IR 05000413/1981005
| ML20009D988 | |
| Person / Time | |
|---|---|
| Site: | Catawba  |
| Issue date: | 04/07/1981 |
| From: | Herdt A, Kleinsorge W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML20009D966 | List: |
| References | |
| 50-413-81-05, 50-413-81-5, 50-414-81-05, 50-414-81-5, NUDOCS 8107240559 | |
| Download: ML20009D988 (8) | |
Text
-
.
S UNITED STATES
.* N -
-
c%
NUCLEAR REGULATORY COMMISSION
- !
$
REGION 11
"
101 MARIETTA ST.. N.W.. SUITE 3100 ATLANTA, G EoRGIA 30303
,
.....
Report Nos. 50-413/81-05 and 50-414/81-05 Licensee:
Duke Power Company 422 South Church Street Charlotte, NC 28242
.
Facility Name:
Catawba Occket Nos. 50-413 and 50-414 License Nos. CPPR-116 and CPPR-117 Inspection at at ear Lake Wylie, South Carolina
,
-#
Dri M
Inspector: E
' - - -
-
WPPV)fernsorge
'Ohte SYgned Accompanying Pers n
. Y. Chen Approved by:
/
8/
A. R. Herdt, Section Chief Date ' Signed Engineering Inspection Branch Engineering and Technical Inspection Division SUMMARY Inspected on March 17-20, 1981 Areas Inspected This routine, unannounced inspection involved 30 inspector-hours on site in the areas of licensee action on previous inspection findings (Units 1 and 2),
material storage (Units 1 and 2), reactor coolant pressure boundary piping -
observations of work and work activities (Unit 2), safety-related piping -
observation of work and work activities (Unit 2), containment structural steel
-
welding - observation of work and work activities (Unit 1) and safety-related l
structures - observation of work and work activities (Unit 1).
l Results Of the six areas inspected, no violations or deviations were identified in three l
areas; two violations were found in three areas (Violation
" Inadequate Measures
'
to Control Welding" paragraphs 6.a., 7.b.(1), 7.b.(2) and 9.a.(1); Violation -
" Failure to Follow Bead Width Procedure Requirements" paragraph 7.b.(3)).
-
!
0107240559
.a
-
.
_
-
-
,,
.
,.w..
_
-
-
-
. -.
-_.
_-
.
. -_-
,
-
,
.
.
.
. a b_
.
REPORT DETAILS 1.
Persons Contacted Licensee Employees D. G. Beam, Project Manager
- T. D. Mills, Construction Engineer Mechanical
- R. A. Morgan, Senice QA Engineer
- J. C. Shropshire, QA Engineer
- M. R. Hemphill, QA
- D. C. Mattern, D/E Mechanica'
- H. D. Mason, QA
- A. R. Hollins, Construction
- W. Duncan, QA Audit Division
- C. Brackins, QA Audit Division Other licensee employees contacted included construction craftsmen, techn tcians, and office personnel.
Other Organizations
- C. F. Toegel, Jr., Authorized Nuclear Inspector (HSBII)
NRC Resident Inspector
- P. K. VanDoorn
- Attended exit interview 2.
Exit Interview The inspection scope and findings were summarized on March 20, 1981 with those persons indicated in paragraph 1 above. The inspector identified the areas inspected and discussed in detail the violations and the unresolved item. No dissenting comments were received from the licensee.
,
,
.
L 3.
Licensee Action on Previous Inspection Findings i
i a.
(Closed) Infraction 413, 414/80-29-01:
" Inadequate Measures for i
Flammable Storage".
Duke Power Company letter of response dated December 12, 1980 has been reviewed and determined to be acceptable by i
Region II. The inspector held discussions with the project manager and i
l examined the corrective actions as stated in the letter of response.
The inspector concluded that Duke Power Company had determined the full extent of the subject noncampliance, performed the necessary survey and follow-up actions to correct the present conditions and developed the
. _ -,
.
-. -
. -.
. - -, -. _ -. - - -. - _ _. -
-.. - -... - - -
.
-. -. -
.... -. - -. -.
.
.
.
.
.
.
a b-
.
necessary corrective actions to preclude recurrence of similar circumstances.
The corrective actions identified in the letter of response have been implemented.
b.
