IR 05000424/1982005
| ML20054G738 | |
| Person / Time | |
|---|---|
| Site: | Vogtle, 05000525  |
| Issue date: | 03/26/1982 |
| From: | Herdt A, Kleinsorge W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML20054G719 | List: |
| References | |
| 50-424-82-05, 50-424-82-5, 50-425-82-05, 50-425-82-5, NUDOCS 8206220254 | |
| Download: ML20054G738 (10) | |
Text
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ig UNITED STATES
NUCLEAR REGULATORY COMMISSION o
c REGION il
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101 MARIETTA ST., N.W., SUITE 3100 o
ATLANTA, GEORGIA 30303
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Report Nos. 50-424/82-05 and 50-425/82-05 Licensee: Georgia Power Company 270 Peachtree Street Atlanta, GA 30303 Facility Name:
Vogtle Docket Nos. 50-424 and 50-425 License Nos. CPPR-108 and CPPR-109 Inspection at o e
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near Waynesboro, Georgia Inspector:
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W.P.K insorge
/Date Signed
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Approved by:
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A. R. Herdt, Section Chief Dat: Signed Engineering Inspection Branch Division of Engineering and Technical Programs SUMMARY Inspection on March 9-12, 1982 Areas Inspected This routine, unannounced inspection involved 31 inspector-hours on site in the areas of licensee action on previous inspection findings, construction progress (Units 1 and 2), safety related piping (Units 1 and 2), and steel structures and supports (Units 1 and 2).
Results Of the four areas inspected, no violations or deviations were identified in three areas; one violation was found in one area (Violation - " Failure to Follow Inspection Procedure" paragraph 7d(1)).
8206220254 820610 PDR ADOCK 05000424 O
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REPORT DETAILS 1.
Persons Contacted Licensee Employees
- H. H. Gregory, III, Construction Project Manager F. D. Groover, QA Site Supervisor
- C. Sarver, Sr. QA Engineer
- B. F. Barrett, Sr. QA Field Representative
- M. H. Googe, Manager of Field Operations
- D. F. Wilkerson, Sr. Welding Specialist
- B. C. Harbin, Civil Project Section Supervisor
- D. P. Ross, Civil Engineering Supervisor Other licensee employees contacted included construction craftsmen, tech-nicians and office personnel.
Other Organizations
- H. R. Reuter, Resident Engineer, Bechtel Power Company Corporation (BPC)
- W. G. Uhouse, Resident Engineer, "N" Stamp, BPC
- J. P. Runyan, QA Manager, Pullman Power Products (PPP)
C. L. Fields, Welding and QA Superintendent, Chicago Bridge and Iron (CB&I)
B. McMillian, QA Technician, CB&I NRC Resident Inspector
- W. F. Sanders
- Attended exit interview l
2.
Exit Interview The inspection scope and findings were summarized on March 12, 1982, with those persons indicated in paragraph 1 above. The inspector described the
areas inspected and discussed in detail the inspection findings listed l
below. No dissenting comments were received from the licensee.
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(0 pen) Violation -
425/82-05-01: " Failure To Follu,e Inspection Proce-dure" paragraph 7d(1)
(0 pen) Unresolved Item - 424, 425/82-05-02:
" Determination of Undercut
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Acceptance Criteria" paragraph 7d(2)
(0 pen) Unresolved Item - 424, 425/82-05-03: " Specific Acceptance Criteria for Repair Cavity Geometry" paragraph 6b(1)(b)
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(0 pen) Unresolved Item - 424, 425/82-05-04:
" Extraneous Marking" para-graph 6a(2)
(0 pen) Unresolved Item 424,425/82-05-05: " Grout Inspection" paragraph 5.
(0 pen) Inspector Follow-up Item 424, 425/82-05-06:
" Control of Grinding Particles in Piping" paragraph 6a(1)
(0 pen) Inspector Follow-up Item 425/82-05-07:
" Material Identification" -
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paragraph 6b(1)(a)
3.
Licensee Action on Previous Inspection Findings a.
(Closed) Violation 424, 425/81-02-01:
" Stud Welding Control." GPC letters of response dated March 11 and March 20, 1981 have been reviewed and determined to be acceptable by Region II. The inspector held discussions with the site QA supervisor and examined the correc-tive actions as stated in the letter of response.
