IR 05000412/1980004
| ML19331B861 | |
| Person / Time | |
|---|---|
| Site: | Beaver Valley |
| Issue date: | 05/09/1980 |
| From: | Durr J, Mcgaughy R, Narrow L NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML19331B854 | List: |
| References | |
| 50-412-80-04, 50-412-80-4, NUDOCS 8008130426 | |
| Download: ML19331B861 (10) | |
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l U.S. NUCLEAR REGULATORY COMMISSION O
orrICE or INSeeCTt0N AND eNr0aCsMcNT Region I Report No. 50-412/80-04 Docket No. 50-412 License No.CPPR-105 Priority _
Category A
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Licensee:
Duouesne Licht Comoany 435 Sixth Avenue Pittsburgh, Pennsylvania 15219
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racility Name:
Beaver Valley Power Station, Unit 2 Inspection at:
Shippingport, Pennsylvania Inspection con ted:
pi 7-11, 1980 Inspectors:
Wo a/[h [
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L.Aarro actor Ingector J-
/atk.- /W WM'/Ao ddte s'1gned J.
. Durr ctor'Insp tor th ad W W W
S. D. Reynolds, Jr.,
eactor Inspector dite s'igned Approved by: //[/N/4 ban R.'W.McGaughy,ThNf,ProjectsSection date signed
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RC&ES Branch Inspection Summary:
Inspection on April 7-11. 1980 (Report No. 50-412/80-04)
Areas Inspected:
Routine, unannounced inspection by three regional based inspectors for observation of pipe welding in progress and review of s;elding records; review of structural steel welding procedures and welding inspector qualifications; and
. review of the status of Bulletins, Circulars and outstanding items.
The inspection involved 72 inspector hours onsite and in the licensee's office by three regional based inspectors.
Resul ts: Of the four areas inspected, no items of noncompliance were identified in three areas and one item of noncomoliance was identified in one area:
railure to provide evidence of evaluation and disposition of indications identified in radiographs of welds.
(Paragraph 3)
Regica I rorm 12 (Rev. April 77)
8008180 %
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DETAILS 1.
Persons Contacted
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Duquesne Light Company (DLC)
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W. Blackwell, Engineer, Project Group (Pittsburgh)
- H. N. Crooks, Assistant Director of Quality Control
- R. Coupland, Director of Quality Control
- F. G. Curl, Construction Engineer
- C. R. Davis, Senior QA Engineer
- D. W. Denning, Assistant Director of Quality Control D. Gasper, QC Inspector M. Hartaan, Training Supervisor E. J. Huesmann, Administrative Coordinator (Pittsburgh)
J. Long, Inspection Supervisor, Structural G. Martin, NDE Level III
- W. Sikorski, QA Supervisor
- R. Washabaugh, Manager, Quality Assurance Department R. L. Williamson, Quality Control Inspector
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Stone and Webster (S&W)
.M.Bendiksen,AssistantProjectEngineer(Boston)
- C. R. Bishin, Superintendent of Construction
- S. M. De., Head, Site Engineering Office
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- A. C. V,cIntyre, Site Engineering Office V. W. Pardo. Resident Engineer
- J. E. Wiiliams, Resident Manager J. Winn, Electrical Engineer, SE0 Pittsburgh-Des Moines Steel Company (PDM)
J. Madden, QA Manager Sci.neider, Incorporated J. Hilster, Project Manager J. Sekely, Project Welding Engineer G.-Timko, QC Engineer
.The inspectors also interviewed other licensee and contractor personnel during the inspection.
- Denotes those present at the exit interview.
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2.
Plant Tour
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The inspector observed work activities in progress, completed work, and construction status in several areas.
Work items were examined
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for obvious defects and for noncompliance with regulatory requirements and licensee connitments.
Specific activities observed by the inspector included welding of structural angle clips to embedment plates, welding of the containment dome and installation of concrete form work.
No items of noncompliance were identified.
3.
Review of Safety Related Piping Radioaraphs
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Nine radiographs of circumfrential butt welds in safety related piping systems were selected for review.
The review was performed to verify that the radiographs satisfy the requirements of the ASME III Code, Appendix IX, and the Nondestructive Testing Procedure RT-10.
The following listed pipe weld radiographs were reviewed:
Weld No.
