IR 05000424/1986069

Insp Repts 50-424/86-69 & 50-425/86-32 on 860804-08.No Violation or Deviation Noted.Major Areas Inspected:Rcpb piping,safety-related Piping,Structural Welding & Inspector Followup Items

ML20209F900
Person / Time
Site:	Vogtle
Issue date:	08/29/1986
From:	Blake J, Crowley B NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
To:
Shared Package
ML20209F890	List: IR 05000424/1986069 ML20209F885
References
50-424-86-69, 50-425-86-32, NUDOCS 8609120301
Download: ML20209F900 (13)

Text

UNITED STATES

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'f t>R HToq'o NUCLEAR REGULATORY COMMISSION

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-[ p REGION 11

$ j 101 MARIETTA STREET, *

, g ATLANTA, GEORGI A 30323 .

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Report Nos.: 50-424/86-69 and 50-425/86-32 Licensee: Georgia Power Company P. O. Box 4545 Atlanta, GA 30302 Docket Nos.: 50-424 and 50-425 License Nos.: CPPR-108 and CPPR-109

. Facility Name: Vogtle 1 and 2 Inspection Conducted: August 4-8, 1986 Inspector: o I 2f I B.' R. Crowley Date Signed Accompanying 1: . Menning Approved by. _ 2 V 9 '2Cf 6

, . lake,'Section Chief Date Signed '

E i ering Branch D,vi ion of Reactor Safety SUMMARY Scope: This routine, unannounced inspection was in the areas of reactor coolant pressure boundary piping (Unit 2), safety-related piping (Unit 2), structural welding (Unit 2), inspector followup items (Units 1 and 2), and 50.55e items (Units 1 and 2).

Results: No violations or deviations were identified.

i 8609120301 860703

PDR ADOCK 05000424 l

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REPORT DETAILS Persons Contacted Licensee Employees

• R. H. Pinson, Vice President, Project Construction

• M. H. Googe, Project Construction Manager

• E. D. Groover, QA Site Manager, Construction

• G. A. McCarley, Project Compliance Coordinator C. R. Brewer, Assistant QC Manager

• H. W. Swain, Mechanical QC Section Supervisor R. Perry, Compliance Other licensee employees contacted included construction craftsmen, engineers, QC personnel, security force members, and office personne Other Organizations J. L. Leamon, Sr, Licensing Engineer, Southern Company Services (SCS)

• J. E. Miller, QA Manager, Pullman Power Products (PPP)

R. G. Davis, Assistant QA Manager, PPP W. A. Stiger, QA Supervisor, PPP NRC Resident Inspectors

• H. Livermore, Senior Resident Inspector

• R. J. Schepens, Resident Inspector

• Attended exit interview Exit Interview The inspection scope and findings were summarized on August 8,1986, with i those persons indicated in paragraph'1 above. The inspector described the areas inspected and discussed in detail the inspection finding No dissenting comments were received from the licensee. The licensee did not identify as proprietary any of the materials provided to or reviewed by the inspectors during this inspectio . Licensee Action on Previous Enforcement Matters (Closed) Violation 424/85-11-02, Failure to Follow Procedure for Field Welding Inspection. Georgia Power Company's (GPC) letter of response (X78G10-C1) dated May 6, 1985, has been reviewed and determined to be acceptable. The inspector examined corrective actions as stated in the letter of response and discussed the corrective actions with responsible

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l licensee personnel. . As part of the corrective action, GPC decided to

! conduct a special 30 day surveillance of PPP weld inspection activities. The

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inspector reviewed documentation of these activities identified as GPC

] correspondence QCP-11 ;

, Unresolved Items

Unresolved items were not identified during the inspection.-

1 Independent Inspection Effort Housekeeping (548348), Material Identification and Control (42902B) and'

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Material Control (429408) (Unit 2)

i The inspectors conducted a general inspection of the auxiliary and i reactor buildings to observe activities such as housekeeping, material identification and control, and storage, Employee Concerns

! The inspectors reviewed the licensee's files relative to an employee

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concern that reactor coolant piping could have been welded using stainless steel weld wire obtained from the Diametrics classroom rather than from a controlled weld material storage area. The concern was referred to the licensee by NRC for investigation (See GPC letter X7RG54 dated July 29,1986). In addition to reviewing the files, the inspector discussed the concern with responsible licensee personnel.

i The licensee concluded that the weld rod control program was adequat In addition, if classroom material was inadvertently used, the material was purchased to the same requirements as rod room issued material.

