IR 05000482/1982010

IE Insp Rept 50-482/82-10 on 820510-14.No Noncompliance Noted.Major Areas Inspected:Followup on Previous Insp Findings;Observation of Work Activities Re Class IE Pipe Support & Restraintsys & Review of Records for Pipes

ML20054M549
Person / Time
Site:	Wolf Creek
Issue date:	06/14/1982
From:	Randy Hall, Hunnicutt D, Clay Johnson, Tomlinson D, Whittlesey K NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
To:
Shared Package
ML20054M540	List: IR 05000482/1982010 ML20054M539
References
50-482-82-10, NUDOCS 8207130572
Download: ML20054M549 (10)

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APPENDIX U. S. NUCLEAR REGULATORY COMMISSION

REGION IV

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NRC Inspection Report: STN 50-482/82-10 Docket: STN 50-482 -Category A2 Licensee: Kansas Gas and Electric Company P. O. Box 208 Wichita, Kansas 67201 Facility Name: Wolf Creek, Unit 1 Inspection at: Burlington, Coffey County, Kansas Inspection conducted: May 10-14, 1982

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Inspectors: ./ ft/

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~ c[c w P. TofnTins'on,' Reactor Inspector, Engineering Section h-d-FF Date (Paragraphs 1,2,3,5,6,and8)

f,hn le - ti - 8 C. E. Johnson, Re6ctor Inspector, Engineering Section Date (Paragraphs 1, 2, 3, and 4)

bh Y uurNeuXt K. A. Whittlesey, Reactor Inspector, Engineering Section b/}Y/0 D' ate /

(Paragraphs 1, 2, and 7)

i V hA' . Ym m,%,9 d/9/82.

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D. M. Hunnicutt, Chief, Engineering Section Date /

(Paragraphs 1, 2, ano /)

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Reviewed: .

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E.[Ha{,' Chief, Reactor Project Section C Ddte '

Approyed: h?! lAf m n & WI' $//Y/S2" D. M. Hunnicutt, Chief, Engineering Section Date'

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R-8207130572 820617 PDR ADOCK 05000 0 , _ - - . . . . - _ _

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-2-Inspection Summary 4 Inspection Conducted May 10-14, 1982 (Report STN 50-482/82-10)

Areas Inspected: Routine, unannounced inspection covering followup on previous inspection findings; observation of work activities related to Class IE pipe support and restraint systems; review of records for pipe supports and restraints; visual examination of welds and review of welding records for pipe supports; review of welding material control and welders qualifications; review of records, work in progress, and procedures related to containment electrical penetrations; and general plant tour The inspection involved 110 inspector-hours by four NRC inspector Results: Within the six areas inspected, no violations or deviations were identifie ,

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-3-DETAILS

, Persons Contacted Principal Licensee Employees

• D. W. Prigel, QA Manager

• J. L. Stokes, Construction Project Superintendent

• 0. L. Thero, QA Surveillance

, *C. E. Parry, Supervisor, QA Systems

• D. A. Colwell, QA Systems

• P. M. Burck, QA Engineer

• R. A. Bird, QA Engineer Other Personnel

• J. L. Walker, Autnorized Nuclea'r Inspector, Hartford Steam Boiler

• V. L. Turner, Project QA Engineer, Daniel International Corporation (DIC)

G. Robertson, Project Manager, GE0 Construction Testing During this inspection, other site management, engineering, QC, and construction personnel were contacte * Denotes those attending the exit intervie . Site Tour The NRC inspectors walked through various construction and storage areas to observe construction activities in progress and to inspect the general state of cleanliness and adherence to housekeeping requirement The tour included the reactor building, reactor auxiliary building, and several outside storage area No violations or deviations were identifie . Licensee Action on Previous Findings (0 pen) Unresolved Item (STN 50-482/81-15): NRC Inspection Report STN 50-482/81-15 identified an enresolved item concerning WP-VII-208, Revision 5 which requires additional alteration and cut of support material to shape and size by mechanical or thermal means without engineering approval. Pending final approval of WP-VII-208, Revision 10, this item remains ope (Closed) Unresolved Item (STN 50-482/79-09-03): NRC Inspection Report STN 50-482/79-09 identified an unresolved item concerning piping forma-tions fabricated by Gulf and Western Energy Products (G&W). A review of the radiographs of the welded pipe joints revealed that the minimum requirements of the ASME Code for film quality had not been met. The

