ML17207A332
| ML17207A332 | |
| Person / Time | |
|---|---|
| Site: | Saint Lucie  |
| Issue date: | 06/14/1979 |
| From: | Economos N NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML17207A329 | List: |
| References | |
| 50-389-79-07, 50-389-79-7, NUDOCS 7909040043 | |
| Download: ML17207A332 (6) | |
See also: IR 05000389/1979007
Text
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UNITED STATES
NUCLEAR REGULATORY COMMISSION
REGION II
101 MARIETTAST., N.W., SUITE 3100
ATLANTA,GEORGIA 30303
Report No. 50-389/79-07
Licensee:
Florida Power and Light Company
9250 West Flagler Street
Miami, Florida 33101
Facility Name: St. Iucie Unit 2
Docket No. 50-389
License No. CPPR-144
Inspection at St. Lucie Unit 2 near Hutchinson Island, Florida
+~1
Inspector:
N. Economos
7
Date
igned
Approved b
T.
.
onion, Section Chief,
RCES Branch
ate
igned
SUMMARY
Inspection
on May 15-18,
1979
Areas Inspected
This routine,
unannounced
inspection involved 25 inspector-hours
onsite in the
areas
of reactor
coolant loop piping and other safety-related
piping - welding
procedure specifications
and quality assurance
procedures
review; welder perform-
ance qualification procedure
and record review; welder qualification and training
facilities; control of preheat practices.
Results
Of the five areas
inspected,
no apparent
items of noncompliance
or deviations
were identified in two areas;
two apparent
items of noncompliance
were found in
three
areas
(Deficiency - Documentation
of Specific Variables
Used to Qualify
Weld Procedure Specifications,
paragraph
6; Infraction - Failure to Follow Radio-
graphic Procedure
and Code Requirements for welder Qualifications, paragraph 5.c.
No apparent deviations were found in the areas
inspected.
'0
V999 040
f ~
DETAILS
Persons
Contacted
Licensee
Employees
B. J. Escue,
Site Manager
- J. D. Kirk, Assistant Site Manager
- W. J. Taylor, Project Superintendent
-W. M. Hayward,
QA Supervisor
- W. F. Jackson,
Welding Superintendent
J.
R. Behris,
QC Supervisor
-J.
W. Adams,
QA Engineer
(Mechanical)
- B. M. Parks,
QA Engineer
Other licensee
employees
contacted
included construction craftsmen
and
technicians.
-Attended exit interview
Exit Interview
The inspection
scope
and findings were summarized
on March 18,
1979, with
those persons
indicated in Paragraph
1 above.
The inspector identified the
areas inspected which i'ncluded weld procedure specifications
and qualification
records; welder performance qualifications; welder training and qualification
facilities;
control of weld joint preheat.
Two items of noncompliance
were discussed
in detail.
No dissenting
comments
were received
from the
licensee.
Licensee Action on Previous Inspection Findings
(Closed)
389/78-11-01
Inadequate
procedure
for control of heat treatment.
Construction Site Procedure
(CSP) - 41, "Control of Heat Treatment"
has
been
revised
and is
now identified as
SQP-42.
With regards to the appli-
cable
code edition covering heat treatment of welds, the revised procedures
requires that,
"The proper
code edition and addenda
of the applicable
codes
shall apply" and that,
"the postweld heat treat
(PHT) procedure
must have
been prequalified through the PQR and approved by the welding superintendent".
Section IX 1977 Edition of the ASME Code with Summer 78 addenda
was indicated
as applicable
on WPSs involving thermal treatment.
The inspector stated that this action was sufficient to close the question
concerning the applicable
code edition.
The inspector stated
however, that
the question
concerning control of preheat
had not been adequately
addressed
and would therefore
be identified as unresolved
item 389/79-07-04.
This
matter is discussed
in paragraph 5.d of this report.
-2-
4.
Unresolved Items
Unresolved
items
are matters
about which more information is required in
order to ascertain whether they are acceptable
items, items of noncompliance,
or deviations.
Unresolved
items identified during this inspection
are
discussed in paragraphs
5.b and 5.d.
5.
Independent Inspection Effort
a ~
Welder Training and Qualification Facilities
An inspection of the welder qualification shop
was conducted in order
to observe the craft working on performance tests
and to discuss with
those
taking tests
specifics
of this activity.
At this
time the
inspector witnessed efforts to qualify procedure
WPS-71C to be used
on
certain primary coolant welds.
b.
Review of Welder Performance Qualification Procedures
The licensee
has revised the current welder/welder operator qualifica-
tion procedure
CSP-6, which is now superseeded
by site quality procedure
(SQP),
SQP-10.