Within the area examined no violations or deviations were identifie . Reactor Coolant Pressure Boundary Piping (Unit 2)

! The inspector examined welding and nonwelding activities for reactor coolant pressure boundary piping to determine whether applicable code and procedure

! requirements were being met. The applicable code for reactor coolant

! pressure boundary piping is the ASME Boiler and Pressure Vessel Code,

Section III, 1977 Edition with Addenda through W77.

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l ,0bservation of Welding Activities (551738) (Unit 2)

i The inspector observed in-process welding of the below listed welds at various stages of completion:

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150 Weld Size Status 2K4-1204-042-01 042-W-07 6"X.719" Completing repair 2K4-1201-049-02 049-W-02 12"X1.125" Fitup in-process 2K4-1208-002-03 002-W-15 3".438" Fitup in-process 2K4-1204-025-02 025-W-04 6"X.719" Welding fill passes The welding was observed to determine whether:

(1) Work was being conducted in accordance with a document which coordinates and sequences operations, references procedure, establishes hold points, and provides for production and inspection approva (2) Weld identification and location were as specifie (3) Procedures, drawings, and other instructions were at the work station and readily availabl (4) Welding Procedure Specification (WPS) assignment was in accordance with applicable code requirement (5) Welding technique and sequence were specified and adhered t (6) Welding filler materials were of the specified type and traceable to certification (7) Weld joint geometry was in accordance with applicable procedure and was inspecte (8) Alignment of parts was as specifie (9) Preheat and interpass temperatures were in accordance with procedure (10) Electrodes were used in positions and with electrical characteristics specifie (11) Shielding gas was in accordance with the welding procedur (12) Welding equipment was in good conditio (13) Interpass cleaning was in accordance with applicable procedure (14) Temporary attachments were removed in accordance with applicable procedure (15) Welding and inspection personnel were qualifie (16) Weld history records were adequat .

(17) Gas purging, if specified, was used in accordance with applicable procedure (18) Process control system has provisions for repair (19) Welders were qualifie (20) Inspection personnel were qualifie WelderQualification(551778)(Unit 2)

Qualification status records and initial qualification records were reviewed for the following welders who welded on the welds listed in paragraph a. above:

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DW3 DT R1 Welding Material Control (551728) (Unit 2) .

The inspector reviewed PPP's program for control of welding materials including procurement, receiving inspection, storage, and issu The following specific areas were examined:

(1) Establishment of procedures for procurement receiving, storing, distributing and handling welding materials (2) Material identification (3) Control of weld material at work locations and at Unit 2 Weld Material Distribution Center (WMDC)

(4) Welding material procurement and receiving records including vendor material test reports were reviewed for the following welding materials:

ER308L: 1/16" Ht. 26245

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3/32" Ht. 05394 1/8" Ht. P0443 Insert Ht. 5242T308L Insert Ht. 4894T308L E308L: 3/32" Control No. HH011 1/8" Control No. HH016 E705-2: 1/16" Ht. 97401 3/32" Ht. 97401 l 1/8" Ht. F7164

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Insert Ht. 4250B131 l

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E7018: 3/32" Control No. MM081 1/8" Control No. MM069 Special Welding Applications (551788) (Unit 2)

The inspector examined repair activities relative to weld 042-W-07 on IS0-2K4-1204-042-0 The repair operations were compared with applicable code and procedure requirements in the areas of:

