IR 05000518/1979012
| ML19208B271 | |
| Person / Time | |
|---|---|
| Site: | Hartsville  |
| Issue date: | 07/05/1979 |
| From: | Blake J, Herdt A NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML19208B250 | List: |
| References | |
| 50-518-79-12, 50-519-79-12, 50-520-79-12, 50-521-79-12, NUDOCS 7909190444 | |
| Download: ML19208B271 (7) | |
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'o UNITED STATES
! ' ),( [,g NUCLEAR REGULATORY COMMISSION
" - r REGION 11
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o, 101 MARIETTA ST., N.W., SUITE 3100 g
ATLANTA, GEORGI A 3o3o3
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Report Nos. 50-518/79-12, 50-519/79-12, 50-520/79-12 and 50-521/79-12 Licensee: Tennessee Valley Authority 500A Chestnut Street
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Chattanooga, Tennessee 37401 Facility Name: Hartsville Nuclear Plant Docket Nos. 50-518, 50-519, 50-520 and 50-521 License Nos. CPPR-150, CPPR-151, CPPR-152 and CPPR-153 Inspection at:
i e Nuclear Plant Near Hartsville, Tennessee Inspecto :
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J. Bla Date Signed 7-8'7f Approved by:
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A. R. Herdt, Secf. ion Chief, RC&ES Branch Date Signed SUMMARY Inspection on June 4-7, 1979 Areas Inspected This routine unannounced inspection involved twenty-eight inspector hours onsite in the areas of steel structures and supports - welding procedure specifications and QA procedures; welding material control; obse:vation of welding activities within containment; visual examination of welds; weld heat treatment; welder qualification; and special welding applications; previous inspection findings; and allegations concerning concrete pour in unit A-1.
Results Of the nine areas inspected, no apparent ites of noncompliance or deviations were identified in six areas; three apparent items (s) of noncompliance were found in three areas: Deficiency - outdated QA program description (Paragraph, 7); Infraction - welding material control in Unit A-1 (Paragraph, 8); Infraction -
and welding control procedures do not clearly define requirements (Paragraph, 3).
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DETAILS
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Persons Contacted Licensee Employees
- R. T. Hathcote, Project Manager
- W. T. Quinn, Construction Enginecc
- W. R. Brown, Construction Engineer
- G. A. Gonsalves, Site QA Supervisor
- A. W. Crevasse, QA Manager - Power
- F. W. Miles, OEOC QA
- H. S. Sheppard, Assistant Construction Engineer QC
- L. H. Jackson, Assistant Construction Engineer, QC
- E. Loupe, Welding QC Supervisor
- S. Stagnolia, Welding QC Supervisor Other licensee employees contacted included several construction craftsmen, 0". technicians, Engineers, and office personnel.
- Atterded exit interview 2.
Exit Interview The inspection scope and findings were summarized on June 7,1979, with those persons indicated in Paragraph I above. The items of noncompliance were discussed in detail. The Project Manager and his staff agreed that the item concerning the welding control procedures had not had proper attention but would be corrected and implemented by July 31, 1979.
3.
Licensee Action on Previous Inspection Findings (Closed) Unresolved item (50-518, 519, 520, 521/78-16-03): Weld control procedures do not clearly define requirements. The inspector reviewed the status of the licensee action to define the weld control requirements in the areas of documentation of welder identification, filler material use and preheat checks for welds which took more than one day to complete. The inspector found that not only had there been very little action by the licensee on this ites since its identification by NRC in November 1978, but a procedure generated by welding QC of Plant A to control welder identifi-cation on welds was signed by Plant A personnel in September 1978, but had not been isssued because plant B personnel would not sign the procedure without some wording being changed. The inspector informed the licensee that this matter of having weld control procedures appropriate for the level of work on site would be closed as an unresolved item. However, this item would be reopened as an item of noncompliance in the infraction retegory since the licensee has not complied with Criterion V to Appendix B, 10 CFR 50, as implemented by the PSAR Section 17.1A.5 and is identified as number 50-518, 519, 520, 521/79-12-03, Welding control procedures do not clearly define requirements.
