IR 05000483/1981024
| ML20039D359 | |
| Person / Time | |
|---|---|
| Site: | Callaway  |
| Issue date: | 12/15/1981 |
| From: | Danielson D, Key W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML20039D350 | List: |
| References | |
| 50-483-81-24, NUDOCS 8201040014 | |
| Download: ML20039D359 (8) | |
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U.S. NUCLEAR REGULATORY COMMISSION
REGION III
keport No. 50-483/81-24 Docket No. 50-403 License No. CPPR-139 Licensee: The U Slectric Company Post Office Box 149 St. Louis, MO 63166 Facility Name: Callaway Plant, Unit 1 Inspection At:
Callaway Site, Callaway Launty, M0 Inspection Conducted: November 4-6, 1981 IM/b % % b
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Inspector:M.J. Key h
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Approved By:
D. H. Danielson, Chief f
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Materials and Processes Section Inspection Semmary Inspection on November 4-6, 1981 (Report No. 50-483/81-24)
Areas Inspected: Followup of licensee corrective actions relating to Inver.tigation Report No. 50-483/81-04; followup and close out of 50-55(e)
report regarding Gulf and Western supplied piping. The inspection involved a total of 24 inspector-hours onsite by one NRC inspector.
Results: No items of noncompliance or deviations were identified.
8201040014 811215 PDR ADOCK 05000483
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DETAILS Persons Contacted Union Electric Company (UE)
- M. I. Dayne, General Superintendent
- R. L. Powers, QA Superintendent
- J. V. Laux, Supervising Engineer, QA
- H. W. Millwood, QA Engineer
- R. Ventch, Assistant QA Engineer
- S. M. Hogan, QA Engineer Daniel International Corporation (DIC)
- H. J. Starr, Project Manager
- P. Van Nort, VP Qa-s
- A. D. Arnold, Project Quality Manager
- J.
R. Lee, Piping Engineer
- R. A. Somers, Assistant QC Manager
- Denotes those present at the entrance and exit interviews.
Functional or Program Areas Examined 1.
Followup of Investigation Report No. 50-483/81-04 During an investigation conducted during Febrt.ary 20, March 3-6, 23-27, 1981. One ite.n of noncompliance was identified related to a pipe piece identified as No. SP.
During this inspection the inspector re-examined the radiograph of the long seam of this pipe at location markers 13-14.
It is rpparent that the indication identified was caused by a momentary pause or excess wire feed of the automatic welding machine causing excess material to be deposited on the inside surface of the pipe and appears as nonfussion on the radiograph.
Prior to the investigation this excess material had been removed by grinding. A liquid penetrant and radiographic examination of the area was performed by the licensees constructor showing the weld to be ac-ceptable.
Further visual and radiographic examinations were conducted during the investigation and witnessed by the NRC inspectors.
These examinations also show the weld meets ASME Code acceptance requirements. The licensee's corrective action and response to this item was satisfactory. This item is considered closed.
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Followup of a 50-55(e) Licensee Event Report On November 2, 1979, the licensee, Union Electric Company, informed the Region III office of deficiencies identified in (3) three pre-assembly piping formations supplied by Gulf and Western (G&W), of Paola, Kansas. The formations involved were Numbers A-18-151, A-47-135, and A-52-135.
G&W was contracted to supply 32 safety-related piping formations for the Callaway site, and 32 formations for the Wolf Creek site. These assemblies form part of the following systems, a.
b.
Chemical and Volume Control (BG)
c.
Component Cooling Water (EG)
d.
High Pressure Coolant Injection (EM)
In April and May of 1979, the licensee conducted inspections and audits of preassemblies delivered to both job sites. These inspections and audits revealed rejectable weld deficiencies to specifications and ASME Code requirements'in the following areas:
a.
Radiographic technique b.
Incomplete penetration c.
Incomplete fussion d.
Slag inclusions e.
Surface porosity f.
Improper weld profiles The licensee placed a hold on installation of all safety-related formations supplied by G&W.
Following some rework and meetings between G&W and the licensee, all rework, reinspection, and repairs of preassembly formations were trans-ferred from G&W to the contractor (Daniel International Corporation) at both job sites.
The rework, repairs and reinspections were performed at the job site in accordance with the Coctractors Quality Assurance Program and applicable codes. The cause of the problem was determined to be inadequate control of welding and nondestructive examinations by G&W.
The following 15 safety-related G&W formations were re-radiographed reworked, replaced or repaired, and reinspected to meet specifications and ASME code requirements.
FORMATIONS A9/111 - 7 welds were radiographed, 2 of the 7 were rejected and j
repaired or replaced.
A12/111 - 15 welds were radiographed, 9 of the 15 were rejected and repaired or replaced.
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A15/131 --22 welds were radiographed, 8 of the 22 were rejected and repaired or replaced.