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Procedure qualification

- Repair Technique 1

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Base and filler materials

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Nondestructive examination (NDE)

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Records

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Welder Qualification (Walder R1) Observation of Non-Welding Activities (490538) (Unit 2)

The inspector observed the work activities listed below to determine whether requirements were being met in the following areas, as applicable:

(1) Inspection and/or work procedures (2) Record keeping requirements (3) Construction / installation specification requirements

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(4) Issuance of specified materials (5) Utilization of qualified inspection and NDE personnel (6) Performance of prescribed NDE Specified activities observed were:

- Fitup, protection, handling and grinding weld prep at weld 049-W-02 on ISO 2K4-1201-049-02

- Temporary storage of pipe spool 1201-036-S-04 in building

- Grinding weld prep at weld 025-W-01 on ISO 2K4-1204-025-02 Within the areas inspected, no violations or deviations were identified.

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The inspectors examined welding and non-welding activities for safety-related piping to determine whether applicable code and procedure requirements were being met. The applicable code for safety-related piping

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is the ASME Boiler and Pressure Vessel Code,Section III,1977 Edition with Addenda through W77.

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a. Observation of Welding Activities (55183) (Unit 2)

The inspectors observed in-process welding of the below listed welds at various stages of completion:

ISO Weld Size Status 2K4-1202-231-02 231-W-06 8"X.322" Welding fill passes 2K4-1204-020-02 201-W-4AA 8" Fitup in-process 2K3-1302-029-01 029-W-09 4"X.438" Fitup complete 2K3-1202-406-01 406-W-08 4"X.437" Welding fill passes 2K3-1202-145-01 145-W-113 2"X.154" Final weld complete 2K3-1204-037-02 037-W-095 4".337" Final weld repair The welding was observed to determine whether:

(1) Work was being conducted in accordance with a document which coordinates and sequences operations, references procedure, establishes hold points, and provides for production and inspection approva (2) Weld identification and location were as specifie (3) Procedures, drawings, and other instructions were at the work station and readily availabl (4) WPS assignment was in accordance with applicable code requirement (5) Welding technique and sequence were specified and adhered t (6) Welding filler materials were of the specified type and traceable to certification (7) Weld joint geometry was in accordance with applicable procedure and was inspecte (8) Alignment of parts was as specifie (9) Preheat and interpass temperatures were in accordance with procedure (10) Electrodes were used in positions and with electrical characteristics specifie (11) Shielding gas was in accordance with the welding procedure.

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(12) Welding equipment was in good conditio (13) Interpass cleaning was in accordance with applicable procedures.

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(14) Temporary attachments were removed in accordance with applicable procedure (15) Welding and inspection personnel were qualifie (16) Weld history records were adequat (17) Gas purging, if specified, was used in accordance with applicable procedure (18) Process control system has provisions for repair (19) Welders were qualifie (20) Inspection personnel were qualifie b. Welder Qualification (551878) (Unit 2)

The inspectors reviewed the qualification status records and initial qualification records for the following welders who welded on the welds listed in paragraph a. above:

SF3 VC NR1 CF4 GR c. Welding Material Control (551828) (551828) (Unit 2)

The welding material control inspection documented in paragraph for reactor coolant piping also applies to safety-related pipin d. Special Welding Applications (551888) (Unit 2)

The inspectors examined repair activities relative to weld 037-W-09B on ISO 2K3-1204-037-02. No welding was required. The wcld was ground and re-radiographed, e. Observation of Non-Welding Activities (490638) (Unit 2)

The inspectors observed the work activities listed below to determine whether requirements were being met in the following areas, as applicable:

(1) Inspection and/or work procedures (2) Record keeping requirements (3) Construction / installation specification requirements (4) Issuance of specified materials

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(5) Utilization of qualified inspection and NDE personnel (6) Performance of prescribed NDE Specific activities observed were:

