IR 05000508/1980017
| ML19343C696 | |
| Person / Time | |
|---|---|
| Site: | Satsop |
| Issue date: | 01/08/1981 |
| From: | Bishop T, Dodds R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V) |
| To: | |
| Shared Package | |
| ML19343C676 | List: |
| References | |
| 50-508-80-17, 50-509-80-17, NUDOCS 8103250047 | |
| Download: ML19343C696 (7) | |
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I 50-508/80-17 r
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Report !*o.
50-509/80-17
Docket !:c.
50-508, 50-509 a m.:3CPFR-154. -155 3afer,uards creue __
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Washington Public Powgr Supply System
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treensee:
P. O. Box 1223 m
Elca, Washington 98541 j
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Washington Nuclear Project: Nos. 3 and 5 (WNP-3/5)
Facility :a e:
1.tP-3/5 Site, Elma, Washington Inspection at:
December 8 to 19, 1980 Inspectica conducted:
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Inspectors:
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[T.li. ifishopi Sr. Resident Inspecor Ja:a signec Ca:e signeu
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T'. Ccdds,"CM ef, Support Section
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- e sisaed Reacter Construction and Engineering Support Branch Su==ary:
Insoection during the oeriod of Cacember 8 to 19,1980 (Recort Nos. 50-508/
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80-17 ana 50-509/80-17)
Areas Inscacted: Routine, unannounced inspection by the resident inspector or construction activities including: containment welding quality implementing precedures, work activities, ar.J review of quality records; safety related-pipe support systems; structural steel welding; followup on a concern regarding closecut of Quality Finding Reports; investigation of allegations relating
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to HVAC welding; and followup on previous inspection findings.
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. The inspection involved 44 inspection hours onsite by one NRC Inspector.
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Results: Of the eight areas inspected one item of noncompliance was identified i-(Failure to properly perform welder qualification tests, paragraph 7.d).
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CETAILS 1.
Persons Contacted The inspector interviewed various engineering, tanagement, inspection and construction personnel of the organizations listed below.
Key personnel including those who attended the exit interview are specifically identified below, a.
Washinoton Public Pcwer Sunoly System (WPPSS)
G. E. Dobson, Project l'anager, WiiP-3/5
- J. C. Lockhart, Project Quality Assurance Manager J. Kovacs, Sr. Quality Enaineer R. Davis, Sr. Project Cuality Enaineer J. 'dalker, Sr. Quality Engineer
- J. A. Puzauskas, Sr. Project Quality Engineer D. Cutting, t'elding Engineer b.
Ebasco Services. Inc. (Ebasco)
- A. !1. Cutrona, Deputy Project Quality Assurance Manager
- J. C. ?!urphy, Project Superintencent L. F * dams, Sr. Project Guality Engineer L. n. Sast, croJect Quality Engineer C. :1. PcClaskey, Lead Project Quality Engineer c.
I'orrison-Knudsen, Inc. ('X)
F. C. Edler, Froject Quality Manager d.
Uallace/Sucerior (US)
' W. Frost, Project Director J. Sandifer, Project fianager A. Smith, Quality Assurance l'anager
- Denotes those present at the f1RC exit interview on December 19, 1980.
2.
Licensee Acticn on Previous Inscection Findings a.
(Ocen) 50-508/509-80-13-C4:
Project l'anacement Reorganization The Ebasco activities related to reorganization of WfiP-3/5 project nanagerent were reviewed with Ebasco representatives.
It was reported that a tcntative organizational structure has been approved, PSAR changes devaloped, and procedure /ranual changes undeniay.
It is-noted that the proposed on-site Ebasco QA organization has effectively the sate structure as the current WPPSS/Ebasco consolidated organization, since both the. licensee and Ebasco have found'the existing structure to be effective. Personnel indoctrination is intended to start in January 1981. Licensee activities related to the reorganization and further irrplermntation of Ebasco actions will be examined
during a f 4ture inspection.
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(Ocen) 50-508/509/80-11: SALP Actions to imorove preplanning and crecaraticn of contractor work (kork Proceaures)
One of the tcoics covered in the recent Systematic Appraisal of Licensee Performance (SALP) neeting addressed inconsistencies in centractor's procedures. This subject was reviewed with licensee and Ebasco representatives during the current inspection period.
It was stated that a task force has been developed and has thus far generated four " generic" precedures.
In addition tha licensee has started extensive work session 5 to rcsiew and improve the HVAC contractor's work orocedures (contract 3240-232). The implementation of the " generic" orocedures as well as plans for other site contractors will be reviewed durina a future insoection.