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(0 pen) Unresolved item (50-518, 519, 520, 521/79-04-01) 50.55(e) item -
Inaccurate reporting. The inspector reviewed the status of this item with the site QA fupervisor. The QA supervisor showed the inspector a memorandum from Mr. H. H. Mull, Director, Division of Construction, dated February 14, 1979, concerning the responsibilities for the accuracy of reports to NRC concerning 50.55(e) items. The QA staff at the site is still in the process of implementing a program that will ensure that everything reported to NRC has been inspected for accuracy by the site QA. This item will remain open pending full implementation by the site QA.
4.
Unresolved Items Unresolved items were not identified during this inspection.
5.
Previously Identified Inspector Follow-up Items (Closed) Inspector Follow-up item No. 50-518, 519, 520, 521,/78-16-05, Lack of demonstration of NDE procedures. The inspector reviewed the documentation for the demonstration of the liquid penetrant, magnetic particle (AC & DC),
and radiographic inspection procedures to the ASME B & PV Code Inspector.
6.
Licensee Identified Items The inspector was informed on the first day of the inspection, that a cracking problem had been identified in the base material of the reactor support pedestal. This cracking was occuring approximately 1/4-inch below a horizontal weld in the pedestal. At the time of this inspection a 6-inen square piece of material had been cut out of the affected area and samples were being sent to the licensee's laboratory and the pedestal vendor for examination. Preliminary examination by the licensee at the site indicated that the cracking was in a weld build-up on the edge of the base material.
This build-up had not been documented by the vendor. The inspector informed the licensee that the item would be identified as Item No. 50-518, 519, 520, 521/79-12-05, Reactor Pedestal Cracking. This item will be examined in subsequent inspections to ensmine the results of tests and corrective actions.
7.
Steel Structures and Supports - Welding Procedure Specifications and Quality Assurance Procedures The inspector reviewed the licensees quality assurance procedures and welding procedure specifications associated with steel structures and supports welding activities. The codes in affect for this welding are ASME Boiler and Pressure Vessel Code 1974 Edition with summer 74 addenda and AWS D1.1.
The quality assurance procedures reviewed were the following Construction Engineering Procedures (CEP) and Quality Engineering Control Instructions (QCI):
CEP - 4.01 Procurerant Document Control CEP - 7.01 Evaluation and Selection of Supplies 29\\
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CEP - 3.01 Field Change Request CEP - 3.05 Design Information Request CEP - 7.02 Receiving Inspection CEP - 2.02 Quality Assurance Items CEP - 5.04 Work Packages CEP.- 8.03 Control of Welding Materials CEP - 9.03 Qualification of Welding Procedures CEP - 9.05 Welding Control CEP - 2.01 Construction Engineering Quality Assurance Program Description QCI - N-502 Visual Inspection of AWS Welds QCI - N-503 Visual Examination of ASME III, Division 2, Stud Welds Welding Procedure Specifications reviewed included the following:
(a) Shielded Metal Arc Welding Process SM-11-B-9 R1 SM-11-B-11 R1 SM-CLAD-18-2 R1 (b) Gas Metal Arc Welding Process GM-11-B-6 R1 GM-FC-U-1 During the review of the Quality Assurance Procedures the inspector noted that CEP-2.01 Construction Engineering Quality Assurance Program description is not accurate. Procedures listed as part of the program description of CEP 2.01 are not issued or have been cancelled and other procedures in the manual are not listed in CEP 2.01.
The inspector informed the licensee that this problem with the program description would be an item of noncom-pliance in the deficiency category against Criterion VI of 10 CFR 50, Appendix B, Document Control.
This item is identified as item no. 50-518, 519, 520, 521/79-12-01, Cutdated QA program description.
There wcre no other items of noncompliance or deviations noted in this area of the inspection.
8.
Steel Structures and Supports - Welding Material Control (Units A-1 & B-1)
The inspector reviewed the licensees procedures for the purchase and control of welding filler materials. The procedures reviewed were:
CEP-4.01 Procurement Document Control CEP-8.03 Control of Welding Material The inspector reviewed the control, storage and issue of welding materials at the issue stations adjacent to the Unit A-1 containment and the unit B-1 containment. Inspections were made on both day and evening shifts.
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During observation of welding activities in both A-1 and B-1 containments the innpector observed the control of the shielded metal are electrodes with pc.rt.able rod warme s.
The inspector verified that the rod warmers were plut,ged in and operating for six or seven welders in each containment.
The inspector also verified that the electrode in each man's possession was the size and type issued to him.
