ML20140D434
| 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: |
| References | |
| 50-424-85-40, 50-424-85-60, NUDOCS 8601290308 | |
| Download: ML20140D434 (10) | |
See also: IR 05000424/1985060
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UNITED STATES
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NUCLEAR REGULATORY COMMISSION
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REGION ll
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101 MARIETTA STREET, N.W.
- .
ATLANTA, GEORGI A 30323
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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
,
W. F
'
'le; p%~a
Date Signed
l'/!b6
Approved by:
l.dI
J
J.
Bla'ke, Se Kion Chief
Date Signed
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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).
$[
00
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.
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
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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
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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)
,
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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)
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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
determine whether adequate records exists to confirm
i
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)
The inspector reviewed pertinent work and inspection records
i
for structure / support listed below to determine whether those
records meet established procedures and whether those records
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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'y records.
r
(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
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
Welding at three locations on the Condensate Storage
Tank (Unit 2)
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Ingals
,
,
Stack Support Frame M0lG-S-416A, Rev. O
Trash Rack Screen Cage Structure M0lG-S-311A, Rev. O
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Stack Platform M0lG-S-400A, Rev. O
PPP
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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)
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.
27-III/I-8-08-12, Rev 4/14/83, had drawn welder filler
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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
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material with 35 amps, contrary to the assigned WPS,
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27-III/I-8-0B-12 which specifies a welding current range of
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100-150 amps for use with 3/32-inch diameter filler material.
The inspector discussed the above with the licensee who
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agreed that the welder deviated from the assigned welding
3
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
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groove weld, and second it is not possible to make a weld on
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the inside of the tube steel on the second bevel face.
Ingals welders prepared and welded the joint with flair bevel
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joint preparation.
The inspector discussed the above with
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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
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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.
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(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
,
Analysis Report associated with safety-related HVAC systems had been
a
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
"
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:
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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
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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-
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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.
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b.
Installation Activities
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The inspector witnessed portions of the installation activities
indicated below +o verify the following:
The latest issue (revision) of applicable drawings or procedures
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is available to the installers and is being used.
>
Modifications to supports are approved by appropriate personnel
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before implementation.
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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
Drawing AX2D67W013 revision 6 on P/K-F 6700W Stick No. 2 was missing
4
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
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JP-3.1 Revision 10a, "D . ign Control" paragraph 4.5, which require
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FCRBs to be distributeo and posted to the applicable drawings
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immediately.
At the time of this inspection, this FCRB was 13 days
old.
The inspector, could not determine daring this inspection the
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extent of unposted drawing charges.
Pending further NRC inspection in
,
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this area, this matter will be identified as unresolved item
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424/85-60-02 and 425/85-40-02:
"Unposted Drawing Change Documents".
Within the areas examined, no vio?ations or deviations were identified.
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