ML20151W499
| ML20151W499 | |
| Person / Time | |
|---|---|
| Site: | Cooper  |
| Issue date: | 04/25/1988 |
| From: | Barnes I, Gilbert L NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I), NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20151W468 | List: |
| References | |
| 50-298-88-10, NUDOCS 8805030413 | |
| Download: ML20151W499 (5) | |
See also: IR 05000298/1988010
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APPENDIX B
U.S. NUCLEAR REGULA10RY COMMISSION
~ EGION IV
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NRC Inspection Report:
50-298/88-10
Operating License:
Docket:
50-298
Licensee: Nebraska Public Power District (NPPD)
P.O. Box 499
Columbus, NE 68601
Facility Name:
CooperNuclearStation(CNS)
Inspection.At:
CNS, Nemaha, NE
Inspection Conducted: April 4-7, 1988
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Inspector:
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L. 0. Gilbert, Reactor Inspector, Materials
Uate '
and Quality Programs Section, Division of
Reactor Safety
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Approved:
/-
434
Y 2.6
Date
f .jBarrps, [hief, Materials and Quality
frograms Section, Division of Reactor Safety
Inspection Summary
Inspection Conducted April 4-7, 1988 (Report 50-298/88-10)
Areas Inspected:
Routine, unannounced inspection of licensee action on
previously identified inspection findings, welding activities, and allegation
assessment.
Results:
Within the three areas inspected, one violation was identified
(failure to perform Quality Assurance surveillance to verify that welding is
conducted in accordance with procedures, paragraph 3).
8805030413 880427
ADOCK 05000298
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DETAILS
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1.
Persons Contacted
- G. R. Horn, Division Manager of Nuclear Operations
- G. E. Smith, Quality Assurance (QA) Manager
- E. M. Mace, Engineering Manager
- R. A. Jansky, Outage and Modification Manager
- D. M. Norvell, Maintenance Manager
- J. M. Meacham, Senior Manager, Technical Support
- J. Hilgenkamp, Lead Mechanical Engineer
- G. R. Smith, Licensing Supervisor
- J. L. Smith, Technical Weld Specialist
- L. E. Bray, Regulatory Compliance Specialist
Bechtel Energy Corporation
- P. M. Steeb, Bechtel Field Engineer
Power Plant Maintenance (PPM)
J. Hearn, Welding Coordinator
Southwest Engineering Corporation (SEC0)
T. Love, Quality Control Inspector
NRC
- W. R. Bennett, Senior Resident Inspector
- E.
A. Plettner, Jr. , Resident Inspector
The NRC inspector also interviewed other licensee and contractor employees
during the inspection.
- Denotes those attending the exit interview.
2.
Licensee Action on Previously Identified Inspection Findings
(92701
and 92702)
(Closed) Open Item (298/8720-01):
Editorial Discrepancies Concerning
Revisions to the Welding Procedure Specifications in Maintenance
Procedure 7.7
The welding procedure specifications in Maintenance Procedure 7.7 have
been rewritten and issued as separate procedures.
The NRC inspector
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reviewed 13 of the revised procedures.
No revision inconsistencies were
identified in the new procedures.
This open item is considered closed.
(Closed) Unresolved Item (298/8720-02):
Technical Discrepancies in
Procedures with Materials Requiring Notch Toughness Properties - The
licensee has reviewed the applications of the procedures containing
technical discrepancies and determined that the safety-related welds that
are in the facility were performed within the qualified ranges of the
procedures.
The technical discrepancies in WPS P1-B and NPS P1-G have
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been corrected and the prccedures rewritten and rectalified. The licensee
has deleted WPS P1-F (CVN) because it was applicabie to a single plant
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modification, which has been completed.
This unresolved item is considered closed.
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(Closed) Violation (298/8720-03):
Failure to Perform a Required
Examination - During this outage, the welds for the replacement of valve
RWCU-MOIS were liquid penetrant examined in accordance with the
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. construction code, ASME Section III,1983 Edition through Sumer 1983
Addenda. One weld was rejected, repaired by filing the surface, and
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accepted after reexamination.
The repaired weld also passed the ASME
Section XI inservice inspection examination using the liquid penetrant
method. The licensee has issued Station Procedure 0.30, "ASME Section XI,
Repair / Replacement Program" to ensure that similar violations do not
occur.
This violation is considered closed.
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3.
Welding Activities
(55050 and 55100)
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a.