Remarks 2-RSS-021-F02 View 3-0 a linear indication at end of penetrametsr, not dispositioned.
2-RSS-021-F03 None.
2-RSS-021-F04 View 1-2, linear indication on film in area of interest, backup film should be rejected due to processing marks.
2-RSS-021-F05 View 0-1, linear indicatien at the "0" marker, not dispositioned.
2-RSS-021-F06 None.
2-RSS-021-F07 View 2-3, porcsity, not dispositioned.
2-RSS-021-F08 None.
2-RSS-062-F06 View 0-1, approximately 1" from marker 1, rounded / tailed indication, not dispositioned.
2-QSS-078-F02 None.
As indicated in the " Remarks" above, five of the nine films bore indications which were not interpreted and dispositioned on the interpretation report. This is contrary to the ASME III Code, Appendix IX, paragraph IX-3340, and 10 CFR 50, Appendix B, Criterion IX.
This item is a noncompliance (80-04-01).
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4.
-Spalling of Concrete During'the~ plant tour for observation of work in progress and completed
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work, the inspector observed spalling of concrete at the bottom of embedded anchor plates to which angle clips had been welded.
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condition was observed at Elevation 700.92 feet on Column 12 and 13.
The inspector examined similar installations on adjacent embedded anchor plates but identified no other cases of spalled concrete.
The condition was described on Nonconformance & Disposition Report (N&D)
No. 1323.
This-item is unresolved pending review by an NRC inspector of the disposition and corrective action.
(80-04-02)
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5.
Requirements for Maintenance of Welding Records During review of QC and construction procedures, the inspector noted that specific requirements had not been established to identify the
.information to be shown on structural welding inspection records. The inspector
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examined reports of inspections which had been performed and observed that they identified the welder, weld locations and description, and
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-the date. This information together with the information on the weld
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rod issue slips provided an adequate welding record.
However, the
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requirement for maintaining these inspection records was not included in the inspection procedure.
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This item is unresolved.
(80-04-03)
6.
Filler Metal Control and Identification During observation of welding in progress on weld 2-QOS-078-F10 and
review of other austenitic stainless weld records, it was observed that the VPS Precedure Technique Sheet SPBV H indicated that all i -
filler metal utilized.for the welding shall have the ER308 filler metal chemistry. The " flag tagged" GTAW filler metal being utilized was of both ER308 and ER308L chemistry.
The substitution of ER308L for ER308 does not constitute an essential variable change, but does constitute a non-essential variable change. Upon informing the licensee of this problem, the following action by the licensee was observed:
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An immediate.stop work order from the S&W Resident Manager to
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Schneider, Inc. was processed.
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A training session on issuance of filler metals was held on April 9,'1980.
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S&W was' requested to provide a written engineering appraisal of the consequences of.the substitution to formalize their iamediate verbal technical opinion that the substitution was technically -
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acceptable.
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d.
Schneider started to make revisions to their austenitic stainless steel welding technique sheets to permit either ER308 or ER308L.
This is an unresolved item until such time as the S&W engineering p(osition and the Schneider WPS revisions are complete and acceptable.
80-04-04)
7.
Identification of Consumable Inserts in POR Document
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During the review of the aforementioned welding documentation, it was observed that the filler metal chemistry for the consumable insert utilized for the test assembly for PQR 760532 was not recorded on the PQR form, however, it was stated that the welding uas conducted in
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accordance with SPBV 300H which requires an ER308 consumable insert.
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The licensee was infonned of this discrepancy and will have Schneider review the problem.
This is an unresolved item until the PQR document is corrected.
(80-04-05)
8.
Observation of Containment Dome Welding During the plant tour, in progress welding activities were observed on the containment liner dome.
The licensee was performing shielded metal arc welding on a leak chase covering insert plate RSS-104. The inspector noted that the welder was unprotected from the weather and that a fairly-strong, gusty wind was blowing. The welder was using a covered, 8018-C3 electrode which depends, to some extent, on a gas atmosphere to protect the transferred weld metal.
It was determined that the applicable welding specification, WPS-97, paragraph 13.3.2,
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recomends that, "...no welding be done...during periods of hioh wind unless the welders...are properly protected." Unit No.1 meteorolbgy records establish that the wind was blowing between 12 to 16 miles per hour during the period in question.
