ML20244B600

Insp Rept 50-458/89-12 on 890327-31.Violation Noted.Major Areas Inspected:Welding Activities.Welding Program Well Defined & Includes Monitoring by Qc.Weakness in Welder Qualification Program Noted

ML20244B600
Person / Time
Site:	River Bend
Issue date:	04/06/1989
From:	Barnes I, Gilbert L NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
To:
Shared Package
ML20244B587	List: ML20244B584 ML20244B594 ML20244B600
References
50-458-89-12, NUDOCS 8904190285
Download: ML20244B600 (6)

See also: IR 05000458/1989012

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t.. APPENDIX B

U.S. NUCLEAR REGULATORY' COMMISSION

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REGION IV

NRC Inspection Report:/ 50-458/89-12 Operating. License: NPF-47 <

.. . Dock'et: : 50-458

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< Licensee:.' Gulf States Utilities CompanyL q

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E Facility Name: River Bend Station :I

Inspection At: ' River Bend Station, St. Francisville, Louisiana

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. Inspection Conducted:' March 27-31, 1989

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. Inspector: /

L.) D.. Gilbert,' Reactor Inspector, Materials

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and Quality Programs ~Section, Division of -

Reactor Safety. ,

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Approved:

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Barnes, Chief Materials and Quality

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Date

Programs Section, Division of Reactor Safety

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Inspection Summary

Inspection Conducted March 27-31, 1989 (Report 50-458/89-12)

Areas Inspected: Routine, unannounced inspection of welding activities.

Results: In general, the welding program, including welder qualification and

. filler material control, is well defined and includes monitoring by quality

control. However, a weakness in the welder qualification program was identified

and is discussed in paragraph 2. In the area of welding, one violation was

identified (paragraph 2) for failure to follow procedures and ASME Section IX

Code requirements for qualifying welding procedure specifications.

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DETAILS

1.' Fersons Contacted

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• J. C. Deddens, Senior Vice President

• T. F. Plunkett,_ Plant Manager

• M. F. Sankovich, Manager, Engineering Department

• T.'L. Crouse, Manager.-Quality Assurance-

• K. F. Suhrke, Manager,' Project Management

• J. E.' Booker, Manager, River- Bend Oversight

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• L. A.: England, Director, Licensing .

• W. H. Odell, Manager.: Administration 4

• G. Mahan, Senior Welding' Engineer

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• J. R. Hamilton, Director, Design Engineering

• T. L. Weir, Director, Materials Management

-*M. S. Feltner, Engineer - Nuclear Licensing

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• A'. J.' Kugler, Process System Supervisor

• J. W.' Cook, Lead Environment Analyst - Licensing.

NRC-

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'*E. 'J. Ford, Senior Resident Inspector

• W. B.: Jones, Resident Inspector

The NRC inspector also interviewed other licensee employees during the

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inspection.

• Denotes attendance at exit interview conducted on March 31, 1989.  ;

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Welding Activities (55050 and 55100)-

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2. ]

a. Review of Welding Program and Procedures

The NRC inspector reviewed the licensee's program for controlling

safety-related welding activities to assure that welding is controlled

and accomplished by qualified personnel using qualified procedures in

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accordance with applicable codes, standards, specifications, criteria,  ;

and other special requirements. The following licensee documents were

included in the review:

' Procedure No. ENG-3-003, " Repair / Replacement Program," Revision 1

• Procedure No. EDP-ME-61 " Handling of ASME Section XI

Repair / Replacement Packages and Preparation of NIS-2 Reports,"

Revision 4

• Procedure No. SPP-7001, " General Welding Procedure ASME/ ANSI,"

Revision 2

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Procedure No. SPP-7004, " Qualification of Welding Procedure

Specification," Revision 3

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Procedure. No. SPP-7006, " Welder Perfomance Qualification

Procedure," Revision'6 )

'* - Procedure No. SPP-7009, " Storage, Handling and . Issuing Filler

Material," Revision 5

Procedure No. SPP-7010. " Preparation of Weld Data Sheets,"- 4

Revision 3 l

Procedute No. QCI-3.11, " Monitoring of Welders, Brazers and

Welding Operators," Revision 4  ;

In addition to the above programmatic procedures, the following

welding procedure specifications (WPSs) and their supporting procedure . ,

qualification reports (PQRs) were reviewed:  !

