ML20137V029
| ML20137V029 | |
| Person / Time | |
|---|---|
| Site: | Hatch  |
| Issue date: | 02/06/1986 |
| From: | Blake J, Crowley B NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML20137U990 | List: |
| References | |
| 50-321-86-02, 50-321-86-2, 50-366-86-02, 50-366-86-2, NUDOCS 8602190407 | |
| Download: ML20137V029 (9) | |
See also: IR 05000321/1986002
Text
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UNITED STATES
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NUCLEAR REGULATORY COMMISslON
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REGION 11
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101 MARIETTA STREET N.W.
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ATLANTA, GEORGI A 30323
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Report Nos.: 50-321/86-02 and 50-366/86-02
Licensee: Georgia Power Company
P. O. Box 4545
Atlanta, GA 30302
Docket Nos.: 50-321 and 50-366
License Nos.: DPR-57 and NPF-5
Facility Name: Hatch 1 an! 2
Inspection Conducted: JanJary 6-10, 1986
.2 [ [
Inspector:
>,
B.
. Ttow
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'Da e igned
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Approved by.
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'Date Signed
J.
ite, Section Chief
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En in ring Branch
0 vi on of Reactor Safety
SUMMARY
Scope:
This routine, unannounced inspection entailed 41 inspector-hours on site
in the areas of inservice inspection (Unit 1), nuclear welding (overlay welding
and induction heat stress improvement) (Unit 1), and inspector followup items
(Units 1 and 2)
Results: One violation was identified - failure to follow procedure for sign off
of traveler steps for IHSI - paragraph 7.b.(2)(b).
8602190407 860213
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ADOCK 05000321
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REPORT DETAILS
1.
Persons Contacted
Licensee Employees
- H. C. Nix, Site General Manager
- T. V. Green, Deputy General Manager
- C. T. Jones, Manager of Engineering
- T. Setz, Manager of Maintenance
- J. L. Wilkes, Manager of Special Projects
D. A. McCusker, Superintendent of Quality Control (QC)
- T. L. Elton, Supervisor of Regulatory Compliance
J. Hadden, QC Supervisor
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C. L. Powell, Senior Methods Training Specialist
P. Norris, Senior Plant Engineer
D. J. Vaughn, Senior QA Representative
G. R. Brinson, Senior QC Specialist
R. K. Godby, Plant Engineer
Other licensee employees _ contacted included QC personnel, engineers,
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mechanics, security force members, and office personnel.
Other Organizations
T. N. Epps, Manager,'nspection, Testing and Engineering, Southern Company
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Services (SCS)
A. G. Maze,. Supervisor of NDE, SCS
- J. M. Agold, Supervisor of Coordination and Documentation, SCS
- D. R. Barnes, ISI Site Coordinator, SCS
- G. A. Loftus, Lead Inspector - Level III, SCS
W. J. McConaghy, Site ~ Project Manager Nutech Engineers, Inc. (Nutech)
J. H. Kessler, QA Site Supervisor, Nutech
R. J. Benoit, Day Shift Supervisor, Nutech
J. D. Frymyer, Welding Engineer, Welding Services, Inc. (WSI)
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NRC Resident Inspectors
- P. Holmes-Ray, Senior Resident Inspector
G. N. Nejfelt, Resident Inspector
- Attended exit interview
2.
Exit Interview
The inspection scope and findings were summarized on January 10, 1986, with
those persons indicated in paragraph 1 above.
The inspector described the
areas inspected and discussed in detail the inspection findings listed
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below. No dissenting comments were received from the licensee.
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(0 pen) Violation 321/86-02-01, Failure to Follow Procedure for Signoff of
Traveler Steps for IHSI - paragraph 7.b.(2)(b)
The licensee did not identify as proprietary any of the materials provided
to or reviewed by the inspector during this inspection.
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3.
Licensee Action on Previous Enforcement Matters
This subject was not addressed in the inspection.
4.
Unresolved Items
Unresolved items were not identified during the inspection.
