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sk# 880 UNITED STATES

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Report No. 50-370/79-08

Licensee: Duke Power CompanyP. O. Box 33189Charlotte, North Carolina 28242

7acility Name: McGuire 2

Licensee No. CPPR-84

Inspection at McGuire site near Lake Norman, North Carolina./ / -Inspector: , s - , .- ..

Date SignedN. Economos -

Approved byf _4 7'l '/ J7

T. E. Conlon, Chief, RC&ES Branch 'DaJ/e Si'gned

SUMMARY

Inspection on March 13 - 15, 1979

Areas Inspected

This routine, unannounced inspection involved 22 inspector-hours onsite in theareas of welding - reactor coolant pressure bc,undary and safety related pipingsystems, housekeeping and storage, equipment batch installation record review.

Results

Of the four areas inspected, no apparent items of noncompliance or deviationswere identified in two areas; two apparent items of noncompliance were foundin two areas (Deficiency - loss of weld and postweld heat treat records, para-graph Sd; Deficiency - failure to document changes to field weld fabricationmethod, paragraph 7) . No apparent deviations were found in the areas inspected.

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DETAILS

1. Persons Contacted

Licensee Employees

J. C. Rogers, Project Manager*G. W. Grier, III, Project Engineer*E. B. Miller, Project Senior QA Engineer*G. B. Robinson, QA Engineer - Mechanical*W. R. Gillispie, QA Technician*W. O. Henry, QA Manager - Construction

Other licensee employees contacted included construction craftsmen andtechnicians.

* Attended exit interview

2. Exit Interview

The inspection scope and findings were summarized on March 15, 1979,with those persons indicated in paragraph 1 above. The inspector identi-fied the areas inspected which included observation of pressure boundaryand other safety-related piping activities (welding), inspection ofstorage areas.

3. Licensee Action on Previous Findings

(Closed) 370-79/04-01 Equipment Hatch Weld Heat Treat Records. Discus-sions with licensee representatives disclosed that an extensive searchof QA, QC and field files failed to locate the postweld heat treatcharts for weld Nos. II-EH-1,4,5,6, and 10. Similarly weld tickets forweld Nos. Il-EH-4,-5,-9, and 10 could not be located and are consideredlost. The inspector stated that he would close this matter as an unre-solved item and would identify it as a noncompliance. This is discussedunder paragraph 5.d of this report.

4. Unresolved Items

Unresolved items are matters about which more information is required todetermine whether they are acceptable or may involve noncompliance ordeviations. New unresolved items identified during this inspection are

discussed in paragraphs 5.C and 6.

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5. Independent Inspection Effort

a. Storage and Housekeeping

An inspection was conducted through the laydown storage areas andwarehouses used to store safety-related material / equipment inorder to determine whether conditions were consistent with appli-cable requirements. Within those areas the inspector noted thatseveral adverse conditions which had been reported earlier inreport RII:78-40 paragraph 6, had improved. Conditions whereproblems existed included deterioration of wooden cribbing, valvesand pipes without end caps and resting on the ground, poor groundkeeping conditions, etc.. The matter which had been identified asan inspector followup item number 370-17-01 is now closed.

b. Weld Rod Issue Station

Rod issue station 3 was inspected to ascertain whether proceduralrequirements were being met in the areas of material storage,identification, segregation and cleanliness, rod oven temperaturecontrol, records and material handling. In addition, the inspector

randomly selected the following consumable heat numbers for a checkof material certifications:

Heat Number Size Type

16797C 3/32" ER30817246C 1/8" ER308

Walk-through Inspection (Fab Shop and Auxiliary Building)c.

A walk-through inspection was conducted in the Fab Shop and AuxiliaryBuilding in order to observe welding activities, control of weldconsumables and housekeeping conditions.

In The Fab Shop

The inspector observed the fitup of a class C weld number INVP1111-2,6"X.134" on ISO-INVP1111. In addition the inspector noted thatseveral welding machines exhibited calibration stickers with overdueexpiration dates. Discussions with the licensee disclosed thecalibration requirement has been deleted as a procedural requirement.In its place, QC inspectors periodically check volt and amps anddocument the results on form M-4D. The inspector reviewed M-4Dforms for the past few months and noted that the recorded datamakes no reference to the machine checked - only the weld, welder,volts, amps, etc.. In discussing this matter, the licensee agreedto review this area and take appropriate steps that would permit

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welding machine traceability to the volt / amp test. This was identi-fied as unresolved item 79-08-01.

d. Equipment Hatch Heat Treat Charts

During the January 23-26, 1979 inspection, the inspector observedinstallation / fabrication activities and reviewed selected QA/QCrecords. Results of this work effort, along with unresolved itemnumber 370-79/04-01, were documented in RIl 50-370/79-04 paragraph5.a. The unresolved item was generated when the licensee failed toretrieve postweld heat treat records (strip charts) of certainequipment hatch welds. Further discussions with the licenseedisclosed that they were unable to retrieve heat treat charts forweld, II-EH- 1,-4,-5,-6,-9 and 10. Moreover the licensee statedthat weld tickets for welds II-EH-4,-5,-9 and 10 were also lost.Nonconforming Item Report 8215 was issued to cover this problem.The licensee stated that the weld tickets and post weld heat treatcharts had been reviewed and signed-off by appropriate QA/QC personnel.The inspector stated that loss of these records is in violation ofparagraph 17.1.17, DPC Topical Report " Duke 1-A", which specifies

that quality assurance records are maintained on site at a locationwhere they can be reviewed to establish that the required qualityhas been assured. The inspector discussed this findin with theelicensee who concurred and agreed to take the nece;aary correctiveaction. Loss of QA/QC records which provide evidence of activitiesaf fecting quality is in noncompliance with Criterion XVII of AppendixB, to 10 CFR 50. This was assigned item number 79-08-04.