3.
Centainrent (Structural Steel Weldinal a.
Quality Inolementina Procedures The inscector reviewed two selected Chicago Bridge & Iron (CBI)
documents for conformance to tne requirements of the contract specification, the ASME B&PV Coce, ano tne PSAR.
Items reviewed included CBI Drawing 85, revision 6 (snell cao details) and Welding Procedure Scacification no. WPS-1 (Lcw Alloy, Standard Performance Qualification).
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The two cocuments exaainec were found to be in conformance with requirements.
However, the Procecure Qualification Records (PQR)
for JPS-1 were not available on site for examination. The inspector requested that copies of the PQR's for WPS-1 be obtained by the contractor.
Licensee and centractor representatives stated that the PQRs would be retrieved. This item wili Le examined further following receipt of the PQR's (50-508/509/80-17-01).
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b.
Chservaticn of 'Jork and Ucrk Activities C3I activities related to Unit 3 containment dome welding and Unit
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5 centainment welding were examined for compliance to approved CBI welding procedures, the contract specification, the ASitE B&PV code, and the PSAR. Observations were made of joint fit up and preheat, identification, preparation, use of specified weld filler materials,
interpass temperature control, welder technique, weld size, and GC coverage. - The joints examined included Unit 3 weld nos. E-13 (two locations), E-15, E-16. E-23 (two locations) and welding of the third ring on the Unit 5 vessel (in four locations). All activities cbserved apceared to be in compliance with specified requirements.
No items of noncompliance or deviations were identified.
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T-3-The inscecter interviewed six welders, a welder foreman and three contracter QA/QC representatives, alcng with selected Ebasco and
'o??SS recresentatives to discuss the high radiographic test rejection
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rate en the Unit 5 ders welds and actions taken to avoid sinilar arcolets on the Unit 3 dore. While no single iten was identified as ccusing the increased rejection rate, several centributinc facto t were offered, including: use of newer welders (while the weiders were cualified it was considered that incroverents in c erator proficiency could be rade); orcblers with plate cistertion at fit up zone; and use of several welders on one joint (inferring a lack of individual accountability for weld defects). To incrove the accentance rate of Unit 3 deme work the centractor nas taken
- tecs to imorove.cceratcr croticiency, accliac additional emonasis to weldinc activity surveillance. anc. utilized a larger nuncer of braces tc centrol cistertien.
C3I activittes for centrol of weldinp filler material at the Unit 3 d:re erect 1on location were exantnec includinc observations of Tterial storace, teccerature control, issuance, and handling for cecciiance.to procecurai recuirerents. No items of nonceroliance or ceviations here identifiec.
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osvie< of Guality Recercs-CSI cuality recoros pertaining to vessel welding were exaninec.
These included: weiding filler material issuance logs; one ragnetic
- rticle east exacinar's qualifications records; qualification recorcs for seven weldars;. two cagnetic particle test recorts for attacr. rents to the Unit 3 sessei; caterial certification records for four heats of E7013 welding electrede in use; and available caterial cartification records, receiving _ inspection records, and choc raie2:e raccrds for Unit 3 dcce platas T-17 and T-20.
No items of ncncompliance or deviatiens were identified.
4.
Safety Related Pica Succort and Eestraint Systers Peter Kiewit Sens' (PKS) preparations for safety related pipe support and restraint.systen;installaticn were reviewed with.PKS and licensee persennel.. TWo issues were identified which are currently under licensee review. The 'first item involved the system to centrol traceability of hancer cicces wnich are not insediately installed, but are precared for welding in such a manner that the traceability infornation has been fully cr partially obliterated. The second item related to the qualificatien of welders perforcing flare bevel groove welds (whether such welders shculd be cualified cn 'open butt joint configuraticns or backing plate
- cenfigurations).
The resolution of concerns for r.aterial traceabilit (50-503/509-80-17-02) and welder.oualification (50-508/509-80-17-03) y will be further examined during a future inspection.
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Structural Steel Welding fiorrison-Knudsen (MK) activities related to weldir.3 filler material control and welder qualification bend testing were examined for compliance
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to the contractors controlling procedures, the contrr.t specification
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(contractno. 3240-263), and the PSAR. The observatir,n included issuance of weld filler material for Units 3 and 5, storage /p.otection/and temperature control of filler raterial, control of bend test sr.nples, and examination of the guided bend testing machine. No items of * oncompliance or deviations were identified.
