IR 05000518/1980004
| ML19312E890 | |
| Person / Time | |
|---|---|
| Site: | Hartsville  |
| Issue date: | 03/11/1980 |
| From: | Blake J, Herdt A, Kleinsorge W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML19312E876 | List: |
| References | |
| 50-518-80-04, 50-518-80-4, 50-519-80-04, 50-519-80-4, 50-520-80-04, 50-521-80-04, NUDOCS 8006180091 | |
| Download: ML19312E890 (7) | |
Text
,
^')
~%
UNITED STATES
!'
NUCLEAR REGULATORY COMMISSION g
,e REGION 11
,
o 101 MARIETTA ST., N.W., SUITE 3100 p
ATLANTA, GEOFGIA 30303
llAR 171980 Report Nos. 50-518/80-04, 50-519/80-04, 50-520/80-04 and 50-521/80-04 Licensee: Tennessee Valley Authority 500A Chestnut Street Chattanooga, TN 37401 Facility Name: Hartsville
/
Docket Nos. 50-518, 50-519, 50-520 and 50-521 License Nos. CPPR-150, CPPR-151, CPPR-152 and CPPR-153
,
Inspection a r
site near Hartsville, Tennessee
/G 3//t // )
/
Inspectors:
,
.
Jf. ~ laR '
B
/
D' ate Signed
~
f
'
Aws=+ = = =v Yhc'
W[
s rge
/
Da'te ' Signed Approved by:
A D
A. R. Herdt, Section Chief, RC&E Branch Date Signed SUMMARY Inspection on February 19-22, 1980 Areas Inspected This routine, unannounced inspection involved 58 inspector-hours on site in the of housekeeping and preservation of plant equipment; welding material areas control; safety 'related piping welding procedure qualification, welder qualifi-cation, observation of work; weld heat treatment; previous inspection findings;
,
and radiographic examination of containment and other safety-related structures.
Results Of the eight areas inspected, no items of noncompliance or deviations were iden-tified in seven areas; one item of noncompliance was found in one area (Failure to follow procedure in weld joint identification paragraph 7.a.(1)).
8006180091
.
L
.
.
DETAILS 1.
Persons Contacted Licensee Employees
- R. T. Hathcote, Project Manager
- W. R. Brown, Construction Engineer
- H. S. Sheppard, Assistant Construction Engineer, QC, STRIDE
- L. H. Jackson, Assistant Construction Engineer, PE, STRIDE
,
'
- G. A. Gonsalves, QA Unit Supervisor
- S. P. Stagnolia, Welding QC Unit Supervisor
- T. L. Carden, Welding QC
- J. R. Gelzer, Construction QA Training
.
- J. T. McGehee, Engineering Management Assistant Other licensee employees contacted included several construction craf tsmen, QC technicians and office personnel.
NRC Resident Inspector
- W. B. Swan
- Attended exit interview.
2.
Exit Interview The inspection scope and findings were summarized on February 22, 1980 with those persons indicated in Paragraph I above. The item of noncompliance and its relationship with the unresolved item concerning QA training of craft welding personne'. Pts discussed in detail. The construction engineer
.
stated that the training would start prior to the end of February and would include the subject of marking of weld joint identification.
3.
Licensee Action on Previous Inspection Findings (Open) Unresolved Item (50-518,519,520,521/79-28-02), Welder QA Training Program. The QA training manual was changed to specify that the supervisor of the welding QC unit was responsible for the classroom training of welding personnel rather than the supervisor of the weld test shop. The QA organi-zation representative also stated that the 16-hour requirement was an esti-mate that would be changed to meet the actual class hours required when the training is formalized. The program was still in the formative stages at the time of the exit interview, but, TVA site management stated that the
. training would start prior to the end of February. This item will remain open pending review of the formal program.
4.
Unresolved Items Unresolved items were not identified during this inspection.
-
'
.
.
-2-
,
5.
Independent Inspection Effort a.
Construction Activities (Unit Al and A2)
The inspectors conducted a general inspection of the Unit Al and A2 fuel, auxiliary and reactor buildings, boilermaker shop, pipe fabrica-tion shop and welder training area to observe construction progress and construction activities such as welding, nondestructive examination,
/
material handling and control, housekeeping and storage.
