IR 05000508/1980004
| ML19331D200 | |
| Person / Time | |
|---|---|
| Site: | Satsop |
| Issue date: | 06/06/1980 |
| From: | Dodds R, Kirsch D, Wagner W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V) |
| To: | |
| Shared Package | |
| ML19331D180 | List: |
| References | |
| 50-508-80-04, 50-508-80-4, 50-509-80-04, 50-509-80-4, NUDOCS 8008270468 | |
| Download: ML19331D200 (11) | |
Text
p
.
V w
.
U. S. NUCLEAR REGULATORY COMMISSION 0FFICE OF INSPECTION AND ENFORCEMENT
-
REGION V
'
50-508/80-04 50-509/80-04 Report No.
License No. 50-508 & 50-509 Priority CPPR-154 & 155 Category Licensee:
Washington Public Power Supply System cp P. O. Box 468 Richland, Washington 99352
.g Facility Name:
WNP-3 and WNP-5 Inspection at:
WMP-3 and WNP-5 Site (Satsop)
Inspection conducted:
May 20-23, 1980
-
Inspectors:
N / d k /- r; g/[po
'
.
D. F. Kirsch, Readtor Inspector Qafe Signed
._
I'Tb 4,
6hff-p JO W. J. Wagner, Reactor Inspector tate'S1gned
- q n.r
~T Date Signed
..
Approved by:
/
trc[
zf [g /' h
.
R. T. Dodds, Chief, Engineering Support Section Ddte/ Signed
~
Reactor Construction and En'J neering Support Branch i
N f Summary:
.,7,4 Inspection during period of fiay 20-23, 1980 (Report Nos. 50-508/80-04 and 50-509/80-04)
Areas Inspected:
Routine, unannounced inspection by regional based inspectors
-
of construction activities including:
licensee action on inspector identified followup items and 50.55(e) items; nonconformance report review; safety related
--
piping and pipe welding procedure review, observation of work and work activities, and quality record review; and structural steel welding and installation procedure
,
review, observation of work and work activities and quality record review. The inspection involved 56 inspector-hours onsite by two NRC Inspectors.
Results: Of the five areas inspected, no items of noncompliance or deviations were identified in four arcas, and two apparent items of noncompliance were identified in the area of safety relatH piping (see paragraph 5.b:
Incomplete root penetration on one weld in each o two piping subassemblies and alignment offset in excess of code requirements on 5 welds of four piping subassemblies).
IE:V Form 219 (1);
'q r
rw68270
_.mt
-
,
DETAILS
,
1.
Individuals Contacted a.
Washington Public Power Supply System (WPPSS)
- W. J. Talbott, Project Division Manager
- J. C. Lockhart, QA Manager
- J. M. Walker, Senior Project Quality Engineer
- C. E. Tewksburg, Senior Project Quality Engineer
- 0. E. Trapp, Project Engineering Manager
- H. Barton, Welding Field Engineer
- J. Puzauskas, QA Engineer Various other Field and Quality Engineering Personnel b.
Ebasco Services, Inc. (Ebasco)
- D. L. Quamme, Manager of Construction
- A. M. Cutrona, Deputy QA Manager
- T. E. Cottrell, Senior Resident Engineer
- L. F. Adams, Senior Project Quality Engineer
- L. A. Bast, QA Engineer Various other Field and Quality Engineering Personnel c.
Peter Kiewit Sons (PKS)
D. W. Paulson, Site Manager J. Skiles, Quality Engineering Supervisor R. McConkey, Welding Engineer Various other Field and Quality Engineering Personnel 2.
General The licensee reported that construction status of Units 3 and 5 was approximately 20% and 9%, respectively.
3.
Nonconformance Report Review The inspector sampled the completed nonconformance report files of two site contractors issued during the period of February 27 j
through April 30, 1980, and examined 15 reports for adequacy of corrective actions and compliance with QA program requirements.
No items of noncompliance or deviations were identified.
~
-2-
-
4.
Licensee Action on Previously Identified Followup Items a.
Open (508/79-08-01) Followup Item:
Peter Kiewit Sons -
i Quality Assurance implementing procedures did not implement certain code and 0A program requirements
'
The inspector examined the licensee's actions to assure that PKS forwards flCR's generated to the Engineer for review and concurrence and had no further questions.
The licensee had issued a memorandum, dated October 18, 1979 clarifying the status of the Owners Design Positions statements.
The 0DP's were stated to be a mechanism to provide guidance and advice to designers on owner preferences and not meant to be mandatory design directives. The inspector noted that both contract 3240-251 and PKS procedure EP-14 specifies owner acceptable adhesive tapes. The inspector examined the chemical certifications for the tape used by PKS and WPPSS/Ebasco for compliance with code specified requirements.
fio items of noncompliance or deviations were identified.
