IR 05000413/1980029
| ML20003A511 | |
| Person / Time | |
|---|---|
| Site: | Catawba  |
| Issue date: | 11/18/1980 |
| From: | Herdt A, Kleinsorge W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML20003A493 | List: |
| References | |
| 50-413-80-29, 50-414-80-29, NUDOCS 8102040180 | |
| Download: ML20003A511 (9) | |
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NUCLEAR REGULATORY COMMISSION g
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REGION 11
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101 MARIETTA sT N.W., SUITE 3100 ATLANT A, GEORGIA 303o3 o
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Report Nos. 50-413/80-29 and 50-414/80-29 Licensee: Duke Power Company P. O. Box 33189 Charlotte, NC 28242 Facility Name: Catawba Docket Nos. 50-413 and 50-414 License Nos. CPPR-116 and CPPR-117
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Inspection at C a ba site near Lake Wylie, South Carolina Inspecto Y
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r6 N. P. Kleinsorge Dafe Slgned Approved by:
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//!/h!80 A. R. Her'dt., Section Chief, RC&ES Branch Date S'igned SUMMARY Inspection on October 14-17, 1980 Areas Inspected
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This routine resident inspection involved 33 inspector-hours onsite in the areas of reactor coolant pressure boundary piping, safety related piping and concern regarding structural welding.
Results Of the three areas inspected, no items of noncompliance or deviations were iden-tified in one area; one item of noncompliance was found in each of two areas.
(Infraction - Inadequate Measures for Flamable Storage" paragraph 7a(1)(a) and Deficiency - Failure to Properly Document PQR Testing" paragraph 8b).
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DETAILS 1.
Persons Contacted
- D. G. Beam, Project Manager
- J. C. Shropshire, QA Engineer (QAE) Mechanical, Welding
- S. W. Dressler, Senior Construction Engineer
- L. R. Davison, Senior QC Engineer
- H. D. Mason, QA
- J. H. Huskey, Safety
- R. E. Davis, Safety Other licensee employees contacted during this inspection included ten construction craf tsmen, six technicians, and three office personnel.
Other Organizations Hartford Steam Boiler Inspection and Insurance Company C. F. Toegel, Authorized Nuclear Inspector (ANI)
- Attended exit interview.
2.
Exit Interview The inspection scope and findings were summarized on October 17, 1980, with those persons indicated in Paragraph I above. The inspector identified the areas inspected and discussed in detail the items of noncompliance, unresolved items and the inspector follow-up item. No dissenting comments were received
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from the licensee.
3.
Licensee Action on Previous Inspection Findings Not inspected.
4.
Unresolved Items Unresolved items are matters about which more information is required to determine whether they are acceptable or may involve noncompliance or deviations.
New unresolved items identified during this inspection are discussed in paragraph nos. 7a(1)(b)1, 7a(1)(b)2 and 8a.
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5.
Independent 1nspection Effort The inspector conducted a general inspection of the Unit I and 2 contain-ments, auxiliary building, fuel building, pipe fabricatior shop, painting and blasting facility warehouse facilities and electrode.ssue station to observe construction progress and construction activities such as welding, material handling and control, housekeeping and storage.
Within the area examined, there were no items of noncompliance or deviation.
Reactor Coolant Pressure Boundary Piping (Unit 2)
The inspector observed non-welding and welding work activities for reactor coolant pressure boundary (RCPB) piping. The applicable code for installa-tion of RCPB piping is the ASME B & PV code, 1974 Edition plus addenda through summer 1974.
Observation of Non Welding Activities a.
Observation of specific work activities were conducted to determine conformance, where applicable, with the following; inspection and/or work procedures, record keeping, installation specifications or plans, specified materials, NDE, calibration and use of proper test equipment and qualified inspection and NDE personnel.
Activity System or Component.
Procedure Protection Reactor Coolant CP-170 Rev. 7 40* Elbow b.
