ML20127E876
| ML20127E876 | |
| Person / Time | |
|---|---|
| Site: | Vogtle  |
| Issue date: | 03/29/1985 |
| From: | Blake J, Crowley B NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML20127E850 | List: |
| References | |
| 50-424-85-11, 50-425-85-11, NUDOCS 8505200241 | |
| Download: ML20127E876 (14) | |
See also: IR 05000424/1985011
Text
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NUCLEAR REGULATORY COMMISSION
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101 MARIETTA STREET, N.W.
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ATLANTA, GEORGI A 30323
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Report Nos.: 50-424/85-11 and 50-425/85-11
Licensee: Georgia Power Company
P. O. Box 4545
Atlanta, GA 30302
Docket Nos.: 50-424 and 50-425
License Nos.: CPPR-108 and CPPR-109
Facility Name:
Vogtle 1 and 2
Inspection Co
d.
March 11-14, 1985
Inspecti pr:
3 A7 f
) 4B
C dwl y
Dat'e Signed
Approv
by:
3 #1 M .
J
Klike, Section Chief
Date Signed
g eering Branch
v sion of Reactor Safety
+
SUMMARY
Scope:
This routine, unannounced inspection entailed 33 inspector-hours on site
in the areas of reactor coolant pressure, boundary piping and safety-related
piping.
Results:
One violation was identified - Failure to follow procedure for field
welding inspection - paragraph 7.b.
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REPORT DETAILS
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1.
Persons Contacted
Licensee Employees
M. H. Googe, Project Construction Manager
- E. D. Groover, Quality Assurance (QA) Site Manager
- B. C. Harbin, Manager Quality Control (QC)
- G. A. McCurley, Project Compliance Coordinator
- S. D. Haltom, QA Engineering Support Supervisor
- C. M. Burke, Senior QA Field Representative
.
Other licensee and contractor employees contacted included construction
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craftsmen, QC inspectors, engineers, security force members, and office
personnel.
Other Organization
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- J. R. Steele, QA Manager, Pullman Power Products
(PPP)
T. C. Clark, Assistant QA Manager, PPP
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H. E. Brumitt, Training Officer, PPP
J. M. Sheppard, Lead QA Engineer - Materials, PPP
D. Hayes, Welding Engineer, PPP
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H. Tucker, Lesd Welding Superintendent, PPP
hRC Resident Inspectors
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- W. F. Sanders, Senior Resident inspector
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R. Schepens, Resident Inspector
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- Attended exit interview
2.
Exit Interview
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The inspection scope and findings were summarized on March 14, 1985, with
those persons indicated in paragraph 1 above.
The inspector described the
areas inspected and discussed in detail the inspection findings listed
below. No dissenting comments were received from the licensee.
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(0 pen) Inspector Followup Item 424, 425/85-11-01, Clarification of Pipe
WeldingWPSs-Paragraph 6.a.(2).
(0 pen) Violation 424/85-11-02, Failure to follow procedure for field welding
inspection - paragraph 7.b.
>
The licensee did not identify as proprietary any of the materials provided
to or reviewed by the inspectors during this inspection.
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3.
Licensee Action on Previous Enforcement Matters
This subject was not addressed in the inspection.
4.
Unresolved Iters
Unresolved items were not identified during the inspection.
5.
Independent Inspection Effort (92706B) (Units 1 and 2)
Construction Progress
The inspector conducted a general inspection of auxiliary and reactor
buildings to observe construction progress and construction activities such
as welding, material handling and control, housekeeping and storage.
Within the areas examined no violations or deviations were identified.
6.
Reactor Coolant Pressure Boundary Piping
The inspector examined welding and nonwelding activities for reactor coolant
pressure boundary piping to determine whether applicable code and procedure
requirements were being met.
The applicable code for reactor coolant
pressure boundary piping is the ASME Boiler and Pressure Vessel Code,
Section III, 1977 Edition with Addenda through W77.
a.
