IR 05000250/1991017
| ML17348B036 | |
| Person / Time | |
|---|---|
| Site: | Turkey Point  |
| Issue date: | 06/28/1991 |
| From: | Blake J, Chou R, Kleinsorge W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML17348B035 | List: |
| References | |
| 50-250-91-17, 50-251-91-17, NUDOCS 9108160134 | |
| Download: ML17348B036 (15) | |
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UNITED STATES N
CLEAR REGULATORY COMMISSION
REGION II
101 MARIETTASTREET, N.W.
ATLANTA,GEORGIA 30323 Report Nos.:
50-250/91-17 and 50-251/91-17 Licensee:
Florida Power and Light 9250 West Flagler Street Miami, FL 33102 Docket Nos.:
50-250 and 50-251 Facility Name:
Turkey Point 3 and 4 Inspection Condu ted:
May 13-17, 1991 Inspector License Nos.:
P.
K e)nsorge, P.E.,
Reactor Inspector c, ck
~
ou, P. E., Reactor Inspector Approved by:
~
~
~ Blake, Chief M
erials and Processes Section Engineering Branch Division of Reactor Safety Date Signed Date S)gned z~gf/
Date Signed SUMMARY Scope:
This routine, unannounced 'inspection was conducted in the areas of Welding, Heating Ventilating and Air Conditioning (HVAC), and Pipe Supports.
Results:
In the areas inspected, no violations or deviations were identified.
The licensee's welding program is very effective in most areas reviewed.
Licensee management involvement and the licensee's technical staff assure that technical issues are resolved from a conservative standpoint.
Personnel qualifications safeguards are effective and many of the licensee's administra-tive and Welding Control Manual procedures are well written and contain good technical information.
Completed welds are indicative of a commendable welder-skill level.
The welding filler material control program appears to be running effecti vel REPORT DETAILS Persons Contacted Licensee Employees
- J. Arias, Technical Assistant to Vice President
"W. Bladow, guality Manager
"W. Brown, Site Onsite Services Manager
~T. Fina, Assistant Operations Superintendent
"S.
Franzone, Lead Nuclear Engineer JPN
"R. Gil, Manager - Civil Engineering
"S. Hale, Engineering Project Manager
"M. Huba, JPNS
"J. Knorr, Regulatory Compliance Super visor
- V. Kaminiskas, Operations Superintendent
"T. Plunkett, Site Vice President
- D. Powell, Licensing Superintendent
- G. Rogers, Welding Supervisor
"D. Sipos, Director of Nuclear Construction
- M. Wayland, Maintenance Superintendent
~A. Zielonka, Technical Department Supervisor Other licensee employees contacted during this inspection included engineers, mechanics, technicians and administrative personnel.
NRC Resident Inspectors R. Butcher, Senior Resident Inspector (SRI)
~G. Schnebli, Resident Inspector (RI)
"L. Trocine, Resident Inspector (RI)
- Attended exit interview Acronyms and initialisms used throughout this report are listed in the last paragraph.
Welding (55050)
The inspectors reviewed procedures, observed work activities, con'ducted interviews with licensee/contractor personnel, and reviewed selected records to determine whether:
the licensee's welding specifications and procedures meet applicable American Society of Mechanical Engineers Boiler and Pressure Vessel (ASME B8PV)
Code, regulatory and contract require-ments; welding activities are performed in accordance with the ASME BEPY Code and FSAR commitments; records are prepared, evaluated, and maintained in accordance with the ASME B8PV Code, applicable commitments, and/or requirements; and welding specifications, procedures, production equipment and established licensee quality control systems are adequate for production of sound welds.
Specific areas examined are discussed below:
e The welding program for backfit/construction is implemented by Florida Power and Light (FPL) Welding Control Manual, with Bechtel Power Company (BPC)
and Stone and Webster (SLW) welding pers'onnel, and S8W Quality Control (QC)
personnel working under the umbrella of the FPL Quality Assurance (QA) program.
