IR 05000445/1978022
| ML19276E490 | |
| Person / Time | |
|---|---|
| Site: | Comanche Peak  |
| Issue date: | 01/10/1979 |
| From: | Crossman W, Renee Taylor NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19276E485 | List: |
| References | |
| 50-445-78-22, 50-446-78-22, NUDOCS 7903140272 | |
| Download: ML19276E490 (6) | |
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U. S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT
REGION IV
Report No. 50-445/78-22; 50-446/78-22 Docket No. 50-445; 50-446 Category A2 Licensee:
Texas Utilities Generating Company 2001 Bryan Tower Dallas, Texas 75201 Facility Name:
Comanche Peak, Units 1 & 2 Inspection at:
Comanche Peak Steam Electric Station, Glen Rose, Texas Inspection conducted:
December 1-31, 1978 N
/[/0/77 Inspect
R. G. Taylor, Resident Inspector, Projects Section D' ate Approved:
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W. A. Crossman, Chief, Projects Section Date ~
Inspection Summary:
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Inspection on December 1-31, 1978 (Report No. 50-445/78-22; 50-446/78-22)
Areas Inspected:
Routine inspection by the IE Regional Resident Inspector TRRI) of safety related construction activities including welding of reactor coolant and emergency core cooling piping sy3tems; storage and maintenance of equipment; and concrete placement activities. The inspection involved sixty-two inspector-hours by one NRC inspector.
Results: No items of noncompliance or deviations were identified.
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DETAILS 1.
Persons Contacted Principal Licensee Employees
- J. B. George, TUSI, Project General Manager
- R. G. Tolson, TUGCO, Site QA Supervisor
- J. V. Hawkins, TUGC0/G&H Product Assurance Supervisor R. V. Fleck, TUGC0/G&H Civil Inspection Supervisor
- D. E. Deviney, TUGC0, QA Technician
_0ther Personnel
- H. O. Kirkland, B&R, Project General Manager B. C. Scott, B&R, QA Manager J. P. Clarke, B&R, QC Manager The RRI also interviewed a number of other site construction craft and quality control employees during the course of the inspection.
- denotes those individuals attending management interviews.
2.
Licensee Action on Previous Findings (Closed) Unresolved Item (50-445/78-16): Reactor Coolant System Weld Quality. As noted in paragraph 6 of the referenced IE inspection report, this unresolved item consisted of two separate problems.
Problem one r,egarding unauthorized and undocurcrante weld repairs was reported by the licensee on October 23,1978p as a potentially reportable significant construction deficiency, based primarily on the possible consequences of the repairs having been made without a backside shielding gas.
The licensee has deter-mined that the absence of the shielding gas was not critical to the quality of the welds, a determination informally concurred in by NRC personnel very knowledgeable in welding and metallurgy.
The licensee notified the NRC RIV office of the nonreportability of the problem by letter dated December 15, 1978.
IfErroneously indicated as October 24, 1978 in the referenced inspection report.
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The second problem included in this unresolved item was the detection of numerous linear indications during liquid penetrant examination of the weld root area of several reactor coolant system welds. The causes of the indications have been removed as evidenced by subse-quent liquid penetrant examinations; two such examinations having been verified by the inspector.
The licensee's Nonconformance Reports covering these problems have been dispositioned to document each of these actions and welding has resumed.
(Closed) Deviation (50-445/73-16; 50-446/78-16):
Failure to Comply With Regulatory Guide 1.10.
The licensee notified RIV by letter dated December 8, 1978 that Cadweld helpers would no longer be utilized and that construction procedures would be revised to reflect this decision. The RRI has verified these actions and has no further questions.
3.
Plant Tour The RRI toured one or more plant areas several times weekly during the reporting period to observe the progess of safety related instal-lation work and general construction practices including housekeping.
Three of the tours were conducted during portions of the second shift.
The second shift continues to be from one-quarter to one-third the size of the day shift with the bulk of the effort in the civil con-struction areas; i.e., installation of reinforcing steel and formwork.
Effort was also being made in installation of cable tray and piping system hangers. Very limited safety related pipe welding was observed to be occurring during the second shift.
No items of noncompliance or deviations were identified.
4.
Stored Safety Related Components The RRI continued to observe the storage condition of various safety related cmponents both in the site warehouses, lay-down yards and in-place within plant buildings. The reactor vessel and vessel head continue to be well protected from contaminants and damage although work is going on in and around them in their current positions in the Unit I reactor building. As of December 18, the Unit i reactor vessel internals continue to be stored in warehouse areas well protected from any damaging environmental condition.
Other semi-installed components were observed to be adequately protected by coverings and where appro-priate, electric motor space heaters were energized.
No items of noncompliance or deviations were identified.
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The second weld joint selected was FW-7A of isometric CT-1-SB-040 in line 16-CT-1-024-30lR2.
Review of the weld data package revealed that the original weld (FW-7) had been completely removed, apparently due to improper fitup, and was being replaced by FW-7A.
The weld was being accomplished by welder "ATZ" utilizing procedure 88023R4 as authorized by Weld Data Card 06643.
Material being utilized was ER 308, heat 04184, issued on WMR A030817. The RRI had previously established that the welder, procedure and weld material met all applicable requirements of the ASME B&PV Code, Sections II, III and IX. During the observation, a technician assigned by the Project Welding Engineer made measurements of the welding parameters in accordance with project procedure CP-CPM 6.9, " General Piping and Inspection Procedure." The technician's measurements indicated that welder "ATZ" was working well within the parameters of proceudre 88023R4.
In addition to the above direct observations of welding operations, the RRI selected two welds for examination of acceptance level radiographs. These joints were identified as FW-1 on isometric BRP-CT-SB-01 in line 16-CT-007-151R2 and FW-20A on isometric BRP-SI-1-SB-14 in line 4-SI-1-300-150lR2.
The welds were found to be consistent with acceptance criteria of ASME Section III, Subsection NC.
No items of noncompliance or deviations were identified.
7.
Reactor Coolant System Pipe Welding
'ihe RRI made several observations of the limited welding operations being accomplished on the reactor coolant loop piping during the report period. On December 14, the RRI observed fitup activities for FW-7 and FW-8 in the loop 1 piping between the reactor vessel and the pump. On December 18, the initial root passes made on the ID of FW-8 were visually examined.
On December 20, the RRI was able to observe welding on the CD area of FW-16 in loop 2 at the vessel. The weld process being utilized was automatic gas shielded tungsten arc weld (GTAW) with two "Dimetric's" machines in accordance with weld procedure 99028Rl. Weld machine operators were "AXA" and
"BAU," both of whom have been qualified under ASME Section IX as has procedure 99028Rl. The RRI observed that one of two machine control panels had control settings consistent with those indicated in procedure 99028Rl. The RRI also reviewed the certified material test report for the ER 308 weld wire being utilized on the machines and found it to be consistent with article NS-2400 of Section III and SFA 5.9 of Section II.
No items of noncompliance or deviations were identified.
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8.
M_anagement Meetings The RRI met with licensee representatives as denoted in paragraph 1 on Decemember 12 and 20 to discuss inspection findings. The RRI expressed concern about both the high percer.tage of safety related welds requiring repair and the number of repair cycles being utilized on some welds. The RRI stated that he had found no specific evidence of welders not following the weld procedure nor had he found any welders who had not been properly qualified under the Code.
The licensee representatives indicated that they too were very concerned about the problem and would investigate a range of corrective actions and implement whichever appeared most satisfactory.
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