ML20203A923
| ML20203A923 | |
| Person / Time | |
|---|---|
| Issue date: | 04/04/1986 |
| From: | Merschoff E, Petrosino J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
| To: | |
| Shared Package | |
| ML20203A896 | List: |
| References | |
| REF-QA-99901001 99901001-86-01, 99901001-86-1, NUDOCS 8604170632 | |
| Download: ML20203A923 (8) | |
Text
. O ORGANIZATION: GENERAL ELECTRIC COMPANY NUCLEAR FIELD SERVICES DEPARTMENT KING OF PRUSSIA, PENNSYLVANIA REPORT INSPECTION INSPECTION N0.: 99901001/86-01 DATE: 1/27-31/86 JN-SITE HOURS: 60 CORRESPONDENCE ADDRESS: General Electric Company Nuclear Field Services Department ATTN: Mr. G. C. Nelson, Manager 1000 First Avenue King of Prussia, Pennsylvania 19406 ORGANIZATIONAL CONTACT: Mr. Vincent P. Kenney, QA Manager TELEPHONE NUMBER: (215) 962-6007 NUCLEAR INDUSTRY ACTIVITY: The General Electric (GE) Nuclear Plant Services Department offers NRC licensees the following services: (1) ASME Section III Code Work; (ASME Stamps "N", "NA", and "NPT" are held by GE) and (2) 10 CFR Part 50 Appendix B modification, repair, maintenance, and replacement services. The area of services may be mechanical, electrical, civil, or structural.
ASSIGNED INSPECTOR: (
Date J. f.[dtros~ino, Reactive Inspection Section (RIS)
OTHER INSPECTOR (S): E. H. Gray, Region I, Engineering Programs Branch K. G. Aspinwall, Brookhaven Naticnal Laboratory APPROVED BY: C h u jb E. W. Merschoff, Chief ( RIS, Vendor Program Branch Dhte INSPECTION BASES AND SCOPE:
A. BASES: 10 CFR Part 21, Appendix B of 10 CFR Part 50 and ASME Section IX.
B. SCOPE: This inspection was made to: (1) verify the Quality Assurance (QA) program implementation in the a:eas of welder performance qualifi-cations and welding procedure qualification; (2) review and obtain copies of specific GE " Service Advice Letters;" and (3) discuss LER "50-219/85-14 concerning low oil level in two GE transformers at the Oyster Creek station.
PLANT SITE APPLICABILITY: Recent GE services were provided at: Hope Creek 1 & 2 (50-354/355); Indian Point 2 (50-247); Limerick (50-352); Oyster Creek (50-219);
Peach Bottom 2 (50-277); Perry (50-440); Pilgrim (50-293); Salem (50-272);
Susquehanna 1 & 2 (50-387/388); and Wolf Creek (50-482).
8604170632 860414 PDR GA999 ENVGENE 99901001 PDR
o ORGANIZATION: GENERAL ELECTRIC COMPANY NUCLEAR FIELD SERVICES DEPARTMENT KING 0F PRUSSIA, PENNSYLVANIA REPORT INSPECTION N0.: 99901001/86-01 RESULTS: PAGE 2 of 6 A. VIOLATIONS:
None.
B. NONCONFORMANCES:
- 1. Centrary to Criterion V, " Instructions, Procedures, and Drawings,"
of Appendix B to 10 CFR Part 50, and Article III, " Welding Performance Qualifications," of Section IX of the ASME Boiler and Pressure Vessel Code, no procedures or instructions had been written or implemented to assure that full supervision and control of the ASME Section IX welder performance qualification testing is achieved. (85-01-01)
- 2. Contrary to Criterion XVIII, " Audits," of Appendix B to 10 CFR Part 50 and Section 18, " Audits," of GE's QA Manual PIA-AE-11, GE failed to adequately carry out a planned and periodic management audit system, and verify compliance with all aspects of the quality assurance program, specifically: (85-01-02)
- a. Internal audits have not been scheduled or performed at the Devon, Pennsylvania welder performance qualification testing facility.
- b. The 1985 " Management Audit of the Program" has not been performed.
- c. The scheduled 1984 " Management Audit of the Program" was not performed as scheduled. However, a make-up audit for 1984 was performed in March of 1985.
C. UNRESOLVED ITEMS:
None.
D. STATUS OF PREVIOUS INSPECTION FINDINGS:
Not applicable.
E. OTHER FINDINGS OR COMMENTS:
- 1. Welder and Welding Procedure Qualifications The areas of welder performance qualification and welding procedure qualification were examined for ccmpliance to the ASME Code Section IX requirements as applictole to the nuclear safety related systems.
N ORGANIZATION: GENERAL ELECTRIC COMPANY NUCLEAR FIELD SERVICES DEPARTMENT KING 0F PRUSSIA, PENNSYLVANIA REPORT INSPECTION N0.: 99901001/86-01 RESULTS: PAGE 3 of 6 Welder performance qualification testing for the Limerick nuclear station was in progress during the NRC inspection. Different portions and aspects of the performance testing were observed, as follows:
- a. ASME Code Section IX requirements.
- b. 10 CFR Part 50, Appendix B requirements.
- c. Welder identification verification.
- d. Documentation of test observation.
- e. Pipe position, dimensions, and materials.
- f. Supervision of testing.
- g. Documentation of acceptability of test coupon.
- h. Documentation of ASME Section IX form for qualification.
- i. Coupon orientation marking.
- j. Utilization of procedures and instrumentation for assuring acceptable fit-up and tack welding, visual inspection of root pass, etc.