(Closed) Deficiency 413, 414/80-29-02: " Failure to Properly Document PQR Testing". Duke Power Company letter of response dated December 12, 1980 has been reviewed and determined to be acceptable by Region II.
The inspector held discussions with the project manager and examined the corrective actions as stated in the letter of response.
The inspector concluded that Duke Power Company had determined the full extent of the subject noncompliance, performed the necessary survey and follow-up actions to correct the present conditions and developed the necessary corrective actions to precl0de recurrence of similar circumstances.
The corrective actions identified in the letter of response have been implemented.
c.
.(Closed) Unresolved Item 413, 414/80-24-03: " Chloride Control". This concerned whether ASME Code requirements were being met for control of thread cutting fluid. This item was addressed in RII 50-413, 414/80-36 and left open because it could not be determined whether Duke had addressed the requirement for removal of fluid prior to seal welding per Code paragraph NX-4713. The inspector determined that the cleaning requirements of NX-4713 are adequately controlled by QAP L-80, paragraph 5.1.6.
Therefore this item is co.isidered closed.
d.
(Closed) Unresolved Item 413, 414/80-29-04:
" Inconsistent Pipe Bend Inspection Requirements and Practices".
This concerned whether QAP M-25 was consistent with Duke commitments and M-25 apparent procedural inconsistencies. Duke has ammended M-25 to eliminate the conflicts.
The inspector determined that M-25 is consistent with Duke's commit-ments. This item is considered closed.
e.
(Closed) Unresolved Item 413, 414/80-29-05:
"Omitted Rinse After l
Bending". This item concerned control of fluid used during bending of stainless steel pipe. This item was addressed in RII 50-413, 414/80-36
-
'
l and left open because CP-479 was not clear as to whether rinsing was
!
required. Also Duke had not performed a safety evaluation of material used to date without rinsing. Duke has ammended CP-479 to clarify the
_
f rinsing requirement, and has made the necessary safety evaluation. It l
was determined that rinsing of previously performed bends is not l
required.
The inspector has no further questions. Thi: 'Lem is i
considered closed.
4.
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 this inspection are discussed in paragraph 5.b.
l l
k
-
~
.
.
.
.
aW_
.
5.
Independent Inspection Effort (Units 1 and 2)
a.
Construction Activities The inspector conducted a general inspection of the Unit 1 and 2 containments, auxiliary buildings, fuel buildings, pipe fabrication shop, outdoor storage areas and electrode issue station to observe construction progress and construction activities such as welding, material handling and control, housekeeping and storage.
b.
Material Storage With regard to the inspection of paragraph 5.a. the inspector on March 19, 1981 noted a large number of piping assemblies, both safety-related and balance of plant, with deteriorated (cracked and brittle)
plastic seal end caps. The extent of damage caused by the deteriorated caps could not be determined at the time of this inspection.
The licensee indicated that they would look further into the matter. The inspector stated that the above would be identified as an unresolved
.
item 413, 414/81-05-03: " Deteriorated Pipe Caps".
Within the areas examined, there were no violations or deviations ident1-fied.
6.
Reactor Coolant Pressure Beundary Piping - Observation of Work and Work Activities (Unit 2)
The inspector observed welding work activities for reactor coolant pressure boundary (RCPB) piping. The applicable code for installation of RCPB piping is the ASME B and PV code,Section III, Subsection NB 1974 edition plus addenda through summer 1974.
The inspector observed field welding of reactor coolant pressure boundary piping at various stages of weld completion.
.
a.
The inspector examined weld joints where the root pass (only) has been completed to determine; weld / welder identification, qualified welder /
'
weld procedure, physical appearance of weld and evidence of QC
_
'
verification. The following weld joint was examined:
,
,
Joint No.
Unit No.
Isometric System
,
2-NI-66 Residual Heat Removal With regard to the above inspection, on March 17, 1981, the inspector noted the traveler for the above joint specified Field Weld Cata Sheet (FWDS) No. L-234 as an approved welding procedure specification for the joint in question. The above joint has a "J" bevel weld preparation.
L
.
.
.
,
.
.
a W_
.
FWDS L-234 is applicable to "V" bevel weld preparation only. The above indicates inadequate measures to control welding and is an example of violation 413, 414/81-05-01.
