ML20140D434

Insp Repts 50-424/85-60 & 50-425/85-40 on 851216-20. Violation Noted:Failure to Comply W/Welding Requirements

ML20140D434
Person / Time
Site:	Vogtle
Issue date:	01/14/1986
From:	Blake J, Kleinsorge W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
To:
Shared Package
ML20140D426	List: ML20140D421 ML20140D427 ML20140D434
References
50-424-85-40, 50-424-85-60, NUDOCS 8601290308
Download: ML20140D434 (10)

See also: IR 05000424/1985060

Text

- - . _ _ . _ . . . _ .

.

p Cfog UNITED STATES

Do NUCLEAR REGULATORY COMMISSION

[ n REGION ll

y' j 101 MARIETTA STREET, N.W.

• . * ATLANTA, GEORGI A 30323

'+,*....so

Report Nos.: 50-424/85-60 and 50-425/85-40

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 Condu&el1: ecember 1985

Inspector: . . . . . _d , Ih

'le; p%~a

'

W. F Date Signed

Approved by: l.dI J l'/!b6

J. .j Bla'ke, Se Kion Chief Date Signed

En neering Branch

Di i'sion of Reactor Safety

SUMMARY

Scope: This routine, unannounced inspection entailed 39 inspector-hours on site

in the areas of housekeeping (54834B), material identification and control

(429028), material control (429408), steel structures and supports, and safety-

related heating ventilating and air conditioning (HVAC) systems (50100).

Results: One violation was identified " Failure to Comply with Welding

Requirements" - paragraph 6b(1).

$[

o

00 [

.

REPORT DETAILS

1. Persons Contacted

Licensee Employees

• M. H. Googe, Project Construction Engineer

• E. D. Groover, Quality Assurance (QA) Manager (Construction

• C W. Hayes, QA Manager

• T. L. Weatherspoon, Assistant Manager Quality Control (QC)

• N. Lankford, Civil QC Section Supervisor

• D. L. Dalenberg, Senior Construction QC Inspector

G. A. McCorley, Project Compliance Coordinator

Other licensee employees contacted included construction craftsmen,

engineers, technicians, and office personnel.

Other Organization

Bechtel Power Company (BPC)

• D. W. Strohman, Project QA Engineer

NRC Resident Inspectors

H. H. Livermore, Senior Resident Construction

J. F. Rogge, Senior Resident Operations

• R. J. Schepens, Resident Inspector

• Attended exit interview

2. Exit Interview

The inspection scope and findings were summarized on December 20, 1985, with

those persons indicated in paragraph above. The inspector described the

areas inspected and discussed in detail the inspection findings. No

dissenting comments were received from the licensee.

(0 pen) Violation 424/85-60-01 and 425/85-40-01: " Failure to Comply with

Welding Requirements" - paragraph 6b(1).

(0 pen) Unresolved Item 424/85-60-02 and 425/85-40-02: "Unposted Drawing

Change Documents" - paragraph 7b.

The licensee did not identify as proprietary any of the materials provided

to or reviewed by the inspector during this inspection.

.

2

3. Licensee Action on Previous Enforcement Matters

This subject was not addressed in the inspection.

4. Unresolved Items

Unresolved items are matters about which more information is required to

determine whether they are acceptable or may involve violations or devia-

tions. New unresolved items identified during this inspection are discussed

in paragraph 7.b.

5. Independent Inspection Effort (Units 1 and 2)

Housekeeping (548348), Material Identification and Control (429028) and

Material Control (429408)

The inspector conducted a general inspection of the power plant construction

site to observe activities such as housekeeping, material identification and

control; material control, and storage.

Within the areas examined, no violations or deviations were identified.

6. Steel Structures and Supports (Units 1 and 2)

1he inspector observed welding and nonwelding work activities and reviewed

records for steel structures and supports as described below to determine

whether applicable code and procedure requirements were being met. The

applicable code for containment fabrication welded by Chicago Bridge & Iron

(CB&I) is the American Society of Mechanical Engineers Boiler and Pressure

(ASME B and PV) Code Section III,1974 edition with addenda through summer

1975, and Section VIII,1974 edition with addenda through summer 1975. The

applicable code for electrical and civil structures described herein welded

by Cleveland is AWS D1.1-81 and Ingalls is AWS D1.1-75. The applicable code

for HVAC supports described herein, welded by Pullman /Kenith - Fortsom Co.

