IR 05000413/1981011
| ML20005B547 | |
| Person / Time | |
|---|---|
| Site: | Catawba  |
| Issue date: | 06/11/1981 |
| From: | Bryant J, Van Doorn P NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML20005B537 | List: |
| References | |
| 50-413-81-11, 50-414-81-11, NUDOCS 8107080356 | |
| Download: ML20005B547 (8) | |
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REGION 11
o 101 MARIETTA ST.. N.W., SUITE 3100 ATLANTA, GEORGI A 30303
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Report Nos. 50-413/81-11 and 50-414/81-11 Licensee: Duke Power Company 422 5 uth Church Street Charlotte, NC 28242 Facility Name: Catawba L1-ket Nos. 50-413 and 50-41r License Nos. CPPR-116 and CPPR-117 Inspection at Catawba site near Rock Hill, South Carolina
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Inspector:
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Approved by:
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.- e J. C,e Bryant, S.ection Chief, Resident and Date Signed Reactor Project Inspection Division SUMMARY Inspection on April 26 - May 25,1981 Areas Inspected This routine, unannounced inspection involved 163 resident inspector-hours on site in the areas of reactor coolant pressure boundry piping - observation of welding and non welding activities (Unit 2); safety-related piping - observation of welding and non-welding activities (Unit 2); review of nonconforming item reports (Units 1 and 2); containment concrete -observation of work and work activities (Unit 2); containment penetrations - observation of work activities (Unit 2); review of records for vendor supplied valves (Unit 2); safety-related pipe support and restraint systems (Unit 1); reactor vessel internals -
observation of work and work activities (Unit 1); observation of magnetic particle inspection (Units 1 and 2); containment structural steel welding -
observation of work and work activities (Unit 1).
Results Of tne areas inspected, no violations or deviations were identified.
CB107080356 810615 h"PDR ADOCK 05000413 G
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DETAILS 1.
Persons Contacted Licentee Employees
- D. G. Beam, Project Manager
- J. C. Rogers, Incoming Project Manager
- S. W. Dressler, Senior Construction Engineer
- R. N. Johnson, Assistant General Superintendent L. R. Barnes, Manager Supports / Restraints
- R. A. Morgan, Senior QA Engineer T. D. Mills, Construction Engineer Mechanical J. C. Shropshire, QA Engineer Supervisor
"H. D. Mason, QA Engineer Supervisor C. R. Baldwin, QC Technical Supervisor Welding /NDE
- J. N. Warren, QC Engineer Civil / Electrical J. R. Pettit, Supervisor Technician NDE D. E. Gadd, Welding Engineer s
D. H. Llewellyn, Welding Engineer M. R. Hemphill, QA Engineer
- H. L. Atkins, QA Engineer
- W. T. McClure, QA Technician R. D. Blackwelder, QA Technician R. G. Rouse, QA Technician Other licensee employees contacted included 20 construction craftsmen, six office personnel, and six inspectors.
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- Attended exit interview 2.
Exit Interview The inspection scope and findings were summarized on May 22, 1981 with those persons indicated in Paragraph 1 above.
The unresolved item described in
' paragraph 5.c. was discussed in detail.
The licensee was informed of the unresolved item described in paragraph 5.d. on May 26, 1981.
The latter unresolved item was also discussed in a management meeting on May 1, 1981.
The licensee informed the inspector that Mr. D. G. Beam, Project Manager was retiring and would be replaced by Mr. J. C. Rogers, on June 1,1981.
3.
Licensee Action on Previous Inspc-ction Findings a.
(Closed) Unresolved Item (413, 414/80-24-04) - Description of Practical Test Objects. This item concerned the fact that description practical test objectr. used for qualification of welding inspectors were not contained in the inspector certification records.
The inspector verified that the descriptions were available and traceable to numbered samples.
The licensee has placed the descriptions and associated records into the inspector qualification file. The inspector verified
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this through random surveillance of inspector certification records.
Licensee actions are considered satisf actory.
b.
