IR 05000460/1980002
| ML19344D748 | |
| Person / Time | |
|---|---|
| Site: | Washington Public Power Supply System |
| Issue date: | 03/18/1980 |
| From: | Dodds R, Haist D, Wagner W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V) |
| To: | |
| Shared Package | |
| ML19344D740 | List: |
| References | |
| 50-460-80-02, 50-460-80-2, 50-513-80-02, 50-513-80-2, NUDOCS 8004280094 | |
| Download: ML19344D748 (8) | |
Text
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U. S. NUCLEAR REGUL\\ TORY COMMISSION
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OFFICE OF INSPECTION AND ENFORCEMEhf
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REGION V
50-460/80-02 Report No.
50-513/80-02 CPPR 134 & 174 Docket No.
50-450, 50-513 ttcen3, no, Safeguards croup Licensee:
Washington Public Power Supply System P. O. Box 968 Richland, Washington 99351 Facility Name:
Washington Nuclear Project Numbers 1 & 4 (WNP 1 & 4)
Inspection at:
WNP 1 & 4 Site - Benton County, Washington Inspection conducted:
February 11-15, 1980 Inspectors:
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D.P.[laist,ReactorInspector
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3//g)go g E J. Wagt(er, Reactor Inspector date Signed
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Date Signed Approved by:
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R. T. Dodds, Chief, Engineering Support Section
/ Da(e Signed Date Signed Summary:
Inspection during the period February 11-15, 1980 (Report Numbers 50-460/80-02 and 50-513/80-02)
Areas inspected:
Routine unannounced inspection by regional based inspectors of construction activities including:
safety related components, safety related piping installation, welder training, weld filler material control, weld procedure qualification, and licensee action on previous inspection findings.
The inspection involved 65 inspector hours onsite by two NRC inspectors.
Results: No items of noncompliance or deviations were identified.
RV Form 219 (2)
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DETAILS 1.
Persons Contacted The inspectors interviewed various engineering, management, inspection, t
supervision and craft personnel of the organizations listed below, Key personnel including those who attended the exit interview are specifically identified below.
a.
Washington Public Power Supply System (WPPSS)
A. D. Kohler, Project Manager
T. J. Houchins, Project Quality Assurance Manager
G. D. Dyekman, Engineering Manager
M. Witherspoon, Quality Assurance Manager
A. M. Sastry, Project Management Specialist
J. P. Thomas, Deputy Project Manager
R. Webring, NSSS Engineer b.
United Engineers and Constructors (UE&C)
R. S. Millne, Deputy Project Manager
R. Siever, Senior Quality Assurance Engineer c.
J. A. Jones Construction Company (JAJ)
B. Roe, Project QA Manager E. Freeman, N0E Level III S. Wellenbrock, QV-Lead
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T. Daines, Project Welding Engineer T. D. Higgenbotham
- Denotes those attending exit interview.
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2.
Construction Status Licensee representatives reported that as of January 10, 1980, construction of WNP-1 was 35.4% complete, and WNP-4 was 13.4%
complete.
3.
Site Tour
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Upon arrival at the site, the inspectors toured the WNP-1 plant area to observe construction activities, completed work, equipment storage and housekeeping.
No items of noncompliance or deviations were identified.
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Licensee Action on Previous Inspection Findings a.
(0 pen) Unresolved Item (50-460/79-09/02): The inspector had identified use of a revision to J. A. Jones, Form JAJ-224 prior to approval by the architect engineer and discrepancies between two welder performance qualification records and corresponding radiographic test sheets for the test coupons.
The inspector had also identified a welding record containing a radiographic test sheet but not the corresponding welder performance qualification record.
The inspector verified that the contractor had submitted the welder performance qualification procedure, JAJ-WQ-1 containing the revised form JAJ-224 to the architect engineer and had obtained approval without coments on January 10, 1980. The contractor explained that the discrepancies between the two welder performance qualification recordt and corresponding radiographic test sheets were due to an incorrect pipe diameter entry on the radiograph test sheet. This was confirmed by the weld procedure number entered on the report and the radiograph setup sketch on the report. The inspector had no further questions in these two areas and they are considered closed.
The licensee had not located the welder performance qualification record corresponding to the radiographic test sheet for welder
- A-5 dated December 5, 1978 for position 6G. This item will remain unresolved pending review of the corresponding welder performance qualification record, b.
(0 pen) Open Item (50-460/79-14/04):
Delta ferrite checks on production welds. The inspector had identified an apparent lack of implementing procedures for delta ferrite checks on production welds to type 316 stainless steel.
The inspector reviewed contract Waiver Request (CWR) - number 5001 for contracts 211 and 257 which allowed determination of
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ferrite content of filler metal in accordance with Regulatory Guide 1.31 Revision 3 in lieu of production checks. This CWR was approved on July 14, 1978.
