance to QW 409. 1 and QW 200.2 requirements.

A review of the generic implications was also requested.

Cognizant licensee personnel informed the inspector that a

review of welding procedures qualified to Section IX and Section III of 'the ASME Code had been completed.

This included 14 procedures qualified to Section III with impact test performed.

These procedures satisfy the requirements of QW 409. 1 with a provision for weld metal volume control through maximum weave and maximum thickness of any pass.

Further, that an evaluation of.EBASCO specification for structural steel CAR-SH-AS-7 established that no carbon steel materials in the plant were from those P-1 ASME Section IX materials which required impact tests.

WPS 1F1, Rev.

8 was used on carbon steel weldments which did not require impact tests.

Also, an evaluation of,EBASCO specification for General Power Piping CAR-SH-M-30 was made which indicated that impact test is required on carbon steel material (P-1) for code class 1, 2; 3 and MC.

The welding engineer responsible for piping stated that WPS 1F1 has not been used for code class 1, 2, 3 and MC welds.

Further, that any potential future use of WPS 1F1 on materials requiring notch toughness was eliminated since its use was now prohibited on ASME Section III welds.

After review of background documentation, the inspector concluded that the licensee actions were sufficient to satisfy NRC concerns.

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 deviations.

New unresolved items identified during this inspection are discussed in paragraph V

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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.

During the above inspection, the inspector noted damage to the cooling fans of HVAC Air Handler No.

1AH-4 at elevation 286 on Unit 1 containment.

This damage was apparently due to unauthorized climbing. on permanent plant equipment by construction craftsmen who were completing piping weldments on top of air handler 1AH-4.

Cognizant ilicensee personnel informed the inspector that protective screening had been removed in order to connect manifolds to the chiller coils and not replaced.

Further, that climbing on permanent plant equipment was considered an unauthorized temporary construction load and prohibited by paragraph 3.10 of WP-48

"Temporary Construction Loads Supported from Permanent Plant Components,"

unless the responsible area engineer granted a construction load release.

Also, that an earlier gA Surveillance had identified unauthorized application of temporary construction loads, (including unauthorized climbing on permanent plant equipment),

as the root cause for damage to other permanent plant equipment.

The inspector reviewed supporting documentation including written notification to all site personnel prohibiting unauthorized climbing on equipment which was issued by the Daniel Project General Manager on October 3, 1984, and Nonconformance Report (NCR)

No.

85-0490 issued February 22, 1985, which identified continuing problems in this area.

The inspector noted that efforts to accomplish adequate corrective action appear unsuccessful as of the date of this inspection and this matter will be identified as unresolved item 400/85-12-01

"Adequacy of Corrective Action to Protect Permanent Plant Equipment."

Safety-Related Piping (Unit 1)

The inspector observed work activities and reviewed records for non-welding and welding work activities for safety-related piping as described below to determine whether applicable code and procedure requirements were being met.

The applicable code for safety-related piping is the ASME-BSPV Code,Section III, Subsections NC and ND, 1974 edition with Addenda through Winter 1976.

Non-nuclear safety-related high energy piping identified as seismic Category 1 is fabricated to ANSI B31.1 (73S73)

and post-weld heat treated when required to ANSI B31.1 (77W77).

a.

Review of Non-welding guality Records (49065)

The inspector selected various safety-related piping components (e.g.,

pipe, fittings and welded-in components)

for review of pertinent records to determine conformance with procurement, storage and installation specifications and gA/gC site procedure w

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Records of the following items were selected for review to ascertain whether they (records)

were in conformance with applicable requirements relative to the following areas:

material test reports/cer tifications; vendor supplied NDE reports; Nuclear Steam Service Supply (NSSS)

quality releases; site receipt inspection; storage; installation; vendor nonconformance reports.

Item Heat/Control No.

~Ss tern 3" sched.

40 pipe M3415 Chemical and volume control 3" diaphragm valve 3" sched.,

40 pi pe 3" diaphragm valve WR-1850 M3053 WR-1851 Chemical and volume control Chemical and volume control Chemical and volume control 2" sched.

40 pipe M2132 Chemical and volume control 3" x 2" 3000¹ sockolet P528 Chemical and volume control 2" sched.

40 pipe 05211 Chemical and volume control 2" weldolet 3" sched.