The licensee noted that procedure PKS-WI-302 (Cleanliness Control) was still under revision and review and that appropriate controls over the removal of marking material or pressure sensitive tape would be included.
This item will be examined during a future inspection.
b.
(Closed) (509/80-03-01) Followup Item:
Wcld Surface Contamination on Unit 5 Containment Vessel Oil was detected on the weld-prep surface of weld K1G-5.
The source of oil was from a defective air compressor used to supply air to the preheat burners prior to welding. The concern of oil contamination on the weld surface during welding is that hydrogen-produced porosity may be encountered along with an increase in carbon content.
The licensee concluded that the possibility of the above conditions occurring was very remote because the oil, which passes through the preheat burners, was volatilized or driven off by the heat before the fusion stage is reached. The inspector reviewed approximately 25 feet of radiographic film of weld K1G-5 and found no evidence of porosity or other discontinuities.
This item is close,
-3-l 5.
Safety Related Piping a.
Review of Quality Assurance Implementing Procedures The inspector examined the below listed sample of the PKS work and ouality assurance implementing procedures for compliance with the PSAR, Code and QA program requirements:
-
(1) PKS-CP-3:
Pipe Fabrication and Installation Procedure (2) PKS-CP-4: Component Support Fabrication and Installation Procedure (3) PKS-CP-7: General Welding Procedure (4) PKS-QP-6:
Calibration (5) PKS-QP-7:
Inspection and Examination (6) PKS-QP-8:
Inspection Status (7) PKS-QP-14:
Cleanness Examination (8) PKS-QP-15: Visual Weld Examination (9) PKS-WI-303: Piping Tolerances (10) PKS-WI-401: Component Support Tolerance (11) PKS-WI-701: Filler Metal Control (12) PKS-WI-702: Welder Qualification and Administrative Controls (13) Welding Procedure Specification Nos. PKS-WPS-2S and 45 and associated Procedure Qualification Record Nos. PQR 1, 2, 4 and 5.
No items of noncompliance or deviations were identified.
b.
Observation of Work and Work Activities The licensee informed the inspector that PKS had not yet begun quality class 1 welding on any safety related application at the time of the inspection.
The inspector examined welding filler material controls applied in the PKS shop, used for welder qualification activities, and the PKS rod room at Unit 3 elevation 335 feet or compliance with PKS procedure and ASME code requirements. Attributes examined included cleanliness, storage conditions of unopened rod cans of filler metal, oven temperatures and evidence of temperature indicating devi.a calibration.
Licensee representatives had informed the inspector that, while no safety related welding had been conducted by PKS, the weld filler metal controls applied to non-safety related welding were to be as required by PKS-WI-701 (Filler Metal Control). The rod room attendant at the Unit 3 335 ft elevation, expressed certain concerr.s to the inspector regarding training of personnel.
It appears that the attendant had been assigned filler cetal control duties at that location on the morning of May 22, 1980 with no prior indoctrination regarding the PKS filler metal control requirements ard the attendant, on questioning, indicated
-4-
'
.
.
that the filler metal control procedure (PKS-WI-701) was not available at the station. The inspector informed the licensee of the conditions described and expressed concern regarding implementation of the PKS filler metal control system.
The licensee agreea to evaluate the circumstances and effect corrective action to assure that rod room attendants have adequate knowledge and training. This item will be examined during a future inspection.
(50-508/80-04-01)
The inspector sampled and examined ASME Class 3 and Class 2 pipe spools, stored outside at the Saginaw storage area, for compliance with licensee procedures and ASME B&PV code requirements.
The spools were provided with end caps and stored on dunnage.
A total of eight ASME Class 3 carbon steel (CS) spools for the component cooling water system and four ASME Class 2 stainless steel (SS) spools (three for the containment spray system and one for chemical and Volume control system) were examined.
The inspector also visually examined the exterior welds of stainless steel spool Nos. 3-20D-20-040-5 and 3-2CS-20-018-1, while the licensee examined the interior condition of these spool welds. A summary of the spools examined and findings fellows:
Spool No.
11aterial Finding 3-3CC12-008SA-4 CS Weld appeared code acceptable Spool interior free of rust.and water 3-3CC24-0305A-5 CS Three welds appeared code acceptable Spool interior free of rust and water 3-2CS20-018-1 SS Spool interior clean and free of water Five welds appeared code acceptable 3-2CS20-017-1 SS Spool interior clean and free of water Three welds appeared code acceptable
.
.
-5-
.
,
'
'
.
.