WeldingProcedureSpecifications(WPS)andQualityAssuranceProcedures
(551718)(Units 1and2)
(1) The in-
ctor reviewed preparation, qualification, approval /
certification, distribution and revision requirements for WPS's as
covered by:
PPP " Nuclear Quality Assurance Program Manual, ASME,
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Section III, Division I (8/29/84)
Section I, " Organization"
Section IX, " Control of Processes"
Section V " Instructions, Procedures, and Drawings"
PPP IX-12. " Welding Procedure Qualification" (6/3/81)
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(2) The PPP general welding standard and WPSs including supporting
Procedure Qualification Reports (PQRs), listed below were reviewed
to verify:
compliance with procedures of paragraph (1), above
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that all essential variables, supplementary essential
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variables, and nonessential variables are defined in accor-
dance with ASME Code requirements
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that WPS has been qualified and supporting PQR is on file
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that PQRs list ~ the essential variables and that values and
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ranges of variables are consistent with WPS and code
requirements
that all mechanical tests required by code have been
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completed and properly documented
that PQR has been properly approved / certified
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that changes to WPS essential variables are supported- by
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requalification
that changes to WPS nonessential variables are properly
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identified and documented
that WPS meets applicable Regulatory Guides
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General Welding Standard GWS-III/I (6/19/84)
WPS250-III/I-8-KI-Al(11/29/83)
WPS(W)32-III/I-8-12(3/9/83)
WPS24-III/I-8-KI-12(9/16/83)
WPS38-III/I-8-KI-1(9/18/80)(PCN1)
During reviewing the above WPSs and supporting PQRs the inspector
noted areas where procedure needed clarification:
WPS(W)~32-III/I-8-12
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The shielding gas flow rate is given as eight cubic feet per hour
(CFH)withnominimumormaximum.
The electrode weave is given as three times the electrode core
diameter with no minimum or maximum.
Note 2 on the weld design sketch (page 3) refers to the use of
back gouging when using E7018. E8018, and E9018 electrodes and
welding from one side.
The procedure 'is a stainless steel
procedure.
WPS 250-III/1-8-KI-Al
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Supporting PQR 139 indicates a test assembly position of 1G. This
appears to be a typographical error as the 6G position was used.
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WPS 24-III/I-8-KI-12
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The table of welding parameters indicates that the shield metal
arc welding (SMAW) process can be used for the root and fill
passes.
Although the procedure is a K-insert procedure, under
allowable joint designs, an open butt design is allowed.
For a
K-insert or an open butt design, it is not practical to use the
SMAW process for the root pass.
The licensee and PPP agreed to revise the above procedures to make
necessary clarifications.
Pending review of the revised proce-
dures, this matter is identified as Inspector Followup Item 424,
425/85-11-01, Clarification of Pipe Welding WPS's.
b.
ObservationofWeldingActivities(551738)(Unit 2)
The inspector observed in-process welding of the below listed welds at
various stages of completion:
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Size
Status
2X4DL4A17
010-W-01
27"
Welding cap
2X4DL4A17
006-W-01
31"
Welding fill passes
- 3/4 full
2X4DL4A17
001-W-01
29"
Welding fill passes
- 1/2 full
2X4DL4A17
005-W-01
31"
Fitup
The welding was observed to determine whether:
(1) Work was being conducted in accordance with a document which
coordinates and sequences operations, references procedure,
establishes hold points, and provides for production and inspec-
tion approval.
(2) Weld identification and location were as specified.
(3) Procedures, drawings, and other instructions were at the work
station and readily available.
(4) WPS assignment was in accordance with applicable code. require-
ments.
(5) Welding technique and sequence were specified and adhered to.
(6) Welding filler materials were of the specified type and traceable
to certifications.
(7) Weld joint geometry was in accordance with applicable procedure
and was inspected.
(8) Alignment of parts was as specified.
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(9) Preheat and interpass temperatures were in accordance with
procedures.
(10) Electrodes were used in positions and with electrical charac-
teristics specified.
(11) Shielding gas was in accordance with the welding procedure.
(12) Welding equipment was in good condition.
(13)
Interpass cleaning was in accordance with applicable procedures.
(14) Temporary attachments were removed in accordance with applicable
procedures.
(15) Welding and inspection personnel were qualified.
(16) Weld history records were adequate.
(17) Gas purging, if specified, was used in accordance with applicable
procedures.
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(18) Process control system has provisions for repairs.
(19) Welders were qualified.
(20)
Inspection personnel were qualified,
c.