Welder Qualification
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The NRC inspector reviewed the welders qualification program for
contract welders qualified for making safety-related welds.
The NRC
inspector noted that the method of documenting the qualification of
the Power Plant Maintenance (PPM) welders was not adequately
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specified in the NPPD Station Procedure for Welder Performance
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Qualification, Procedure 7.7.2.1.
This is an open item pending the issuance of a change to
Procedure 7.7.2.1 to clarify the administrative controls associated
with the qualification of contract welders and the documentation of
actual test conditions by the person conducting the test.
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(293/8810 01)
b.
Observation of Work Activities
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The NRC inspector observed safety-related activities associated with
fabricating supports for two design changes.
In addition to
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observing weldments for the supports, the following related documents
were reviewed:
(1) Design Change 87-113
Maintenance Work Request 88-1156
Weld Checklist 88-292
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Pipe Support Orawing SX933N
Pipe Support Drawing SK924N
Receipt Inspection Report for P.O. 264295
Station Procedures 7.7.16, WPS for PI-STRUCT
(2) Design Change 87-063
Maintenance Work Request 88-1049
Weld Checklist 88-362
Drawing SKE-HV-12
CMTR for P.O. 264295 (E7018)
Station Procedure 7.7.13 WPS for AWSD1.1
In the areas inspected, the work was consistent with the design
requirements, the weld filler material was that required by the weld
procedure specification (WPS), the welders were qualified for the
WPS, and the entries on the weld checklist were consistent with the
status of the work.
However, the welders were not familiar with the
WPS and the foreman of the welders performing the work did not have a
copy of the WPS in the work area. The NRC inspector determined that
QA surveillances had not been performed in this aree if special
processes. control and the surveillance checklists were r.ot available
for accomplishing surveillances to assure that special processes are
conducted in accordance with written and approved procedures,
drawing, and/or instructions.
This is an apparent violation for failure to perform QA surveillances
is conducted in accordance with written and
to verify that welding (298/8810-02)
approved procedures.
4.
Allegation Followup (99014)
(Technically closed) Allegation (4-88-A-022): An allegation was made to
the NRC that PPM welders for the moisture separator modification work
were:
(a) welding test plates in other than the proper position to
qualify for the horizontal, vertical, and overhead positions, and
(b) welding test plates for other welders who were not able to qualify
themselves.
The alleger later provided the names of two PPM welders who
the alleger did not believe could pass the qualification tests.
The NRC inspector interviewed eight PPM welders, interviewed the person
conducting welder performance qualification testing for PPM, reviewed the
welder performance qualification logs for testing of PPM welders, and
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observed the qualification testing of PPM welders that were welding in the
vertical and overhead positions.
The safety analysis report for CNS classifies the moisture separators as
nonessential; therefore, the moisture separators are not safety-related.
Southwest Engineering Corporation (SECO) is contracted to perform the
modifications to the moisture separators.
SEC0 is using PPM welders who
pass the performance qualification test for four'SEC0 welding procedures.
The NRC inspector reviewed the qualifications of the two PPM welders
who were alleged had others complete their qualifications tests because
they were unable to pass the qualification tests.
The two welders were
documented as qualified for welding the moisture separators but did not
pass all the qualification tests and therefore, were limited to one or two
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of the four SECO welding procedures. One of the two welders had all
qualifications cancelled on March 16, 1988, for unacceptable workmanship
on the moisture separator welds.
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The remaining PPM welders used for welding the nonsafety-related moisture
separators are qualified to SEC0 welding procedures and would have to be
retested using NPPD welding procedures before welding any safety-related.
work.
Tiicre was no information provided during the interviews of already
qualified welders that would indicate that the test plates used in their
original qualifications were not positioned as required by procedure and
therefore the (a) portion of the allegation could not be substantiated.
in regard to the (b) portion of the allegation, while it was not
conclusively verified that welders other than those documented as
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qualified made the test coupons as alleged, it does appear.that at least
one of the two welders identified by the alleger as unqualified may not
have been able te pass the test. The allegation is therefore considered
to be partially substantiated. As noted above, the welded components
involved are not safety-related and thus not within the licensee's QA
program nor within the normal regulatory purview of the NRC.
There were
no additional technical issues in this allegation.
5.
Exit Interview
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The NRC inspector summarized the inspection scope and findings on April 7,
1988, with those persons identified in paragraph 1.
The licensee was notified on April 15, 1988, that the QA surveillance of
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welding activities wss being changed from an open item to an apparent
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violation.
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