6.
Concern Recardino the Closecut of a cuality Findino Reoort The inscector received an anonymous note exoressing concern about the closecut of a particular Quality Findino Report (OFR). The inscector selected this 0FR and five others for examination. The specified corrective teasures for eacn 0FR were reviewed and were found to be appropriate for the conditions descriceo in the QFR.
It is noted that some of the corrective measures had not yet been implemented, but are scheduled for implementation in a timely manner. This inspector had no further questions.
7.
Allecations to h7FSS/Ebasco Recard1no Contract 3240-232 Weldino Activities a.
-Initial NRC Mot 1fication On Decem~oer 10, 1980 a licensee representative notified the I4RC that allegations of improper perionr.ance of welding activities had been received frcm a former fiVAC contractor employee (Wallace/
Superior, Ccatract 3240-232). The allegations included the following:
welder qualifications were not properly performed (no QC monitoring a.
during qualification, changing of welding machines during qualification, welding out of designated position, substitution of one welder's qualification test plate for another's),
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improper use of welding filler material (exchange of filler material between welders and use of the wrong filler material).
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Stamping of a weld with an incorrect welder symbol number (in the Turbine-Generator Building, non-safety related).
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Contractor and Licensee Actions It was determined that the contractor had been notified of the allegations on December 9,1980 and had issued a self imposed stop work order at that time. The centractor investigated the allegations during the period of Decerter 9-12,
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e-5 1980 and cencluded that the allegations were inaccurate (exceot for the inccrrectly stamped weld).
A licensee investigaticn into the allegations was also initiated on December 9, 1980. This investigatien was still in progress as of Decerber 19, 1990s While the contractor had concluded frem his investigation that thare were no prcblems with the welder cualification procran, to discal doubts a decision was made to recertify all welders beginning Cecember 15, 1980. This activity was monitored by the NRC inspector (see paragraph 7.d belcw).
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MFC Investication Initial PRC investigation of the allecations involved interviewing five velcers (or font.er welders), a weieing foreman, ard three CC r:presentatives.
These interviews included the alleger and the indivicual to wncm some of the allegations were attributed (welding cut of position anc suostitution of a qualificaticn test plate).
Nith the exception of the alleger, none of those interviewed expressed any '<nowledge of iraproper weider qualification practice or misuse of
- eldr.g filler material. The iroroper stamping of the weld was a known case.
The inspector diso examined the qualification records of 10 welders for ccrpiiance with AWS D1.1 code and procedural requirements.
Partions of scme of the record documents were found to lack signatures (weldr U44) or dates (weldar U12), however these conditions had recently ccen identified by the contractor.
Further investis;ation will te accomplished following completion cf the licencee's activities in this area (50-508/509-80-17-04),
d.
Mlated Actions The contractor initiated welder requalification on December 15, 1980 using the standard 1" test plates as described in Ah'S D1.1. On December 16, 1980 the inspector observed the requalification welding of two welders, the preparation of test samples for guided bend testing, and the guided bend test jig. The activities and equipment were examined for compliance to the requirements of the AUS D1.1, Structural Helding Code. The examinaticn of the bend test jig revealed that the plunger and interior die radii were approximately 1" and 1-7/16" respectively. The AUS D1.1 Structural Welding Code provides that for the material being used by the contractor for welder requalification (ASTM A36) the radii should be 3/4" for the plunger and 1-3/16" for the die. Use of an oversized guided-bend test jig vculd result in insufficient bending of the test sample, thereby invalidating test results.
Contractor representatives stated that the test jig in questien had been in use to qualify the contractor's welders since April 1980. The failure to properly perform welder
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-6-qualification tests is an apparent iten of noncompliance with the requirements of 10 CFR 50, Appendix B, criterion IX.
(50-508/509/
80-17-05).
Ito other items of noncompliance or deviations were identified.
On December 17, 1980 the licensee issued a stoo work order to the centractor citing violations in the welder cualificatien program (use of the oversized test jig) and incomolete imolecentation of corrective actions denoted on Quality Finding Reports.
8.
Manacer.ent Interview The inscector met with licensee and Ebasco representatives on December 19, 1980. Those attending tne meeting are cenoteo in paragraph 1.
During the reeting tne inspector summarizea the scope anc fincings of the inspection identifying the item of noncomoiiance oiscussec in paragraph 7.d.
Licensee representatives indicated tnat immediate action would be initiated on the concerns identifieo.
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