(Unit B1 and B2)
The inspectors made a general inspection of the "B" plant construction site to observe preservation activities.
b.
Welding Filler Material Control The inspectors observed activities at welded material issue stations at the "A" plant construction site and adjacent to the boilermakers shop to determine adequacy of weld material storage / segregation, oven temperatures, issue records and return of unused weld materials. The inspectors also observed work areas for uncontrolled weld materials.
There were no items of noncompliance or deviations in this area of the inspection.
"
6.
Inspector Follow-Up Items (Inspector Follow-Up Item 50-518,518,520,521/79-23-01).
The inspectors reviewed the status of the correction of the ASME survey deficiencies. The authorized nuclear inspection agency reviewed the correction of the deficien-cies and reported the findings to the ASME survey team. The deficiencies were corrected to the satisfaction of ASME and the site certificates were issued. This item is closed.
7.
Safety-Related Piping-Observation of Welding Activities (Unit A1)
The inspectors observed in-process welding activities of safety-related piping field welds as described below to determine if applicable code and procedure requirements were being met.
The applicable code for safety-related piping is the ASME B and PV Code Section III 1974 Edition with
~ addenda through Summer 1974.
a.
Welding The below listed welds were examined in process to determine work conducted in accordance with traveler; welder identification and location; welding procedure; WPS assignment; welding technique and
_.
. _ _,
,
.
-3-
.
sequence; materials identity; weld geometry; fit-up; temporary attach-ments; gas purging; preheat; electrical characteristics; shielding gas; welding egoipment condition; interpass temperature; interpass cleaning; process control system; identity of welders; qualification of inspection personnel; and weld history records.
Weld Number Unit Size System A1 ALP 0021003 Al 14" x 0.436 Low Pressure Core Spray (LPCS)
A1AHP0031002 A1 16" x 1.0131 High Pressure Coolant Injection (HPCI)
A1AHP0230018 A1 1" Socolet HPCI
,
(1) The inspector, on February 21, 1980, noted four butt welded joints of the High Pressure Coolant Injection (HPCI) and the Low Pressure Core Spray (LPCS) Systems, located in the Al auxiliary building with improper or missing required markings as indicated below:
.
Joint Number System Fabrication Stage Famarks (Marking)
A1 ALP 0021004 LPCS Welding Complete No "T" Prefix j
A1 ALP 0021003 LPCS Welding in Progress No Joint Number i
No Welder Symbol i
No "T" Prefix A1AHP0031001 FPCI Welding Complete No "T" Prefix AIAHP0031002 HPCI Fit-Up Inspection
"T" Prefix Complete Added After the Inspector Stated TVA Requirement to Welder TVA Procedure for the Hartsville site SOP-34, Revision 1, " Weld Inspection Documentation", paragraph 6.2, requires the inspector,
'
at the time of the weld joint fit-up, to verify that the tack welder had stamped the work with his symbol prefixed by the letter "T" and that the joint has been stamped with the correct weld number, in accordance with SOP-17, " Welder Ident.fication of Welds".
The licensee stated that SOP-17 had not been issued.
Therefore, the welders were not stamping the welds correctly, nor the inspectors examining in this area. Failure to accomplish activities affecting quality in accordance with procedures and failure to issue procedures for activities affecting quality, prior to the commencement of that activity, is in noncompliance
.
.
-4-
,
with 10 CFR 50, Appendix B, Criterion V.
This is an infraction and is assigned item number 50-518/80-04-01, " Failure to Follow Procedure in Weld Joint Identification".
b.
Weld Heat Treatment The below listed welds were examined in process relative to weld joint preheating to determine procedures available; procedures specify acceptable preheating method; procedures provide monitoring and recording requirements; and procedure ccmpliance.
!
Weld Number Unit Size System A1 ALP 0021003 A1 14" x 0.436 LPCS A1AHP0031002 A1 16" x 1.0131 HPCI
.
c.
Welder Qualification The inspectors reviewed the TVA program for qualification of welders and welding operators for compliance with the QA procedures and the ASME code requirements.