'A16/112 - 19 welds were radiographed, 13 of the 19 were rejected and repaired or replaced.
A17/111 - 15 welds were radiographed, 9 were rejected and repaired or replaced.
A18/151 - 27 welds were radiographed, 21 were rejected and repaired or replaced.
A31/113 - 17 welds were radiographed,10 were rejected and repaired or replaced.
A32/113 - 16 welds were radiographed, 9 were reje. ted and repaired or replaced.
A33/132 - 36 welds were radiographed, 27 were rejected and repaired or replaced.
A34/112 - 6 welds were radiographed, 4 were rejected and repaired or replaced.
A35/111 - 6 weld were radiographed, 2 were rejected and repaired or replaced.
A47/135 - 22 welds were radiographed, 6 were rejected and repaired or replaced.
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A49/135 - 22 welds were radiographed, 10 were rejected (1 was rejected by UT) and repaired or replaced.
A51/135 - 22 welds were radiographed,10 were rejected and repaired or replaced.
A52/135 - 20 welds were radiographed, 9 were rejected and repaired or replaced.
Welds in the following safety-related formations were re-examined by the constructor following surface grinding by the liqud penetrant method and accepted.
A-39-112 A-43-135 i
A-44-135 l
A-45-135 A-46-135 A-47-la5 A-48-135 C-8-242
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C-9-242 C-10-242 C-11-242
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C-12-242 C-13-241 C-14-241 During this inspection the NRC inspector reviewed documentation packages, G&W radiographs, and radiographs of reworked and repaired welds. All rework including nondestructive examinations were per-formed onsite by the licensees constructor.
Documentation Package Review G&W Formation A-16-112 NCR-2-2718-P, DR-2SD-1057-P WRP-1703 SW2, R2 RT Report No. 04694 WRP-1443 SW3, R1 RT Report No. 04740/04566 WRP-1444 SW6, R1 RT Report No. 04491 WRP-1739 SW8, R2 RT Report No. 05316 WRP-1445 SW11, R1 RT Report No. 04683 WRP-1447 SW12, R1 RT Report No. 04459 WRP-1807 SW14A, R1 RT Report No. 04994 WRP-1442 SW15A RT Report No. 04697 WRP-1737 SW16A
.RT Report No. 04677 WRP-1819 SWSB RT Report No. 05320 WRP-1441 SW7A RT Report No. 04678 WRP-1450 SW17, R1 RT Report No. 04492 WRP-1479 SW18, R1 RT Report No. 04506 G&W Formation A-17-111 NCR-2-2717-P, DR-2SD-1053-P WRP-1472 SW1, R1 RT Report No. 04386 WRP-1672 SW4A RT Report No. 04698 WRP-1469 SW5, R.'.
RT Report No. 04448 WRP-1463 SW6, R1 RT Report No. 04445 WRP-1462 SW7, 41 RT Report No. 04447 WRP-1701 SW8, R2 RT Report No. 04682 WRP-1724 SW12, R2 RT Report No. 04681 WRP-1471 SW15, R1 RT Report No. 04388 WRP-1473 SW14,R1 RT Report No. 04378 G&W Formation A-18-151 DR-2SD-1533-P WRP-1892 SW1, R1 RT Report No. 05200 WRP-1893 SW2, R1 RT Report No. 05197/UT-00693 WRP-1896 SW3A RT Report No. 05198 WRP-2031 SW4, R3 RT Report No. 05449 WRP-1894 SW5, R1 RT Report No. 05199 WRP-1976 SW6 RT Report No. 02329 WRP-1906 SW6A RT Report No. 05319 WRP-1944 SW22, R1 RT Report No. 05263 WRP-2025 SW23, R2 RT Report No. 05448 WRP-1921 SW24A RT Report No. 05302 WRP-1939 SW25, R1 RT Report No. 05241 WRP-1940 SW26, R1 RT Report No. 05244-5-
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G&W Formation A-31-113 NCR-2-4092-P, DR-2SD-1054/2SD-2632-P.
WRP-1571-SW6, R2 RT Report No. 05452-WRP-1439 SW8, R1 RT-Report No. 04326, PT. 01755 WRP-1459 SW9, R1 RT Report No. 04327-
.WRP-1458
'SW10, R1 RT Report No. 04328.
WRP-1457.
