IR 05000456/1984036

Insp Repts 50-456/84-36 & 50-457/84-34 on 841120-850730.No Violation or Deviation Noted.Major Areas Inspected:Hvac & Electrical Contractor Welding Activities & Related Procedures

ML20134G345
Person / Time
Site:	Braidwood
Issue date:	08/16/1985
From:	Danielson D, Jacobson M NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
To:
Shared Package
ML20134G327	List: IR 05000456/1984036 ML20134G323
References
50-456-84-36, 50-457-84-34, NUDOCS 8508230228
Download: ML20134G345 (5)

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~ U.S. NUCLEAR REGULATORY COMMISSION

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REGION III

~ Report =Nos. 50-456/84-36(DR5); 50-457/84-34(DRS)

Docket Nos. 50-456; 50-457 License Nos. CPPR-132; CPPR-133 .

Licensee: : Commonwealth Edison Company Post Office Box 767 Chicago, Illinois 60690

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Facility Name: Braiowood Station, Units 1 & 2 s Inspection At: BraidwoodSite,Braidwod, Illinois Inspection Conductec: November 20-21, December 5-6, 17-19, 26-27, 1984 and May 1, 17~ June 14 July 16, 25-26, 30, 1985

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..i?fgL,an][ m I'.. Jaccosor f'n.'

inspector:g' Datt s

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Approved Ey: D. H. Danielson, Chief 0#.5,",

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Materials and Processes Section Date Insoection Summary Inspection on N:,vember 20-21,-December 5-6, 17-19, 26-27, 1984, and May 1. 1 June 14, July 16, 25-26, 30, 1985 (Report hos. 50-456/84-36(DR5);

50-457/84-34(DRS))

Areas Inspected: Unannouncec, routine safety inspection to review the HVA; contractor's welding activities and related procedures tc evaluate the technical adequacy of both ongoing and past'weiding activities; and resi .

o .of the electrical contractor's welding relatea procedures. Tt,u

! inspectior. involvec a total of 112 inspector-hours onsitt- Dy one NR" -

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Resultt: Within the areas inspectec, no violations or ces1ationi cert i

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DETAILS

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1. Persons Contacted

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Common ealth Edison Company (CECO)

"L. De1 George, Assistant Vice Presioent .

• C. Schroeder, Licensing and Compliance Superintendent

• J. Dierbeck, PCD Engineer

• P. Barnes, Licensing Engineer

• E. Netzel, QA Supervisor

• L. Kline, PLC Supervisor

• Groth, Assistant Construction Superintendent

• J. Gieseker, PCD Engineer --

Pullman sneet Metal Works, Inc. (PSM)

D. Grant, OA Site Supervisor F. Weiner, Engineering Manaaer L Ewalc. Welding Engineer k C oastori I. Dewalc, 0: Supervisor E 5eltmann, OA Manager T. Simile. Level III Welding Superviser

"Denetet those attending the exit reetin . Review of HVAC Activities A comprehensive review of Pullman Sneet Metal Works, Inc. (P5M) welaing activities and relatec proceaures at the Braiowood Site was performe The objective of this inspection was to evaluate the technical acequacy of both ongoing and past welding activitie The following procecures anc avalifications, currently in use, were

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reviewed and founc te be acceptable:

• D;-1F . Revision 2, anc Li :-;, Revision 1. General Welding Proceduret

• Bi-12F, Revi; ion 2. Flu > Corec Ar belainc (E71T-11)

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B5-31r, kev ision 0, Snicidad Metal Arc Welaing (E309)

• B5-32F. Revision C. Shielard Metal Arc belding (E6013)

• BT-32F. Revision 3, rie> Cerec Arc beldinc (E71T-11)

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Bi-115 Resision 4. Sn,e ce: Peta ~ Ar: be'cing (E7018)

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04-11. Res1sior C . Gat tt A': wCc,n; (E705-2)

b$-32i, kevision 2, Ges-Metai Ar: belcing (EP33E)

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BC-33r, Revision 1, Get Metal Arc beiding (ER309)

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EU-34F , Revision 0. Ga: Vete'. Ar: Weicing (ER309)

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BF-31F, Revision 2, Flux Cored Arc Welding (E71T-GS)

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B2.1.F, Revision 4, QA/QC Personnel Qualification and Certification

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B9.1.F, Revision 5, Welder Qualification The following proceoures, currently it use, were reviewed and found to be deficient:

• BG-31F, Revision 1, Gas Metal Arc Welding (ER705-3). ' This procedure .

was cualified in accordance with AWS 01.3-78 which states that a qualification test with a " tee" joint also qualifies a lap joint but not vice versa. Contrary to this requirement, this procedure was qualified utilizing a lap joint while the procedure permitted welding utilizing a " tee" join As a result of this NRC inspection finding, BG-31F, Revision 1, was removed from the field to preclude its use. It was concluded that no weloing had been performed nor welders cualified to this proceoure since issuanc PSM will revise this procedure at some later date should the need arise for its us '

B9.2.F. Revision 2, Control of Welding filler Metal. -This procedure allowec for reconditioning of los nydroger (E701E) electroces at c temperature c' 250 F when exposec tc int atmosphere ma e thar 4 nour:

Tnt AW5 D1.1 Coce reovires that these eiectroces De reconditienec e; e- tempe atur e between 450 ; anc 500 /4 temaeraturt of 250' r.a s :

b( sufficient to remove abso-r.ec nyarecer wnich may cause unceroest cracting of welos. As a result of this inspection, the procecure we revised to incluoe the reauirements of AW5 D1.1. Tnis item reau1re:-

further review upon the licensee evaluation of work performed usin; this procedure and is consioerec an open item (456/84-36-01(DRS)).

