ML20055A908
| ML20055A908 | |
| Person / Time | |
|---|---|
| Issue date: | 06/08/1982 |
| From: | Ellershaw L NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20055A904 | List: |
| References | |
| REF-QA-99900761 NUDOCS 8207200113 | |
| Download: ML20055A908 (8) | |
Text
ORGANIZATION:
RELIANCE ELECTR:C COMPANY SYSTEMS & CONTROL DIVISION STONE MOUNTAIN, GEORGIA KtFuki INSPECTION INSPECTION NO..
99900761/82-01 DATE(S) 3/8-12/82 ON-SITE HOURS: 31 CORRESPONDENCE ADDRESS:
Reliance Electric Company Systems & Control Division ATTN:
Mr. R. Morrow, Manager, Quality Assurance 4900 Lewis Road Stone Mountain, Georgia 30083 ORGANIZATIONAL CONTACT:
Mr. R. Morrow, Manager, Quality Assurance TELEPHONE NUMBER:
(404) 938-4888 PRINCIPAL PRODUCT: Control Board Panels NUCLEAR INDUSTRY ACTIVITY: Approximately 10% of Reliance Electric Company's work is for the commercial nuclear industry.
Current work is for Georgia Power Co.'s Alvin W. Vogtle, Jr. Nuclear Plant, Unit 1 and 2, and modification of panels for Texas Utilities Generating Company's Comanche Peak, Unit 1 and 2.
ASSIGNED INSPECTOR: J8%
e/r/F 2-
[ L. E. Ellershaw, Reactive & Component Date Program Section (R& CPS)
OTHER INSPECTOR (S): E. Hines,R& CPS APPROVED BY:
8%
4 /FN2 I. Barnes, Chief, R& CPS Date INSPECTION BASES AND SCOPE:
A.
BASES:
SCOPE:
This inspection was made as a result of:
(1) allegations received by NRC's Region II office regarding control panels fabricated and shipped to Waterford Generating Station, Unit 3, and pertaining to the use of uncalibrated welding power source meters and uncertified welders in the manufacture of these panels, shipping of known defective welds, wiring not (cont. on next page)
PLANT SITE APPLICABILITY:
(1) 50-382 (2) 50-454, 50-455, 50-456, 50-457, 50-329, 50-330, and 50-483 DESIGNATED ORiv u d
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PA 99900761
ORGANIZATION:
REllANCE ELECTRlC COMPANY SYSTEMS & CONTROL DIVISION STONE MOUNTAIN, GEORGIA REPORT INSPECTION NO.
99900761/82-01 RESULTS:
j PAGE 2 of 6 1
SCOPE: (Cont.)
in accordance with IEEE Standards, failure to correctly identify and document part numbers / serial numbers of component parts; and (2) an NRC Region III request to inspect specific control panel fabricators due to defective welds identified in panels supplied to Byron Station, Unit 1 and 2, Braidwood Station, Unit 1 and 2, Midland Plant,' Unit 1 and 2, and Callaway Plant, Unit 1.
The areas selected for this inspection included:
aelding process control; welding procedure specifications; qualifications of inspection personnel; and control of nonconformances and corrective actions.
A.
VIOLATIONS:
Contrary to paragraph 21.6 of 10 CFR Part 21, neither Section 206 of the Energy Reorganization Act of 1974 nor current copies of 10 CFR Part 21 were posted on the premises.
B.
NONCONFORMANCES:
1.
Contrary to Criterion V of Appendix B to 10 CFR Part 50 and QA Manual Section 16, reports defining problems found during periodic reviews to identify significant conditions, including causes of the conditions and the corrective actions to be taken, had not been made from March 1976 until January 1982.
2.
Contrary to Criterion V of Appendix B to 10 CFR Part 50 and AWS D1.1 Section 5,' welding procedure specification (WPS) no. 6, Revision 3 dated May 16, 1978, a gas metal arc welding procedure, permitted changes to essential variables which were in excess of that which is allowed, without establishing a new procedure by qualification.
The following essential variable changes were permitted by the WPS:
a.
A change of more than 10% above or below the specified mean amperage; b.
A change of more than 7% above or below the specified mean arc voltage; and c.
A decrease of 10% or more in the flow rate of shielding gas or mixture.
ORGANIZATION:
RELTANCE ELECTRIC COMPANY SYSTEMS & CONTROL DIVISION STONE MOUNTAIN, GEORGIA REPORT INSPECTION NO.-
99900761/82-01 RESULTS:
PAGE 3 of 6 3.
Contrary to Criterion V of Appendix B to 10 CFR Part 50 and QA Manual Section 5, the NRC inspector observed gas metal arc welding (GMAW) being performed on auxiliary relay panels for Georgia Power Company's Alvin W. Vogtel, Jr.
Nuclear Plant, which was not in accordance with the Welding Procedure Specification in that;
- a. Two different welders were using 135 and 140 amps, respectively, while the WPS specified 110-115 amps
- b. Two different welders were using a gas flow rate of 30 CFH, while the WPS specified 22-24 CFH It was further observed that an Argon flow meter was being used to monitor the flow rate of carbon dioxide gas.
4.
Contrary to Criterion V of Appendix B to 10 CFR Part 50 and ASME Code Section IX, the NRC inspector observed in process GMAW on auxiliary relay panels for Georgia Power Company's Alvin W. Vogtle, Jr. Nuclear Plant in which three different welders, qualified only in the upward progression for vertical welding, were welding in the downward progression while making vertical welds.
5.
