ML20244B600
| 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: |
| References | |
| 50-458-89-12, NUDOCS 8904190285 | |
| Download: ML20244B600 (6) | |
See also: IR 05000458/1989012
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APPENDIX B
U.S. NUCLEAR REGULATORY' COMMISSION
REGION IV
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NRC Inspection Report:/ 50-458/89-12
Operating. License: NPF-47
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. Dock'et: : 50-458
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< Licensee:.' Gulf States Utilities CompanyL
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Facility Name:
River Bend Station
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- Inspection At: ' River Bend Station, St. Francisville, Louisiana
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. Inspection Conducted:' March 27-31, 1989
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. Inspector:
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L.) D.. Gilbert,' Reactor Inspector, Materials
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and Quality Programs ~Section, Division of
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Reactor Safety.
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Approved:
.I. Barnes, Chief Materials and Quality
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Programs Section, Division of Reactor Safety
Inspection Summary
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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
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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
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- J. E.' Booker, Manager, River- Bend Oversight
- L. A.: England, Director, Licensing
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- W. H. Odell, Manager.: Administration
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- G. Mahan, Senior Welding' Engineer
- J. R. Hamilton, Director, Design Engineering
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- T. L. Weir, Director, Materials Management
-*M. S. Feltner, Engineer - Nuclear Licensing
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- A'. J.' Kugler, Process System Supervisor
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- 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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2.
Welding Activities (55050 and 55100)-
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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
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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
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Specification," Revision 3
Procedure. No. SPP-7006, " Welder Perfomance Qualification
Procedure," Revision'6
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Procedure No. SPP-7009, " Storage, Handling and . Issuing Filler
Material," Revision 5
Procedure No. SPP-7010. " Preparation of Weld Data Sheets,"-
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Revision 3
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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 .
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qualification reports (PQRs) were reviewed:
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WPS W3-01, Revision 4
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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
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identified two discrepancies concerning the qualifications of WPSs.'
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The first discrepancy noted was that the 500*F maximum interpass
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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
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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
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training on Procedure SPP-7009. The welding material storage ovens
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were within the temperature range specified in Procedure.SPP-7009 for
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each type of coated electrode. The welding materials were marked with
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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. welded on these four
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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
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SPP-7004, two discrepancies were~ identified concerning the
qualifications of. welding procedure specifications.
The first
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discrepancy is that Welding Procedure Specification W3-01,
Revision.4 specifies a 500
F maximum interpass temperature which
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was not qualified by the supporting procedure qualification
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reports for materials requiring impact properties and post weld
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heat treatment'.
The maximum interpass temperature recorded on
Procedure Qualification Report No. 86-1-2 is 325
F, therefore
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the maximum interpass temperature qualified is 425
F per
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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
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88-11-WP and 89-88-TW-2 stdte that the qualifications were
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
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Addenda for one and Summer 198~8 Addenda for the other.
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U.S. NUCLEAR REG ULATORY COMMISSION
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