The following superseded procecures were reviewed ano found to be acceptable:

• BPSM-FWP-300. Revision 8, Gas Metal Arc Welding (E705-2)

BP5M-FWr-300B, Revision 2, Gas Metal Arc Welding (E705-2)

BP5M-FWP-301C, Revision 4, Shielded Metal Arc Welding (E6013)

• BPSM-FWD-304. Revision 5, Gas Metal Arc Welding (E309)

• BPSM-FWP-304E, Revision 1, Gas Metal Arc Weloing (E309)

Twelve of tne 86 weioer: employed by PSV as of December 17 1984, werr selected by int insnector for welaer.cualification revie All 12 of tre inoiviouais were f ouno to be procerly cualified to the apolicable cocet in addition to the occument review , tne inspector selectec eight welaers to demonstrate their actuai welding proficiency. Weld joint configuratio-the welding process / pro:edure anc caterial thickness selections were made by tne inspector. The inspecto otserved the weldinc anc sucsecuent Den tests o' tot welo coupens The cemonstratior establishec that tnt wt i> " : :t s!&c eoecaea stilis an~ that int seiectec weldinc Druce;5/pt'oceoL'e was 8 Iso aceoUate it Derforc Quality HVAC weldin ~

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Documentation packages for the following hanger and duct installations

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51640 0-2170 51630 D-2144 51327 L-21EE 51326 0-2129 51304 0-2169 51312 All documentation for these installations was found to be acceptabl As of August 1983-welding procedures to be used for a specific installation are specified on a Weld Process Sheet. The Weld Process Sheet is also used to cocument AWS D1.1 Code required preheat. Prior to August 1983, no documentation af-preheat exists. PSM has issued NCR No. 747 to document and resolve this deficiency. Technical justificatior, for acceptance of welds installed without evidence of recuireo preheat will be based on the cualification of a welding procedure using both E6013 and E7018 eiectroces with no prehea Tnis is consioered an open iter pendine the inspector's review of th-corn'ieter cosiifications (456/Sc-36-02(DR5);.

Inspectior. Renor he. 50-456/83-09 ioentifiec certain P59 prograr ati:

oeficienciet At a result of a meeting betweer t nt licensee an:

Region II: personnei on FeDruary 2;,19EE, the licensee agreec tc 4 deveiot a welc sample program to sia in tne evaluation of preslous work Tne program consists of th( removal anc subseouent tensile testing o' approximately 70 welds representing approximately 3E installec hange .

In addition, a sample of sneet metai tc sheet metal and sheet metal tc structure joints will be teste This is consicerec an open item pending the inspector's review of the completed testing (456/er-36-03(DR5)).

3. Review of Electrical Contractor Weldino Procedures A review of all L. F. Comstock welding procedures used for fabrication and installation of cable trays and supports was performec. The following procecures and oualifications, currently in use, werc resiewec and found tc ce acceptabie: -

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4.'.'.. hevision C, Weiaer Ferformance Oualificatier Tests

' 4.1. 2. Eevision F, Welding Procecure Structural Attachnients (7018)

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4.1 2 3, Revisior A, beiding o' Aluninue

' 4.1.3.2. Revisior: A. Welding o' Stainless Stee

' 4.3.2.1, Resision D, welding Procecure (6013)

int 4 o . % . n; 5 w 5ece: o mcece es meri re$iewec anc founc tc h ac cer.ta: a

' 4.1 14. Revisior 9/17/8C, Welding of Stainless Stee

' 4 E.;. Revision 6/14/83, Welcing o' Aiuminun ( 4.3.2.1, Resision A, L, and C, Welding Frocecure (6013)

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4.3.3, Revision A, E, C, D and E, Welding Procedure Structural

Attachments (7018)

A deficiency related to a welding practice was identified curing this inspectio Per AWS D1.1 Welcing Loce, welding on galvar,izec material is not pernitted unless a proccc rt it specifically qualified for that application. While Comstock aces welc on galvanized materials, their undocumented actual practice is to remove (by grinding) ~the galvanize prior to welding. The NRC inspecter verified this practice by interviewing several welders in the fieic. To preclude the possibility of any questionable work arising from a failure to remove the galvanize coating before weloing, the licensee has instructed L. K. Comstock to qualify a procedure for welding with the galvanized coating in plac This is considered an open item pending review of tne welding proceoure cualificatior, test results (456/84-36-04(DRS)).

4 Open Iten Open iters arc o.atters which have beer ciscussed with the licensee, whicn v.ill te review.c c f urtner by the insuc tors , anc whict. inve' .a sou actie .

or. trm ptri of tne fi: c- licensee c' botr 0xr item d rciesec curir.;

the ir,stie: tic: a rt ciSCusscc ir, Faragrapr.. E and f. Exit Ir.te r s e, The inspector met witr. representatives (cenctec in Po son: Centactec paragraph) at tne conclusion o' int inspection. Inc inspector surr,a rize:

the scope anc findirci of tnc ir s pectiers notec ir, thu t er t. T inspector aisc ciscussed tne likely informational cor.to1 u: int inspection report witt. regarc to occurents or processes ret;cred by the inspector curing tne inspection. Tne licensee did not icentify any sucr documents / processes et proprieter).

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