A review of this procedure for technical content
and
adequacy,
disclosed that the it was lacking specific information with
respect to supervision,
indoctrination, training (formal/informal) and
related documentation of welders/welder operators.
I
In discussing this matter with the licensee's
cognizant representative
the inspector
noted that requirements
for establishing
a
documented
comprehensive
training and testing program for welding personnel
was
contained
in sections
QP 9.1
and
QP 2.5 of the site
QA manual.
The
licensee's
representatives
stated
that although
the training program
was not documented in a formal procedure,
such
a program did exist and
was being implemented.
However the licensee
agreed
to look further
into this matter
and the inspector stated that this would be identified
as
unresolved
item 389/79-07-03 until RII has
the opportunity to
review the licensee's
documented program in this area.
c ~
Welder Performance Qualification Record Review
Randomly selected
welder performance qualifiication test records
were
reviewed in order to ascertain
whether they (records)
were complete,
accurate
and consistent
with code
requirements.
The qualification
records selected
were as follows:
Welder Stencil No.
Test Method
- 0
PQS
PSS
PQK
"13-512
106
5
89
24
43F(Fillet)
15
Mechanical
(bend)
Radiography
Radiography
Radiography
Fracture
Only
Radiograph
-3"
- The radiograph of this weld test was reviewed by the inspector.
Within the areas the inspector noted the following:
Radiography
of welders
qualification tests
was
performed
in
accordance
with procedure
$1-9.3 revision
1,
which references
Section
V of the
Code.
Acceptance
standards
for these
radiographs
are
as specified in Section IX of the
ASME Code
1977
Edition thru
S78
addenda.
As
a result of the film review and
disucssion
with NDE personnel,
the inspector
noted that certain
code
and procedural
requirements for the identification of radio-
graphs
were
not being followed.
Instead,
each
radiograph
was
given
a generic type number e.g.
), 2,
3 etc which corresponded
with that on
a log maintained by the radiographer.
The inspector
stated that this method of film identification was not consistant
with procedural and/or code requirements.
The matter was discussed
at length with the licensee's
representative
who agreed to provide
a more definitive indentification method.
2)
Also, the inspector noted that even though the "Radiographic Test
and Interpretation Report" (reader sheet)
had provisions (blanks)
for listing the type of acceptable/rejectable
indications that
were found in the weld test;
the reader
sheets
were not being
marked except for a notation indicating whether or not the welder
has
passed
the test.
Moreover, this notation
appeared
on the
welder's
PgR form without any specific reference
to the reader
sheet
which was kept in a seperate file by the welding superinten-
dent.
Also the inspector
noted that
gA did not appear
to have
any control over this phase
of the welder qualification program
as
evidenced
by the fact that they did not review welder test
radiographs,
reader
sheets
nor did they
do
any surveillance
and/or
audits in this
area.
Instead quality control
(gC)
and
construction
appear
to have
sole control over this phase of the
program, e.g.,
(}C approves the NDE results
an construction certifies
the welder's qualifications.
The review of the welder performance qualification records disclosed
that,
welder
PgK
was
required to take
a fillet weld test for
WPS-43F
on
a one half-inch pipe with a 0.109 inch wall thickness.
Paragraph
gW-303.6,
Section
IX of the
Code
states
that
welders
who make fillet welds
on
a pipe or tube less than 2.875
inch outside
diameter
must pass
the pipe fillet weld test per
gW-452.4 which requires
both macro
and fracture test to be per-
formed.
The
inspector
noted
however,
that
the qualification
records
showed results for the fracture test only and the macro
tests protion of the test
had been omitted and marked "N/A'.
The
inspector discussed this matter with the licensee's
representative
who stated that the welder had previously taken
an open butt test
on WPS-43 which qualified him for fillet welds under this
WPS and
that the fillet weld test
was
a site imposed requirement.
However
the inspector stated that their decision to require the welder to
-4-
take the fillet weld test
on
a one-half inch pipe size invokes
the test
requirements
presribed
by gW-452.4 which are fracture
and
macro tests.
The inspector
stated
that in this
case,
the
code contains
no provisions for selecting or taking exceptions
to
one of the
two tests listed in table
gW-452.4.
Consequently,
failure to perform both tests
appeared
to be contrary to code
requirements.
These findings were discussed
with the licensee
who concurred
and
agreed
to take the necessary
corrective action to rectify this
problem.
These findings represent
two (2) examples of failure to
follow code and/or procedural requirements,
which is in noncompli-
ance with Criterion V of Appendix B, to 10 CFR 50.