40 90'll 3" sched.

40 pipe 3" sched.

40 45'll 3" sched.

160 pipe 3" sched.

160 motor operated gate valve 8" sched.

40 pipe 8" sched.

40 90'll 8" sched.

40 pipe 8" sched.

40 90'll PG08 NB1565 M3058 54037 N15015 NB ¹ W19165 M3349 W4HKH 26565 JMXS Chemical and volume control Residual heat removal Residual heat removal Residual heat removal Residual'eat removal Residual heat removal Containment spray Containment spray Containment spray Containment spray

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Welding Activities (1)

Observation of Work (55183)

The inspector observed in-process welding activities of service water piping field welds inside of containment as described below to determine whether applicable code and procedure requirements were being met.

The below listed welds were examined in-process to verify work conducted in accordance with traveler, welder identification and location, welding procedures, WPS assignment, welding technique and sequence, materials identity, weld geometry, fit-up; temporary attachments, gas purging, preheat, electrical characteristics, shielding gas, welding equipment condition, interpass temperature, interpass cleaning, process control systems, qualifications of inspection personnel, and weld history records.

Weld No.

1-SW-505-1-SW-1 1-SW-505-1-SW-2 1-SW-505-1-SW-3 1-SW-505-1-SW-4 1-SW-505-1-SW-6 1-SW-505-1-SW-7 1-SW-451-1-SW-1 Descri tion 4" x.237" Carbon Steel (CS) pipe to 6" x 4" CS reducing tee 4" x.237" CS pipe to 4" 1505'S weld neck reducing flange 4" x.237" CS pipe to 6" x 4" CS 90'educing ell 4" x.237" CS pipe to 4" 150b'S weld neck reducing flange 6" x.280" CS pipe to 6" x 4" CS 90'educing ell 6" x.280" CS pipe to 6" x 4" CS reducing tee 4"

CS 90'll to 4" 1508 CS weld neck reducing flange The following inspector qualification status records and

"QA/QC Inspector Qualification/Certification" records were reviewed relative to inspection of the weld joints listed above and in paragraph 6.b.(2)(a).

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Visual Inspection of Welds (55185)

T e Certification VT-II VT-II VT-II VT-II VT-II VT-II VT-II VT-II VT-II VT-II VT-II VT-II VT-II VT-II VT-II VT-II VT-II VT-II The inspector visually examined completed welds as described below to determine whether applicable codes and procedure requirements were being met.

(a)

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 strikes and weld spatter; finish-grinding or machining of weld surface, finish and absence of wall thinning; surface defects, cracks, laps, lack of penetration, lack of fashion, porosity, slag, oxide film and undercut exceeding prescribed limits.

Weld No.

Descri tion Chemical and Volume Control System 1-CS-265-FW-399 1-CS-265-FW-400 1-CS-265-FW-402 3" x.216" stainless steel (ss)

pipe to 3" ss diaphragm valve 3" x.216" ss pipe to 3" ss diaphragm valve 3" x.216" ss pipe to 3" ss diaphragm valve

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1-CS-265-FW-403 1-CS-379-FW-947 3" x.216" ss pipe to 3" ss diaphragm valve 2" x.154" ss pipe to 3" x 2" ss sockolet 1-CS-381-FW-953 2" x.154" ss pipe to 2" ss weldolet Residual Heat Removal System 1-RH-2-7-SW-1 1-RH-2-7-SW-2 1-RH-2-7'-SW-3 3" x.216" ss pipe* to 3" ss 90'll 3" x.216" ss pipe to 3" ss 90'll 3" x.216" ss pipe to 3" ss 90'll 1-RH-2-FW-9 3" x.216" ss pipe to 3" ss 45'll 1-RH-2-FW-10 3" x.438" ss pipe to 3"

motor operated gate valve

• 3" x.438" ss pipe counter bored to.216" Containment Spray System 1-CT-1-FW-15**

8" x.322" ss pipe to 8" ss 90'll 1-CT-1-FW-16***

8" x.322" ss pipe to 8" ss 90'll

• • Weld repaired and evaluated for excessive shrinkage.

Inservice inspection ( ISI) required.