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-4-unacceptable film quality combined with the rough surface conditions of the welds resulted in radiographs that could not be reliably interprete Several of the piping welds were cut for confirmation, and it was found that rejectable conditions existed in the welds that could not be evaluated on the original radiographs. Several other pipe joints were reradiographed using an acceptable technique that resulted in adequate film quality. Gross internal anomalies were discovered, and it was determined that all of the G&W piping formations should be rejected. A stop-work order was issued by KG&E for the instal-lation of these piping subassemblies. KG&E decided to disassemble and rebuild all of the G&E piping formations. The rework and inspection of the affected piping was performed by Southwest Fabricators, and the subassemblies have been returned to the sit The NRC inspector randomly selected eight of the piping formations as a representative sample for reevaluation. The radiographs for these 8 represented approximately 30 welds. Each film was reviewed to ascertain that at least the minimum film quality requirements were being met. This examination was to determine the adequacy of film densities, penetrameter selection, penetrameter placc.ent, proof of coverage,and film identification. Concurrently the film was examined to verify that correct interpretations and evaluations were being mad An independent evaluation of each radiograph was made by the inspector, and the NRC results were compared with the attendant reader sheets. No discrepancies between the film evaluations and the ASME Code requirements were noted. This review of the radio-graphic sample indicates that the welding quality and radiographic quality of the piping formations are now acceptabl Based upon the NRC inspector's review of the radiographs, this item is considered close . Safety-Related Pipe Support and Restraint Systems Review of Procedures / Specifications The NRC inspector reviewed five procedures and three specifications during the course of the inspection. Means have been established in the procedures / specification that technical requirements, '

acceptance criteria, and required documentation are specifie Means have also been established to verify that design and field changes are adequately controlled. Procedures / specifications reviewed by the NRC inspector are listed below:

Procedures WP-VII-208, Revision 9, " Installation of Component Supports" WP-VII-209, Revision 11, " Preparation and Processing of Travelers"

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-5-QCP-VII-204, Revision 1, " Inspection and Documentation of Supports" QCP-VII-209, Revision 0, " Quality Review of Travelers" QCP-VII-504, Revision 3, " Weld Repair" Specifications 10466-M-204, " Specification for the Field Fabrication and Installation of Piping and Pipe Supports to ASME Section III for the SNUPPS" 10466-M-205, " Specification for the Field Fabrication and Installation of Piping and Pipe Supports to ANSI B3 for the SNUPPS" 10466-M-216, " Specification for the Fabrication of Non-Catalog Pipe Supports for the SNUPPS" No violations or deviations were identifie b. Observation of Work The NRC inspector selected eight pipe support travelers that were in process. The supports were on the high pressure safety injection (EM), containment spray (EN), component cooling water (EG), and chemical and volume control (BG) systems. The NRC inspector visually inspected and compared each support with the documents contained in the traveler. During this visual examination of the supports, the NRC inspector observed that there was not enough information in the traveler to perform an adequate inspection. Many discrepancies were identified by the inspector; e.g., incorrect dimensions, welding not as per drawing, NCR's and DR's not accompanying the traveler, and no quality inspection checklist (QIC). The traveler contained bill of materials, the hanger drawing, and weld control records (WCR).

The NRC inspector informed the licensee and constructor of the areas identified, but was informed by both that the travelers selected were of the old system used and that the new program developed using QIC's was not totally complete and that final quality acceptance had not been performed on any of these supports. The NRC inspector questioned the constructor as to when this revised program on supports would be completely inplemented. The constructor gave no definite time period; however, ?.he constructor stated that all completed supports would be in accordance with the procedures and drawing The constructor informed the NRC inspector that there were only approximately 22 completed supports. The NRC inspector noted to both licensee and constructor that problems which could be identi-fied in process are not always evident in the final as-built conditio ._ ____

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-6-The NRC inspector will perform an inspection on completed as-built supports on a subsequent inspectio No violations or deviations were identifie Review of Records The NRC inspector reviewed 18 hanger support travelers. There were 7 small bore travelers and 11 'arge bore traveler The small bore travelers were completed. All required documentation was present. The NRC inspector did not perform a visual field inspection on the small bore travelers because of time restric-tions. The large bore travelers were all in process. Out of the 11 travelers, 8 were visually inspected by the NRC inspecto Discrepancies were noted in the large bore travelers and were dis-cussed in paragraph 4.b. Travelers reviewed by the NRC inspector are listed below:

Small Bore Large Bore EG01 C509-144 *EM01-C044-111 EG01 C511-144 *EM01-R027-112 EG01 R502-142 *EN-02-C006-111 EG26 C514-112 *EN-02-R003-111 EG26 C513-ll2 *EM01-R016-111 EG26 C510-ll2 *BG02-R015-ill

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EG26 C508-112 EG24-R009-lll BG04-R012-lll

• BG04-C035-111 BG24-R009-111

• EG07-R025-112 No violations or deviations were identified.