The inspector concluded that GPC 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 preclude recurrence of similar circumstances. The correc-tive actions identified in the letter of response have been imple-mented.
b.
(Closed) Unresolved Item 424/81-08-03:
" Masking Tape."
This item concerned what appeared to be masking tape inside a residual heat removal system pipe. The licensee determined that the tape noted was soluble purge dam tape consistent with their program.
This item is considered closed.
The subject of piping cleanliness is discussed further in paragraph 6a(1).
c.
(Closed) Unresolved Item 425/81-08-04:
" Delta Ferrite."
This item concerned the safety significance of deposited weld metal delta ferrite less than the minimum allowed by the AE's specification. The inspector determined that the delta ferrite content in question (6.5*J) is within the acceptable range specified by ASME B&PV Code Section III paragraph NX 2433. This item is considered closed.
(Closed) Unresolved Item 424, 425/81-10-02: " Storage Controls for HVAC Air Handling Units." This item concerned the safety significance of, and adequacy of the storage protection and controls for HVAC air handling units stored out doors.
The inspector determined that the units in question are classed as "non-nuclear safety related equip-ment."
The licensee has increased the frequency of monthly storage inspection in this area to weekly. This item is considered closed.
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(Closed) Unresolved Item 424, 425/81-10-03: " Welder Qualification Film Density." This item concerned the density of welder qualification film less than that permitted by the CB&I program.
The test assembly represented by the above film was reradiographed and verified by the inspector to be acceptable. The inspector reviewed additional welder qualification film. The inspector has no further questions. This item is considered closed.
f.
(Closed) Unresolved Item 424, 425/81-14-01: "MT and PT Procedures Do Not Adequately Specify Weld Examination Area." This item concerns the omission of the ASME Section III, Subsection NB requirement to liquid penetrant or magnetic particle inspect h-inch of base material adjacent to the welds so inspected. The licensee has revised procedures IX-MT-W77 and IX-PT-W77 on January 7,1982, to include the-inch require-ment. This item is 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 nos. 5, 6a(2), 6b(1)(b) and 7d(2).
5.
Independent Inspection Effort (Units 1 and 2)
Construction Progress The inspector conducted a general inspection of the Units 1 and 2 contain-ment construction sites, auxiliary building, the CB&I dome fabrication area, and the piping assembly lay down yard to observe construction progress and construction activities such as welding, nondestructive examination, material handling and control, housekeeping and storage.
With regard to the above inspection the inspector, on March 11, 1982, noted rags extending out of concrete pedestals between the concrete and the capping grout.
The inspector discussed the above with the licensee who stated that post grout placement inspection had been completed, for the pedestals in question. The licensee further stated that the only post grout placement inspection required for the above pedestals was related to the i
cure cycle for the grout. As the pedestals were cured with the forms inplace, the embedded rags were not identified during inspection for proper curing.
At the time of this inspection the safety significance of the embedded rags and, the time relationship of the post placement inspection to form removal, could not be determined.
The licensee indicated that they would look further into the matter.
The inspector stated that the above would be unresolved item 424, 425/82-05-05: " Grout Inspection".
Within the area examined no violations or deviations were identified.
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6.
Safety-Related Piping (Units I and 2)
The inspector observed 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 B and PV Code,Section III. Subsection NC and ND 1977 edition with addenda through winter 1977.
a.
Observation of Non-Welding Activities Observat ion of specific work activities were conducted to determine conformance, where applicable, with the following; inspection and/or work procedures, record keeping, installation specifications or plans, specified materials, specified NDE calibration and use of a proper test equipment and qualified inspection and NDE personnel.
SYSTEM OR ACTIVITY COMPONENT UNIT PROCEDURE NCR Control Various 1&2 PPP-XV-2 09/25/81 Cleanliness Various 1&2 PP-XIII-4 12/28/81 PPP-XIII-5 12/29/81 Marking Various 1&2 PPP-VIII-1 08/05/81 Protection Various 1&2 PPP-VII-13 08/24/81 PPP-XIII-5 12/29/81 Installation Various 1&2 PPP-IX-3 12/18/80 (1) With regard to the cleanliness inspection above, the inspector noted a number of examples where grinding was in progress on the standing ends of pipe, with no evident precautions taken, to prevent grinding particles from entering the piping system, or means to remove the particles from the system.