Welder Qualification (551778) (Unit 2)
The inspector reviewed PPP's program for qualification of welders. The
applicable procedure is II-8, " Welder Performance procedure" (12/14/84)
The following specific areas were examined:
Procedures for qualification of welders
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Procedures for maintaining continuity or status records
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Qualification status records and initial qualification records for
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the following welders who welded on the welds listed in paragraph
b above:
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BY4
JX
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CB3
BW4
AJ2
VS2
CJ3
JB1
The following in-process welder qutlification tests were observed:
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Welder BF3: test C22
Welder 1658: test C9
Welder 8993: test S5
The following in-process and completed bend test was examined:
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Welder JH4: test 6G-S4-S16
d.
Welding Material Control (55172B) (Units 1 and 2)
The inspector reviewed PPP!s program for control of welding materials
including procurement, receiving inspection, storage, and issue.
The
applicable procedures are:
PPP VII-2, " Material Control" (13/03/84)
PPP VIII-1, " Identification of Materials, Parts and Components"
(09/10/84 and PCN #1)
PPP VIII-3, " Control of Welding Materials (Field)" (04/17/84 and
PCN #3)
PPP VI-5, " Control of Process Sheets and Weld Rod Stores Requisi-
tions (3/22/84 and PCN #1)
PPP X-5, " Field Receiving Inspection Procedure" (12/16/82)
The following specific areas were examined:
(1) Establishment of procedures for procurement receiving, storing,
distributing and handling welding materials
(2) Material identification
(3) Control of weld material at work locations and at Weld Material
Distribution Centers (WMOC) " Aux #4" and " Double Wide"
(4) Welding material procurement and receiving records including
vendor material test reports were reviewed for the following
welding materials:
ER308L:
.035" Ht. J9513
1/16" Ht. 26245
Insert Ht. 4282R308L
3/32" Ht. 05394
E 308L:
3/32" Ht. P0188 (Control No. HH011)
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E 7018:
1/8" Ht. 73675 (Control No. LLO15)
(Used for safety-related pipe welding,
not reactor coolant pipe welding)
ER70S2:
1/16" Ht. 97401
3/32" Ht. 97401
1/8" Ht. 97401
(Used for safety-related pipe welding,
not reactor coolant pipe welding)
e.
Special Welding Applications (551788) (Unit 2)
The inspector examined repair activities relative to weld 002-W-02 or
ISO 2X4DL4A17.
The repair operations .were compared with applicable
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code and procedure requirements in the areas of:
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Procedure qualification
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Repair Technique
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Base and filler materials
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Nondestructiveexamination(NDE)
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Records
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Welder Qualification (Welder BW4, VS2, BY4 and AJ2)
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f.
Observation of Non-Welding Activities (490538) (Unit 2)
The inspector observed the work activities listed below to determine
whether requirements were being met in the following areas, as
applicable:
(1)
Inspection and/or work procedures
(2) Record keeping requirements
(3) Construction / installation specification requirements
(4)
Issuance of specified materials
(5) Utilization of qualified inspection and NDE personnel
(6) Performance of prescribed NDE
Specific activities observed were:
Installation, rigging, protection, fitup, and marking of reactor
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coolant loop spool 007-S-01 and 009-S-01.
Protection and rigging of reactor coolant loop spools 009-S-01,
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010-S-01 after dry fitup.
Within the areas inspected, no violation or deviations were identified.
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7.
Safety-Related Piping
The inspectors examined welding and non-welding activities for safety-
related piping to determine whether applicable code and procedure require-
ments were being met. The applicable code for safety-related piping is the
ASME Boiler and Pressure Vessel Code Section III,1977 Edition with Addenda
through W77.
Welding) Procedure Specifications and Quality Assurance Procedures
a.
(551818 (Units 1and2)
The procedure review documented in paragraph 6.a. for reactor coolant
piping is also applicable to safety-related piping.
b.
ObservationofWeldingActivities(55183)(Unit 1)
The inspector observed in-process welding of the below listed welds at
various stages of completion:
Size
Status
001-W-02F
4" X .237"
Fi+up in process
IV4-1501-035-01
035-W-09A
21" X .203"
F1 tup in process
053-W-03
4" X .237"
Fitup complete and
signed off by QC
056-W-03
4" X .237"
Fitup in process
IKS-1301-002-01
003-W-07G
4" X 2.063"
Welding fill passes
IK3-1203-055-01
053-W-04J
1" X .375"
Welding fill passes
A07-W-131
1" X .133"
process
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022-W-07A
3" X .438"
Welding fill passes
The welding was observed to determine whether:
(1) Work was being conducted in accordance with a document which
coordinates and sequences operations, references procedure,
establishes hold points, and provides for production and inspec-
tion approval.
