IR 05000482/1990012
| ML20042G139 | |
| Person / Time | |
|---|---|
| Site: | Wolf Creek  |
| Issue date: | 05/01/1990 |
| From: | Barnes I, Garrison D, Stewart R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20042G134 | List: |
| References | |
| 50-482-90-12, NUDOCS 9005110133 | |
| Download: ML20042G139 (11) | |
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APPENDIX
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U.S. NUCLEAR REGULATORY C0ft11SS10N
REGION IV
NRC Inspection Report:- 50-482/90-12 Operating License: Upf-42 Docket: 50-482 Licensee: Wolf Creek Nuclear Operating Corporation (WCN00)
p.0. Box All
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Burlington, Kansas 66839 l
Facility Name: Wolf Creek Generating Station (WCGS)
inspection At: WCGS, Coffey Count', Burlington, Kansas
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inspection Conducted: March 26-30, 1990 Inspectors:
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R. C. Stewat1), ReaRioFInspector, Mater %Ts Date and Qualit'y programs Section, Division of Reactor safety dk/VNA4)
5-fk0 D. L. GarrTs'ori.- Reactor InspectiIt',I MaterTaals Date-and Quality programs Section, Division of Reactor Safety
Approved:
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{///W l. Dernes, CATief, MateriaTs and'huolity Date
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programs Mction Division of Reactor Safety AsppctionSummary inspection Conducted March _26-30.1990 (Repor,t_50-482/90-12)
^ Area Inspected: Routine, unannounced inspection of the control of
. safety-related welding activities.
Results: The. licensee's overall program for control of welding activities was
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'foursiFTo be satisfactory. Welding procedures and personnel were ascertained to
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be appropriately qualified, and suitable controls were noted to be implemented
with respect to_ storage and issue of welding materials.
Inspection of completed
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welds indicated;that craf t possessed appropriate welding skills. As a result of an observation of inappropriate grinding on a completed essential service water system weld,_ it was ascertained that the licensee's procedures did 900511o133 900507 ADocK05 cog 2 Da
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not fully address control of, and requirements for this work activity.. An inspectorfollowupitemwasidentified(paragraph 2.3.6)inregardto verification of inclusion of appropriate guidance in procedures.
Anunresolveditemwasidentified(paragraph 2.5)subsequenttotheinspection, as'a result of the observation during review of surveillance reports for in. process welding, that Quality Control personnel were frequently not verifying welding amperage was within the range required by the welding procedure specification.
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DETAILS
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E,RSONS CONTACTED
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1.1 principal Liceny,ee personnel l
- T. T. Rhodes, Vice President, Engineering and Technical Service
- J. A. Bailey, Vice President Operations
- R. S. Benedict, tianager Quality Control (QC)
- H. K. Chernoff, Supervisor, Licensing
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- H. L. Stubby, Supervisor Technical Training
- J. F. Hall, Supervisor QC
- L. L. Foster, Manager, Modifications
- J. E. Fletcher, Maintenance Engineer
- D. G. Moseby, Supervisor, Operations
- J. M. Pippin, Manager, Nuclear Plant Engineering
- C, M. Sprout, Section Manager, Nuclear Power Engineering, WCGS
- J. Weeks Manager, Operations
- S. Wideman, Licensing Specialist III
- M. G. V1111ams, Manager, Plant Support
- R. B. Flannigan, Manager, Nuclear Safety Engineering
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- C. W. Fowler, Manager, Instrumentation and Control
- R. W. Holloway, Manager, Maintenance and Modifications i
- W. M. Lindsay, Manager, QA
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1.2 NRC personnel t
- M. E. Skow, Senior Resident inspector
- p. C. Wagner, Reactor Inspector, Region IV The inspectors also contacted other members of the licensee's staff during the
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inspection period to discuss identified issues.
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- Denotes those personnel in attendance at the exit meeting held on March 30, 1990.
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2.
CONTROL OF SAFETY-RELATED_ WELDING ACTIVITIES (55050and55100)
The objective of.this inspection was to determine whether the licensee has
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developed and implemented a program for the control of safety-related welding activities that is in conformance with design specifications, consnitnents in
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the Updated Safety Analysis Report (USAR),
-( the requirements of the American i
Society for Mechanical Engineers (ASME) and American Welding Society (AWS)
Codes.