6. Safety Related Piping (Welding) - Observation of Work and Work RelatedActivities (Unit 2)

The inspector observed field welding of safety-related piping outsidethe reactor coolant pressure boundary at various stages of weld cc,mpletion.The applicable Code for safety-related pipe welding is the ASME Code,Section III,1971 Edition including Summer and Winter addenda.

Observation of field welding activities included, the following areas asapplicable; weld identification and location, joint preparation andalignment, specified purge, specified temperature (pre-heat and interpass),welding variables within limits, evidence of QC verification, appearancesuitable for NDE and specified NDE being performed.

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a. Fitup Only

Joint Number Isometric Size System

NV2FW78-3 2NV78 3" Chemical Volume ControlNV2FW47-29 2NV47 2" Chemical Volume ControlNV2FW47-30 2NV47 2" Chemical Volume ControlNV2FW47-31 2NV47 2" Chemical Volume ControlNV2FW47-32 2NV47 2" Chemical Volume ControlNV2FW47-33 2NV47 2" Chemical Volume Control

o. Root Pass Complete

Joint Number Isometric Size System

N12F465 2NI15 6" Safety Injection

c. Radiograph Review

Joint Number Isometric Size System

2-CO-17A Equipment HatchNI2F-585 2NI20 12" Safety Injection

NI2F-57 2NI2 4" Safety Injection

NV2FW162-9 2NV162 3" Chem. Volume ControlNV2FW92-16 2NV92 4" Chem. Volume Control

*NV2FW95-17 2NV95 4" Chem. Volume Control

* Repairs in progress

Within these areas the inspector noted the line items for QC Inspectionof cleanliness and fitup had been bypassed for the aforementioned socketwelds NV2FW47-31 and 33. Discussions with the licensee disclosed thatDPC had decided to waive the inspection requirement for cleanliness andfitup on 50% of class B pipe socket welds. The inspector stated thatRII wished to review the justification used for the relaxation of thisinspection, especially since it does not apply to class B pipe battwelds and is contrary to paragraphs 4 and 5 of ANSI Standard 45.2.1 73.The licensee agreed to provide the aforementioned justification forreview on a future RIl inspection. This was identified as unresolveditem 79-08-03.

7. Reactor Coolant Pressure Boundary Piping (Welding) - Work Observations

Field weld fabrication inspection and testing is being controlled by theASKE Code, Section III, 1971 Edition including Summer and Winter 1971addenda.

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Field welds in various stages of fabrication were randomly selected forobservation in order to determine whether welding QC inspection and NDEwere consistent with code and procedural requirements. Welds selectedfor this work effort were as follows:

a. Fitup Only

Joint Number Isometric Size System

NC2FW26-7 2NC26 3" Reactor Coolant

b. Root Welded

Joint Number Isometric Size System

NC2FW26-7 2NC26 3" Reactor CoolantNC2FW15-2 2NC15 6" Reactor Coolant

c. Welding Out

Joint Number Isometric Size System

NI2F563 2 nil 8 10" Safety InjectionNC2FW22-13 2NC22 14" Reactor CoolantNC2FW36-4 2NC26 83" Reactor Coolant

d. NDE on Complete Joint

Joint Number Isometric Size System

NI2F563 2 nil 8 10" Safety Injection*NC2F3-6 MC7676-4 31" Reactor Coolant*NI2F-572 2NI-9 10" Safety Injection

*PT examination in progress

For the above welds, the inspector reviewed applicable field drawings(ISO's), weld data sheets; weld rod issue slips; process control sheets;weld repair history NDE records and corrective action records. Fitupand alignment, purge, weld prep, bead appearance including undercut, arestrikes, etc. , were checked to verify conformance with code and proceduralrequirements. Work areas were surveyed for uncontrolled weld consumables.QA/QC personnel monitoring work progress appeared to be adequatelytrained to perform the assigned tasks.

Within these areas the inspector noted that a field change in the fitupof weld NC2FW15-2 from consumable insert to open butt type had not beendocumented on the appropriate QC form, M4-A, as required. Instead the

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M4-A showed the initial fitup, made with a consumable insert, signed-offby the welding QC inspector. Failure to document this change in theweld fabrication was in violation of paragraph 4.2 of QA procedure M-4which states in part that the welding inspector shall inspect the (weld)fitup dimensions; whereas paragraph 5.4 of QA procedure F-9 requires (1)the craf tsmen to record appropriate information on form M-4A and (2)that no additional work be performed until the (weld) inspector hasinitialed the hold point on the process control record.

The inspector discussed this finding with the licensee who concurred andagreed to take the necessary corrective action. This finding representsan item of failure to follow procedural requirements which is in noncom-pliance with Criterion V of Appendix B, to 10 CFR 50. This was assigneditem number 79-08-02.

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