The Applicable Codes are indicated below:
ASME B&PV Code Section III Division 1, Subsection NB, NC, and ND 1980 edition and addenda through Winter 1981 (80W80)
Division 1, Subsection NE 80W81 ASME BLPV Code Section IX - Edition and Addenda in effect at the time of qualification ASME B8PV Code Section XI - 80W81 American Welding Society (AWS) Dl. 1 - 1983 except Section 9, Design of New Bridges, does not apply American National Standard (ANS) ANS/ASME B31. 1 - 1983 a ~
The inspectors reviewed the documents listed in NRC Inspection Report 50-250,251/88-04, Table I with revision as listed in Revision 51 to the Index to FPL Weld Control Manual.
b.
C.
The inspectors inspected the weld test shop.
This inspection included:
observation of welder performance qualification testing in process, examination of completed Welder Performance Qualification Test Assemblies (WPQTAs), examination of test specimens removed from WPQTAs, and review of radiographs of WPQTAs.
The inspectors made a survey of ongoing welding activities.
This survey included observation of in process welding,= evaluation of welding filler material control practices, inspection of the welding issue stations, and inspection of welding filler material storage facilities.
d.
The inspectors reviewed the following:
records attesting to the qualification of the welders observed above; and procurement and certification documentation for the welding filler materials used by those welders as well as other selected heats/lots of welding filler materials observed in the issue stations.
e.
The inspectors performed a visual examination on approximately
welds, made during this outage, to verify that those welds conform to applicable requirement Observations
.
Personnel qualifications safeguards are effective and many of the licensee's administrative and Welding Control Manual procedures are well written and contain good technical inform'ation.
Completed welds are indicative of a
commendable welder skill level.
The welding filler material control program appears to be running effectively.
Relative to the inspection of the weld test shop, the inspectors noted the following:
The face bend specimens, removed from welder performance qualification test assemblies, examined by the inspectors, were prepared such that the grinding marks, on the convex surface, from specimen preparation were circumferential with respect to the pipe from which the bend specimens had been removed.
This is of concern because, the expected orientation of cracks on bend specimens is circumferential, Therefore circumferential grinding marks could mask cracks.
Procedure WTS-5,
"Welding Performance gualification Requirements",
Revision 4,
the licensee's procedure for welder performance qualification, does not address bend specimen preparation in sufficient detail to prevent this potential masking.
Procedure WTS-5, Revision 4, specifies the thickness of side bend specimens to be 3/8-inch with no tolerance.
This is of concern because bend specimens whose thickness is less than 3/8-inch are subjected to tensile stress levels, on the convex surface, lower than the stress level intended by ASME B8PV Code Section IX.
The preceding would provide a less rigorous test of a welder performance qualification test assemblies.
No side bend specimens with thicknesses less than 3/8-inch were noted.
Relative to the review of procedures the inspectors noted the following:
Procedure M-3.48, Revision 4, "Structural Steel",
Paragraph 12.8, and Procedure M-3.45, Revision 4, "Nuclear Piping and Components",
Paragraph ll.ll specify that tack welds, which are to be permanent welds
"are to be inspected for dimensions only...".
The preceding is of concern because it would exclude cracks as a rejectable defect for this class of welds.
Procedure M-3.45 Revision 4,
Paragraph 13.3, permits manual flame heating to be used to preheat all materials with a size of 2-inch or smaller, without restriction on flame type.
The preceding is of concern because manual flame heating of austenitic stainless steel, with other than a neutral flame, has the potential of degradation the corrosion resistance of the materia In the areas inspected, no violations or deviations were identified.
3.
Heating Ventilating and Air Conditioning Systems (50100)
The inspectors reviewed procedures, observed work activities, conducted interviews with licensee/contractor personnel, and reviewed selected records to determine whether:
the licensee's gA plans, procedures and instructions for inspection of HVAC systems have been established; technical requirements associated with HVAC have been adequately
'addressed; the installation of HVAC systems is in compliance with applicable codes and commitments/requirements; and records are prepared, reviewed, maintained, and reflect work accomplishment consistent with applicable codes commitments/requirements.
Specific areas examined are discussed below.
a.
The inspectors reviewed the below listed Plant Change/Modification (PC/M) engineering packages with associated selected calculation, evaluation, and commercial grade dedication packages.