Review of Quality Records (1) Records of the following items were selected for review to ascertain whether they (records) were in conformance with applicable requirements relative to the following areas:
Material test reports / certifications; vendor supplied NDE reports; site receipt inspection; storage; installation; vendor nonconformance reports.
Item Heat No.
Sy tem Note 40* Elbow 2588-2 Reactor Coolant No CMTR 33 x 3.22" 40* Elbow 08936-2 Reactor Coolant 33 x 3.22" The note "No CMTR" indicates that the certified material test reports for those items were not retreivable during this inspec-tion. The licensee indicated that they would look further into the matter.
The inspector stated that the retreivability of these CMTR's would be an inspector follow-up item No. 414/80-29-06,
" Unavailable CMTR".
c.
Observation of Welding Activities The iInspector observed field welding of reactor coolant pressure boundary piping at various stages of weld completion.
(1) The inspector examined weld joints of pipe to pipe / fitting (PPF)
and pipe to component (PC) where welding was beyond the root pass to determine; weld / welder identification, qualified welder / weld
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procedure, periodic checks of welding variable, use of specified weld material, proper interpass temperature and where applicable pre-heat and post-weld heat treatment and physical appearance of weld (e.g. starts, stops, undercut and surface imperfections).
The following weld joints were examined:
Joint No.
Unit No.
Isometric Size System NC-13-3
2NC-13 33" x 3.22 Reactor Coolant NC-9-3
2NC-9 33" x 3.22 Reactor Coolant (2) Observations of weld material control included; identification, segregation, oven temperatures, issue slips and control of unused material at issue stations and work areas.
(3) During observation of welding activities it appeared that a sufficient number of qualified inspection personnel were at the work site.
Within the areas examined, there were no items of noncompliance or deviations.
7.
Safety-Related Piping (Unit 2)
The inspector observed non-welding and welding work activities for safety-related piping outside of the reactor coolant pressure boundary.
The applicable code is stated in Paragraph 6.
a.
Observation of Non Welding Activities (1) Observation of specific work activities were conducted to determine conformance, where applicable, with the following; inspection and/or work procedures, record keeping, installation specifications or plans, specified materials, specified NDE, calibration and use proper test equipment and qualified inspection and NDE personnel:
l Activity System of Component Procedure Storage Pipe Fitting &
QAP P-3 Rev. 12 Piping assemblies (various)
Kandling 2KF-45-4 CP-170 Rev. 7 (Spent Fuel Cooling)
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Bending 2NV-171-AA M-25 Rev. 9 (Chemical & Volume Control)
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Hachining 2RN-58-5 M-61 Rev. 9 (Nuclear Service Water)
Fitting 2LD 45-10 F-9 Rev. 2 (Diesel Generator H-4 Rev. 17 Engine Lube 011)
(a) On October 15, 1980, the inspector accompanied by a representa-tive of the licensee made an inspection of storage activities in Warehouse Nos. 2 and 5.
The inspector noted, in Warehouse No. 5, an outboard motor boat, with attached tank, containing gasoline, stored in close proximity to safety related motor operated valves. The inspector noted in Warehouse No. 2 six aerosol cans of flammable liquid penetrant cleaner in the
"QC Hold" area, adjacent to nuclear steam supply system components.
Duke Quality Assurance Program Procedure P-3 Revision 12,
" Storage Inspection", paragraphs 2 and 4.1.1 require storage to be in accordance with ANSI N45.2.2.
" Packaging, Shipping, Receiving, Storage and Handling of Items for Nuclear Power Plants (During the Construction Phase), Paragraph 6.3.3 states " Hazardous chemicals, paints, solvents and other materials of alike nature shall be stored in well ventilated areas which are not in close proxmity to important nuclear plant items".
The licensee stated that site implementation procedures do not address the above prohibition.
Therefore the licensee did not provide adequate measures to control storage of safety related valves and nuclear steam supplies components. Failure to establish adequate measures to control storage is in noncompliance with 10CFR50 Appendix B Criterion XIII. This is an infraction and is assigned item No. 413, 414/80-29-01:
" Inadequate Measures for Flammable Storage".