The inspector noted a number of examples of grit (grinding particles) in piping systems. PPP procedure XIII-4 requires precautions be taken to avoid contamination of crevices, blind holes, dead legs, undrain-able cavities and inaccesible areas, but provides no guidance to J
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that end. The licensee indicated that they would look into the matter further.
The inspector stated that the above would be inspector follow-up item 424, 425/82-05-06: " Control of Grinding Particles in Piping" (2) With regard to the marking inspection above the inspector noted a number of examples of extraneous markings on installed stainless steel tanks and piping. The inspector stated there was no reason-able assurance that the extraneous markings were produced with the approved marking materials.
The licensee indicated that they would look further into the matter. The inspector stated that the above would be an unresolved item 424,425/82-05-04: " Extraneous Marking".
b.
Observation of Welding Activities The inspector observed in process welding activities of safety-related piping field welds as described below to determine whether applicable code and procedure requirements were being met.
(1) Welding The below listed welds were examined in process to determine work conducted in accordance with traveler; welder identification and location; welding procedure 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; identity of welders; qualification of inspection personnel; and weld history records.
UNIT SYSTEM 226-W-02 1K3-1202-226-01
Nuclear Service I
Cooling Water 144-W-03A 1K3-1208-144-07
Chemical Volume Control l
122-W-06A 1K3-1202-122-01
Nuclear Service Cooling Water
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l REPAIR WELOS 006-W-14A 1K3-1204-006-01
Safety Injection 007-W-083 2K3-1205-009-01
Residual Heat Removal 013-W-01 2K3-1205-003-01
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REPAIR WELDS (Continued)
040-W-01 2K3-1205-004-01
Residual Heat Removal 040-W-02 2K3-1205-004-01
Residual Heat Removal (a) With regard to repair weld 007-W-088, the weld process sheet (traveler) incorrectly indicated that the added pipe section was part of the original spool by not listing any unique material identification for the pipe. This will be identi-fied as inspector follow-up item 425/82-05-07:
" Material Identification".
(b) With regard to the repair welds above, the inspector noted that the PPP program requires preweld visual inspection of repair cavities, but does not provide any acceptance criteria for cavity geometry. The licensee stated that they depended on the welding inspectors previous welding experience to assure suitable cavity geometry. The inspectors stated that the above would not provide uniform assurance of acceptable repair cavity geometry.
The licensee indicated that they would look into the matter further.
The inspector stated that the above would be unresolved item 424, 425/82-05-03:
" Specific Acceptance Criteria for Repair Cavity Geometry".
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(2) Welder Qualification The inspector reviewed the PPP and CB&I programs for qualification of welders and welding operators for compliance with QA procedures and ASME Code requirements.
The applicable Code for welding qualification is ASME B&PV Code Section IX as invoked by GPC Specifications X2AG06 Rev. 4 and X4AZ01, Section P.1, Revision 8.
(a) The following welder qualification status records a r.d
" Records of Performance Qualification Test" were reviewed relative to the weld joints listed in paragraphs 6b(1) and 7a.
WELD SYMBOL ORGANIZATION APPLICATION KK PPP Safety Related Piping YB PPP Safety Related Piping ZD PPP Safety Related Piping BK PPP Repair Safety Related Piping YP PPP Repair Safety Related Piping JTR CB&I Steel Structures & Supports I
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WELD SYMBOL ORGANIZATION APPLICATION
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DFP CB&I Steel Structures & Supports SWM CB&I Steel Structures & Supports LKR CB&I Steel Structures & Supports DTC CB&I Steel Structures & Supports CEH CB&I Steel Structures & Supports JCB CB&I Steel Structures & Supports MPH CB&I Steel Structures & Supports DLH CB&I Steel Structures & Supports NJR CB&I Steel Structures & Supports RJH CB&I Steel Structures & Supports (b) The inspector reviewed radiographs for the below listed welder qualification tests.
WELDER SYMBOL WPS APPLICATION RFB E-7018 Steel Structures & Supports RB E-7018 Steel Structures & Supports (3) Welding Filler Material Control l
The inspector reviewed the CB&I and PPP programs for control of I
welding materials to determine whether materials are being purchased, accepted, stored, and Sandled in accordance with QA procedures and applicable code requirements.