PC/M ID Unit Title 87-109 354 DC Equipment/Inverter Rooms HVAC 90-070 90-071'0-144 90-146 90-211
354 Load Center and Switchgear Rooms Chilled Water Air Conditioning Load Center and Switchgear Rooms Chilled Water Air Conditioning Platform for Unit 3 Load Center and Switchgear Room A/C Platform for Unit 4 Load Center and Switchgear Room A/C Replacement of Control Room HVAC Condensing Sections b.
The inspectors conducted a detailed walkdown inspection of Unit 3, A
train, chilled water air conditioning system for the load center and switchgear rooms.
c.
The inspectors observed work activities associated with PC/M package Nos.90-070, 90-071,90-144, and,90-146, including welding, fitting, installation of equipment, insulating, and system balancing.
d.
Observations The inspectors noted that the flexible conduit case nipple retaining lock nuts were not properly secured on three of four operating newly installed air handling units examined, in the 3A load center and
switch gear room air conditioning system.
The preceding indicates lack of.attention to detail on the part of the installing electricians.
There is a conflict as to the appropriate edition of B31. 1 for pipe welding covered by PC/M Nos.90-070 and 90-071.
The preceding PC/Ms
,specify B31.1-1986 directly and the Welding Control Manual, which in turn specifies B31. 1-1983.
The licensee indicated that they would look into this matter and make the necessary clarifications.
In the areas inspected no violation or deviations were identified.
4.
Pipe Supports The inspectors reviewed procedures and plant change/modification (PC/M)
and inspected pipe supports on safety-related piping systems.
The purpose of the inspection was to see if the licensee's activities or.performance complied with their commitments, procedures, specification, and the detail drawings.
The inspectors'alkdown reinspection was completed with assistance from the licensee's and/or Bechtel engineers and a licensee Quality Control (QC)
mechanical inspector who is also qualified as a
welding inspector.
The supports were partially reinspected against detail drawings, including Change Request Notices (CRN), for configuration, anchor bolt edge distances, anchor bolt diameters and length marks, base plate sizes, identification, member size, weld sizes, component identifi-cation numbers, maintenance, damage/protection.
a.
As-built Isometrics and Pipe Support Drawing Verification Due to past difficulties in retrieving all the necessary drawings for an Inservice Inspection-(ISI-),
emer gency, or modification, the licensee initiated an as-built verification program to combine all the existing outstanding drawings; such as original drawings, previous walkdown information, QC inspections, 79-14 walkdowns, modification, change request notice, etc., into a new single drawing.
All the new single drawings were issued as Revision 0, in 1990.
During the issue of the new drawings discrepancies or conflicting information were found.
To resolve those conflicts, the licensee initiated a punch list of about 2270 pipe supports to verify through field walkdown and engineering evaluation.
The punch list includes items such as weld sizes, dimensional discrepancies, anchor bolt embedments, etc.
The licensee uses procedure No.
MN 3. 12, As-built Verification of Safety-related Piping and Pipe Supports, Rev.
0 and 1,
as a guideline for punch list walkdowns.
During the walkdown, the licensee engineers also checked the items listed in Attachment A of the above procedure which contains more general information besides the punch list, such as support location, direction of restraint, grouted penetration, general pipe support configuration, etc.
The licensee has almost completed the punch list, with 30 supports remainin To verify the accuracy of the new single drawing (as-built drawing)
and punch list walkdown verification the inspectors randomly selected 10 pipe supports, and portion of piping, for walkdown reinspection from High Head Safety Injection System No.
62 for Unit 3 and Auxiliary Feedwater System for Units 3 and 4.
The piping inspected was acceptable.
The supports inspected are listed below.
Item No.
Support No.
Rev.
No.
Discrepancies/
Comments
80117" H"340-06
80117-H-340-07
The fillet weld size at south end of connection between Items 4 and
was measured 3/16".
The drawing required 3 II
80117-H-340-08
Same as above except at both ends
~
80117" H-341-23 80117"H"341-24 3-SIH-45 3-PRWH-3 3-PRMH-4
Item 7, plate, was measured 5"x4"xl".
- The drawing showed 6 3/16"x4"xl".
The orientation of Item 5, shim plate, in field was 90'iffering from the drawing shown.
The baseplate was measured 18"x9<"x3/4".
(1)
The drawing did not show the orientation of unequal angle 4"x3"x3/8".
(2)
No weld existed on bottom of both ends of connection between Items
and 4.