(Closed) Unresolved Item (413, 414/81-01-01) - Control of Grinding on Piping Base Material.
This item concerned availability of site procedures to control grinding on piping. It was determined that site procedures are available to control and document grinding on piping.
Requirements are contained in site procedures M4 and M49.
These procedures are considered adequate.
c.
(0 pen) Violation (413/81-02-02, 414/81-02-04) - Apparent Generic Items or Trends not Recognized nor Forwarded to Management.
This item concerned inadequate documentation / evaluation of generic problems. The
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licensee has committed to complete implementation of corrective actions by August 26, 1981.
As an ongoing effort to assure improvement in documentation and evaluation of nonconforming items the inspector i
reviewed numerous Nonconforming Item Reports (NCI's) at various stages l
of completion. A general improvement it the quality of documentation and evaluation of NCI's was noted. Some NCI's were identified which need further documentation / evaluation.
The inspector informed the licensee that followup inspections would be performed concerning these NCI's. The NCI numbers, their subjects and additional action required are as follows:
(1) NCI-10917 and 11620 - inadequate weld symbols on hanger drawings.
I Inspector needs to verify generic improvement in practices of Design Engineering Division.
(2) NCI-11050 generic deficiencies in penetration welds.
Verify documentation of generic corrective action and evaluation for reportability.
It appears that evaluation was not performed within the time frame allowed by NRC.
(3) NCI-11324 - verification of use of viewing ports for pipe weld repairs and performance of required inspections.
Document and verify generic corrective action and evaluatiun for reportability.
(4) NCI-11325 - rejection of accepted radiographs for FW system.
It appears that initial documentation and evaluation of generic corrective action was not adequate. The licensee is performing additional corrective action but has not yet documented this action. Improved documentation and evaluation will be verified.
(5) NCI-11367 generic problem concerning control of material changes implemented by drawing changes.
Verify corrective action and evaluation for reportability.
(6) NCI-11385 - use of uncertified weld filler material.
It appears that generic corrective action was not performed or documented.
Improved corrective action and documentation will be verified.
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No violations or deviations were identified.
d.
(0 pen) Violation (413/81-02-04) - Incomplete QA Documentation. Followup concerning this item was combined with the followup inspection as described in paragraph 3.c. above.
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No violations or deviations were identified.
4.
Unresolved Items Unresolved items are matters about which more information is required to determine whether they are acceptable or may involve noncompliance or deviations.
New unresolved items identified during this inspection are discussed in paragraphs 5.c. and 5.d.
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5.
Independent Inspection Effort (Units 1 and 2)
a.
The inspector conducted general inspections of site work and work activities and observed equipment protection / storage and housekeeping in the auxiliary building, containment buildings, pipe fabrication shop and storage areas.
b.
The inspector reviewed manufacturing records of two vendor supplied ASME Class 2 valves, Tag Nos. 2NI342 and 2NI136B for conformance to code and specification requirements. Included in this review were code data reports, material certifications, welding material certifications, vendor QA certifications, records of NDE surface inspections and radiographic film.
c.
The inspector observed magnetic particle (MT) inspection of portions of
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Unit I steam generator enclosure weld 3-1-0 for conformance to site procedure (NDE-22, Rev. 6) and code (ASME III, NE, 71S72) requirements.
On May 13,1981 the inspector noted that a fixed leg yoke was being
utilized for the above MT inspection. The site procedure (Appendix A)
requires the inspector to obtain essentially flat contact between the yoke and test item. Use of the fixed leg yoke prevented flat contact in this case since the weld was a corner weld. The inspector requested that the licensee perform tests to assure that the technique being utilized in the field was technically adequate. Tests were conducted
and witnessed by the inspector utilizing a Magnetic Particle Field l
Indicator and a welded test plate containing numerous small cracks.
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Simulation of the technique utilized in the field showed a slight i
decrease in sensitivity to detection of small cracks wnen compared to the procedure required tachnique but appeared equally as sensitive when utilizing the Magnetic Particle Field Indicator. The Magnetic Particle
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Field Indicator is the code accepted method of determining adequacy of I
a magnetizing force.