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-7- Safety-Related Structures - Visual Examination of Welds and Review of Welding Records While touring the auxiliary building, the NRC inspector visually examined the welding on eight completed piping support Examined were the support locations and configurations, as well as the weld sizes and contours. The NRC inspector noted all identifying numbers on each support and the welders I.D. numbers for each wel The record packages for these supports were located and reviewed for complete-ness and accuracy. The actual locations of the supports were checked against the construction drawings and were found to be correc The records 'f preweld fit-up inspections were examined, and the identification of each inspector and welder was recorded for later use. The NRC inspector reviewed all other pertinent documentation in each record package including weld filler material slips, weld repair records, and records of all nondestructive examinations performed. The' record packages for the supports selected were complete and all entries that were checked against the hardware did reflect the existing as-built condition No violations or deviations were identifie . Safety-Related Structures - Welding Material Control and Welders Qualification The NRC inspector reviewed Daniel International Procedures CWP-503 and CWP-525 for control of welding consumables and for control of welding consumables at offsite testing facilities for welder qualification No inspection was performed at the offsite facility. Rod Issue Rooms No. 1 and No. 3 were toured during this inspection, and the issue room attendants were interviewed by the NRC inspector. Each attendant appeared to be cognizant of the procedural requirements and to have a thorough understanding of the filler material issue system. The NRC inspector reviewed the calibration records for 10 of the rod storage ovens and verified that the temperatures of each were within the required limits. The NRC inspector compared the welders' qualification list against the previously recorded I.D. numbers of the welders involved in manufacturing and installing piping supports. A compari-son of the qualification dates of the welders and the dates the welds were produced indicated that all welders were properly qualifie The records for all 12 welders checked were found to be in conformance with the requirements of Daniel International Procedures CWP-501, CWP-503, and CWP-510 for welding procedure qualification, qualification of welders, and maintenance of welder qualifications. No witnessing of welder qualification was accomplished during this inspection as no welders were being teste No violations or deviations were identifie .

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-8-7. Containment Electrical Penetrations KG&E and their contractors discovered discrepancies in almost all of the containment electrical penetrations supplied to the Wolf Creek site by Bunker-Ramo Corporation, Connector Division, Space and Missle Systems (SAMS). These discrepancies have been identified and documented by

, KG&E and their contractors, and KG&E is in the process of correcting /

repairing the The NRC inspectors reviewed the Wolf Creek onsite QA organization and the functional relationship of the QA program to the containment electrical penetrations. This review and related discussions with KG&E personnel verified that the Wolf Creek QA plans, instructions, and procedures have been established and are being implemente These QA plans, instructions, and procedures met the Wolf Creek facility QA program as described in Chapter 17 of the Wolf Creek FSAR. KG&E Procedure KP9-501, "KG&E Construction Disposition of Nonconformance Reports," was reviewed as a supporting document to the overall docu-mentation of the containment electrical penetration The NRC inspectors determined that KG&E Procedure KP9-501 was being adhered to as committed by KG& The NRC inspectors determined that the following activities had been controlled and performed in accordance with FSAR commitments, QA plans, instructions, procedures, and NRC requirements: Shipping, receipt, identification, storage, handling, and protec-tion of the containment electrical penetration assemblie Installation and welding of the containment electrical assemblies.

l Testing and auditing by KG&E and their contractors revealed basic manufacturing problems with the containment electrical penetrations supplied by Bunker-Ramo Corporation. The licensee is in the process of correcting / repairing and verifying the corrective action / repairs j for each of these containment electrical penetration The docu-mentation " package" for each containment electrical penetration contains the "as-found," "how corrected," testing data, verification information, and other related data and information.

l l Subsequent to installation of the Bunker-Ramo Corporation manufactured l containment electrical penetrations, the licensee and contractor personnel

! performed inspections on each of the penetrations. A summary of the l identified discrepanceis included the following:

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-9- Some of the lugs on electrical leads were improperly crimpe Licensee tests and inspections could not confirm the vendor's certifications regarding type and qualit, .f the cable in a number of the electrical penetration Various discrepancies between the drawings and "as received" condition of the electrical penetration The NRC inspectors selected two completed document packages from approximately 35 document packages for review. These two packages contained data for electrical penetrations designated ZNE-279 and ZNE-290, and each contained the required documentation, including the following: Bechtel P.O. 10466-E-035-1 RMI-E-035, "Special Receiving, Storage, and Maintenance Instructions and Inspection Requirements," Revision 15 for nitrogen gas pressure surveillance Pneumatic proof and gas leak rate test Containment RODR Mechanical Booklet Information on KG&E identified improper crimping of electrical termination lugs (MRR-31258 for ZNE-279 and MRR-33157 for ZNE-290) Specification 10466-E-035-Q j Traceability documentation (AS-181-16 for ZNE-279 and AS-198.2.1 i

for ZNE-290)

j' Physical and chemical certifications (material certs)

l Data on 3-inch weld neck flanges - WFF S/N ENJ-l through 18 .

BR S/N AS-193-1 through 18 Verfications and certifications

' Test data sheett Positioning and alignment of each penetratio No violations or deviations were identified during this portion of

the inspection.

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-10-8. Exit Interview An exit interview was conducted on May 14, 1982, with the licensee representatives (denoted in paragraph 1) to discuss the scope and findings of this inspection.

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