The drawing required 5/16" fillet weld.
(3)"
The fillet weld at the connection between Items
and
was measured, as 1/8".
The drawing required 1/4".
(4)
No welds were found at the sides of the connection between Items 13-and 3 The drawing required bevel groove weld.
However, additional welds,were found on top of those connection Item Suppor t No.
No.
3-PRMH-5 Rev.
No.
Discrepancies/
Comments Meld condition at connections between Items 12 and 13 were found as follows:
No bevel groove weld on side of west end of Item-12.
No fillet welds on bottom of both ends for Item 12, the drawing required 5/16" fillet weld; 1/8"-
3/16" fillet weld existed on top of Item 12, the drawing required 5/16".
The licensee will add new welds and restore as the drawing required.
(2)
The, fillet weld at connection between Items
and 19 measured 1/8".
The drawing required 1/4".
HGR-281-1 (3)
No bevel groove welds existed at
,sides of.
connection between Items
and
as drawing required.
Item 3, plate was measured as 12"x4"xl/2".
The drawing showed 12"x4"x3/4".
(2)
The fi 1 1 et we 1 d at connecti on between Items 4 and 5 was measured 3/16".
The drawing required 1/4".
(3)
The 1/8" fillet weld on top and 3/16" fillet weld on bottom were measured at connection between Items
and 4.
The drawing required 1/4".
SR-245 Notes:
1.
Five supports from are in Drawing No.
80117-H-340-06 to 80117-H" 341-24 5610-P-818.
2.
Six supports from No. 5613-H-599.
3-SIH-45 to SR-245 are in Drawing The licensee will revised the drawings and calculations to resolve the discrepancies found by the inspectors except that the weld undersize or missing welds between Items
and 13 of Support No.
3-PWRH-5.
Those welds will be modified and restored to the drawing requirements since the existing condition for those two
connections does not meet the Final Safety Analysis Report (FSAR)
requirements.
However, the inspectors questioned the licensee's engineers why so many discrepancies between the new as-built drawings and the as-built field condition still exist.
The licensee s
engineers stated that the discrepancies found by NRC inspectors were errors from the original walkdown.
Before the initial stage of the punch list walkdown, the licensee had gC inspectors walk down 700 pipe supports to compare the new as-built drawings with the as-built field condition.
The gC inspectors found the similar discrepancies and five out of the 700 pipe supports did not meet FSAR requirements.
To avoid the costly reanalysis to qualify the supports the licensee modi.fied those five supports in order to meet the FSAR require-ments.
The licensee evaluated all discrepancies found by the gC inspectors and concluded that the majority of discrepancies were minor and could be resolved through revision of drawings and calculations.
The licensee justified that it was unnecessary to risk more radiation exposure and money in order to catch a few of supports which might not meet the FSAR requirements.
Therefore, the licensee decided to walk down the supports or piping for the punch list and general items only.
On June 17, 1991, the licensee telephoned Region II and stated that Support No.
3-PWRH-5 has met the FSAR requirements without modification.
This support was evaluated, and qualified, based on the as-built field condition without modification to increase the weld sizes by removing excessive conservatism in the stress calculation.
However, the licensee still plans to modify the'upport by increasing the weld sizes to the drawing requirement in order to increase the margin;-
Modification of Charging Pump Discharge Drain and Relief Valve Piping and Supports The licensee has experienced repeated failures 'of the piping and welds on the drain line and relief valve line downstream of each charging pump in Units
and 4.
Failure analysis results by the licensee indicates that fatigue.caused by vibration of the lines is the cause of the, repeated failures.
Modifications were necessary to reduce the vibration induced stresses and increase the natural frequency of the piping.
The modification of the drain lines will replace a socket welded, double shutoff valve with butt welded piping and a very light weight valve.
The modification of the relief valve piping to 2" schedule 160 butt welded pipe from the current 3/4" socket welded pipe and addition of supports to the relief valve line wi 11 improve and raise the natural frequency of piping.
PC/M No. 90-55 and 90-56 are used for modifications on Units 3 and
respectively.
The licensee has completed the modification in Unit 3 and is in progress in Unit 4.
The inspectors inspected two pipe supports in Unit 3 to compare the as-built condition with the documented drawings in the detail such as weld size, member size, dimensions, etc.