2.1 Review of Welding Program and Procedures The inspectors performed a review of Sections 3.0 and 17.2 of the USAR and the
' documents listed in the Attachment, in order to ascertain whether the program i
for control of welding activities was in accordance with the following codes:
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- ASME Section 111 - 1974 Edition through Summer 1975 Addenda
' ASME Section IX - 1989 Edition ASME Section XI - 1980 Edition through Winter 1981 Addenda
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ANSI B31.1 - American National Standards power Piping Code - 1973 Edition
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through Summer 1975 Addenda
AWS 01.1-1975 - Specification for Welding of Structural Steel The licensee's overall prograni fer controlling safety-related welding activities was found to be adequately detailed and appeared to be in general conformance with the requirements of the ASME and AWS Codes. The Veld procedure Specifications (WpS) and supporting procedure qualification records
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were found to be consistent with the requirements of Section IX of the ASME Code.
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2.2 control of Welding Materials The inspectors reviewed implementation of the licensee's program for control of welding materials with respect to storage conditionis, control of the issuance of filler material, and segregation of materials while in storage.
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2.2.1 Storage The inspectors began the inspection by observing the storage conditions and inventory in the licensee's main warehouse. The materials storage was found to be satisfactory at this location. The licensee issues welding electrodes from the maintenance shop and also from a substation in the hot tool room. When
issue is required from the hot tool room, the rod room attendant goes to the i
tool room and issues the materials on presentation of a complet;d field weldits material requisition (FWMR).
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The inspectors reviewed the procedural requirements and inspected the issue and storage areas with respect to the following procedural attributes:
Cleanliness of the area, rod room' environment, access, general storage, and security
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Storage and identification of unopened containers of filler materials, and identification, storage, and segregation of opened materials Maintenance of required temperature range (i.e.,150 to 250*F) in coated
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electrode storage ovens and assurance that electrodes were segregated in the oven bins according to classification, size, heat number, and Kansas Gas and Electric lot nuuber
Identification, segregation,andstorageofbarewire(rollsandwirerod)
in individual bins i
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-5-Maintenance of adequate rod stub buckets and portable heater caddies, and
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performance of oven surveillances The inspectors verified that temperatures of the four electrode storage ovens in the main issue station were monitored at the beginning of each shift using a Multipoint Thermocouple probe, with the results entered into a log. The device was observed to have a current calibration sticker and checks by the inspectors on two different occasions showed the ovens were within the required
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temperature range of 150-250'F. The inspectors noted that the 150*f minimum
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temperature steted in the procedure was below the 250'F minimum stated in AWS D1.1-1975 for E7018 coated electrodes.
It was also noted, however, that this code provides for a change in the temperature requirement, if an engineering justification is established. Licensee personnel provided the inspectors a copy of a study which satisfactorily justified use of lower oven temperatures. The inspectors also observed that the licensee discards low hydrogen electrodes that are returned af ter issue and does not attempt to recondition the electrodes for further use. This practice provides additional assurance that minimum moisture contents are maintained in the electrode coating.
Identification, storage, and segregation of welding materials were found to be satisfactory, with one minor procedural noncompliance noted. The noncompliance pertained to an observed instance of stor39e of two types of coated electrodes in an oven, which was not permitted by procedure. The observation had no safety significance in that the oven was identified to contain the second type and the electrodes were properly segregated within the oven. The second type of electrodes was removed from the oven in response to the observation.
2.2.2 Filler Material Issue The rod room attendant was found to maintain a current copy of the administrative procedure (ADM-08-302) and to be knowledgeable of its requirements.
In addition, the attendant maintained a list of individuals who are authorized to sign the TWMR.
fif teen FWMRs were randomly selected and reviewed for conf-ormance to the requirements.
It was noted that the forms were completed properly, and that the welders to whom weld rod was issued were qualified for the weld procedare that was to be used in the work. The welders were issued the number of rods
required, a hot electrode caddie with FWMR attached, and a rod stub bucket.
The amount of rod returned was also logged.
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Two rod caddies with weld rod were examined in the reactor containment building;
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one was issued for welding to the AWS code and one for welding to the ANSI B31.1
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code. Each caddie was found to be hot, plugged into a line receptacle FWMR
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attached, and contained the required number and type of welding electrodes.
2.3 In-process and Completed Welds The inspectors examined the six different welds described below that were in process or completed. During this part of the inspection, the welders were
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verified to be qualified for the welds performed and the welding work packages were reviewed for correctness and completeness and required sign-offs.
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2.3.1 Reactor Containment
Work Request 00567-90-1. This weld was to ANSI B31.1 requirements for
safety class instrument supports and was completed when inspected. The weld requirement was for a 4-inch fillet weld as shown on Drawing
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J-07G01(Q), Revision 10. The items welded were a 6-inch by 6-inch carbon
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steel tube to a 12-inch by 12-inch carbon steel plate and was visually
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acceptable.