5.
Independent Inspection Effort (548348) (429028) (429408) (Unit 1)
The inspector conducted a general inspection of portions of the reactor and
auxiliary buildings to observe activities such as housekeeping, material
identification and control, and .naterial storage.
Within the areas inspected no violations or deviations were identified.
6.
Inservice Inspection - Observation of Work and Work Activities (737530)
(Unit 1)
The inspector observed the ISI activities described below to determine
whether these activities were being performed-in accordance with regulatory
requirements and licensee procedures.
The applicable code is the ASME
Boiler and Pressure Vessel Code,Section XI,1980 Edition, W80 Addenda.
(See RII Report 50-321/85-35 for a previous-inspection in this area).
As.noted in RII Report 50-321/85-35, the first 10 year. interval inspections
are to be completed during the current outage.
In addition, the licensee is
inspecting 100% of the 130 stainless steel welds in the Reactor
Recirculation (RECIRC), Residual Heat Removal (RHR), and Reactor Water
Cleanup (RWCU) Systems.
Also, the licensee is performing Intergranular
Stress Corrosion Cracking (IGSCC) mitigation techniques using weld overlays
or Induction Heat Stress Improvement (IHSI) on welds not previously
mitigated.
T.3 observations detailed below pertains to inspections of the
stainless steel welds.
Prior to IHSI, ultrasonic (UT) inspection was performed on an original
sample of 22 stainless steel welds. As a result of finding indications, the
sample was expanded to 49 welds (23 - 12" RECIRC, 2 - 27" RECIRC, 3 - 28"
RECIRC and 21 - 6" RWCU).
Seventeen of the 49 welds were found to contain
reportable indications (2 - 28" RECIRC, 2 - 22" RECIRC, 9 - 12" RECIRC and 4
- 6" RWCU).
The decision was made to overlay weld 8 (4 - 12" RECIRC and 4-
6" RWCU) of the 17.
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a.
Personnel qualification / certification records for two level I-UT, four
level II-UT and 3 level II-PT examiners associated with the inspections
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of paragraphs b. and c. below were reviewed.
In addition to the SNT-TC-1A, qualification, the inspector verified that
the examiners had completed the applicable qualification / demonstration
The level II examiners inspecting for IGSCC
. ere required to have passed the recent EPRI NDE center course on
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IGSCC detection.
The Level II examiners inspecting weld overlays were
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required to have satisfactorily completed the EPRI NDE Center practical
exam portion of the EPRI NDE center weld overlay workshop.
In addition,
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for overlay inspections, the inspector noted that a level III examiner
with qualifications in IGSCC detection and sizing as well as overlay
inspections was involved in a supervisory or overview position on each
shift.
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b.
A portion of the in-process UT inspection, including calibration
activities, was observed for the following welds:
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Weld Condition
Examination
1831-1RC-12AR-F-1
Post IHSI
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1831-1RC-12E R-C-2
Overlay
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1831-1RC-12BR-C-3
Overlay
0
1831-1RC-12BR-D-3
Overlay
0
Overlay *
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Overlay
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1831-1RC-28A-4
Post IHSI
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1831-1RC-28A-5
Post IHSI
45
IB31-1RC-12AR-F-2
Overlay
Creeping Wave
1831-1RC-12AR-F-3
Overlay
Creeping Wave
1813-1RC-12BR-E-3
Overlay
60
IB31-1RC-12BR-E-2
Overlay
60
Overlay
60
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- Demonstration of UDRPS equipment - exam not official.
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Tha inspections identified above for overlay welds were for overlay
weins made during previous outages. There are a total of 23 previously
madt overlays.
For the current inspection the surface of these welds
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~had .len prepared by grinding and in some cases additional welding.