3-2CS20-040-5 SS Spool interior clean and free of water Six welds appeared code acceptable 3-2CH20 150-7 SS Spool interior clean One exterior weld appeared code acceptable 3-3CC12-009SA-1 CS Incomplete root penetration on pipe / elbow weld in 3 areas (total circumferential distance of approximately 2.5-3")
Spool interior contained water and appeared very rusty 3-3CC24-067S8-8 CS Incomplete root penetration on pipe weld (total circumferential distance of
,
approximately 12")
Spool interior contained water and appeared very rusty 3-3CC24-06758-4 CS Pipes at one weld joint were approximately 5/32" offset in inside diameter due to misalignment for a circumferential distance of about 6" 2 other welds appeared code acceptable Spool interior clean 3-3CC24-030SA-2B CS Inside diameter offset of approximately 5/32" due to misalignment of pipes to be joined for about 6" and 8" of circumferential distance on first and second welds, respectively, from the elbow opening Spool interior contained water and appeared rusty
-.
.
.
. -..
-6-
,
,
.
3-3CC24-040SB-5 CS Inside diameter offset of approximately 5/32" for about 6" of circumferential distance of one weld Spool interior appeared rusty 3-3tC24-020SA-1 CS Inside diameter offset of approximately 3/16" for about 3" of circum-ferential distance on pipe / elbow weld Two other welds appeared code acceptable The piping spools for this project are being manufactured at Associated Piping and Engineering Corporation shops located in Clearfield, Utah and Compton, California to the terms of Specification tio. 3240-4 (Piping and Piping Supports - WPPSS Quality Class I, II and G). All of the above pipe spools had been code stamped and the applicable code Date Report for Fabricated tiuclear Piping Subassemblies (Form tiPP-1) indicated that the subassembly material, design, construction and workman-ship complies with t. e ASME Code,Section III, Class 3 (for the carbon steel piping observed), 1974 Edition through Summer 1976 Addenda. Specification flo. 3240-4, Division 2, Section 2A, paragraph 6.01a specifies that "All fabrication covered by this specification shall be in accordance with ASME Section III" and paragraph 6.0ld-tii states "The ends of the pipe-to-pipe, pipe-to-fitting and pipe-to-valve joints shall be aligned as accurately as practical within the existing com.ercial codes and standards tolerance of pipe diameters, pipe wall thickness and out-of-roundness." The specification further states, in paragraph 6.04h, that "All pipe welds except socket welds and where otherwise stated on the contract drawings shall be full penetration welds." The ap'plicable contract drawings require full penetration welds for spools 3-3CCl2-0095A-1 and 3-3CC24-0675B-8. The ASME B&PV Code, 1974 Edition, Summer 1976 Addenda, Subsection flD, Figure flD4233-1 requires 1/32" maximum uniforn nismatch around joints with concentric centerlines and a 3/32" maximum mismatch at any one point around the joint for pipe joints with offset centerlines.
The licensee's procedure for " Receiving Inspection and Material Requisition" requires a visual inspection for shipping damage, protective covers and seals, cleanness and physical damage and a verification of identification and markings, application of coatings and preservations, and documentation. The procedure
-7-
.
.
'
.
.
specifically excludes inspections for workmanship, dimensional criteria and weld preparations _ for those items inspected at the source. Since the piping subassemblies are apparently source inspected, the excluded inspections are not performed.
The existence of incomplete root penetration on two welds is an apparent item of noncompliance (50-508/80-04-02) and the existence of alignment offset in excess of code requirements is an apparent item of noncompliance.
(50-50-508/80-04-03)
The licensee was obligated to issue piping to PKS from the storage area in a clean condition and the installation contractor conducts an inspection prior to acceptance of custody. The licensee indicated that a purchase order would be issued to obtain hydro-lance equipment and rust inhibitors to assure pipe cleanliness prior to subassembly turnover.
In addition, the licensee stated that a care and maintenance instruction would be issued to remove a specified number of pine caps each month and inspect the piping for evidence of oxidation, condensation and foreign material. This item will be examined further during a future inspection.
(50-508/80-04-04)
The inspector observed two areas of grindout on the external wall of piping subassembly 3-2CS20-40-5 and observed the requested ultrasonic thickness measurement in the areas of grindout to verify that minimum wall requirements had not been violated. In addition, two trunnion assembly attachment welds were visually examined on that piping subassenbly.
No other items of noncompliance or deviations were identified.
c.
Review of Quality Records The inspector examined the following quality documentation, as applicable, for piping subassemblies 3-3CCl2-009SA-1, 3-3CC12-008SA-4, 3-3CC24-067SB-8, 3-3CC24-0675B-4, 3-2CH20-150-7, 3-2CS20-017-1 and 3-2CS20-040-5 for compliance with code and specification requirements:
magnetic particle examination reports
.
liquid penetrant examination reports
.
radiographic examination reports
.
cleaning inspection reports
.
code data reports (form NPP-1)
.
weld data sheet
,
material certificates of compliance
.
ferrite control reports
.
production travelers
.
ds-built thickness reports
.
ultrasonic test reports
.