.SW11, R1 RT Report No. 04323~
kRP-1456 SW12, R1 RT Report No.'04324 WRP-1551 SW14, R2 RT Report No. 04536 WRP-1454 SW22, R1 RT.' Report No. 04754
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SW31, R2 RT Report No. 04535 G&W Formation,.A-32-113 NCR-2-2716-P, DR-2SD-1320-P WRP-1864 SW2, R1 RT Report No. 05005'
kRP-1855 SW5, R1 RT Report No. 05038-WRP-1861 SW8A RT Report No. 05515 WRP-1862 SW9, R1 RT Report No. 05022 WRP-1863 SW10, R1 RT Report No. 05074 WRP-1860 SW12, R1 RT Report No. 05021 WRP-2086 SW14A, R2 RT Report No. 05646 kRP-1887 SW15A RT Report No. 05073 WRP-1886 SW16A RT Report No. 05114 G&W Formation A-33-132 DR-2SD-1172-P, 2SD-1173-P WRP-1656 SW2, R1 RT Report No. 04794 WRP-1652 SW3, R1 RT Report No. 05040 WRP-1669 SW5, R1 RT Report No. 04858 WRP-1668 SW6, R1 RT Report No. 04873 WRP-1757 SW7A RT Report No. 04849 WRP-1666 SW9, R1 RT Report No. 04820 WRP-1972 SW10A, R3 RT Report No. 05351 kRP-1677 SW11, R1
'RT Report No. 04841 WRP-1678 SW12, R1 RT Report No. 04773 WRP-1830 SW13, R2 RT Report No. 05301 WRP-1673 SW14, R1 RT Report No. 04728 kRP-1659 SW18, R1 RT Report No. 04772 WRP-1776 SW21A RT Report No. 04941
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WRP-1870 SW29, R2 RT Report No. 05004 kRP-2036 SW44, R1 RT Report No. 05896 G&W Formation, A-34-112 NCR-2-2723-P, DR-2SD-1084-P WRP-1488 SW10, R2 RT Report No. 04285 WRP-1412 SW11, R2 RT Report o. 04258-6-
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G&W Formation, A-35-111L
NCR-2-2722-P, DR-2SD-1083-P WRP-1309 SW9, R1 RT. Report No. 04102 WRP-1394 SW10,.;RI.
RT Report No. 04297
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G&W Formation,. A-47-135 t
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DR-2SD-1348-P-WRP-1865
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.RT Report No. 05042 WRP-1866 SW13,1R1 RT Report No. 05158-WRP-1867; SW15, R1 RT Report No. 05056 WRP-1938 SW16, R2-RT Report No. 05201 1,
WRP-1875 SW17, R1 RT Report No. 05043
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G&W Formation,;A-49-135
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DR-2SD-0998-P, 2SD-2076-P.
WRP-1685 SW6, R1 RT Report'No. 05265
WRP-1687 SW11, R1 RT Report No. 05124
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WRP-1691-SW16, R1 RT Repsrt No. 05112 WRP-1690 SW17, R1 RT' Report No. 05129 WRP-2083 SW13, R41 RT Report-No. 05661, PT. 02584 WRP-1686 SW19, K1 RT Report No. 05182
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WRP-1688 SW20. R1
.RT Report No. 05174 WRP-1674 SW21, R1
- RT Report No.-05111
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- WRP-1689 SW26, RI-RT Report No. 05384 i
WRP-2092 SW27, R2 RT Report No. 05660, UT-00792
WRP-1692 SW30, R1 RT Report No. 05110, UT-00390 G&W Formation, A-51-135
- DR-2SD-2071-P,' 2SD-0954-P
. WRP-1476 SW3, R1 RT Report No. 04662
WRP-1570 SW6, R2 RT Report i'o. '05125 WRP-1477 SW9, R1 RT Report,o. 04507 WRP-1478 SW11, R1 RT Report-No. 04508 WRP-1474 SW15, R1 RT Report No. 04661 WRP-1468 SW16, R1 RT Report.No. 04802
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- WRP-1999 SW24, R1 RT Report No. 05387
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Radiographic Review-
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The following G&W supplied radiographs of shop welds, rejected by the licensee for not meeting specification and ASME Code requirements, were
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reviewed by the NRC inspector.
Formation, A-18-151,' Welds No. 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12,
- and 13.
i The following radiographs of formation welds, repaired, or reworked by DIC, were reviewed by the inspector.
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e Formation A-47-135
' Welds Nos. 2R1, 3, 4, 5, 6, 11, 12, 13R1, 14, 15R1, 16R2, 17R1, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, and 30A.
Formation A-51-131 Welds Nos. 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20R1, 21, and 22.
Formation A-9-11 Welds Nos. 2, 3, 4, 5, 6AR1, 7, 8RI.
Formation A-18-151 Welds Nos. 1R1, 2R1, 3A, 4R2, SR1, 6A, 7R1, 22R1, 23R1, 24A, 25R1, 26R1, and 27.
Formation A-17-111 Welds Nos. IR1, 2, 3, 4A, SR1, 6R1, 7, 8R1 and R2, 9, 10, 11, 12R1 and R2, 13R1, and 14.
Exit Interview The inspector met with licensee personnel (denoted under persons contacted)
at the conclusion ~of the inspection on November 6, 1981. The inspector sum-marized the purpose and findings of the inspection. The inspector further stated that as a result of this inspection the 50-55(e) report regarding formations supplied by Gulf and Western was considered closed.
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