(P/K-F), is AWS D9.1-80 and AWS D1.1-77. The applicable code for pipe

supports described herein, welded by Pullman Power Products (PPP), is

ASME B & PV Code Section III NF 77W77.

a. Nonwelding Activities

(1) Review of Quality Assurance Implementation Procedures

(48051B)(480618)

The inspector reviewed the below listed documents to determine

whether appropriate and adequate procedures are included or ,

referenced in the Quality Assurance (QA) manual to assure that the '

following specific activities are controlled and performed I

according to NRC requirements and Safety Analysis Report (SAR)

commitments in the following areas: inspection quality control

(QC) and work procedures identify items, including hold points,

where witnessing or inspection is required; receiving inspection

contain provisions for assuring that steel components are

undamaged and are in conformance with purchase specifications, and i

l

1

..

3

include any special requirements; marking or other identification

is as specified; as-received cleanliness and protection

,

requirements are met; reports of receiving inspections meet

established procedures; inspection (QC) procedures which cover

storage, protection, issue, identification and records of

materials and components used for safety-related structures and

supports, include requirements to verify that applicable

requirements are met; and inspection (QC) procedures which cover

installation of these structures and supports contain requirements

to assure that, type, size, location tolerances of components such

as flanges, bolt holes, anchors and mounting pads are as

specified, nondestructive examinations and inspections meet

requirements, and installation records meet established

procedures.

,

Documents:

?

" Pullman Power Products Vogtle Project Quality Assurance Manual" -

Revision 10/21/85.

" Nuclear Quality Assurance Manual" (CB&I) for Contract 33711/25

dated 10/1/85

"Vogtle Electric Generating Plant Quality Assurance Manual"

Revision 8, Georgia Power Company (GPC)

GPC-GD-A-30, " Receipt, Receipt Inspection, Storage, and Handling,"

Revision 9.

GPC-MT-12, " Receipt Inspection and Storage / Issue of Pipe, Pipe

Components and Weld Filler Material", Revision 8.

PPP-VII-2, " Material Control", Revision 7/10/85

NISCO-ES-4028-Vogtle 3, " Steam Generator Supports and Final

Setting Procedure", Revision F

GPC-CD-T-16, " Structural Steel and Q Decking", Revision 8.

GPC Specification X4AZ06 " Major Component Field Handling,

Installation and Setting", Revision 7.

(2) Observation of Work and Work Activities (48053B)(480638)

The inspector observed work performance, partially completed work

and/ completed work on structures / supports as indicated below to

determine whether applicable requirements, as well as work and

inspection procedures, were being met in the following areas:

receipt inspection and storage; installation / erection; testing and

nondestructive examination (NDE); inspection; utilization of

J

--- , -- --

,.,,--nnw.-,,n--.. -

r.e.w._ e

.-

7 -. , , , , _ - -.,-.a ,- ,,w -

_ . _ _ . . _. __

.

4

4

qualified NDE and inspection personnel; calibration and use of

proper test equipment.

Structures / Supports (Inside Containment)

, Pressurizer Relief Tank Serial No. 2355.10 (Unit 1)

l Upper Lateral Support for Loop 2 Steam Generator (Unit 1)

'

Vertical Columns for Loop 2 Steam Generator (Unit 1)

Column Base plates Loop 2 Steam Generator (Unit 1)

Structures / Supports (Outside Containment

Residual Heat Removal System Pump Support (Unit 1)

l No. 1-1205-P6-002

Refueling Water Storage Tank (Unit 1)

I

(3) Review of Quality Records

(a) Containment (Steel Structures and Supports) (48055B)

'

1 The inspector reviewed pertinent quality and material

records for the structures / supports indicated below to

i determine whether adequate records exists to confirm

that quality requirements have been met in the following

areas: material test reports / certification records;

'

vendor manufacturing and inspection records /certifi-

,

cations (where applicable); receiving inspection

reports (including nonconformance reports); and tests

on structural steel (where applicable).

,

Supports / Structures

Pressurizer Relief Tank Serial No. 2355.10 (Unit 1)

Upper Lateral Support for Loop 2 Steam Generator

(Unit 1)

Vertical Columns for Loop 2 Steam Generator (Unit 1)

Column Base Plates for Loop 2 Steam Generator (Unit 1)

-2 The inspector reviewed pertinent work and quality

records for the structures / supports listed in paragraph

6a(3)(a)1 above to determine whether those records are in

conformance with established procedures and whether the

records reflect work accomplishment consistent with

applicable requirements in the following areas:

installation / erection and inspection (QC) records.

(b) Safety-Related Structures Outside of the Containment (48065)

i

The inspector reviewed pertinent work and inspection records

for structure / support listed below to determine whether those

records meet established procedures and whether those records

,

!

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

_.