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2.3.2 fabrication Shop
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Work Request 5076-89. This work package was generated to replace four
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valves in the chemical and volume control system in a line supplying seal water to the reactor coolant pumps. ine welds joined the ASME Section 111
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Class II, 1-inch stainless steel valves to an ASME Section 111. Class II, 1-inch stainless steel pipe of 3/8-inch wall thickness. The inspectors
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observed the tack welding and completed weld PW 3301 for pipe to Valve 02632,(Valve 02620)pectedcompletedweldsPW3297(Valve 02631),
and also ins and pW 3292 The welds were observed to be visually
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satisfactory.
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2.3.3 Reactor Containment Work Request 2931-88. This welding was to AWS requirements and was for a
bioshield door at elevation 2000 in the reactor containment building.
Actual welding had not commenced at the time of the inspection because the door had to be taken out of the containment and to the shop for modifications. The inspector examined the support plate weld preparation, cleanliness, and wold rod issued to the welder.
In addition, the
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inspector discussed the welding procedure requirements with the welder and
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verified that the welder was knowledgeable concerning the process and weld parameters.
2.3.4 Fabrication Shop
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Work Request 01555-90._ The welding consisted of joining a nonsafety-related
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8-inch stainless steel pipe to an 8-inch stainless steel flange. The inspecter observed in-process welding of the root pass and 18 inches of the third pass. Subsequent visual examination of the completed weld on March 29, 1990, did not reveal any weld defects.
2.3.5 field Stored Pipe
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Work Request 05110-89. The root passes of two completed welds, pW 3410 and 3411, in a replacement 30-inch diameter spool piece for the essential service water system (EF) return line were visually inspected from the,
inside of the pipe. The finished exterior of the weld could not be fully
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-7-examined because of the application of primer paint. The welding was accomplished by a combination procedure for carbon steel (WpSI-0000),
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which required the root pass to be made with gas tungsten arc welding and completed with shielded metal arc welding. The inside surfaces of the root passes were observed to meet the visual requirements of the procedure.
2.3.6 EF System pipe pit
Work Request 05111-89. The inspectors visually examined weld F158-083 which was a single vee groove weld joining a 30-inch diameter carbon steel pipe to a 30-inch check valve that was performed as part of a major nodification on the EF line on the "A" train. The e-1d was performed to Weld procedure WpSI-0000, Revision 1, which is a coination weld process as previously described. The initial visual examination was performed with the weld having a primer coat of paint. The inspectors noted what appeared to be sharp ridges at both sides of the weld and requested the licensee to remove all of the primer from the weld surface. After the removal of the primer, the original weld was visually examined by the inspectors, welding engineer, and QC supervisor.
It was observed that the warkmen who ground the weld in preparation for nondestructive examination (14DE), had overground on both sides of the weld with a thin high-speed disc, which resulted in producing a series of sharp ridges.
The licensee specifications and procedures required that as welded surfaces be free from ripples grooves, overlap, and abrupt edges, to meet thesurfacerequirementsforfinalNDE. These requirements are consistent with the requirements of Section 111 of the ASME Code. The procedures did not, however, address control of grinding other than a requirement for care to be taken to avoid reducing weld.or base material below required thickness.
It was verified that the weld had been examined by the megnetic particle method end accepted. The licensee welding engineer rejected the weld from the standpoint that the sharp corners constituted a stress riser and initiated repair work request 0511-89-01, in repairing the weld, the licensee's welders ground the crown off of the weld and made five additional passes which produced an acceptable profile.
Observation of the finished weld did not reveal that any of the previous condition existed. Other similar welds were examined for a like condition and none were found.
The welding engineer discussed with the inspectors the need to provide additional criteria for post + eld cleanup activities and stated that procedure WpSI-0000, "ASME.At4SI Ceneral Requirements " would be appropriately revised. Verification of this activity is considered an inspector followup item.
(482/9012-01)
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i 2.4 Qualificat,1,on of Welding Inspectors
The licensee maintains a cadre of permanent welding inspectors and supplements their prograra during outages with contract personne p l
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o-8-The inspector reviewed the qualification package for one permanent Level 11 QC inspector and one contract Level 11 QC inspector. The qualifications of the inspectors were found to be consistent with the requirements of ANSI N 45.2.6-1973, including training, proficiency testing, and evaluation.
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2.5 Surveillance of in-process Welding The licensee QC weld inspection group performs random in-process welding surveillances in accordance with procedure QC1 12.1-007, Revision 1.