-8-
.
.
.
In addition, the inspector examined code data reports for piping subassemblies 3-3CC24-030SA-2 and 3-3CC24-040SB-5. The code data reports indicated that the subassemblies had been inspected and accepted by the Associated Piping and Engineering QC Manager and by the Authorized Code Inspector.
The licensee informed the inspector that all radiographic film was required to be examined and accepted by the New York Office of Ebasco prior to shipment of the piping subassemblies.
The inspector did not examine weld radiographic film because the film was returned to the subassembly manufacturer following examination by Ebasco in New York.
The inspector examined welder qualification documentation for four PKS welders for compliance with code and procedural requirements.
In addition, the documentation of personnel training and examination for a PKS QA Engineer, construction manager and general foreman were examined for procedural compliance.
fio items of noncompliance or deviations were identified.
6.
Licensee Action on 50.55(e) Item (0 pen) (50-508/80-04-05):
Microcracks in Unit 3 Shutdown Cooling Heat Exchangers.
The existence of microcracks in the Unit 3 Shutdown Cooling Heat Exchangers was reported to the NRC - Region V office on May 22, 1980.
The microcracks are located on the stainless steel weld overlay on the interior and face of the heat exchanger flange.
This condition was revealed during liquid penetrant (PT) examination following repair welding of the stainless steel weld overlay.
Upon further PT examination, microcracks appeared over a larger area of the weld
,
overlay covering the interior and face of the flange.
The inspector examined the microcracking reported on the two Unit 3 Shutdown Cooling Heat Exchangers. The two Unit 5 heat exchangers were sealed for protection from overhead construction but are expected to be examined by the end of May.
The results of Unit 5 evaluation will be included in the final 50.55(e) report.
Shutdown cooling heat exchangers were designed by Combustion Engineering and built by Ametek.
7.
Steel Structures and Supports (Morrison-Knudsen)
a.
Welding Procedure Specifications The inspector examined the following Morrison-Knudsen (MK)
welding procedures for compliance with ASME Section iX or AWS D1.1 requirements as applicable:
1)
WP-AWS-1 WPPSS Rev.1 - Stud Welding Procedure flo. AWS-1 2)
WP-06 WPPSS Rev. 3 - Welding Procedure for Inert-Gas Shielded Tungsten-Arc Welding of Carbon Steel to Austentic Stainless Steel Pipe and Structural Welds i
.
-9-
.
.
.
3)
WP-20 WPPSS Rev. 3 - Weld Procedure fio. 20 for !>.anual Metal-Arc and Inert-Gas Shielded Tungsten Welding of Stainless Steel Pipe and Structural Welds 4)
WP-21 WPPSS Rev.1 - Welding Procedure flo. 21 for Inert-Gas Shielded Tungsten-Arc Welding of Stainless Steel Pipe and Structural Welds 5)
WP-73 WPPSS Rev. 2 - Standard Procedure Specification tio. 73 for Manual !!etal-Arc Welding of Carbon Steel Pipe and Structural Welds for Low-Temperature Service tio items of noncompliance or deviations were identified.
b.
Observation of Welding Activities Outside Containment Welding activities outside the Unit 3 containment vessel were observed. The observation included an examination of in-process welding and visual examination of completed welds.
These activities were examined to ascertain compliance with AWS D1.1 standards, and Morrison-Knudsen welding specifications.
The following welds were examined:
1)
In-process welding of closure plates to deck (SW-482) at the 390 feet elevation. These consisted of 3 inch long fillet welds on 9 inch centers. The welding at the joint was examined for correct filler material, proper weld filler metal control, weld type and identification, weld joint geometry and welding technique.
2)
Three completed welds on beams 77H, 77K, and 78A were visually examined for location, size, shape, surface condition and appearance. -The quality records of these welds were examined for weld history, quality and required inspections.
The personnel qualification records of the QC inspectors for the above welds were examined for proper certification and adequacy.
flo items of noncompliance or deviations were identified.
c.
Review of Quality Records The inspector examined the installation and inspection records of two installed structures outside the containment vessel.
Adherence to construction specifkations and inspection records, including qualification of inspection personnel were included in the examination.
Tio items of noncompliance or deviations were identified.
__
i
.
.
.
-10-
.
.
8.
Exit Interview The inspectors met with licensee representatives, denoted in paragraph 1, at the conclusion of the inspection on May 23, 1980 and summarized the inspection scope and findings. The inspector also contacted the licensee's Quality Assurance Manager on May 29, 1980 and summarized those items considered inspector followup ite.ms.
The licensee acknowledged the items of noncompliance identified in paragraph 5.b.
>
a e
i
, _ _. _,
_
. _ _ _. _