The
aspections were compared with applicable procedures in the
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fol' awing areas:
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(1) Availability of and compliance with approved NDE procedure
(2) Use of knowledgeable NDE personnel
(3) Use of NDE personnel qualified to the' proper level
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(4) Recording of inspection results
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(5) Type of apparatus used
(6) Extent of coverage of weldment
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(7) Calibration requirements
(8) Search units
(9) Beam angles
DAC curves
Reference level of monitoring discontinuities
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.id of demonstrating penetration
(13) Ln,ts of evaluating and recording indications
(14) Recording significant indications
(15) . Acceptance limits
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c.
In-process liquid penetrant (PT)
inspection of overlay- weld
IB31-1RC-28A-10 was observed and compared with the requirements of the
applicable procedures and code in the following areas:
(1) Availability of and compliance with approved NDE procedures
(2) Use of knowledgeable NDE personnel
(3) Use of NDE personnel qualified to the proper level
(4) Recording of inspection results
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(5) Method consistent with procedure
(6). Penetrant materials identified and consistent with ASME. Code
(7) Certification ' of sulfur and halogen content for penetrant
materials
(8) Surface preparation
(9) Drying time following surface cleaning
(10) Penetrant application and penetration time
(11) Examination surface temperature
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12) Penetrant removal
13) Drying of surface prior to developing
14) Developer type, application and time interval after penetrant
removal
(15) Time interval between developer and application and evaluation
(16) Evaluation technique
(17) Reporting examination results
d.
Certification records for the batches of inspection materials listed
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below, used for the inspections of paragraphs b. or. c. above, were
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reviewed.
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UT Couplant.
- Batch No. 42285
Penetrant
- Batch No. 828035
Cleaner
- Batch No. 85J058
Developer
- Batch No. 85H029
Within the areas inspected, no violations or deviations were identified.
7.
Nuclear Welding (55050) (Unit 1)
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The inspector examined the welding and IHSI activities detailed below -to
determine whether applicable code and regulatory requirements were being
met.
The applicable code is the ASME Boiler and Pressure Vessel Code,
Section XI, 1980 Edition with addenda through W80.
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a.
Welding
Welding Services, Inc. (WSI) is the welding contractor'for overlay
welding.
The welding is being accomplished under the Georgia Power
Company (GPC) QA program using GPC procedures.
Welders are being
qualified by GPC.
(1) The inspector observed welding and reviewed associated records for
the following in-process overlay welds:
1831-1RC-12AR-H-3 (Exi' ting Overlay surface improvement)
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IB31-1RC-12AR-G-3 (New Overlay)
Th.? welding was observed to determine whether:
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Work was conducted in accordance with a document which
coordinates and sequences operations, references procedures,
established hold points, and provides for production and
inspection approval.
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Procedures, drawings, and other instructions were at the work
station and readily available.
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WPS assignment was in accordance with applicable Code
requirements.
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Welding technique and sequence were specified and adhered to.
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Welding filler materials were the specified type and
traceable to certifications.
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Weld joint geometry was in accordance with applicable
procedure and was inspected.
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Alignment of parts was as specified.
Temporary attachments were by qualified welders in accordance
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with a qualified WPS.
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Preheat and interpass temperatures were in accordance with
applicable procedures.
Welding technique was in acc6rdance with applicable
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procedures.
Electrodes were used in positions and with electrical
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characteristics specified.
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Shielding gas-was in accordance with the welding procedure.
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Welding equipment was-in good condition and automatic welding
equipment was calibrated.
Interpass cleaning was in accordance with applicable
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procedures.
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Temporary attachments were removed in accordance with
applicable procedures.
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Gas purging, if specified, was used in accordance with
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applicable procedure.
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-Process control system had provisions for repairs.
Welders were qualified.
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No peening performed on root and surface layers.
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.(2) The inspector verified by review of qualification records
(including RT film) that the following. welding. operators, who were
welding on the welds listed in paragraph (1) above, were currently
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qualified to weld under the applicable procedure.
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WSI-07
WSI-11
WSI-14
WSI-18
WSI-23
b.
IHSI was being performed on .99 (all welds not overlayed) stainless
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steel welds in the RECIRC, RHR, and RWCU systems.