(1) The following welders and welding operators' status records and
" Records of Performance Qualification Test" were reviewed relative to the weld joints listed in paragraph 7.a above.
Welder Symbol FABK
-
FABQ FAED (2) The inspectors observed in process performance qualification testing for the below listed welders:
Welder Symbol or Qualification Pay Number Test FAGI GT-7-0-1-L(a)
BAIP GT-6-0-1-L 5-574 SM-4-H 5-902 SM-4-H (3) The inspectors reviewed the below listed radiographs of welder performance test assemblies.
GMA FC 6BH1 3GBAHU GMA 11 B5 3GBADA GMA FC 6BH1 ASME BACT 3G GMA FC 6BH1 3GBAFX
. _ _.
_
,
.
.
-5-
.
d.
Welding Procedure Specification The inspectors reviewed the TVA program for preparation, qualification, approval / certification, distribution, and revision of Welding Procedure Specifications (WPS) compliance with the QA procedures and the ASME code requirements.
(1) The inspectors reviewed the below listed WPS and the supporting Procedure Qualification Record (PQR) to determine whether essen-
,
tial, supplementary and/or nonessential variables including s'
thermal treatment were consistent with code requirements; whether WPSs were properly qualified and their supporting PQRs were accurate and retrievable; whether all required mechanical tests had been performed and the results met the minimum requirements; whether the PQRs had been reviewed and certified by appropriate personnel and, whether any revisions and/or changes to nonessential variables were noted.
WPS Process GT-SM-11-0-3B-R6, Gas Tungsten Arc and Shielded Metal Arc Welding No items of noncompliance or deviations except as described in para-graph 7.a(1) were identified.
8.
Safety-Related Structures-Nondestructive Examination (Unit A1)
The inspectors observed inspection activities and reviewed NDE documentation for the Unit Al containment and safety-related structures. This inspection included the following:
Observation of radiographic film review and interpretation for weld a.
number AIPSW00023 on the 14-inch thick reactor shield wall fabricated to AWS requirements. During the review of the film it became obvious
,
that there had been some set-up and technique problems. The licensee's film reviewer rejected the shots because of incomplete coverage of the weld. The incomplete coverage was due to the fact that the shield wall is fabricated of two concentric steel cylinders (about 40-inch difference in diameter) with various plates welded between the cuter I
surface of the inner cylinder and the inner surface of the outer cylinder. Weld number AIPSW00023 is a horizontal or girth weld on the outer cylinder and was shot with the radiographic source on the outside (at 20-inch source to film distance) and the film on the inside. The plates welded between the outer and inner cylinders interfered with the placement of the film cassettes resulting in incomplete coverage.
The inspectors discussed this situation with the welding QC supervisor and the film interpreter after visually inspecting the weld.
The welding QC supervisor was pursuing the possibility of cutting back the plates to allow better placement of the cassettes. The inspectors
.
.
-6-informed the QC supervisor that the inability to cut the plates would probably not be an acceptable excuse for less than complete coverage of the weld in that the outside surface was not obstructed and it appeared that the 20-inch source-to-film distance could be attained with the source on the inside. The QC supervisor stated that the best possible effort would be used to assure proper coverage of the weld.
b.
Observation of visual and liquid penetrant inspection activities on the welds for the stainless steel fuel transfer tube being fabricated in the licensee's shop facilities. During the visual inspection of
,
'
, the reactor shield wall structure, the inspectors noted that a welding QC inspector was starting to inspect a weld in the transfer tube assembly. The inspectors observed the visual inspection of the weld and the cleaning and penetrant application operations of the inspections.
During the drying time between cleaning and penetrant application operations, the inspectors quizzed the QC inspector as to the proce-dure requirements and the acceptance criteria for the inspections.
The QC inspector appeared to be knowledgeable of the requirements and in control of the situation.
Review of NDC documentation included the independent review of contain-c.
ment weld radiographs which had been reviewed and accepted by the licensee's film interpreter. The RTs reviewed were of the following welds:
A1CS00113 A1CS00114 A1CS00118 AICS00225 A1CS00228 A1CS00231 There were no items of noncompliance or deviations in this area of the inspection.
l l
f l