The quality assurance personnel were unable to define "high wind" conditions or what threshold values of wind speed would necessitate protection of the welder.
This, item is considered unresolved pending the licensee establishing
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definitive values for wind protection of welders and assurance that the lack of these values has not degraded weld quality.
(80-04-06)
9.
Structural Welding Procedures The inspector reviewed the Field Construction Procedures (FCP's) and Inspection Procedures (IP's) listed below for conformance to the requirements of Section 17 of the PSAR and the applicable sections of Specification 2 BVS-412, " Specification for Structural Steel."
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FCP-601.2, " Welding Procedure Qualifications", January 16, 1979;
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FCP-601.3, " Welder Performance Qualification Tests", July 14,
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1978; FCP-601.4, "Non-ASME Weld Documentation", Change No. 3, May 3,
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1979; FCP-601.5, " Weld Material Control", Change No. 7,. January 18.
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1980; FCP-601.10. " Control of Welded Attachments", December 22, 1978;
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FCP-601.11, AWS-Non Code Weld Profile Criteria and Weld Examination",
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November 22, 1978; IP-9.1, " Welder Performance Qualifications", May 25, 1979;
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IP-9.3S, " Structural Welding Control-AWS", March 26, 1980.
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No items of noncompliance were identified.
10. Qualifications of Personnel The inspector reviewed personnel and qualification records of structural welders and inspection personnel.
Two welders are presently employed by PBI, the structural steel erection contractor, on welding of structural steel.
They had been qualified in accordance with the applicable FCP's and the requirements of AWS D1.1-72, for the type of welding they were perforniing.
The inspector also examined the personnel and qualification records of the welding inspector and QC supervisor.
These records showed them to have been qualified and certified for Level II and Level III welding inspectors respectively, in accordance with ANSI 45.2.6 and the training procedures shown below.
TP-1, " General";
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TP-2, " Qualification and Certification".
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No items of noncompliance were identified.
11. Weld Rod Control The inspector examined the PBI weld rod issue stations, the logs of storage area and storage oven temperature records and the list of personnel authorized to sign weld rod requisitions and to issue welding materials.
No items of noncompliance were identifie _ _ _ _ _ _ _ _ _ - _ _ _ _ - _ _ _ _ _ _ _ _ _ _ _ _ _ - _ _ _ _ _
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12.. Safety Related Piping - Observation of Work and Review of Quality Records The inspector selected two welds for observation from initial setup to completion, one weld for observation during welding and four completed welds for visual inspection.
The quality records for all welds were reviewed. These welds were selected for review to determine if the welds met the licensee's commitments and ASME B&PV Code Section III.
~The following Class 3 welds were observed from setup to completion.
2-SWS-329-F05;
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2-SWS-301-F500.
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The following C? ass 2 welds were visually inspected upon completion.
2-QQS-078-F02:
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2-RSS-021-F08;
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2-RSS-021-F06;
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2-RSS-021-F04.
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The following Class 2 weld was observed during welding.
2-QQS-078-F10.
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The audit on the aforementioned was performed to assure the following:
Welds were conducted in accordance with travelers, properly
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identified and located, welding procedures properly qualified, welding conducted in accordance with WPS, welding consumables records correct, QC personnel properly trained and qualified and weld history records adequate.
No items of noncompliance were identified.
13.
Licensee Action on NRC Bulletins
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a.
The following Bulletins were sent to the licensee for information only and are closed since the information has been made available to interested persons in the licensee's organization.
Bulletin 79-05 and Supplements, " Nuclear Incident at Three
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Mile Island";
Bulletin 79-13, " Cracking in Feedwater System Piping";
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Bulletin 79-17, " Pipe Cracks in Stagnant Boraled Water
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System at PWR Plants";
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Bulletin 79-18, " Audibility Problems Encountered on Evacuation
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of Personnel From High Noise Areas";
Sulletin 79-21, " Temperature Effects on Level Measurements";
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Bulletin 80-04, " Analysis of a PWR Main Steam Line Break
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With Continued Feedwater Addition";
Bulletin 80-06, "Engir,eered Safety Features (ESF) Reset
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Controls".
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The following Bulletins are closed based on evidence that the Bulletin has been forwarded to S&W and, if necessary, to Westinghouse for corrective action; and that such action is in progress.