While observing the welding operations in unit A-1, the inspector noticed that a welder working on the weir wall structure had removed a handful of electrodes from his holding oven and laid them on the structure adjacent to the weld that he was working on. While the inspector and welding QC techni-cian watched the welder took about a 10-minute break and then started welding with one of the electrodes previously removed from the oven.
As a result of this observation the welding supervisor was notified, welding was stopped on this weld joint, and disciplinary action initiated against the velder.
The welding QC personnel provided the inspector with a copy of the TVA weld test shop QA orientation program which instructs welders to "take only one electrode at a time from the oven".
The inspector informed the licensee that this incident would be cited as an item of noncompliance in the infraction category against Criterion IX of Appendix B,10 CFR 50, and identified as number 50-518/79-12-02, Welding material control in Unit A-1.
There were no other items or noncompliance or deviations identified in this area of inspection.
5.
Steel Structures and Supports Observation of Welding Activities Within containment (Units A-1 and B-1)
The inspector observed welding activities in the Unit A-1 and B-1 cortain-ments. The welding involved the reactor pedestal, the weir wall stru:ture and the containment vessel.
The inspector reviewed the work package for the unit A-1 reactor ouilding containment vessel (work package no. D014-M1).
and the work package for the Unit B-1 reactor pressure vessel pedestal to baseplate weld (work package D 506-MI). These work packages were reviewed to ensure that work was conducted in accordance with a document which coordinates and sequences the work operations.
The inspector observed welding on the following veld joints:
Unit B-1 Pedestal B1 PED 00001 B1 PED 0059
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Unit A-1 Pedestal
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A1 PED 00010 The following nondestructive examinations vers observed:
Visual and !ff Inspection Weld No. Al CBL PO 1304
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Liquid Penetrant inspection of temporary Veld No. Al C50011E
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attachment removal site There were no items of noncompliance or deviations in this area of inspection.
10.
Steel Structures and Supports - Visual Examination of Welds The inspector inspected the completed vertical velds in the first ring of both Unit A-1 and B-1 containment vessels. The welds were inspected for conformance to the subsection NE of Section III ASME B&PV code 1974 Edition through summer 74 addenda.
The inspector checked for weld surface, reinforcement, and finish requires.
as well as removal of temporary attachments and evidence of weld relateo defects.
There were no items of non-compliance or deviations in this area of inspection.
11.
Steel Structures and Supporta - Weld Heat Treatment The inspector reviewed the requirements for veld joint preheating and inspected the weld joints in process in both containments and reactor pedestals for compliance to preheat requiresent.
There were no items or noncompliance or deviations in this area or the inspection.
12.
Steel Structures and Supports - Welder Qualification The inspector reviewed the licensees program for the training and qualifi-cation of welders. The inspector noted that a new QA training manual had been issued on May 1, 1979, which specified that a welder would receive 16 hours1.851852e-4 days <br />0.00444 hours <br />2.645503e-5 weeks <br />6.088e-6 months <br /> of training each time he reported to the veld test shop to take a welding test (test time is included in the 16 hours1.851852e-4 days <br />0.00444 hours <br />2.645503e-5 weeks <br />6.088e-6 months <br />). The inspector informed the licensee that the implementation of this new QA training program would be an inspector follow-up item no. 50-518, 519, 520, 521/79-12-04, (QA training program for welders) for a detailed review of the welder training area.
The inspector selected six welders at random during the observation of welding activities for a review of the record of perfonsance qualification fa o [eIM m#
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There were no items of noncompliance or deviations in this area 6f inspection.
13. Allegations Concerning Concrete Pour in Unit A-1 The Region II office was contacted by an individual who expressed concere regarding improper material left in concrete poured at the site.
The alleger stated that two 3 1/i inch air hoses are embedded in the basemat o';
the auxiliary building No. I at a location 25 feet east of the fuel building line on the north side.
The inspector contacted the civil QC supervisors for the A and B units and discussed this allegation. Records for the concrete pours in the Unit A-1 auxillary building were reviewed with no record of improper material in this area. The records for the Unit B-1 auxillary building pours show that two QC investigation reports were written; one for excess electrical ground cable rolled up in the concrete and the other for an electrical extension cord partially covered in concrete. These QCIR's were properly dispositioned.
Without additional information the inspector was unable to substantiate the allegation.
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