. _ _ . - _ _ _ _ . - -. -- -- - ..- -

. - - - , _ - _ - .

5

reflect work accomplishment consistent with NRC requirements

and SAR commitments in the following areas: materials,

installation / erection; inspection (QC) records, -and

nonconformance/ deviation records.

Structure / Support

Residual Heat Removal System Pump Support (Unit 1)

No. 1-1205-P6-002

Refueling Water Storage Tank (Unit 1)

b. Welding Activities

(1) Welding

The below listed welds were examined in-process to determine work

conducted in accordance with traveler; welder identification and

location; welding procedure assignment; welding technique and

sequence; materials identity; weld geometry; fit-up; temporary

attachments; gas purging; preheat; electrical characteristics;

shielding gas; welding equipment condition; interpass temperature;

interpass cleaning; process control systems; identity of welders;

qualification of inspection personnel; and weld histo'yr records.

(a) Inside Containment (551538)

PPP

Hanger V1-1201-064-H009, Rev. 2

Support No. VB1 on drawing SKI-300 Sheet 6, Rev. 2

Hanger V1-1204-021-H015, Rev. 1

CB&I

Welding at eight locations on structure shown on

CB&I-E2, Rev. 1

(b) Outside Containment (551548)  !

l

Cleveland

Tray Support TS-179-53 (AX-2D-11N 179, Rev. 3) Detail

8-66 No. 32, Rev. 12

Tray Support TS-183-13 (AX-2D-11-183) Detail 17-66

No. 32, Rev. 12

CB&I

Welding at three locations on the Condensate Storage

Tank (Unit 2)

l

1

.- _ _ ._ _ _ __ ___ _ . _ _ __ . - . . . - _ _ __

i .

1

6

Ingals ,

,

Stack Support Frame M0lG-S-416A, Rev. O

Trash Rack Screen Cage Structure M0lG-S-311A, Rev. O

i Stack Platform M0lG-S-400A, Rev. O

PPP

i

i

Hanger V2-1202-037-H030, Rev. 1

Hanger V2-1202-147-H642, Rev. O

Hanger V2-1202-122-H020, Rev. 3

P/K-F

! Duct Support 2118109-33

. Duct Support 211A115-95

! Duct Support 11A102-48

,

With regard to the inspection above, the inspector noted the

following:

-

The welder of record for support V2-122A-174-H642, Rev. O,

<

was assigned Welding Procedure Specification (WPS)

.

27-III/I-8-08-12, Rev 4/14/83, had drawn welder filler

!

material 3/32-inch diameter and had his welding machine set

'

at 35 amps. Had the NRC inspector not questioned the welder

regarding welding parameters, the welder would have completed

the weld joint using 3/32-inch diameter welding filler

i material with 35 amps, contrary to the assigned WPS,

i 27-III/I-8-0B-12 which specifies a welding current range of

j 100-150 amps for use with 3/32-inch diameter filler material.

1 The inspector discussed the above with the licensee who

3

agreed that the welder deviated from the assigned welding

'

procedure specification without proper authorization.

-

Drawing M0lG-S400, Rev, at E7, for the connection of Pc.A to

Pc.C, requires a complete penetration double bevel groove

weld to be made where the end of a square tube steel section

butts against the side of second square tube section of the

,

'

same size. The welding symbol on the drawing is improper for

two reasons. First, the joint is a flair bevel weld due to

the radius on the tube steel section, not a double bevel

i groove weld, and second it is not possible to make a weld on

I the inside of the tube steel on the second bevel face.

Ingals welders prepared and welded the joint with flair bevel

!

joint preparation. The inspector discussed the above with

! Georgia Power Company (GPC) QC inspector responsible for the

Ingals shop who indicated that the drawing was in error and

that a flair bevel was " intended". The GPC QC inspector

further stated that he had accepted many other weld joint

fit-ups with the same deviation from drawing weld symbol

!

,

t

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

_,___.,_---_.___m___ ,_ _ _ . . _ _ , , _ _ _ . , , , - - ,m,- _,---- -_.--- , _ = _ , --------,--.,.r-

.

7

requirement because the flair bevel was " intended" by the

designer. The GPC QC inspector stated that there was no

documentation to support the " designer's intentions".

This NRC inspector discussed the above with the licensee,

indicating that QC inspectors function is to inspect, accept

or reject and document their findings based on actual

documented requirements, and not to accept work that deviates

from actual documented requirements based on undocumented

information or knowledge.

The above indicates that the welder failed to follow the

welding procedure specification. The designer provided a

drawing with an inappropriate acceptance criteria (weld

symbol), and the QC inspector accepted work that deviated

' om documented requirements. Failure to follow documented

.