This will be an unresolved item until further evaluation can be performed and the licensee addresses the fact that i
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i personnel did not comply with procedure requirements.
This is
UNRESOLVED ITEM 413, 414/81-11-01 - Control of Magnetic Particle Inspection Technique.
Note: See paragraph 11.b. for another example of this same problem.
d.
The inspector reviewed new construction procedure CP-604, Investigation of Linear Indications in Carbon Steel (issued March, 1981) for
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technical adequacy. This procedure allows generic acceptance of linear
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indications in carbon steel piping base material provided filing or
grinding of one area of the indication coes not reduce the material below minimum wall thickness. The licensee informed the inspector that justification for this procedure was based on metallurgical evaluations performed to evaluate indications found at other Duke sites.
The
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inspector reviewed selected portions of the metallurgical reports.
It appears that evaluations were performed on a limited number of material
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heats and on piping primarily from one manufacturer.
In addition,
I typical guidance for surface finish contained in ASTM standards
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requires removal of certain surface defects (e.g. scabs, seams, laps, tears or slivers) deeper than 5. percent of the nominal wall thickness.
Use of the minimum wall thickness criteria would typically allow acceptance of these defects if depth was within 121s percent of nominal
wall thickness.
It, therefore, appears that the procedure is too generic in allowing acceptance of linear indications.
The inspector i
expressed this concern initially on May 1,1981. The licensee withdrew the procedure on May 1, 1981 until further evaluation could te
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performed.
The inspector inforn.ed the licensee that evaluation af j
indications where this procedure has been utilized to cate is also
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required. The licensee was also requested to determine if this concern affects other Duke sites. This is Unresolved Item 413, 414/81-11-02 -
Control of Evaluation of Linear Indications in Carbon Steel Piping.
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No violations or deviations were identified.
6.
Containment (Structural Concrete) - Observation of Work and Work Activities (Unit 2)
The inspector observed portions of the Unit 2 containment dome concrete Pour
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No. 4701 for conformance to requirements in the areas of performance of i
required in process inspection; calibration of test equipment; preplacement i
precaration; adequacy of crew, equipment and techniques; and control of special technique requirements implemented for the dome pour. The inspector also witnessed portions of Unit 2 dome Pour No. 4716 with an NRC regional
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inspector. This inspection is documented in NRC Report No. 413, 414/81-09.
No violations or deviations were identified.
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7.
Containment (Structural Steel Welding) - Observation of Work and Work Activities (Unit 1)
Containment fabrication is being performed in accordance with the ASME Boiler and Pressure Vessel Code, (Class NE) 1971 edition plus addenda through summer 1972.
The inspector observed portions of Unit 1 equipment hatch sleeve weld No.1-C for conformance to code and procedure requirements in the areas of weld identification, use of specified and approved welding procedures, joint preparation and alignment, use of specified weld material, verification of weld material certification, verification of welder qual-ification, performance and documemtion of required inspections, verifi-cation of inspector qualification and control of preheat and interpass temoerature. The inspector also observed control of filler metal at the job site and control and issue of filler metal at the rod issue station.
No violations or deviations were identified.
8.
Containment (Penetrations) - Observation of Work Activities (Unit 2)
The inspector observed installation in progress for piping Penetration Nos.
2M352 and 2M377 for conformance to procedure and drawing installation requirements. Areas observed included method of assembly, protection of materials, installation welding (included verification of weld location, weld design, purging, welder qualification, in process documentation and filler metal certification) and performance of required inspections.
I No violations or deviations were identified.
9.
Reactor Vessel Internais - Observation of Work and Work Activities (Unit 1)
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The inspector witnessed portions of the lifting and trial fitup of the reactor vessel upper and lower vessel internals.
The inspector observed controls placed on rigging, observed cleaning operations and discussed measurements with Westinghouse QA personnel.
No violations or deviations were identified.
10.
Safety-Related Pipe Support and Restraint (Systems Unit 1)
a.