This apparent
noncompliance
was assigned
item number 389/79-07-01.
d.
Control on Preheat
and Interpass
Temperatures
As stated in paragraph
3 above the inspector
reviewed procedure
SgP-42
"Control of Heat Treatment"
and discussed its contents with the licensee
representative.
'
With regards
to preheat
methods,
controls
and interpass
temperature
checks.
The inspector noted that the aforementioned
procedure did not
address
these
areas.
The inspector
stated
that
such
areas
as
(1)
frequency of interpass
temperature
checks
and methods to be used,
(2)
application of preheat
(3) control and maintenance
during interrupted
welding needed to be addressed
either in the new procedure or elsewhere.
The licensee
agreed
to look into this matter further.
The inspector
stated that this would be identified as unresolved item 389/79-07-04.
6.
Reactor
Coolant
I,oop Piping - Welding Procedure Specification
and equality
Assurance
Procedures
n'0
The licensee's
"equality Procedures"
and
gP 2.4 "Preparation
and Revision of
equality Instructions",
establish
methods
to be followed for the approval,
development,
distribution
and control of quality procedures
(gP)s
and
quality instructions
(gl)s.
gP 9.1 "Control of Special
Processes
for
Construction", delineates
the requirement for the control of special processes
which include welding, heat treatment
and
NDE during plant construction.
In addition, this document assigns
specific areas of responsibility at the
various levels of site management
with regards to the aforementioned special
processes.
Requirements
control, qualification and documentation
of weld
procedure
specification
(WPS)
and other special
processes
are established
thru procedure
ASP-6 Rev.
0 "Control of Special Processes".
Section IX of
the ASME Code 1977 Edition with Summer 1978 addenda controls the qualification
of WPS applicable to reactor coolant loop (RC) piping.
Four randomly selected
WPS involving shielded
metal arc,
(S11AW)
and
gas
arc
(GTA) processes,
or
a combination of both, were selected for
review.
These were identified as follows:
WPS-6 Rev
1
WPS-24
WPS-50
WPS-68
Process(es)
GTA/SHAM
GTA/SHAM
GTA/SHAW
GTA
Performance Quality
Records
(P R)
88-4.2-6
11-2.4-24"1
88-4.2-50
18-.75-68
Each of the above WPS(s)
and their supporting PQR's were reviewed to ascertain
whether essential,
supplementary
and/or nonessential
variables
including
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 minimum requirements;
whether the
had been reviewed
and certified
by appropriate
personnel
and,
whether
any revisions
and/or
changes
to
nonessential
variables were noted.
Within the areas,
the inspector noted that in certain instances
the recorded
information concerning essential/nonessential
variables
on the
was not
consistent
with paragraph
QW-201.2 of ASHE section IX.
This requires that
specific facts
involved in qualifying a
WPS be recorded
on
a
PQR.
The
inspector
stated
that in several
instances
PQRs did not show variables
as
specific quantities but rather
as ranges, e.g., volts, amps, preheat temper-
ature
and,
in other
cases
some
variables
(nonessential)
were
omitted.
These
included
amps/volts
QW-404.6,
shield
gas
flow QW-408.3,
preheat
QW-406.1 and .2, shield gas
cup size QW-410.3, joint design and the thickness
of weld metal deposited
by each process
when
a combination of processes
were involved QW-201.2,
and
3.
In discussing this matter,
the licensee's
representative
stated that in the case
where variables
were given in terms
of ranges
on the
PQR, both ends of the range
had been
used for the qualifi-
cation of the procedure
and that records
were available for varification
purposes.
The inspector stated that since the PQR is the supporting document
for qualification of the
WPS, it should contain all the specific details
used in the
WPS qualification as stated in the code.
This would preclude
the
need to retrieve supporting
records
whose retrievability could not be
assured
over the time span these
records
must be retained.
The licensee's
representative
agreed to take appropriate corrective action on the matter.
Failure to include all pertinent information in the qualification records
of VPSs is in nonconformance with Criterion XVII of Appendix B, to
This apparent
noncompliance
was assigned
item number 389/79-07-02.
Other Safety Related
Piping,
Welding Procedure
Specifications
and Quality
Assurance
Procedures
The procedure
review and inspection results of paragraph
6 above also apply
to safety-related
pipe welding in that safety related piping will be welded
under the
same control procedures
as the procedures
used for reactor coolant
pressure
boundary piping.
The welding
code
referenced
in paragraph
6
applies,
except that subsections
NC and
ND are applicable in lieu of subsec-
tion NB.