Contrary to Criterion V of Appendix B to 10 CFR Part 50, AWS D1.1, ASME Code, and QA Manual Section 10, the NRC inspector observed the following on a shutdown transfer panel for Texas Utilities Generating Company's Comanche Peak Steam Electric Station, Unit 2, in which the welds had been accepted by QA/QC as shown on the Fabrication Inspection Report dated March 3, 1982:
a.
Excessive weld spatter, some of which was easily removed by hand; b.
Lack of fusion on several welds; and c.
Weld wire remnants, fused and protruding from completed welds, ranging from 1/2" up to 4" in length.
C.
UNRESOLVED ITEMS:
None
ORGANIZATION:
RELTANCE ELECTRIC COMPANY SYSTEMS & CONTROL DIVISION STONE MOUNTAIN, GEORGIA REPORT INSPECTION NO.
99900761/82-01 RESULTS:
PAGE 4 of 6 D.
OTHER FINDINGS OR COMMENTS:
1.
Follow-uo Inspection Regarding Allegations a.
Uncalibrated welding power sources - A review of the cali-bration records for welding power sources revealed certifi-cations were on file from two different calibration subcontractors.
The certifications, showing that calibra-tion had been accomplished, were dated 7-9-74, 6-9-75, 9-8-76, 2-1-79, 8-11-79, 1-24-80, and 6-26-81.
There were no certifications for the period 9/8/76 through 2/1/79 because Reliance Electric Company (REC) performed the calibrations themselves.
A card for each welding power source is maintained, with pertinent calibration information recorded, relative to REC's calibration activities.
b.
Uncertified welders - A review of welders' qualification records revealed that the five currently employed welders have been qualified in accordance with ASME Section IX requirements since at least November 7, 1978.
In addition, two welders have also been qualified in accordance with AWS 01.1 since, at least, October 31, 1975.
Former welders' qualification records dated back to 1970.
c.
Shipping of known, defective welds - An inspection of welding activities demonstrated that current welding process controls and inspection were not consistent with QA program requirements,as evidenced by Nonconformance B.2, B.3, B.4 and B.S.
d.
Wiring not in accordance with IEEE Standards - REC customer design documents delineate the IEEE standards.
REC passes these requirements on to their suppliers, who are surveyed /
audited on a triannual basis, as a minimum.
A review of REC audit records and purchase orders pertaining to six wiring subcontractors confirmed this.
In addition 10 CFR Part 21 is also imposed on subcontractors if it has been imposed on REC, or if REC considers the procured items as being safety related.
e.
Failure to calibrate component parts - The NRC inspector was unable to substantiate this specific allegation in that there was no in process testing of safety related components being performed.
1 1
ORGANIZATION:
RELIANCE ELECTRIC COMPANY SYSTEM & CONTROL DIVISION STONE MOUNTAIN, GEORGIA REPORT INSPECTION NO.-
99900761/82-01 RESULTS:
PAGE 5 of 6 However, a review of wiring inspection reports, electrical test inspection reports, pneumatic test inspection reports and final inspection reports was performed on the Waterford control board panels.
The inspection reports reflected adherence to the QA Program commitments.
f.
Failure to correctly identify and document part numbers / serial numbers of component parts - This area was inspected by review-ing the Summary of Materials for selected panels supplied to Comanche Peak, Unit 2.
The traceability of specific switches, taken from the Summary of Materials, was established by reviewing the REC purchase orders to the subcontractors, the REC receiving inspection reports, the subcontractors' packing releases, and the certificates of conformance.
The alleger stated to the NRC Region II investigator that these allegations were based upon identified QA internal audit findings.
Review of internal audit reports by the NRC inspector did not disclose, however, any findings with respect to the allegation subject material.
With the exception of the nonconforming conditions identified in regard to welding, no basis was indicated by inspection for the remaining allegation subjects.
2.
NRC Region III Request:
NRC Region III requested that an inspection be performed at specific control panel fabricators, based on defective welds found in panels supplied by the fabricators to the Byron Station, Braidwood Station, Midland Plant, and the Callaway Plant.
In addition to the areas inspected regarding the allegations, the following areas were also selected:
a.
Control of Nonconformances and Corrective Actions - Approximately 15 rejection tickets and nonconforming labor tickets were reviewed to determine if the deficient conditions had been corrected and to verify that the corrective actions had been provided.
A review of required, formal reports dealing with nonconforming labor tickets was performed and as a result, nonconformance B.1 was identified.
l i
b.
Welding Procedure Specifications (WPS) - REC's two WPSs and their l
procedure qualification records were reviewed.
WPS No. 6 is a gas metal arc welding (GMAW) procedure used for AWS D1.1 welding, while WPS No. 7, a GMAW procedure, is an ASME Section IX procedure.
Nonconformance B.2 was identified.
l l
L
ORGANIZATION:
RELIANCE ELECTRIC COMPANY SYSTEM & CONTROL DIVISION STONE MOUNTAIN, GEORGIA REPORT INSPECTION NO.-
99900761/82-01 RESULTS:
PAGE 6 of 6 Welding Process Control - The NRC inspector observed in process c.
GMAW being performed by three welders, on auxiliary relay panels for Georgia Power Company's Alvin W. Vogtle, Jr. Nuclear Plant.
Nonconformances B.3 and B.4 were identified.
d.
Qualifications of Inspection Personnel - The qualifications of three welding inspectors, including results of required, annual eye examinations were reviewed.
In addition, the NRC inspector observed welds in a shutdown transfer panel being supplied to Comanche Peak, Unit 2, and which had been accepted by a welding inspector.
Nonconformance 8.5 was identified.
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