ML20024C148

Interim Deficiency Rept Item 96 Re Defective Field Welds on Bergen-Paterson Pipe Hangers Previously Accepted by QC Welding Inspectors & Item 72 Re Undersize Skewed Tee Fillet Welds on Seismic I Pipe Hangers.Final Rept by 831003

ML20024C148
Person / Time
Site:	Harris
Issue date:	07/01/1983
From:	Parsons R CAROLINA POWER & LIGHT CO.
To:	James O'Reilly NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
References
CON-NRC-94 10CFR-050.55E, 10CFR-50.55E, NUDOCS 8307120316
Download: ML20024C148 (5)

Text

.. ,

• t USNRC REnia :I ATLANT .

. . , . . . - ..,.>y li Pop & L ( Company 83 asummmmama P. O. Box 101, New Hill, N. C. 27562 p-4 0 8 July 1, 1983 p.qo(

Mr. James P. O'Reilly NRC-94 United States Nuclear Regulatory Commission Region II 101 Marietta Street, Northwest (Suite 2900) -

Atlanta, Georgia 30303 CAROLINA POWER & LIGHT COMPANY SHEAR 0N HARRIS NUCLEAR POWER PLANT 1986 900,000 KW - UNITS 1 & 2 SEISMIC PIPE HANGERS PREVIOUSLY ACCEPTED BY QC WELDING INSPECTOR - ITEM 96 UNDERSIZE SKEWED TEE FILLET WELDS ON SEISMIC I PIPE HANGERS - ITEM 72

Dear Mr. O'Reilly:

Attached is an interim report on the subject items which were deemed reportable per the provisions of 10CFR50.55(e), on August 13, 1982 (Item 96) and November 5,1982 (Item 72). CP&L is pursuing this matter, and it is currently projected that corrective action and submission of the final report will be accomplished by October 3, 1983.

Thank you for your consideration in this matter.

Yours very truly, y g,+ ^ =>

R. M. Parsons Project General Manager Shearon Harris Nuclear Power Plant RMP/dh Attachment cc: Messrs. G. Maxwell /R. Prevatte (NRC-SHNPP)

Mr. V. Stello (NRC)