Bulletin 78-14, " Deterioration of Buna-N Components in ASCO
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Solenoids";
Bulletin 79-06 and Supplements, " Review of Operational
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Errors and System Misalignments Identified During the Three Mile Island Incident".
c.
Bulletin 78-12 and Supplement, " Atypical Weld Material in Reactor Pressure Vessel Welds". This Bulletin is closed based on DLC letter to NRC dated June 29, 1979 identifying a Combustion Engineering (CE) Generic Report, " Atypical Weld Material in Reactor Pressure Welds", which had been submitted to NRC on June 9,1979; and attaches a certification by CE that the report addresses all of the materials used for the Beaver V. alley Unit 2 reactor pressure vessel.
14.
Licensee Action on NRC Circulors The following Circulors are closed based on evidence that they were forwarded to S&W and, if necessary, to Westinghouse for corrective action and that such action is in progress.
Circular 76-01, " Crane Hoist Control-Circuit Modifications";
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Circular 77-16, " Emergency Diesel Generator Electrical Trip
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Lockout Features";
Circular 78-18 UL Fire Test";
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Circular 79-05, " Moisture Leakage in Stranded Wire Conductors";
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Circular 79-10, "Pipefittings Manufactured of Unacceptable
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Material";
Circular 79-13, " Replacement of Diesel Fire Pump Starting l
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Contractors";
Circular 79-17, " Contact Problem in SB-12 Switches on General i
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Electric Metalclad Circuit Breakers";
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. Circular 79-19, " Loose Locking Devices on Ingersoll Rand Pumps";
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Circular 79-20, " Failure of GTE Sylvania Relay, Type PM Bulletin
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7305, Catalogue SU12-11-AC With a 120V AC Coil".
Circular 77-11 " Leakage of Containment Isolation Valves With Resilient Seats", remains open.
The problem identified in this circular and another problem of adherence of the bonded seats to valve bodies, described in S&W Problem Report PR-P-115 are discussed in DLC-SQCL-0578E dated February 8, 1980.
Inspection of all valves on site is in progress.
This item remains unresolved.
(77-CI-11)
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Licensee Actions on Previous Inspection Finoings (Closed) Unresolved Item (78-01-01):
Licensee action on circulars.
The inspector reviewed licensee action on outstanding circulars.Circulars
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previously identified as open have been closed. The inspector had no further questions concerning this item.
(0 pen) Noncompliance (79-09-01):
Failure to maintain control of drawing changes.
During review of cable tray arrangement drawings the inspector had observed the failure to maintain the required separation of trays.
The inspector discussed the corrective actions taken with the licensee and S&W representatives. They stated that all Category I cable tray drawings had been reviewed; nonconformances to separation criteria were identified on seven drawings and all nonconforming conditions corrected.
S&W letter 2 DLS-9949 to the licensee, dated February 29,
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1980, identified the drawings and corrective action and also stated that Project Procedure ? BVM-41 will be revised to require that all final Category I cable tray drawings be reviewed for conformance to separation / barrier requirements. The inspector examined the identified drawings and observed that they had been revised to require installation
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of barriers where separation distances between trays were inadequate.
The inspector observed that in all seven cases the lack of adequate separation had resulted from a drawing change.
Six of the seven changes had been made in the Boston Office and one change had been made in the
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field. The inspector questioned the adequacy of drawing change review in view of the number of revisions which had not been identified as
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nonconforming. The inspector was informed by S&W engineering personnel that engineering had deliberately disregarded the separation requirements in their review of drawing changes since they knew that final cable drawings would be reviewed and barriers installed were necessary. Neither the procedures nor the drawings identified separation requirements for later review or astablished a requirement that the design permit installation of barriers j
at a later date.
This item remains unresolved pending corrective action
which will provide better control of changes and the change review.
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16. Unresolved Items Unresolved items are matters about which more information is required in order to ascertain whether they are acceptable items, or items of noncompliance.
Unresolved items identified during this inspection are discussed in Paragraphs 4, 5, 6, 7 and 8.
17.
Exit Interview The inspector met with licensee and contractor representatives (denoted in Paragraph 1) at the conclusion of the inspection on April 11, 1980. The inspector summarized the scope and findings of the inspection as described in this report.
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