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U.S. NUCLEAR REGULATORY C0tiMISSIONOFFICE OF INSPECTION AND ENF0kCEffENT

REGION III

Report No. 50-461/80-07

Docket No. 50-461 License No. CPPR-137

Licensee: Illinois Power Company500 South 27th StreetDecatur, IL 62525

Facility Name: Clinton Power Station, Unit 1

Inspection At: Clinton Site, Clinton, IL

Inspection Conducted: April 22-24, 1980

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8 80Inspector: . W. K. Lee -

irm a. / nApproved By: D. H. Danielson, Chief 8 d'#

Engineering Support Section 2;

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Inspection Siunmary

Inspection on April 22-24, 1980 (Report No. 50-461/80-07)Areas Inspected: Reactor coolant pressure boundary and safety related

!piping and welding QA manuals, procedures, and work activities. TheI

inspection involved a total of 18 inspector hours on site by one NRCinspector.

Results: Of the six areas inspected, no apparent items of noncompliancewere identified in five areas; three apparent items of noncompliance wereidentified in one area (infraction - failure to properly store weldingmaterial - Paragraph 2.b; infraction - failure to verify conformance withrequirements during inspection - Paragraph 8; infraction - failure to con-form with procedural parameters - Paragraph 3).

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DETAILS

Persons Contacted

Principal Licensee Employees

*G. M. Brashear, Manager, Clinton Site*R. J. Canfield, Director, Construction*L. Dozier, Piping and Mechanical*R. W. Folck, Construction, Quality Assurance*J. F. Hampton, Supervisor, Construction, Quality Assurance*M. Tindill, Quality Assurance Specialist

Other Personnel

*R. D. Bennett, Manager, Technical Service, Baldwin Associates (BA)*F. Camasta, Piping, BA*J. Findley, Project Engineer, BA*S.G. Hall, Quality Control Engineer, General Electric Company*J.R. Hilding, Quality Assurance Manager, BA*M. J. King, Authorized Nuclear Inspector, Hartford Steam Boiler Ins. Co.*J. Linehan, Manager, Quality Control, BA*E. Muelhausen, Piping, BA*H. R. Swift, Assistant Project Engineer, BA*T. Walker, Senior Quality Control Engineer, BA*C, Winfrey, Quality Control, BA

The inspector also talked with and interviewed several other licensee andhis contractor's employees, including a member of the technical servicesstaff, Quality Control and Quality Assurance personnel, and craftsmen.

* Denotes those present at the exit interview.

Functional or Program Areas Inspected

1. Reactor Coolant Pressure Boundary and Safety Related Piping - WeldingProcedures, Specificatiuns, and Quality Assurance Procedures

a. Quality Assurance Procedures

The inspector reviewed the Baldwin Associates, Incorporated (BA)Quality Assurance manual and procedures related to the weldingof reactor coolant pressure boundary and safety related piping.It was established that the manual and the procedures have notbeen revised since the last review (Report No. 50-461/80-03 ex-cept for four procedures. The revised portion of the fourprocedures were reviewed and determined to be acceptable.

b. Welding Procedures

The inspector reviewed the following BA welding procedures:

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*(1) GE/NP-1-1-BA-2L, Revision 2, and Procedure Qualification

Record (PQR) Nos. 20 and 21.

(2) GE/NP-8-8-BA-2L, Revision 2, and PQR No. 3183.

(3) NP-1-1-BA-L, Revision 4, and PQR Nos. 0606, 24, 25 and26.

(4) NP-8-8-BA-M, Revision 4, and PQR No. 109-16.

(5) N-1-1-B-S, Revision 7, and PQR Nos. 6907 and 44.

It was determined that ASME B&PV Code Section IX requirementswere met.

No items of noncompliance or deviations were identified.

2. Reactor Coolant Pressure Boundary and Safety Related Piping - WeldingMaterial Control

The inspector reviewed the following documents:a.

(1) BA procedure No. BTS-402, Revision 14, " Procedure Specificationfor the Procurement, Storage, and Control of Welding FillerMaterials."

(2) BA procedure No. BTS-402 (GE/ Weld Control), Revision 2," Procedure Specification for the Procurement, Storage,and Control of Welding Filler Materials."

(3) Receiving Inspection Reports, Material Certifications, andPurchase Orders for ER 309 welding rods with heat No.C3287T309, No. D3313T309, No. A3287T309, No. 6J12A mix 19,No. 6N22B mix 15, and No. 7A12B mix 9.

It was determined that the above requirements met the PSAR, 10 CFR50, Appendix B, and the applicable code and procedure requirements.

b. Control of Materials

The inspector toured the welding material issuance station No. 4.It was determined that (1) the welding materials are properlyidentified and segregated; (2) the temperature of the rod ovenis maintained; (3) records are properly kept; (4) issuance andreturn of welding materials are controlled in accordance with

approval procedures and (5) sandwiches were being stored ina rod oven, No. TS-192. This condition represents an item ofnoncompliance identified in Appendix A (461/80-07-01).