Nutech Engineers,
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Inc. was the contractor for the IHSI with Thompkins-Beckwith, Inc.
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furnishing labor as a subcontractor to Nutech.
The work was being
accomplished under the Nutech QA Manual.
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(1) Procedure Review
The inspector reviewed the following documents controlling the
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IHSI:
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Nutech "Quali ty Assurance Manual" including Quality
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Engineering Procedures (QEPs) - ,The QA manual was not
reviewed in detail, but to the degree necessary to determine
that QA requirements such as procedure issue and control,
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process control, qualification certification of personnel,
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control of inspections, control of nonconformances, and
control of records was covered by procedures.
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Nutech Procedure XGP-11-100
Revision 0,
" Procedure for
Induction Heating Stress Improvement at Edwin I. Hatch
Nuclear Power Plant Unit 1".
(2) Observation of Work Activities and Review of Quality Records
The inspectcr performed the following observatior.s/ reviews and
compared the results with applicable procedures:
(a) Welds 1B31-1RC-28A-17 and 1831-1RC-22AM-1BC-1:
Observed
in-process activities associated with IHSI
(b) For the follcwing IHSI completed welds, the IHSI Weld
Packages, including heat. charts, were reviewed:
IB31-1RC-12AR-G-1
1831-1RC-12AR-F-1
IB31-1RC-22AM-3BC-1
IB31-1RC-12AR-K-1
IB31-1RC-28A-16
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During review of the above records, the inspector noted that
in some cases Nutech personnel signing traveler inspection
steps were the same individuals as the individuals signing
the traveler for performing the activities being inspected.
This is in violation of paragraph 10.1.2 of the Nutech QA
Manual which requires that " Inspection personnel shall be
individuals other than those who performed or directly
supervised the activity being inspection -- ".
Further
investigation revealed that the steps were being perfonned by
Thompkins-Beckwith
(T&B)
craft
personnel
(Nutech's
subcontractor) reporting to T&B craft supervision even though
the steps were being signed off by Nutech.
This is in
violation of Nutech QEP 9-4, paragraph 2.5, which requires
that subcontractors sign or stamp the traveler indicating
that their described operation is completed. This failure to
follow procedure is in violation of criterion V of Appendix B
to 10 CFR 50 and is identified as item No. 321/86-02-01,
Failure to Follow Procedure for Signoff of Traveler Steps for
IHSI.
(c) The inspector reviewed personnel training / certification
records for personnel involved with the IHSI of the welds
listed in paragraphs (a) and (b) above.
Within the areas inspected, no violations, except as noted in paragraph
7.b.(2)(b), or deviations were identified.
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8.
Inspector Followup Items (92701B) (Units 1 and 2)
a.
(Closed) Inspector Followup Item 321/85-35-01, Revision of Procedures
UT-H-400 and UT-H-470 to Specify Qualification to the EPRI Program.
Deviation 001 to procedure UT-H-400 and Deviation 001 to procedure
UT-H-470 have been issued to specify qualificacion to the EPRI NDE
center program,
b.
(Closed) Inspector Followup Item 321/85-35-02, Revision of Procedure
UT-H-408 for UT of Overlay Welds.
Deviations 001, 002 and 003 have
been issued to procedure UT-H-408 to clarify and amplify procedure
requirements in the areas of personnel qualification, search Unit
angles, surface finish and gain setting for scanning.
c.
(Closed) Inspector Followup Item 321/85-35-03, Revision of MT Procedure
MT-H-501 to Cover Measurement of Black Light Intensity. Deviation 001
has been issued to procedure MT-H-501 to .pecify requirements for
measurement of black light intensity,
d.
(Closed) Inspector Followup Item 321, 366/85-26-02, Review of Revised
PT Procedure.
Revision 0 to procedure 45QC-INS-006-05 has been issued
to take the place of procedure 52IT-MNT-003-0.
Procedure 45QC-INS-
006-0S clarifies requirements in the areas of surface preparation,
temperature requirements, and lighting requirements.
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