(2) Weld identification and location were as specified.
(3) Procedures, drawings, and other instructions were at the work
station and readily available.
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(4) WPS Lassignment was in accordance with applicable code require-
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ments.
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(5) Welding technique and sequence were specified and adhered to,
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(6) Welding filler materials were of the specified type and traceable
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to certifications.
(7) Weld joint geometry was in accordance with applicable procedure
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and was inspected.
(8) Alignment of parts was as specified.
(9) Preheat and interpass temperatures were in accordance with
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procedures.
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(10) Electrodes were used in positions and with electrical characteris-
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tics specified.
(11) Shielding gas was in accordance with the welding procedure.
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(12) Welding equipment was in good condition.
(13) Interpass cleaning was in accordance with applicable procedures.
(14) Temporary attachments were removed in accordance with applicable
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procedures.
(15) Welding and inspection personnel were qualified.
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(16) Weld history records were adequate.
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(17) Gas purging, if specified, was used in accordance with applicable
procedures.
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(18) Process control system has provisions for repairs.
(19) Welders were qualified.
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(20)
Inspection personnel were qualified.
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During observation of the above welding, the inspector noted that for
weld 001-W-02F on ISO 1K4-1508-003-01 the land thickness for the weld
preparation did not meet the required 1/16" i 1/32" as required by WPS
38-III/I-8-KI-1.
The land was ground to a " knife edge" for more than
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half of the circumference.
The visual inspection of the weld joint
configuration had been signed off by QC as being acceptable. Although
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for the particular weld involved, a land thickness less than 1/32" is
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not that critical, the practice of the QC inspector signing off things
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that do not meet procedures is a problem.
The weld preparation in
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question was corrected immediately.
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The acceptance of_a weld configuration that does not meet the WPS is in
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violation PPP procedure X-18. " Field Welding Inspection" (7/18/84),
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paragraphs 4.2 and 7.1.2, which require that the QC inspector verify
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that the joint configuration complies with applicable procedure listed
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on the process sheet prior to signoff.of visual inspection on the
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process sheet.
This violation is identified as item 424/85-11-02,
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Failure to Follow Procedure for Field Welding Inspection.
c.,
WelderQualification(55187B)(Unit 1)
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The inspector reviewed PPP's program for qualification of welders. The
applicableprocedureisII-8,"WelderPerformanceProcedure"(12/14/84)
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The following specific areas were examined:
Procedures for qualification of welders
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Procedures for maintaining continuity or status records
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Qualification status records and initial qualification records for
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the following welders who welded on the welds listed in paragraph
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b above:
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BT1
EF3
ZZ1
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R1
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BM1
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In-process welder qualification tests which were observed are
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listed in paragraph 6.c.
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d.
WeldingMaterialControl(551828)(Units 1and2)
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The welding material control inspection documented in paragraph 6.d.
for reactor coolant piping also applies to safety-related piping.
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e.
SpecialWeldingApplications(551888)(Unit 1)
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The inspection examined repair activities relative to weld A, spool.
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125-5-01 on 150 1K4-1204-125-01 and repair to a saw cut near weld
022-W-07A on ISO 1K3-1208-022-03.
The repair operations were compared
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with applicable code and procedure requirements in the areas of:
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Procedure qualification
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Repair Technique
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Base and filler materials
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Records
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Welder Qualification (Welder R1 and 8M1)
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f.
Observation of Non-Welding Activities (49063B) (Unit 1)
The inspector observed the work activities listed below to determine
whether requirements were being met in the following areas, as
applicable:
(1)
Inspection and/or work procedures
(2) Record keeping requirements
(3) Construction / installation specification requirements
(4)
Issuance of specified materials
(5) Utilization of qualified inspection and NDE personnel
(6) Performance of prescribed NDE
Specific activities observed were:
Spool M28, ISO IV4-1501-035-01:
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Installation, cutting weld preps, and protection.
Spool 001-5-01, ISO 1K4-1508-003-01:
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Installation, cutting weld preps, and protection.