Support No. 7744-A-302-002 was found to have I/16"
gap at bottom of pipe and no gap on top of pipe which is opposite to what the drawing specified.
The licensee attributed the problem to the fact that the pipe might be lifted up due to people working on the
=
valve.
Five supports in Unit 4 are still in construction.
The inspectors observed the installation of a portion of supports and reviewed a
portion of supports completed.
Support No. 7744-A-402-05 was found with a U-bolt installed skewed.
The licensee agreed to correct the problem.
The supports inspected or observed are listed below:
Support Revision No.
,
No.
7744-A-302-002"
Unit No.
Status Completed Di'screpancies/
Comments A 1/16" gap and no gap were found on bottom and top of pipe respectively.
The drawing specified 1/16" gap and no gap on top and and bottom of pipe respectively.
7744-A-302-001
7744-A-402-05
PS-6065
4 PS-6067
4 Support B
PS-6042
Nodification on Small Piping Completed In Progress The U-bolt was installed skewed.
In Progress In Progress In Progress In Progress Several cases of inadequately supported small diameter piping in safety-related systems were identified by FPL, and the'RC during an NRC audit on the Auxiliary Feedwater System.
The licensee committed to upgrade small diameter piping systems in 'its System Review Program.
The 2-inch and smaller piping at Turkey Point was, originally designed and supported using generic standards, but the original installation documents (field sketch isometrics)
did not identify the actual installation locations of the pipe supports.
A.aeneral concern was raised regarding the adequacy of the small diameter piping which exceeded the span criteria and the existing condition of some supports.
The licensee initiated a small Diameter Piping Update Program to walk down, sketch, evaluate, and modify
piping and supports.
Procedure No. 5177-499-G-001 was used in walkdown inspection to collect information and evaluate the results.
Several PC/Ms were issued to repair or modify the various systems.
The inspectors randomly selected
pipe supports in Component Cooling Water System, Unit 3, for walkdown reinspection.
All 17 pipe supports had previously been inspected and accepted'y the licensee gC inspectors.
PC/M 90-263 was used for modification on this system.
The supports reinspected during the current inspection are listed below.
All reinspected supports are found to be acceptable.
Item No.
2
4
6
8
10
12
14
16
Support No.
H-1 H-3 H-4 H-7A H-7B H-7C H-13 H-13B H-18 H-23 H-28A H-34 H-37 H-43 H-46 H-47 H-49 Rev.
Drawing No.
No.
PTN-H-90-263-002
PTN-H-90-263-003
PTN-H-90-263-003
PTN-H-90-263-003
PTN-H-90-263-003
PTN-H-90-263-003
PTN-H-90-263-003
PTN-H-90-263-003
PTN-H-90-263-003
PTN-H-90-263-003
PTN-H-90-263-003
PTN-H-90-263-003
PTN-H-90-263-003
PTN-H-90-263-003
PTN-H-90-263-003
PTN-H-90-263-003
PTN-H-90-263-003 Discrepancies/
Comments One dimension for an unequal leg angle 4"x3$ " was not shown on the drawing.
The licensee will revise drawing.
In general, the work on modification and new installation has good workmanship.
The weld size and quality meet or exceed the requirements.
No violations or deviations were identified.
5.
. Exit Interview The'nspection scope and results were summarized on May 17, 1991, with those persons indicated in paragraph 1.
The inspectors described the
'reas inspected and discussed in detail the inspection results.
Although reviewed during this inspection, proprietary information is not contained in this report.
No dissenting comments were received from the license.
Acronyms and Initialisms A/C ASME ANS-AWS BPC B&PV DPR FPL HVAC ID No.
NRC PC/M P. E.
RI SRI S&W WPQTA Air-Conditioning American Society of Mechanical Engineers American National Standard American Welding Society Bechtel Power Co.
Boiler and Pressure Vessel Demonstration Power Reactor Florida Power and Light Heating, Ventilating, and Air Conditioning Identification Number Nuclear Regulatory Commission Plant Change/Modification Professional Engineer Quality Assurance Quality Control Revision Resident Inspector Senior, Resident Inspector Stone and Webster Welder Performance Qualification Test Assembly