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Marking, identification, location and grinding prep - elbow, Item 5, on field change MFCRB 6382F at weld 201-W-04AA on 150 2K4-1204-020-02 Within the areas inspected, no violations or deviations were identifie . Liquid Penetrant Examination (57060) (Unit 2)

The inspectors examined the liquid penetrant (PT) examination activities described below to determine whether applicable code and regulatory requirements were being met. See paragraph 6. above for the applicable cod The inspectors observed PT examination of a repair to weld 042-W-07 on ISO 2K4-1204-042-01 to verify that: Applicable instructions or travelers clearly specified the procedure to be used and that a copy of the procedure was available for the inspection Sequencing of examinations relative to other operations were specified and in accordance with applicable procedures Personnel performing the examinations were qualified Materials used for the examinations were certified and the certifications met applicable requirements Areas, locations, and extent of examinations were clearly defined The following attributes were as specified in the applicable procedure and consistent with applicable code:

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Surface preparation / cleaning method, type, time, et Penetrant type

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Penetrant application method

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Penetration time

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Temperature of surfaces

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Drying

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Developer, application, type

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Developing time

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Evaluation technique

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-- Acceptance criteria

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Reporting of results

- Within the areas inspected, no violations or deviations were identifie . Structural Welding _(55100) (Unit 2)

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The inspectors examined the licensee's program for structural welding as indicated below to determine whether applicable code and regulatory requirements were being met. The applicable welding code is the AWS Structural Welding Code D1.1-75.

, Welder Performance Qualification The inspectors reviewed the qualification records and status records 4 for the below listed welders relative to the field welds listed in -

l paragraph b. below.

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, Production. Welding The inspectors observed the below listed welds at the indicated status i -of completion:

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Dwg/ Hanger Weld Status i V2-1201-053-H006 Item h to a Welding in-process  ;

V2-1201-053-H005 Item c to a Final weld l'

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V2-1202-18-H017 Item 1 to 7 Final weld AXD11G012 S260M Welding in-process

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The welding was observed to determine whether:

! - Work was being conducted in accordance with a document which

, coordinates and sequences operations, references procedures, i establishes hold points, and provides for production and j inspection approval.

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- Weld identification and location were as specified.

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Procedures, drawings, and other instructions were at the work station and readily available.

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WPS assignment was in accordance with applicable code l requirements.

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- Welding technique and sequence were the specified type and

- traceable to certification Welding filler materials were the specified type traceable and properly inspected

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Alignment of parts was as specifie Preheat and interpass temperatures were in accordance with procedure Electrodes were used in positions and with electrical characteristics specifie Shielding gas, if specified, was in accordance with the welding procedur Welding equipment was in good conditio Interpass cleaning was in accordance with applicable procedure Temporary attachments were removed in accordance with applicable procedure Gas purging, if specified, was in accordance with applicable procedure Process control system had provisions for repair Welders were qualifie No peening performed on root and surface layer Inspection personnel were qualifie c. Welding Material Control Receiving inspection and material certification documentation were reviewed for the following welding material being used for the welding observed (see paragraph 9.b):

3/32" E7018 Control No. MM082 1/8" E7018 Control No. MM069 3/32" E7018 Control No. MM081

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Weld material issue activities were examined for the Unit 2 WMDC in the areas of:

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Storage of materials - identification, segregation and cleanliness

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Temperature control

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Issue control

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Handling of returns Within the areas inspected, no violations or deviations were identifie . Inspector Followup Items (IFI) (92701) (Units 1 and 2)