The inspection determined that the requirements of the ASME Code,Section IX were being met with the exception of welder performance qualification test control. Verification of the welders identity was being performed by GE, Devon, Pennsylvania personnel. This verification was included as a part of the welder performance qualification initial check in process.
However, the Nuclear Field Services Department (NFSD) had not written or used tny procedures or instructions to conduct and control the welder performance qualification testing activities (reference Nonconformance 86-01-01). This was evidenced by several inconsistencies which were observed and noted:
One test pipe assembly (TPA) for a 6G position test did not have the weld procedure process number stenciled on it. (Different weld processes were being performed at this time.)
One TPA had the " Top" reference position (0 degrees) identified at two separate locations around the circum- i ference of the TPA. (This was identified during an j in-process welder performance qualification test.) '
Welders were being qualified for the Limerick project using site specific welding procedures. However, the visual inspection procedure which was being utilized I on January 29, 1386, was for the Peach Bottom site (No. PB-85-7.0), not the Limerick site.
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ORGANIZATION: GENERAL ELECTRIC COMPANY
. NUCLEAR FIELD SERVICES DEPARTMENT KING OF PRUSSIA, PENNSYLVANIA REPORT INSPECTION NO.: 99901001/86-01 RESULTS: PAGE 4 of 6 .
Another welder's performance qualification test was allowed to start without having the " Top" reference location on the TPA identified. This test started and was observed by the NRC on January 28, 1986. Subsequently, the test was started again with a new TPA which was correctly marked.
- 2. Audits The NFSD audit schedule was reviewed for the required system of planned and periodic audits "to determine the effectiveness of the program." Audit reports were reviewed in the areas of quality assurance; ASME Section III, Division I; ANSI-N 626.0; and NFSD program management audits.
A system of planned and periodic audits is controlled by the quality assurance department and is adequate. However, there were two areas in which NFSD failed to implement their program.
Periodic audits were not performed at or planned for the Devon facility for the nuclear safety related activities. The Devon facility is the location where the site specific welder performance qualification testing is performed (reference Nonconformance 86-01-02).
In the area of the annually scheduled NFSD management audits, a review of activities for the last three years was performed.
Annual audits for the years 1983, 1984, and 1985 were reauested.
The review revealed that as of January 30, 1986 (reference Nonconformance 86-01-02):
- a. The 1983 management audit was performed in May of 1983, as scheduled.
- b. The 1984 management audit was not performed within the calendar year as scheduled.' However, an audit was performed in March of 1985 which stated it was the "make-up" 1984 audit.
i
- c. The 1985 management audit was not performed as scheduled.
NFSD indicated that a "make-up" audit was tentatively scheduled for April of 1986.
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ORGANIZATION: GENERAL ELECTRIC COMPANY NUCLEAR FIELD SERVICES DEPARTMENT KING OF PRUSSIA, PENNSYLVANIA REPORT INSPECTION N0.: 99901001/86-01 RESULTS: PAGE 5 of 6
- 3. GE Product Department Service Advice Letters Discussions were conducted with NFSD personnel concerning GE
" Service Advice Letters" (SALs). The NRC inspector requested to review and obtain copies of specific safety related SALs which the King of Prussia office may have in their files. The purpose of obtaining the copies of certain safety related SALs is to aid the NRC in their licensee inspection efforts.
Copies of the requested safety related SALs were not obtained.
However, a listing was developed by NFSD of all of the SAL numbers which were in their files, along with a subject title for each. The listing of the SAL number and subject titles was provided to the NRC inspection team.
- 4. Oyster Creek Substation Transformer Oil Level The Oyster Creek station issued LER #50-219/85-19, dated 8/9/85, concerning low oil levels in two GE safety related transformers.
Discussions were conducted with the cognizant NFSD personnel regarding the areas of receiving, storing, installation practices, liquid level gauge, liquid temperature indicator, pressure-vacuum gauge, required maintenance of oil levels, and oil sampling practices. Additionally, specific information on the Oyster Creek problem and NFSD's subsequent thermographic and visual inspection work was discussed.
The information obtained will be transmitted to and discussed with the cognizant NRC staff to determine if additional inspections or other actions are required.
- 5. NRC Staff Concern The NRC staff had a concern regarding safety related activities performed at locations other tha'n plant sites. The concern was that the safety related activities could not be easily inspected for conformance to codes, standards, and regulatory requirements.
This inspection has concluded that the activities which were observed and examined at the General Electric facilities meet the intent of ASME Code Section IX, and Appendix B to 10 CFR Part 50.
O ORGANIZATION: GENERAL ELECTRIC COMPANY NUCLEAR FIELD SERVICES DEPARTMENT KTNG 0F PRUSSIA, PENNSYLVANIA i
REPORT INSPECTION N0.: 99901001/86-01 RESULTS: PAGE 6 of 6 F. PERSONS CONTACTED:
G. C. Nelson Manager - NFSD
- V. P. Kenney QA Manager
- R. Taron Quality Support Manager
- C. Logan Document Control Specialist R. E. Cameron NDE Specialist E. J. Hirtzo Electrical Service Manager D. J. DiFilippo QC Supervisor D. W. Diefenderfer Service Project Manager T. Byrum Service Supervisor J. F. Plantz Service Supervisor J. E. McClure Welding Supervisor W. S. Fingrutd Welding Engineer S. Ebneter Director, RI, NRC )
- H. Gray Engineer, RI, NRC
- K. Aspinwall Consultant, BNL
- J. J. Petrosino Inspector, VPB, NRC
- present at exit meeting l
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