• • • ISI required (b)

guality 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 ~ >>

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(3)

Welding Procedure Specifications and guality Assurance Procedures (55181)

(a)

Welding Procedure Specification (WPS) applicable to the weld joints listed in paragraphs 6.b.(1)

and 6.b.(2) were selected for review and comparison with the ASNE Code as follows:

WPS Process

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~lg 1BA5, Rev.

GTAW/SMAW 8B2, Rev.

GTAW 1, 5, 28B, 28C 6, 6A, 6BQ 6C 8B4, Rev.

GTAW 8BA6, Rev.

GTAW/SMAW 8BA7, Rev.

GTAW/SMAW 1/GTAW - Gas Tungsten Arc-Welding 7/SNAW - Shielded Metal Arc-Welding

(b)

The below listed documents were reviewed to ascertain whether the welding program for safety-related piping had been approved by the licensee and whether adequate plant and procedures had been established to assure that welding would be controlled and accomplished consistent with commitments and regulatory requirements.

Documents No.

MP-01, Rev.

NP-02, Rev.

MP-03, Rev.

NP-04, Rev.

MP-06, Rev.

Title gualification of Welding and Brazing Procedures gua 1 ificat ion of Welders and Welding Operators Welding Material Control Procedure for Post-Weld Heat Treatment General Welding Procedure for Carbon and Alloy Steel Pipe Weldments

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MP-09, Rev.

Procedure for Welding Equipment Control MP-10, Rev.

Procedure for Repair of Base Materials and Weldment MP-11, Rev.

CQA-1, Rev.

CQA-2, Rev.

CQA-4', Rev.

CQA-5, Rev.

CQA-24, Rev.

CQC-2, Rev.

CQC-19, Rev.

CQC-20, Rev.

TP-17, Rev.

Training and Qualification of Metal lurgy/Welding Engineering and Support Personnel Personnel Training and Qualification QA Document Control QA Records Document Reviews Procurement Control Nonconformance Control Weld Control Post-Held. Heat Treatment Construction Inspection Nonconformance Control SS No. 021, Rev.

Purchasing Welding Materials for Permanent Plant Construction SS No. 030, Rev.

SS No. 031, Rev.

SS No. 034, Rev.

Field Fabrication and Erection of Power Piping Requirements for field welding of Category 1, 2, and 3, or Code Classes 1, 2, and 3 piping components, systems at the SHNPP Project Nondestructive Examination, Visual Inspection and, Testing Require-ments for Code Classes 1, 2, 3, and MC, Seismic and Non-Seismic Structures for Permanent Plant Construction CAR-SH-M-30 Ebasco Specification - General Power Piping

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WP-112, Rev.

(4)

Welder gualification (55187)

Control of Materials and Equipment that may be harmful to stainless steel The inspector reviewed the CP8L program for qualification of welders and welding operator for compliance with gA procedures and ASME Code requirements.

The following welder qualification status records and "Records of Performance gualification Test" were reviewed relative to the weld joints-listed in paragraphs 6.b.(l) and 6.b.(2).

Welder S mbol C53 A60 A74 E21 D65 B7 E39 843 C66 K44 F9 C54 092 WPS 8B4, 8BA6, 1BA5 8B2 8B2 8B2, 8BA7 8B2 8BA6 882 181 1BA5 1B1 8B2 8B2 8B2 The inspector observed completion of qualification test weldments and performance of required mechanical bend testing for confor-mance with applicable code requirements for the following welder qualifications.

Personnel identification was verified.

Identification No.66-806 WPS 1BA5, Rev.

TyyeTest 6G pipe

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1BA5, Rev.

1BA5, Rev.

6G pipe 6G pipe 6G pipe 6G pipe (5)

Welding Filler Material Control (55182)

The inspector reviewed the CPIIL program for control of welding materials to determine whether materials were being purchased, accepted, stored and handled in accordance with gA procedures and applicable code requirements.

The following specific areas were examined:

Purchasing, receiving, storing, and distributing and handling procedures, material identification; and inspection of welding material issuing stations.

Welding material purchasing and receiving records for the following material applicable to the weld joints listed in paragraphs 6.b.(l)

and 6.b.(2)

and welder qualifications listed in paragraph 6.b.(4)

were reviewed for conformance with applicable procedures and code requirements.

~Te E7018 E7018 Size 1/8" 3/32" Heat, Lot, Batch/No.