Subsequent to the onsite inspection, the inspectors reviewed seven QC surveillance reports
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that were genereted in acenrdance with this procedure.
It was noted during the i
review that only one of the seven reports indicated that welding amperage had been verified. This parameter was included in paragraph 7.1 of 001 12.1-007 as one of the parameters, as appropriate, to be verified. The Manager, Quality Assurance was informed of this obs rvation in a telephone call on April 26, 1990. He committed at that time to review the matter and implement appropriate corrective actions. This subject is considered an unresolved item pending review of the QC surveillance program with the licensee. (482/9012-02)
l Welding engineering (during an outage) assigns one of three permanent staff welders to verify compliance of contractor welders with Wps requirements. This activity was vcrified as being performed using a calibrated amprobe and thermocouple probe.
2.6 Welder Qualification At the time of the inspection, there was no activity in the weld test shop; however, an inspection of the shop was aerformed to ascertain its adequacy.
The shop was well equipped with 10 bootis and ample space and supplies including a radiography facility.
The inspectors randomly sampled and reviewed the welder performance qualification test / record package for five performance qualifications and verified that each certificetion was included in the applicable welder qualifichtion status report. Ten additional welder qualifications were verified by taking information from the weld rod issue slips and verifying that
these were included on the applicable welder qualification status report.
The licensee uses a 6G weld position and radiography for qualification of welders, which is consistent with the requirements of the ASME and AWS Codes.
i Qualification status reports were maintained and updated weekly for ASME, AWS, and special process qualifications.
tio violations or deviations were identified during thit nspection.
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LXITINTEE1g The inspectors met with Mr. J. A. Bailey and other members of the plant staff
denoted in paragraph 1 on March 30, 1990, and discussed the results of the inspection. The licensee did not raise any questions or offer any connents concerning the inspection, and did not identify any information discussed at
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- this tneeting as proprietary. The Manager Quality Assurance was notified in a
. telephone conversation on April 26, 1990, regarding the unresolved item (paragraph 2.5) that was identified during review of in-process welding
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surveillance records subsequent to the onsite inspection.
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ATTACHMENT
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Qs_tofDocumentsReviewed n
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Administrative Welding Procedures
ADM-08-300, " Control of Welding Operations," Revision 4, dated
- November 11, 1988
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ADM-08-301, " Preparation and Qualification of Welding / Brazing
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Procedures," Revision 3, dated November 29, 1988
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ADM-08-302, " Welding Filler Material Control," Revision 7, dated
November 11, 1989
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ADM-08-303, " Qualification of Welders," Revision 5, dated October 4,
1988
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WeldProcedureSpecification<(WPS)
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WPSI-0000. "ASME/ ANSI General Requirements," Revision 1, dated l
December 3, 1985
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WPSI-0101, " Welding of P-1 Metals," Revision 3, dated December 15,
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1988 l
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WPSI-0808, " Welding of P-8 Materials," Revision 2, dated October 12, 1988 WPSI-0103, " Welding P-1 to P-3 Materials," Revision 1, dated May b,
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WPSI-0105, " Welding of P-1 to P-5 Metals," Revision 1, dated
- i January 14, 1988
WPSI-0108, " Welding of P-1 to P-8 Materials," Revision 0, dated
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August 1, 1985
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WPSI-0143, " Welding.of P-1 to P-43 Materials," Revision 1, dated January 21, 1986
WPS2-0000, "AWS General Requirements," Revision 2, dated October 12, 1988 l
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QC Inspection Procedures
- QCl-12.1-601, " Inspection of ASME/ ANSI Welds." Revision 4, dated l
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March 14, 1980
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Q01-12.1-007, " Inspection of In-Process Welding," Revision 1, dated
October 12, 1988
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001-12.1-602, " Inspection of AWS Welds," Revision 3 dated December 6, 1989 n
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001-12.1-006. " Surveillance Inspection of Welding consumables,"
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Revision 2, dated June 6, 1988
Licensee Status Reports l
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Welder Qualification Status - ASME Section IX, dated March 11,1990 i
c Welder Qualification Status - AWS D.1.1, dated March 1, 1990
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Licensee Fabrication Procedure
CNT-700, Revision 0, dated August 23, 1985, " Fabrication and Installation of Instrunentation"
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National Standards-
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ANSI N45.2.9-1974, " Requirements for Collection, Storage, and l
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Maintenance of Quality Assurance Records for Nuclear Power Plants" i
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t ANSI N45.2.6-1973, " Qualification of Inspection Examination, and
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Testing Personnel for the Construction Phase of Nuclear Power Plants" i
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