(b) With regard to the inspection of pipe bending activities the inspector reviewed the applicable procedure, observed the bending operation on stainless steel pipe bend No.
2NV-171-AA and noted the following:
Duke QA Program Procedure M-25 Rev. 9,
" Pipe Cold Bending" Paragraph 4.1.5 requires Liquid Penetrant or Magnetic Particle examination on one in each twenty bends. Liquid penetrant or magnetic particle examina-tion is being accomplished on one in each twenty bends of the same diameter, schedule and material.
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practice is less stringent than that required by para-graph 4.1.5 of M-25. At the time of this inspection it could not be determined whether the actual practice is consistent with the licensee's commitments. The licensee indicated that they would look further into the matter.
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-5-The inspection stated that the above would be an unresolved item and identified as 413, 414/80-29-04:
Inconsistent Pipe Bend Inspection Requirements and Practices" 2_
The lubricant used during pipe bending is " Triton X-100" manufactured by Fisher Scientific Company. Catawba Division of Steam Production Directive 2.4.4T Rev. O dated 4-14-80 " Control of Surface Applied Haterial Usage" paragraph (6)(f)
states in part " Triton X-100 --- Product is approved for use on stainless steel followed by a thorough demineralized water rinse."
Directive 2.4.4T is not available to Catawba Division of Construction craft personnel performing pipe bending operations. There is no Catawba Division of Construc-tion documented requirement to rinse stainless steel with demineralized water after the application of Triton X-100.
Triton X-100 is not removed by rinsing with demineralized water after bending operations on stainless steel piping.
At the time of the above inspection the safety significance of the omitted rinse could not be determined. The licensee indicated that they would look further in the matter. The inspector stated that the above would be an unresolved item and identified as 413, 414/80-29-05: "Omitted Rinse After Bending".
b.
Review of Quality Records (1) Records of the following items were selected for review to ascertain whether they (records) were in conformance with applicable requirements relative to the following areas:
Material test reports / certifications; vendor supplied NDE reports; site receipt inspection; storage; installation; vendor nonconfor-mance reports.
Item Heat No.
System Tee, Sch 40 BD6X Diesel Generator Engine 6"x6"x6" Lube Oil (DGELO)
Elbow, 90' Sch 40 YB3K DGELO 6"
Pipe, Sch 40, 6" 826935 DGELO Elbow, Sch 40, 90* ZY3F DGELO 6"
Elbow Sch 160, 90' RW750165 Safety Injection 3"
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Pipe, Sch 160, 3" B-8202 SI Tee, Sch 160 44444 SI 4" x 4" X 3" Pipe, Sch 40, 4" 462414 Chemical & Volume Control (C&VC)
Elbow, 90* Sch 40 RW-249919 C&VC Pipe, Sch 40 3" 464479 C&VC Elbow 90' Sch 40 56085 C&VC c.
Observation of Welding Activities The inspector observed field welding of safety-related piping outside the reactor coolant pressure boundary at various states of weld completion.
(1) The inspector examined weld joints where the root pass (only)
had been completed to determine; weld / welder identification, qualified welder / weld procedure, physical appearance of weld and evidence of QC verification.
The following weld joints were examined:
Joint No.
Unit No.
Isometric Size System ND-26-9
2ND-26 8" x 0.250 Residual Heat Removal (RHR)
ND-24-7
SND-24 12" x 0.375 RHR (2) The inspector examined the following welds where non-destructive testing (NDE) was in progress to determine; surface suitability, specified NDE being performed and with qualified personnel:
Joint No.
Unit No.
Isometric Size System ND-24-12
2ND-24 1" to 12" RHR (3) The inspector observed activities at weld material issue stations to determine adequacy of; weld material storage / segregation, oven temperatures, issue records and return of unused weld material.
Also observed work areas for uncontrolled weld material.
Within the areas examined, there were no items of noncompliance or deviations,*except as described in paragraph 7a(1)(a) identified.
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8.