The following specific areas were examined:
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Purchasing, receiving, storing, distributing and handling procedures, material identification.
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Welding material purchasing and receiving records for the following materials were reviewed for conformance with applicable procedures and code requirements:
PROCESS TYPE SIZE BATCH NO.
APPLICATION SMAW E-308L-16 3/32" 2598267 Safety Related Piping GTAW ER-308L 1/16" 26245 Safety Related Piping GTAW ER-308L 3/32" 05394 Safety Related Piping SMAW E-7018 1/8" DD-064 Steel Structures & Support SMAW E-7018 S/32" CC-051 Steel Structures & Support SMAW E-7018 3/16" DD-047 Steel Structures & Support SMAW E-6010 5/32" 39F Steel Structures & Support Within the areas examined, no violations or deviations were identified.
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7, Steel Structures and Supports (Units 1 and 2)
The inspector observed welding work activities for steel structures and supports as described below to determine whether applicable code and procedure requirements were being met.
The applicable code for contain-ment fabrication is the ASME B&PV Code,Section III 1974 edition with addenda through summer 1975, and Section VIII 1974 edition with addenda through summer 1975. The inspector observed in process welding activities of structural field welds as described below to determine whether applic-able code and procedure requirements were being met.
a.
Welding The following welds were examined in process to determine work conducted in accordance with traveler; welding procedures available; welding technique and sequence; weld geometry; fit-up electrical characteristics; equipment condition:
STRUCTURE UNITS LOCATION OR IDENTIFICATION Containment Dome
Assembly 465A Plate 410-1-1 Containment Dome
Assembly 465A Plate 410-1-2 Containment Dome
Assembly 465A Plate 410-1-3 Containment Dome
Assembly 462A Plate 410-1-44 Containment Dome
Assembly 462A Plate 410-1-45 Containment Dome
Assembly 462A Plate 410-1-46 Containment Dome
Assembly 463A Plate 410-1-4 Containment Dome
Assembly 463A Plate 410-1-5 Containment
Stiffener on 16th Ring at increment No.1 and No. 3 b.
Welder Qualification Welder Qualification is discussed in paragraph 6.b(2).
c.
Welding Filler Material Control Welding filler material control is discussed in paragraph 6.b.(3).
d.
Visual Inspection of Welds The inspector visually examined ie-1 and accepted welds as described below to determine whe h*. 3
'c6ble code and procedure requirements were being met.
The following weld was examined relative to the followin:
location, length, size and shape; weld surface fininsh and appearance; transi-tions between different wall thicknesses; weld reinforcement -- height and appearance; joint configurations of permanent attachments and
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structural supports; removal of temporary attachments; arc strikes and weld spatter; finish grinding or machining of weld surface -- surface finish and absence of wall thinning; surface defects -- cracks, laps, and lack of penetration, lack of fusion, porosity, slag, oxide film and undercut exceeding prescribed limits.
STRUCTURE UNIT LOCATION Shield Tank
AZ-180 (1) With regard to the inspection above the inspector, on March 11, 1982 noted undercut greater than 1/16-inch at the toe of the weld joining plates 8-1 MIL to 8-1MIR.
The above is contrary to GPC Specification X2AP01, Division 5 Section C5.1, Revision 5, paragraph B.3.d.7 which requires under-cut not to exceed 1/16-inch. Therefore the welder and inspector of record failed to follow procedure. Failure to follow procedure for activities affecting quality is in violation of 10 CFR 50 Appendix B, Criterion V.
This violation will be identified as 425/82-05-01:
" Failure to Follow Inspection Procedure".
(2) With regard to the inspection above the inspector noted that GPC Procedure GWS-ST-1, Revision 5, " General Welding Standard-Struc-tural" specifies the following:
"For building and tubular structures, undercut shall be no more than 0.01 in. (0.25mm) deep when its direction is traverse to primary tensile stress in the part that is undercut, nor more than 1/32 in.
(0.8mm) for all other situations."
At the time of this inspection it could not be determined whether welding inspectors had been given adequate training and guidance to determine the direction of primary tensile stress in all structures governed by the above specification.
The licensee indicated that they would look into the matter further.
The inspector stated that the above would be unresolved Item 424,425/
82-05-02: " Determination of Undercut Acceptance Criteria" Within the areas examined no violations or devations were identified except as described in paragraph 7.d(1).