DFFICAC COPY T d 21

~~~

8307120316 830701 PDR ADOCK 05000400

/

8 PDR _

s i

d CAROLINA POWER & LIGHT COMPANY J

SHEARON HARRIS NUCLEAR POWER PLANT UNIT NO. 1 l

INTERIM REPORT 4

i PIPE HANGERS PREVIOUSLY ACCEPTED BY QC WELDING INSPECTORS ITEM 96 J

-UNDERSIZED SKEWED TEE FILLET WELDS ON ,

SEISMIC I PIPE HANGERS ITEM 72 t.

I JULY 1, 1983 N

1

',905'IABLE UNDER 10CFR50.55(e) .

4 d

i'

.<1 w -, m ,4,.f,., -., . _,..,,m,-.y- ,, . ' , - .

.y.,- , . . . , _,__ , .,, ,_ --,

, , , , . . . _ ~ , - . - - .

.g-

SUBJECT:

Deficient field welds on pipe hangers previously accepted by QC welding imspectors.

ITEMS: Seismic Pipe Hangers v

N/A - Hangers furnished by Bergen-Paterson, but problem

- SUPPLIED BY:-

i- deals with field welds.

NATURE OF DEFICIENCY: 1. Missing;and undersized welds

'- 2. Cosmetic weld defects

3. Inaccurate and incomplete QC documentation

4. QC inspections performed by personnel whose work

- was suspect

5. Undersized skewed-tee field welds

• - 6. Poor workmanship

!DATE PROBLEM ,

OCCURRED: Prior to July 29, 1982 DATE PROBLEM EREPORTED: August 13, 1982 - CP&L.(N. J. Chiangi) notified the NRC (A. Hardin) that this item-(Item 96) was reportable

~

under the. provisions-of 10CFR50.55(e). In our November 5, 1982 letter, CP&L (R. M. Parsons) notified the NRC i (J. P. O'Reilly) that this item (Item 72) was reportable under 10CFR50.55(e) .

SCOPE OF PROBLEM: Seismic Category I pipe hangers that were installed or partially installed and inspected prior to June 26, 1982 were identified and reinspected. This reinspection effort included measurement of' skewed-tee fillet welds for under-size (refer to Item 72). Those 349 hangers previously

- reinspected as part of the corrective action to NRC Report 50-400/82-03 were not included.in this reinspection. The June 26, 1982 date was selected because the_QC weld

' inspection program was expanded to include shop welds on installed hangers (refer to Item'95)._' Inspector training was. conducted prior to June 26, 1982 to ensure satisfactory inspector performance. Inaccessible welds encountered during this reinspection are being evaluated by Engineering.

1

,=,'

g' W>4 W 9'

' & 7 w h "' + W '

T wT  % gy'-* gp-" a -'T wr W u'-=

• M'* $ wT9*7

.s = -

, '5AFETY l-UKPLICATION: Deficient welds could cause a safety-related pipe hanger to fail under~ seismic conditions. As a result, if not corrected could adversely affect the safe operation of I this facility.

REASON THE DEFICIENCY IS REPORTABLE: The conditions reported in Item 96, and Item 72 represent a breakdown in the QA Program as well as deficiencies in construction.

CORRECTIVE ACTION: 3,458 hangers were reinspected and some were not reworked at the time of reinspection due to those hangers being in an engineering hold status for various reasons including redesign, reanalysis, pending later drawing revision, voided drawing, etc.. These hangers will be reworked when engineering holds are released.

PREVENTIVE MEASURES TAKEN TO AVOID FURTHER NONCOMPLIANCE: 1. A pipe hanger inspection documentation instruction (QCI) 19.3 was developed and issued.

2. Additional training classes were held with required attendance for both craf t and QC weld inspection personnel involved in pipe hanger inspection. Training classes covered items such as measurement of skewed-tee welds, visual acceptance criteria, proper documentation, applicable work procedures, etc.

3. New QC weld inspector candidates are interviewed by the QA/QC Specialist in addition to passing a written examination to ensure they are aware of project requirements pertinent to their assignments.

4. Each inspector's documentation of weld inspections is reviewed af ter each phase of inspection to ensure complete-ness and correctness.

5. Supervisory audits are routinely performed in accordance with Quality AssuranceL Instruction (QAI) 1.3 on each QC inspector's field work to ensure his satisfactory performance and to ensure that the work complies with the design documents.

• l ,

b

6. A system was developed to aid in the resolution of technical inquiries that inspector supervision is unable to resolve.

Technical inquiries are stated on a Request for Information (RFI) form and forwarded to the QA engineering unit which was established on-site to provide engineering support for inspection activities.

7. Weld Reject Trend Reports are utilized by QC supervisors in conjunction with Welding Engineering to focus attention to problem areas in field weld quality.

8. Field Change Request (FCR) H-979 was developed and issued to provide weld inspection acceptance criteria for both field ind shop welds based on AWS D1.1 code and Bergen-Paterson design criteria. Procedure NDEP-605 was issued to address the specific conditions governing pipe hanger weld inspections.

FINAL REPORT: The above corrective action and preventive measures are considered adequate to close this item. However, to ensure all hangers installed prior to the start of the reinspection were identified, the' pipe hanger work package transmittals are being checked against-the hanger reinspection log to ensure all appropriate hangers were considered for reinspection. The accept / reject status of hangers in the reinspection log is being double checked.

Finally, to ensure that no hangers subject to the reinspection were overlooked, measures will be established to ensure a further check is done when the hanger work packages are reviewed during subsequent installation and inspection phases.

Any hanger inadvertently missed during the initial reinspection effort will.be reinspected and appropriately dispositioned.

A final report will be issued once the measures described above have been completed. It is currently projected that the submittal date will be October 3, 1983.

t l

,;, ,, .- - -, , _ . , , - , - , ,- ,. ,: .-  : .-