This matter is discussed further in paragraph 9.a.(1).
b.
The inspector observed activities at weld material issue stations to determine adequacy of:
weld material storage / segregation, oven temperatures, issue records and return of unused weld material. Also the inspector observed work areas for uncontrolled weld material.
Within the areas examined, there were no violations or deviations identi-fied, except as described in paragraph 6.a.
7.
Safety-Related Piping - Observation of Work and Work Activities (Unit 2)
The inspector observed field welding of safety-related piping outside the
.
reactor coolant pressure boundary at various states of weld completion. The applicable Code '.ar safety-related pipe welding is the ASME B and PV Code,Section III, Subsection NC and ND,1974 edition through summer 1974.
a.
The inspector examined weld joints where the root pass (only) has been completed to determine; weld / welder identification, qualified welder /
weld procedure, physical appearance of weld and evidence of QC verification. The following weld joints were examined:
Joint Number Unit Size Isometric System 2CF-38-5
4"x0.337 2CF-38 Feedwater 2KD-46-15
6"x0.280 2KD-46 Diesel Generator Engine Cooling
-
b.
The inspector examined weld joints of pipe to pipe / fitting (PPF),
fitting to fitting (FF) and pipe to components (PC) where welding was beyond the root pass to determine; weld / welder identification, qualified welder / weld procedure, periodic checks of welding variables, use of specified weld material, proper interpass temperature and where applicable pre-heat and post weld heat treatment and physical appearance of weld (e.g., starts, stops, undercut and surface imper-
_
fections).
Joint Number Unit Type Isometric System 2-CF-38-9
PPF 2-CF-38 Feedwater 2-CF-38-6
PPF 2-CF-38 Feedwater 2-KC-246-3
PPF 2-KC-246 Component Cooling
'
2-KC-246-2
FF 2-KC-246 Component Cooling 2-NI-15-1
Repair 2-NI-15 Safety Injection
-
.
.
.
,
,
W-
.
(1) As a result of the welder qualification review for the above joints the inspector noted on March 17, 1981 the following:
Per_formance Qualification Field Weld Data Sheet L-180, Revision 1 consists of 3/16-inch gas tungsten are weld (GTAW) metal -deposit followed by 9/16-inch shielded metal arc weld (SMAW) metal deposit in a 3/4-inch wall thickness, groove pipe butt weld test assembly.
L-180 states that the above test assembly qualifies welders for unlimited whickness pipe welding. The preceding is contrary to ASME Interpretation IX-78-92 dated September 25, 1978, in that the above test conditions would only qualify the tested welder for a maximum thickness of 1-1/E-inch.
Therefore welders could, by L-180, be granted unlimited thickness qualification when the welders are actually only qualified to 1-1/2-inch thickness maximum.
The above indicates inadequate measures to control special processes and is an example of violation 413, 414/81-05-01. This matter is discussed further in paragraph 9.a(1).
(2) As a result of the procedure review for the repair above, the inspector noted, on March 18, 1981, the following:
(a) The only acceptance criteria for prerepair weld visual inspection is to verify " acceptable repair cavity geometry" as stated in QAP Procedure M-4, Revision 8, " Visual Inspec-tion and NDE of Welds (ASME III)". The inspector determined that the licensee has no documented description of " accept-able repair cavity geometry",
therefore inspectors are inspecting to an undefined acceptance criteria.
(b) The decision of whether to purge the back side of a repair weld is left to the licensee's welding inspectors.
This question is not addressed in Procedure M-4.
The only purge guidance is given in Process Specification L-200 " Gas Tungsten ARC Welding" in terms of numbers of layers of weld in the original weld joint.
The licensee stated that they depend on their welding inspectors'
previous welding experience and good judgement to determine whether repair welding back purge is required.
Therefore inspectors are inspecting to an undefined acceptance criteria.
.
Paragraphs 7.b.(2)(a) and (b) indicate inadequate measures to control welding and are examples of violation 413, 414/81-05-01.
This matter is discussed further in paragraph 9.a.(1).
(3) With regard to the observation of welding on joint 2-NI-15-1, on March 17, 1981, the inspector noted a fill bead, deposited with a 1/8-inch diameter electrode that was 1-1/8-inch wide, for 25's of the joint circumference.