Within the areas inspected, one violation, as noted in paragraph 7.b.,
was identified. No deviations were identified.
8.
Liquid Penetrant Examination (57060) (Units 1 and 2)
The inspector examined the liquid penetrant (PT) examination activities
described below to determine whether applicable code and regulatory
requirements were being met.
See paragraphs 6 and 7 above for the applic-
able code,
a.
PPP procedure IX-PT-1-W-77, " Penetrant Examination Procedure to ASME
Section III, W1977 Addenda" (12/3/84) was reviewed to determine whether
the procedure had been approved in accordance with the QC program.
In
addition, the procedure was reviewed to determine whether the following
parameters were specified and controlled in accordance with applicable
requirements:
Method consistent with applicable codes
Specification of brand names and types of penetrant materials
Specification of limits of sulfur and total halogens for materials
Pre-examination surface preparation and cleaning
Minimum drying time following surface cleaning
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Penetrant application and penetration time
Temperature requirements
Solvent removal
Method and time of surface drying prior to developing
Type of developer and method of application
Examination technique
Time interval for interpretation
Required lighting
Technique for evaluation
Acceptance standards
Reporting requirements
Requalification requirements
b.
The inspector observed PT examination of Unit 1 Lug welds W01 and WO2
on hanger V1-1208-139-H015 and grind out for repair to weld A on spool
125-S-01 on ISO IK4-1204-125-01 to verify that:
(1) Applicable instructions or travelers clearly specified the
procedure to be used and that a copy of the procedure was avail-
able for the inspection.
(2) Sequencing of examinations relative to other operations were
specified and in accordance with applicable and procedures
(3) Personnel performing the examinations were qualified
(4) Materials used for the examinations were certified and the
certifications met applicable requirements
(5) Areas, locations and extent of examinations were clearly defined
(6) The following attributes were as specified in the applicable
procedure and consistent with applicable code:
Surface preparation / cleaning method, type, time, etc.
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Penetrant type
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Penetrant application method
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Penetration time
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Temperature of surfaces
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Penetrant removal
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Drying
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Developer, application, type
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Developing time
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Evaluation technique
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Acceptance criteria
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Reporting of results
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c.
Personnel qualifications / certification records for NDE personnel who
performed the PT inspections of the welds listed in paragraph b. above
were reviewed.
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d.
During examination PT activities as detailed above, the inspector noted
the following problems:
(1) The PT procedure, IX-PT-1-W-77, allowed test temperatures down to
40*F.
However, the procedure was not clear relative to the-
penetrant dwell time between 40F and 60*F.
(2)
In reviewing material certifications for the penetrant materials.
in use, the inspector noted that only a certificate of compliance
(C of C), not actual test results, was on file for the penetrant
and developer. For the cleaner, actual test results were on file.
Review of the purchase order revealed that only a C of C was
specified on the order.
Georgia Power Company specification
X4AZ01, division 9
" Permissible Consumable Materials For Use
During Construction" requires actual test results for PT material.
At the time of the current inspection, site Georgia Power QA
auditors were in the process of conducting a special QA audit
(Audit No. SP01-85/18, PPP NDE Program).
The above problems had
been identified by their audit and will be corrected in accordance
with their corrective action program.
Within the areas inspected, no violations or deviations were
identified.
9.
Inspector Followup Items (92701B) (Units 1 and 2)
(Closed)-Inspector Followup Item 424,425/84-22-03, Verification of Welder
Qualification Prior to Welding.
This item concerned the fact that PPP
procedures did not clearly indicate that the " Welder Qualification Log" is
to be used to determine the welders' qualification status prior to welding.
PCN No. I dated 9/18/84, to procedure VI-5 has been issued requiring
verification of welder qualification using the " Welder Qualification Log"
prior to welding.
(Closed) Inspector Followup Item 424, 425/84-22-04, Welder Qualification
Records for Combination Process Qualifications.
This item concerned the
fact that PPP welder qualification records did not indicate the thickness
deposited with each process for confirmation processes.
The standard form
for welder qualification has been revised to indicate thickness for the gas
tungsten arc welding (GTAW) process and states that the GTAW process be used
for the root and hot pass.
These two passes are considered to be approxi-
mately 1/8" in thickness.
The newer form shows the actual thickness range
for each process.
Within the areas inspected,'no violations or deviations were identified.
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