Concern Regarding Structural Welding The Region II office was contacted by an individual who expressed the following concerns in substance:
a.
Some of the stif feners on the containment walls are " ground slick" from top to bottom even though the welds are not supposed to be ground in any way.
The individual believes the grinding is necessary because the welders may make the pass too wide or put in overlaps on a vertical weld (roll over).
The individual also believes that although the welds are tested, the tests cannot determine if the welds are adequate.
The inspector determined that there is no prohibition for grinding containment liner plate to stiffener fillet welds. ASME B&PV Code Section V paragraph T-221.2, T-641(a) and T-721(a) permit surface preparation by grinding where surface irregularities would otherwise mask indications or be confused with discontinuities. The inspector examined approximately one hundred fifty randomly selected containment plate to stiffiner fillet welds in the second and third courses of Unit 2 containment liner plate. The inspector noted no examples where veld width exceeded that permitted by the applicable Welding Procedure Specification.
Within the area inspected the inspector noted five examples of mechanical undercut, at the toe of stif fener to Unit 2 containment liner plate fillet welds in the liner plate base material. The above undercut was in excess of the 1/32" that is permitted by Section III of the ASME B&PV Code. At the time of this inspection it could not be determined whether the undercut had been evaluated to and was consistent with the type 1 defect criteria (minimum wall not violated, no weld repair required) of Catawba.
Construction Procedure CP-64, " Repair of Arc Strikes and Minor Surface Repairs on Containment Plate." The licensee indicated that they would look further into the matter. The inspector stated that the above would be an unresolved item and identified as 414/80-29-02: " Mechanical Undercut",
b.
The required preheat temperatures were not maintained when two different thicknesses of metal were welded together on the personnel hatch.
The individual said the welders were using " rosebuds" to heat the pipe and it was noted that the temperature was below 175 F degrees. An engineer subsequently said the welds were okay because the outside temperature was above freezing, but when the welds were radiographed twelve inches of bad welds (cracks) were found. The individual stated that the hatch is located at the bottom of the turbine building as one enters the containment through a condui.-
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-8-From other information provided by the individual, the inspector located Nonconforming Item Report (NCI) Serial No. 2669 dated February 10, 1978 covering the item described above. As the result of a review of the above NCI the inspector noted that although there had been a violation of the Welding Procedure Specification (WPS), there was no violation of the ASE B&PV Code. The inspector reviewed the records of radiographic inspection for weld Nos. 2 PAL-205 and 2 PAL-206 identified in NCI No. 2669 the preceeding welds contained 7 3/4" of combined slug.
These welds were properly repaired and accepted by nondestructive examination.
The inspector determined that the close out of NCI 2669 was consistent with ASE B&PV Code requirements, and that the actions taken to prevent recurrence was acceptable.
With regard to the above inspection the inspector noted on October 16, 1980 that Welding Procedure Qualification Record (PQR) L-110A dated August 17, 1977 lists preheat temperature as 60' to 120*F.
ASE Section IX Table QW 255 lists preheat, QW-406.1, as an essential variable.
ASE Section IX Paragraph QW-201.2 requires that specific facts involved, in WPS qualification, be recorded on the PQR. In view of the fact that PQR L-110A qualification testing was accomplished in August the inspector stated that preheat range listed (60*-120*F) was not representative of the actual testing conditions without refriger-The licensee stated that the preheat temperature listed on the ator.
PQR was a range not the actual temperature values used.
Failure to include specific facts involved in WPS qualification on the QPR is in noncompliance with 10CFR Appendix B Criterion XVII. This is a deficiency and is assigned item No. 413, 414/80-29-03: " Failure to Properly Document PQR Testing".
The individual was concerned that the close out action on NCI 2794, c.
concerning forged inspector's initials for a preheat sign-off, was not proper.
The inspector review NCI 2794 dated May 5,1978, including the investiga-tion conducted by the licensee, and determined that the corrective action, investigation to determine extent of the condition and action to prevent recurrence were complete and acceptable.
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