Except as noted, no items of noncompliance or deviations ;ere identified.

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* 3. Reactor Coolant Pressure Boundary Piping - Observation of WeldingActivities

The inspector observed the following activities:

Nuclear Boiler System weld No. B4 on traveller No. IB21-D302B-A-FI.a.,

b. High Pressure Core Spray System weld No. 1-HP-5-9.on travellerNo. HP-5-A.

c. Nuclear Boiler System weld No. C4 on traveller No. 1B21-D302C-A-FI.

d. Recirculation System weld no. A3 on traveller No. B33-G001-A.

It was determined that (1) work was conducted in accordance with thetraveller; (2) proper welding materials were used; (3) welding proce-dure requirements were met; (4) work area was free of weld rod-stubs;(5) physical appearance was acceptable; and (6) the weld bead widthof a fill pass on weld No. A3 on traveller No. B33-G001-A exceededthe welding procedure allowance.

This represents a noncompliance as identified in Appendix A (461/80-07-02).

Except as noted, no items of noncompliance or deviations were identified.

4. Reactor Coolant Pressure Boundary Piping - Observation of NDE WorkActivities

The inspector observed liquid penetrant examination on the followingwelds:

a. Recirculation System weld No. A-10 on traveller No. B33-G001-A.

b. Peactor Water Clean-up System welds No. 1RT-37-5W1, No. 1RT-37-SW2, No. 1RT-37-5W3, No. IRT-37, SW5 and No. 1RT-37-5W6 ontraveller No. FRT-37-A.

It was determined that (1) surface condition was acceptable, (2)procedure requirements were met, and (3) personnel were properlyqualified.

No items of noncompliance or deviations were identified.

5. Reactor Coolant Pressure Boundary and Safety Related Piping - WeldHeat Treatment

a. Review of Procedure

The inspector established that the welding procedures reviewedunder paragraph Ib of this report specified the acceptable pre-heating and monitoring methods.

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' b. Observation

While observing welding activities for items stated in paragraphs3 and 9 of this report, the inspector determined that preheat metthe procedure requirements.

No items of noncompliance or deviations were identified.

6. Reactor Coolant Pressure Boundary and Safety Related Piping - WelderQualification

The inspector reviewed the following documents:

a. BA Procedure No. BTS-401, Revision 9, " General Welding ProcedureSpecification."

b. Qualification records of twelve welders who performed welding onwelds stated in paragraphs 3 and 9 of this report.

The inspector determined that the above documents met the require-ments of ASME B&PV Code Section IX.

No items of noncompliance or deviations were identified.

7. Reactor Coolant I'ressure Boundary Piping - Special Welding Applications

The inspector observed grinding of defects of the Nuclear Boiler Systemweld No. B4 on traveller No. 1B21-D302B-A-FI. It was determined thatprocedure requirements were met and good construction practice was ad-hered to.

No itemt of noncompliance or deviations were identified.

8. Safety Related Piping - Observation of Work Activities

The inspector observed the fit-up and alignment of Residual HeatRemoval System weld No. 1-RH-9-2 on traveller No. RH-9-B. It wasdetermined that the internal surface alignment failed to meet theprocedure requirements. This represents an item of noncomplianceas identified in Appendix A (461/80-07-03).

9. Safety Reltted Piping - Observation of Welding Activities

The inspector observed the welding of High Pressure Core Spray Systemweld No. 1-HP-4-5 on traveller No. HP-4-A and Containment CombustibleGas Control System weld No. 1-HG-8-2 on tras'11er No. HG-8.

It was determined that (1) work was conducted in accordance withtraveller; (2) proper welding materials were used; (3) weldingprocedure requirements were met; (4) work area was free of weldrod-stubs; and (5) physical appearance was acceptable.

No items of noncompliance or deviations were identified.

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Exit Interview

The inspector met with the licensee representatives (denoted under PersonsContacted) at the conclusion of the inspection on April 24, 1980. The in-apector summarized the purpose and findings of the inspection. The inspec-tor again emphasized his concern relative to the monitoring and enforcementof the four hours allowance of electrodes being out of the portable oven asallowed by the weld material control procedure. It was also noted that aboutthirty 1/8" diameter and eight 3/32" diameter coated electrodes at one weldjoint location were not returned to the portable oven prior to the craftsmangoing to lunch, and the electrodes were stone cold. This is contrary to astatement made by a licensee representative during an exit interview onMarch 6,1980, that it is a general practice that electrodes are returned tothe portable oven during lunch break. The licensee acknowledged the infor-mation.

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