27425 KK076 ER70S-6 1/8" x 36" 412S7231 IN308 5/32" E4475T ER70S-6 ER70S-6 ER316 3/32" x 36" 412S7231 3/32" x 36" 49911 3/32" x 36" 744958 ER316 ER316 1/8" x 36" 1/8" x 36" 743379 762549 ER316 3/32" x 36" C3537T ER308 1/8" x 36" C3017 ER308 1/8" x 36" 18302

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ER308 ER308 ER308 3/32" x 36" 3/32" x 36" 1/8" x 36" 464802 465272 A8179 7.

Reactor Vessel Internals Installation (Unit 1)

The inspector reviewed procedures, made a physical inspection, and reviewed quality records to ascertain whether procedures, field activities, and records pertaining to the installation of the reactor vessel internals were consistent with NRC requirements, applicable codes, standards and commitments.

a.

Review of guality Assurance Implementing Procedures (50061)

The inspector reviewed the below listed documents to determine whether provisions had been established relative to the reactor vessel internals to assure conformance with applicable requirements for handling and installation.

Documents

"Westinghouse - Cleaning and Cleanliness Requirements of Equipment For Use in the NSSS - Process Specification 292722, Revision 9.

"Westinghouse

- Reactor Internals Assembly Specification"

- No.

2463A54 601, Revision 8.

b.

Observation of Work and Work Activities (50063)

The inspector observed the temporary installation/storage of Unit 1 upper and lower reactor internals in the refueling cavity of Unit 1 containment.

Internals (identified as item C(L) were inspected for conformance with the documents listed in 7.a.

to determine that installation is being accomplished in accordance with requirements, including special requirements and precautions.

During the above inspection the inspector observed in-process inspection for base-metal arc strikes on the refueling cavity liner floor (Dwg.

SK/A-G-0166-Rev.

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and the floor between the reactor cavity and refueling pool.

The inspector was informed that base-metal arc strikes had been identified during an inspection for cleanliness conducted the previous day in preparation for hydrostatic testing.

Cognizant licensee personnel informed the inspector that the inspection observed was "for information" since responsible NDE personnel had not yet inspected the area in conformance with TP-57, "Hydrostatic Test of Fuel Pool Liners."

The inspector noted that WP-122, "Installation of

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"General Welding Procedure for Stainless Steel Liner Plate."

Further that TP-57 did not address inspection for base-metal arc strikes that could have occurred after completion of nearby weldments.

Licensee personnel responded that procedures were now being written to cover inspection of fuel-pool liner base-metal for arc strikes and would be implemented prior to completion of work under TP-57.

The inspector reviewed work traveler nonwelding (WTNW) documents issued March 21, 1985, which identified base-metal arc strikes on the refueling cavity floor and the reactor cavity stainless steel ring.

The inspector informed cognizant licensee personnel that pending completion of corrective action this matter would be identified as Inspector Followup Item 400/85-12-02

"Arc Strikes on Refueling Cavity Liner Plate".

Review of Quality Records (50065)

The inspector reviewed pertinent quality related work and inspection (QC) records relative to the reactor vessel internals CQL to ascertain whether the records were in conformance with established procedures and whether they reflected work accomplishment consistent with applicable requirements in the area of lifting and handling.

Within the areas examined no violations or deviations were identified.

8.

Licensee Identified Items (92700)

Prior to the inspection, the licensee identified the following items under

CFR 50.55(e):

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400/CDR 80-38

"Safety Injection (Charging)

Pump Operation Following a Secondary Side High Energy Line Rupture" On July 7, 1980, the licensee notified Region II of a 50.55(e)

item concerning potential deadhead operation of safety-injection pumps during a

safety actuation incident.

Corrective actions required revision of design documents to provide alternate miniflow paths to protect the two operable charging pumps whenever an engineered safeguards system actuation signal is present and the normal miniflow path is isolated.

'Fhe alternate paths are placed in service by operation of motor operated isolation valves.

The final report was submitted on January 29, 1985.

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 ver ify that corrective actions identified in the report have been completed.

The inspector also verified that the motor operated valves involved are incorporated in the licensee's valve maintenance progra IE vf I

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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.

Corrective actions required replacement with bolting meeting or exceeding SAE Grade 5 and supplementing gusset stiffener spot welds with fillet welds along each support leg.

The final report was submitted on September 1,

1983.

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 complete "f 4

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