'* WPS W3-01, Revision 4

WPS W3-02, Revision 4

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WPS W3-08-TW, Revision 0-

In reviewing the WPSs and their supporting PQRs the NRC inspector l

identified two discrepancies concerning the qualifications of WPSs.' l '

The first discrepancy noted was that the 500*F maximum interpass

temperature specified by WPS W3-01, Revision 4, was not qualified by

the supporting PQRs -for materials requiring impact properties and

postweld heat treatment. The only testing performed to qualify

materials requiring impact properties and postweld heat treatment is '

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documented in PQR 86-1-2 Which is dated April 16, 1986. The maximum

interpass temperature recorded on this PQR is 325*F; therefore, the

maximum interpass temperature qualified would be 425*F as required by

paragraph QW-406.3 of ASME Code Section IX. The second discrepancy

noted was that the qualification of WPSs was not accomplished using

the latest edition and current addenda of Section IX as required by

Procedure SPP-7004. For example, PQRs 88-11-WP and 89-88-TW-2 state

that the qualifications were perfomed in accordance with Section-IX,

1986 Edition and 1986 Addenda when the current addenda at the time was

the Winter 1987 Addenda for one and Sunener 1988 Addenda for the other.

The failure.to comply with procedural requirements and ASME Section IX  ;

Code requirements in qualifying welding procedure specifications is an  !

apparent violation. (458/8912-01)

b. Observation of Work Activities

The NRC inspector inspected the storage, handling, and issue of

welding filler material for compliance with Procedure SPP-7009. The

welding material was stored in a designated area of the main tool

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issue room and only issued to welders by personnel that had received -

training on Procedure SPP-7009. The welding material storage ovens )

were within the temperature range specified in Procedure.SPP-7009 for j

each type of coated electrode. The welding materials were marked with i

heat and lot numbers for traceability to the manufacturer's certified

matrrial test report and receiving inspection report.

The NRC inspector observed the visual inspection by Quality Control

personnel of the four Class 2 pipe welds in the 14-inch diameter

residual heat removal system. A modification of the system was being

made to install an orifice plate in two pipe lines. The carbon steel

pipe lines were identified as 1RHS014-062-2 and 1RHS014-9-2. The

receiving inspection documents for the welding material used on the

welds were reviewed for compliance with procurement requirements. The

qualification records of the six welders thg. twelded on these four

welds were reviewed for compliance with the requirements of

Procedure SPP-7006. All six welders were qualified using the bend

test which is a less stringent test .than the optional radiographic

test. The initial radiographic examinations of the four pipe welds

were all rejected by Quality Control. This high reject rate would

indicate a weakness in the licensee's welder qualification program.

c. Review of Records.

The NRC inspector reviewed seven completed weld data sheets. Three of

the welds were made as part of a valve replacement in a 6-inch

diameter Class 1 pipe line in the reactor core isolation cooling

system. Four of the welds were made as part of a modification to

delete a bypass line and valve in a 1 1/2-inch diameter Class 1 pipe

line in the reactor water cleanup system. The piping lines and welds

are listed below:

• Line 1-ICS-006-6-1: Welds XI-FWOO2, XI-FW003, and XI-FWOO4

• Line 1-WCS-003-006-1: Welds XI-FWOO4, XI-FW005, XI-FWOO6, and

XI-FWOO7

The weld data sheets were retrievable, readable, and complete.

3. Exit Interview

An exit interview was conducted on March 31, 1989, with those personnel

denoted in paragraph 1. At the exit interview, the NRC Inspector informed

the licensee that the failure to follow procedures for qualifying welding

procedure specifications is an apparent violation. No information was

presented to the NRC inspector that was identified by the licensee as

proprietary.

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Contrary to Criterion IX of 10 CFR Part 50 and Procedure

= SPP-7004, two discrepancies were~ identified concerning the

,,. qualifications of. welding procedure specifications. The first

discrepancy is that Welding Procedure Specification W3-01,

" Revision.4 specifies a 500 F maximum interpass temperature which

a was not qualified by the supporting procedure qualification

reports for materials requiring impact properties and post weld

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-- -- heat treatment'. The maximum interpass temperature recorded on

a Procedure Qualification Report No. 86-1-2 is 325 F, therefore

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the maximum interpass temperature qualified is 425 F per

paragraph 406.3 of ASME Code Section IX. The second discrepancy

"- is that welding procedure specification qualifications are not

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being accomplished using the latest editi'on and current addenda

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of Section IX, for example, Procedure Qualification Reports

• _. 88-11-WP and 89-88-TW-2 stdte that the qualifications were

a performed in accordance with Section IX, 1986 Edition and 1986 '

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Addenda when the current addenda at.the time was the Winter 1987

L Addenda for one and Summer 198~8 Addenda for the other. -

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