05000334/FIN-2007005-02
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Finding | |
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| Title | Weld Overlays on Pressurizer Safety Nozzles Not Initially Qualified for P-1 Materials |
| Description | The inspectors observed the following NDE activities and reviewed completed NDE inspection data records to evaluate compliance with the ASME Code Section V and Section XI requirements and to verify that the indications and defects (if present) were dispositioned in accordance with the ASME Code Section XI requirements. Manual Ultrasonic Examinations (UT) of pressurizer relief valve nozzle weld overlay and pressurizer spray nozzle weld overlay and completed UT examination data records Manual UT examination inspection data report record review of UT-07-1011 Pressurizer longitudinal weld, location RC 740 PZR and Reactor in-vessel automated UT examination report and indication report record review of UT-07- 1012 circumferential weld, location RC-062A-780 Dye penetrant testing (PT) examination record PT-07-1006 review of reinforcement plate to nozzle weld RH-E-1A-N-5 (inlet) & RH-E-1A-N-6 (outlet) PT and magnetic particle testing (MT) examination record review of five pressurizer nozzles prior to weld overlays Bare Metal Inspection (BMI) visual examination records Report No. BOP-VT-07- 031 and digital photographic review of reactor vessel lower head penetrations inspection, and Visual Testing (VT) examination records review of Reactor Vessel and Internals Report No. VT-07-1142, VT-07-1144, VT-07-1145, and VT-07-1146. The inspectors reviewed pressure boundary welds for Class 1 or 2 systems which were completed since the beginning of the previous 1R17 refueling outage to determine if the welding acceptance and pre-service examinations (e.g., VT, PT, and weld procedure qualification tests) were performed in accordance with ASME Code Sections III, V, IX, and XI requirements. During the current 1R18 refueling outage, FENOC mitigated the pressurizer nozzle Alloy 82/182/600 welds to prevent Primary Water Stress Corrosion Cracking (PWSCC) induced through wall cracking in the Reactor Coolant System (RCS) pressure boundary. Mitigation activities included weld overlays on three safety valve nozzles, spray nozzle, and relief valve nozzle on the pressurizer. The inspectors remotely observed automated welding activities associated with the structural weld overlays of the pressurizer dissimilar metal welds on ASME Class 1 pressurizer piping nozzles. The inspectors reviewed procedures and records associated with the welding activity and observed the weld overlay process and ensured that the correct welding variable settings were being employed. In addition, certifications of the NDE technicians performing the manual-driven, encoded phased array UT examinations, as well as ASME Welder Maintenance Logs of the individual contractors performing the weld overlay activities on the pressurizer nozzles were reviewed. On October 2, during installation of weld overlays on pressurizer safety nozzles, it was discovered that welding was being performed with a procedure that had not been qualified for the application, and therefore, did not meet ASME Construction Codes (ASME Section III f65 edition, Winter f66 addenda, ASME Section IX, latest edition) requirements. The PCI Energy Services welding procedure WPS 3-8/52-TB MCGTAWN638 used for the P-1 portion of layer 1 of the weld overlays on pressurizer safety nozzles A, B, and C was not qualified to ASME Section III and IX requirements for P- 1 materials (Condition Report 07-27664). The implemented welding procedure was qualified for P-3 material; therefore, the contractor proceeded to qualify the welding procedure. FENOC made the decision to proceed with the weld overlays at risk while the procedure qualification testing was in progress. The weld procedure was subsequently qualified for P-1 material and acceptable for use. This issue remains unresolved until NRC completes its final evaluation of FENOCfs assessment of the use of the referenced procedure for P-1 material. (URI 05000334/2007005-02, Procedure used for Weld Overlays on Pressurizer Safety Nozzles was not Initially qualified for P-1 Material). |
| Site: | Beaver Valley |
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| Report | IR 05000334/2007005 Section 1R08 |
| Date counted | Dec 31, 2007 (2007Q4) |
| Type: | URI: |
| cornerstone | No Cornerstone |
| Identified by: | NRC identified |
| Inspection Procedure: | IP 71111.08 |
| Inspectors (proximate) | T Moslak D Werkheiser P Kaufman A Ziedonis D Kern D Spindler R Bellamyt Moslakg Smith D Werkheiser J Lilliendahl P Kaufman S Pindale T Fish A Ziedonis P Frechette D Spindler R Bellamy |
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Finding - Beaver Valley - IR 05000334/2007005 | |||||||||||||
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Finding List (Beaver Valley) @ 2007Q4
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