The above beao was not in the cover layer. Process Specification L-300 " Shielded Metal Arc Welding",
..
.
.
.
.
.
-
,..
,
W.
Revision 10, paragraph 9.2, requires bead width of non-cover ' fill passes deposited with 1/8-inch electrodes not to exceed 3/4-inch maximum.
Therefore, the welder failec to follow procedure.
Failure to follow procedure, for activities affecting quality is i n'
violation of 10 CFR 50, Appendix B, Criterion V.
This violation will be identified as 414/81-05-02: " Failure to Follow Bead Width Procedure Requirements".
c.
The inspector observed activities at weld material issue stations to determine adequacy of; weld material storage / segregation, oven temperatures, issue records and return of unused weld material.
Also,
-the inspector observed work areas for uncontrolled weld material.
Within the areas examined, there were no violations or deviations identi-fied, except as described in paragraphs 7.b.(1), 7.b.(2) and 7.b.(3).
'
Observation of Work and Work 8.
Containment Structural Steel Welding
-
Activities (Unit 1)
.The inspector observed field welding activities associated with steel containment structures and steel supports for major equipment within the containment at various stages of weld completion.
a.
The inspector observed welding activities where welding was in progress to determine conformance with specifications and procedures in the areas of; weld identification, specified weld procedures, qualified welders, specified weld material, ucified purge (if applicable);
repair procedures, specified NDE being performed and periodic checks of
- welding variables.
.
_ eld Joints W
Structural Support H-Frame at 572+7-1/2, 300 Detail E on CN-1073-15 The applicab'e Code for the above welding is AWS D1.1-72 b.
Observation of weld material control included; identification, segre-gation, oven temperatures, issue slips and control of unused material
_
at issue stations and work areas.
c.
During observation of welding activities there were a sufficient number of qualified inspection personnel at the work site.
Within the areas examined, there were no violations of deviations identi-fied.
9.
Safety-Related Structures - % ew f on af Work and Work Activities (Unit 1)
The inspector observed fi. id m. ;,ug activities associated with safety-
.
related structures and suppwts outsW containment during various stages of
-
.
e
.
.
.
..e.
.ab_
.
weld completion. Observations were made in order to determine whether the requir ements of applicable specifications, standards, work and/or inspection procedures are being met for the activities involved and in the following stages of weld completion:
a.
The. inspector examined weld joints where welding is in progress to determine whether weld identification, weld procedures, welder qualifi-cation, weld material, defect removal (if applicable), specified NDE and periodic checks of welding variables are in conformance with existing requirements.
Structure / Support Drawing Applicable Code Containment Spray System CN-1220-43, R 10 AWS 01.1-75 Heat Exchanger Support (Repair)
Ice Machine Support 1-E-NF-1001, R8 AWS D1.1-78 (Repair)
Vent Stack CN-1210-012, R9 AWS D1.1-75 Plenum (Repair)
(1) With regard to the above inspection, the inspector, on March 19, 1981, noted that drawing CN-1220-43, R10 erroneously lir s specification No. CNS-1120.0"-00-0001 "230 KV Switching StatSa Low Structures - Structural Steel", as the applicable fabricatson specification for the containment spray system heat exchanger support.
The intended specification was CNS-1121.00-1 "Specifi-cation For Field Fabrication of Structural Steel, Miscellaneous Steel and Other Steel Construction For Nuclear Safety-Related Structures".
Therefore the fabrication drawing referenced an inappropriate fabrication specification.
The above combined with the examples described in paragraphs 6.a.,
7.b.(1) and 7.b.(2) indicate that the licensee does not have adequate measures for the control of welding.
Failure to establish adequate
'
measures to control special processes including welding is in violation
-
of 10 CFR 50, Appendix B, Criterion IX.
This violation will be identified as 413, 414/81-05-01:
" Inadequate Measures to Control Welding".
b.
Observation of weld material control included; identification, segregation, oven temperatures, issue slips and control of unused material at issue stations and work areas.
c.
During observation of welding activities there were a sufficient number of qualified inspection personnel at the work site.
Within the areas examined, there were no violations or deviations identi-fied, except as described in paragraph 9.a.(1).
_