The applicable code for safety-related support and restraint instal-lation is the ASME Boiler and Pressure Vessel Code,Section III, Subsection NF, 1974 Edition plus adaenda through summer 1975.
The inspector observed installed hangers for conformance to requirements (as applicable) in the areas of deterioration and corrosion; defor-mation of materials; tightness of bolts nuts and fasteners; use of lock nuts where required; appearance of welds and conformacne to angular tolerance. Installed hangers observed were 1-A-KC-3033,1-A-KC-3574, 1-A-KC-3646,1-A-KC-3647,1-A-KC-3837 and 1-A-RN-3898. In addition the inspector obs.erved prefabrication in process for hanger Nos.
1-A-WL-3171 and 1-A-WL-3936 for conformance to requirements in the
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4 areas of use of.specified base materials, in process documentation and control of welding.
No violations or deviations were identified.
11.. Safety-Related Piping (Welding) - Observation of Work and Work Activities (Unit 2)
The applicable code for installation of safety-related piping is the a.
ASME Boiler and Pressure Vessel Code,Section III,1974 Edition plus
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addenda through summer 1975. The inspector observed in process welds
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at various stages of c;mpletion and reviewed records for conformance to code and procedure requirements in the areas of documentation of pertinent information and QC signoffs via a weld travler, availability of pertinent instructions, use of appropriate qualified welding procedure, provisions for weld repair provided, certification of filler material, control of welding parameters, verification of welder qualification, use of specified shielding and purge gas, condition of welding equipment, provisions for voltage and amperage checks,
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verification of proper fitup, control of preheat and interpass
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temperature, condition of weld and base metal surfaces, and verifi-cation that appropriate inspections were being performed.
The following welds were observed:
Weld ho.
Size (In. Dia.)
Stage of Welding Observed 2FW39-14
Fitup 2FW76-6
Fitup 2ND15-6
Final
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Fitup plus observation j
of fitup inspection 2NS37-3
Fitup
.I 2NS52-16
Final 2YC1-1
Final plus MT inspection 2YC1-10
Final plus MT inspection 2YC11-19
Final plus MT inspection 2YC12-3
Final plus MT inspection 2YC36-5
Intermediate b.
During observation of MT inspection of weld Nos. 2YCl-1, 2YC1-10, 2YC11-19 and 1YC12-3 on May 13,1981 the inspector noted that the i
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inspection technique was not in accordance with procedure requirements.
The fixed leg yoke was not held essentially flat on the pipe surface.
This is another example of the unresolved item desc*ibed in paragraph 5.c.(Item No. 413,414/81-11-01).
No violations or deviations were identified.
12.
Reactor Coolant pressure Boundary Piping (Welding) - Observations of Work and Work Activities (Unit 2)
The applicable code is delineated in paragraph 11. The inspector observed welds at various stages of completion for conformance to code and procedure requirements in the areas delineated in paragraph 11. The following welds were observed:
Weld No.
Size (In. Dia.)
Stage of Welding Observed 2ND66-5
Final, 2NC13-4
Eitup and Intermediat:
Ei us and intermediate t
No violations or dev'-t'.eu were identified.
13.
Safety-Related Piping ' Observation of Work and Work Activities (Unit 2)
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The applicable code is delineated in paragraph 11.
The inspector observed handling of piping for fabrication of the welds listed in paragraph 11 for conformance to procedure and code requirements in the areas of control of tools for grinding, brushing and filing; use of appropriate handling and rigging equipment; control of cleanliness and control of cold spring where applicable.
No violations or deviations were identified.
14.
Reactor Coolant Pressure Boundary Piping - Observation of Work' and Work Activities (Unit 2)
The applicable code is delineated in paragraph 11. The inspector observed handlir g of piping for fabrication of the welds listed in paragraph 12 for confo.. nance to procedure and code requirements in the areas of control of tools for grinding, brushing and filing; use of appropriate handling and rigging equipment; control of cleanliness and control of cold spring where applicable.
i No violations or deviations were identified.
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