PSAR Deviation No. 3.12-1 dated July 11, 1978 incorporates Regulatory Guide 1.31, Revision 3.
The inspector reviewed the contractor's filler material purchase order for delta ferrite determination requirements. The purchase order (No. 1-0241-391) specifies delta ferrite determination for all heats and batches of stainless steel welding material in accordance with ASME Section III, NB-2400.
However, this does not ensure compliance with Regulatory Guide 1.31, Revision 3.
The licensee stated that the purchase order will be revised to require testing in accordance with Regulatory Guide 1.31, Revision 3.
This item will remain open pending review of the
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revised purchase order, i
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The licensee has reviewd the following filler metal certifications
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which represent all stainless steel filler material that has been received onsite:
ARC 0 LOT TYPE D4154T309 ER309 C4248L309 ER309 9DC-MIX 24 ER309-16 8K24E-MIX 1 ER309-16 SANDVIK HEAT 435038 ER308 The licensee stated that all certifications show that the material was tested in accordance with Regulatory Guide 1.31, Revision 3.
c.
(0 pen) Open Item (50-460/79-14/05): Adequacy of Welder Training.
The inspector had identified inadequacies in the J. A. Jones welder training and indoctrination program in the areas of the interpass temperature control and piping system cleanliness.
The inspector reviewed the welder indoctrination which consists of a list of regulations for welders and familiarization with hanger and piping weld record forms. This indoctrination program commenced on February 4, 1980.
Welders are required to sign a sheet indicating their awareness of the requirements.
The indoctrination program does not address piping system cleanliness.
During observation of welding activities the inspector questioned welders on the control of interpass temperatures and found that they.do not use any means to measure interpass temperatures other than a foreman or QC inspector's occasional checks. The welder indoctrination requires that welders strictly adhere to preheat and interpass temperatures. Contractor personnel stated that temperature indicating crayors with the required halogen content had only recently become available and that welders will be instructed to use them. The contractor will also examine the need to address cleanliness of piping systems in the welder indoctrination.
This area will remain open and will be examined during a subsequent inspection.
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5.
Events Reportable to NRC under 10 CFR 50.55(e) or 10 CFR 21
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a.
WKM Valve Flaw Indications and Nonconforming Relief Valve Retaining Clips - 50.55e and 10 CFR 21 item.
The existence of flaw indications in WKM valve castings was reported to the Resident Reactor Inspector on December 7, 1979 as described in report Number 50-460/79-13. On October 8, 1979 Babcock and Wilcox (B&W) notified the licensee that nonconforming carbon steel retaining rings had been installed in the internal pressure relief valves of 24 WKM valves being supplied to the licensee (12 valves per unit).
Due to this defect all valves manufactured by WKM were shipped back to the factory for repair.
The licensee decided to perform the ASME Section XI visual examinations of the ASME Section III, Class I valves at that time.
Rejectable linear indications were confirmed by liquid penetrant examination on six of the eight valves (1-DHR-V23A and 248, 4-DHR-V23A, 24B, 25A and 26B) examined and cracks were detected in one valve (4-CFS-V31A). All rejectable indications and cracks found, to date, are located in safety systems (low pressure injection and core flood systems).
The NRC received an interim report of the WKM valve flaw indications on January 14, 1980. The licensee is preparing the ASME Section XI repair program and expanding the disassembly and nandestructive examination program to include all valves supplied by WKM. The inspector noted that the interim report did not address cracks that were identified on the lever locking arms. The lever locking arm is not a pressure retaining component, but affects valve operability.
The licensee stated that B&W has analyzed the effect of failure of the lever locking arm and the licensee committed to include this discussion in the final report. The subject of WKM valve defects will remain open pending NRC review of the final report (50-460/80-02/01).
The licensee notified the NRC Resident Reactor Inspector of the nonconforming internal relief valve retaining clips described above on January 30, 1980. A final, 50.55e report was received on February 11, 1980. The carbon steel retaining clips are being replaced with the specified stainless steel retaining clips.
B&W has concluded that this item does not require reporting under 10 CFR 21. The inspector had no further questions at this tim.
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b.
Defective Soot Welds on A1262 Superstrut Material - 50.55e Item The licensee has completed ultrasonic testing of spot welds on Superstrut prefabricated steel struts used as support members for electrical raceway systems (Report No. 50-460/80-01).
A total of 119 tray supports (114 in Unit #1, 5 in Unit #4) were examined. The overall weld reject rate was 14%.
Rejected welds are being repaired as follows:
Single reject - 1-inch fillet weld attaching A1262 side plate to strut.
Two consecutive rejects - 1-inch fillet weld between the two rejected spot welds.