3rocedure and drawing requirements for activities affecting

quality and failure to provide appropriate acceptance

criteria for activities affecting quality is a violation of

10 CFR 50 Appendix B, Criteria V. This violation will be

identified as 424/85-60-01 and 425/85-40-01: " Failure To

Comply With Welding Requirements".

.

(2) Welder Qualification (551578)

The inspector reviewed the licensee's program for qualification of

welders and welding operators for compliance with QA procedures

and ASME Code requirements. The applicable code for weldor

qualification is ASME B&PV Code Section IX as invoked by GPC

Specification X2AG06 Rev. 4 and X4AXZ01, Section P.1.

The inspector observed the following inprocess performance

qualification tests to determine whether the testing was

consistent with the code and regulatory requirements. The

inspector confirmed by positive identification that the person

welding the test weldment was indeed the person being qualified.

CB&I - Welder WLS, WPS-E7018/33710, Rev. 1

(3) Weld Heat Treatment (551568)

Weld Joint Preheating

(a) The inspector reviewed the licensee's program to determine

whether procedures properly specify acceptable preheating

methods, provide requirements for monitoring and recording

preheat temperature before, during, and if specified, after

welding, and whether specified temperature control is

utilized on in-process welds which are required to be

maintained at pre-heat for extended time periods.

. . - . . .. - __ .

.

8

(b) By direct observation and review of records, the inspector

observed / reviewed the preheating activities for the weld

joints listed in paragraph 6b(1) to determine whether preheat

control procedures were being following during field welding

activities.

Within the areas examined, no violations or deviations were identified

except as noted in paragraph 6 b(1).

!

7. Safety-Related Heating, Ventilating, and Air Conditioning (HVAC) Systems

(50100)

l The inspector reviewed the licensee's HVAC program to determine whether the

,

technical requirements detailed or referenced in the facility Safety

a

Analysis Report associated with safety-related HVAC systems had been

adequately addressed in the construction specifications, drawings, and work

procedures. The applicable codes for the fabrication and installation of

HVAC systems are:

AWS-D1.1-77

AWS-09.1-80

AWS-D3.0-77

"

. ASME Section IX-80

ANSI B31.1-77

Observation of Work and Work Activities

a. Personnel Interviews (Installation Practices)

The inspector interviewed six craftsmen engaged in the installation of

seismic supports, and duct work, to confirm the following:

-

Predefined and approved procedures are followed when it becomes

,

necessary to relocate any seismic support or other safety-related

,

equipment from its original location specified on drawings.

-

Any preinstallation field repairs or adjustments to the HVAC

equipment are performed in accordance with the manufacturer's

instructions and specifications to ensure that proper materials,

replacement parts, and supplies are used, performance requirements

are met and are reviewed by engineering for acceptance.

- Personnel engaged in the installation and inspection of safety-

related supports, ductwork, and other safety-related HVAC equip-

ment have received adequate training to understand and perform

work contained in relevant work and inspection procedures and

instructions.

!

i

i

l

i

--.- --

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

- - _ - , _ -.

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

'

.

!

9 t

b. Installation Activities

,

The inspector witnessed portions of the installation activities

indicated below +o verify the following:

- The latest issue (revision) of applicable drawings or procedures

>

is available to the installers and is being used.

- Modifications to supports are approved by appropriate personnel

<

before implementation.

Activity Component

Welding & Fitting Duct Support 211B109-33

Welding & Fitting Duct Support 211A115-95

Welding & Fitting Duct Support 211A102-48

i With regard to the inspection above, the inspector noted that P/K-F

4 Drawing AX2D67W013 revision 6 on P/K-F 6700W Stick No. 2 was missing

FCRB-2775F dated 12/6/85. Examination of the drawing indicated that

the FCRB had never been attached. The above is contrary to P/K-F

Procedures JP-6.1, Rev. 9c, " Document Control" paragraph 6.1.3D and

i JP-3.1 Revision 10a, "D . ign Control" paragraph 4.5, which require

j FCRBs to be distributeo and posted to the applicable drawings

! immediately. At the time of this inspection, this FCRB was 13 days

old. The inspector, could not determine daring this inspection the

!

-

extent of unposted drawing charges. Pending further NRC inspection in ,

this area, this matter will be identified as unresolved item l

!

424/85-60-02 and 425/85-40-02: "Unposted Drawing Change Documents".

Within the areas examined, no vio?ations or deviations were identified.

.

l

I

i

!

I

_ _ _ , ._ , _ . _ _ _ _

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