(Closed) IFI (424, 425/85-11-01): Clarification of Pipe Welding WPSs. This item was opened to followup on apparent discrepancies in three PPP WPS The inspectors reviewed the latest revision of WPS (w) 32-III/I-8-12 (dated March 25, 1985) and the latest revision of WPS 24-III/I-8-KI-12 (dated March 24, 1985), and determined that these discrepancies had been correcte . Licensee Identified Items (10 CFR 50.55e and Part 21) (92700) (Units 1 and 2) (Closed) Item 424, 425/CDR 83-38, Pullman Power Products - Quality of Welds and Radiographs. On Januar 25, 1983, Georgia Power Company notified RII of a potential 50.55(y) e item relative to discrepancies in weld radiographs of spool pieces supplied by PPP. The final Construction Deficiency Report was submitted on June 24, 1983, concluding that the item was not reportable. The inspectors held discussions with responsible licensee personnel and reviewed supporting documentation including an engineering evaluation report dated May 11, 1983. There are no further questions at this tim (Closed) Item 424, 425/CDR 83-52, Quality of Welds and Radiographs. On October 27, 1983, GPC notified RII of a potential 50.55(e) item relative to discrepancies in weld radiographs of spool pieces supplied by PP Interim reports were submitted on February 24, June 29, and October 1, 198 The final Construction Deficiency Report was submit.ted on January 17, 198 The report has been reviewed and determined to be acceptable. The inspectors held discussions with responsible licensee personnel and reviewed supporting documentation including close out of MDs 3318, 3468, 3565, 3490, 3491, and 5596 to verify that corrective actions have been complete (Closed) Item 424, 425/CDR 84-57, Reactor Coolant Crossover Leg Elbo On March 24, 1984, GPC notified RII of a potential 50.55(e) item relative to a linear indication detected on the reactor coolant system

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elbow for steam generator number 3 and adjacent to weld 005-W-02. An interim report was submitted on April 18, 1984. The final Construction Deficiency Report was submitted on June 4,1984, concluding that the item was not reportable. There are no further questions at this tim d. (Closed) Item 424/CDR 85-82, Nuclear Service Cooling Water Pump On July 18, 1985, GPC notified RII of a potential 50.55e item concerning

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the failure to maintain minimum clearances between the seismic bowl restraints and pump columns for the nuclear service cooling water pumps. The final report was submitted on August 15, 1985. The report has been reviewed and determined to be acceptable. The inspector reviewed completed DRs T-1-85-687 and T-1-85-712, completed MWO 1-85-2974, and PPP completed Field Process Sheets for pumps 1-1202-P4-004 and 1-1202-P4-003, e. (Closed) Item 424, 425/CDR 82-26, Pullman Power Products Pipe Spool Weld On June 17, 1982, GPC notified RII of a potential 50.55e item concerning discrepant conditions on PPP shop welds. Interim reports were submitted on July 20 and September 20, 1982. The final report was submitted on November 11, 1982. The final report concluded that no reportable deficiency or substantial safety hazard had occurred. See item 424, 425/CDR 83-51 below for further discussion of this ite f. (Closed) Item 424, 425/CDR 83-51, Pullman Power Products Fabrication Shop Spool Pipe Welds. On October 21, 1983, GPC notified RII of a potential 50.55e item concerning visual weld discrepancies on pipe spools furnished by PP An interim report was submitted on November 11, 1983. The final report was submitted on March 9,198 The report has been reviewed and determined to be acceptable. The inspector reviewed the site documentation package including a sample of completed nonconformance reports (NCRs) and deviation reports (DRs).

The review revealed the following:

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- This item is a continuation of item 424, 425/CDR 82-2 In the

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final report for CDR-26, GPC indicated that if additional problems

were identified, evaluation and appropriate reporting would occu As additional inspections occurred, GPC concluded that reportable conditions existe On June 25, 1982, because of visual discrepancies identified, Bechtel's surveillance program for the PPP shop was changed from level 3 (itinerant) to level 4 (resident). For a 3 month period beginning August 2, 1982, 100 percent visual inspection of welds was performed by Bechtel prior to shipment from the PPP sho Based on the established program by Bechtel at the shop, the site, which had been inspecting 100%, went to a sampling inspection pla In August of 1982, based on problems identified, the decision was made to visually re-inspect all existing PPP shop pipe spools in the shop as well as spools already on site.

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All discrepancies identified were repaired.

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