Series of consecutive rejects - 1-inch fillet weld every six inches. The first weld will be adjacent to the first rejected spot weld and the last weld adjacent to the last rejected weld regardless of spacing.
This item will remain open pending NRC review of the final
' report of this occurrence and the material supplier's corrective actions to prevent recurrence 50-460/80-02/02.
6.
Safety Related Piping - Unit 1 a.
Review of Quality Assurance Implementing Procedures The following procedures were reviewed to ensure the adequacy of instructions for safety related activities and conformance with the ASME code and contractor's quality assurance program:
J. A. Jones Procedures (1) JAJ-WI-016.1 - ASME III Large Bore Pipe-Installation (2) JAJ-WI-015 - Marking and Identification (3) JAJ-WI-024-Tools-Color Coding for Stainless steel.
(4) JAJ-WI-013 - Piping cleaning.
(5) JAJ-ITI-Oll - Verification of Welding Variables.
(6) JAJ-ITI-013 - Measurement and Test Equipment - CeML. cion Frequency Requirements.
(7) JAJ-NDE-007 - Fit-Up Inspection.
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(8) JAJ-flDE-008 - Visual Weld Inspection.
(9) JAJ-flDE-004 - Visual Examination Procedure, fio items of noncompliance or deviation were identified, b.
Observation of Work and Work Activities The inspector examined safety related piping installation activities in the General Services Building.
In addition to the storage and protection of safety related piping, the following areas were examined for conformance to WPPSS contract specification 9779-257, the contractors quality assurance procedures, and the ASME Code Section III:
Line flumber Activity MUS-411496-8, weld 008 Visual inspection, weld marking MUS-411496-7, weld 007 Visual inspection, weld marking MUS-411228-10, weld 002 Fit-up for welding cleanliness and 003 and temporary support tio items of noncompliance or deviations were identified.
c.
Review of Quality Records The inspector reviewed the weld record, liquid penetrant reports, inspector qualification records and welder performance records for MUS-411496-8, weld 8 and MUS-411496-7, weld 7 for conformance to the contractor's work and quality control procedures. No item of noncompliance or deviations were identified.
7.
Safety Related Piping Welding - Unit 1 a.
Observation of Welding Activities The inspector examined root and intermediate pass welding on MUS-41228-10 weld number 002 and fit-up root pass welding on MUS-41228-10, weld number 003. The inspector verified that filler metal, base metal, welder qualification, purge gas, amperage, weld quality and technique, weld record entries, weld identification and location, and removal of adjacent value disks from seats, were in accordance with contractor's quality assurance and work procedures.
flo items of noncompliance or deviations were identified.
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-7-The welder did not have a temperature' indicating crayon or other means to verify preheat and interpass temperatures, but stated that he relied upon his judgment or called for temperature measurement by a foreman or QA inspector when in doubt. The measurement of interpass temperatures is discussed further in paragraph 4C.
b.
Visual Examination of Welds The inspector visually examined 4-inch stainless steel welds MUS-411496-8, field weld number 8 and MUS-411496-1 field weld number 7 for conformance with the contractor's quality assurance and work procedures and the ASME Code Section III. Attributes examined were weld location, size, shape, finish and appearance, height of reinforcement and absence of surface defects exceeding requirements.
fio items of noncompliance or deviations were identified.
c.
Welding Material Control The control, issue, return and storage of weld filler materials was observed by the inspector.
Implementation of these activities was inspected for compliance to the technical specifications and applicable ASME Code requirements.
The material requisition package (MR#P-004) for welding material was reviewed for scope, documentation and technical requirements, and proper approval.
The purchase order (P.O. #1-0241-391)
was checked for approved supplier, review by QA, technical requirements (chemistry, mechanical and ferrite control) and orderly flow of supplier submittals.
In conjunction with this review, receiving records were reviewed to determine compliance with purchase order requiremerts.
flo items of noncompliance or deviations were identified.
A walk through the receiving and storage area was made to verify establishment of receiving and inspection areas.
Storage and environmental (moisture) control, identification of acceptable weld material, and segregation of nonconforming material was inspected.
fio items of noncompliance or deviations were identified.
The control, issue and return of weld filler materials was observed. All of the holding ovens in the three rod rooms inspected were calibrated and operating within the required temperature range and contained only one electrode classificaticn.
All filler material located in holding ovens and in opened containers were correctly identified.
Portable rod warmers
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were being properly maintained.
Filler material that is returned damaged or that has been out of the rod ovens beyond the required length of time is discarded.
flo items of noncompliance or deviations were identified.
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8.
Exit Interview The inspectors and the NRC Resident Reactor Inspector met with the licensee representatives denoted in paragraph 1 on February 15, 1980.
The scope of the -inspection and the inspector's observations and findings were discussed.
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