IR 05000254/1980023
| ML20002C355 | |
| Person / Time | |
|---|---|
| Site: | Quad Cities  |
| Issue date: | 11/19/1980 |
| From: | Danielson D, Ward K NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML20002C347 | List: |
| References | |
| 50-254-80-23, 50-265-80-25, IEB-79-03A, IEB-79-3A, IEB-80-08, IEB-80-13, IEB-80-8, NUDOCS 8101100153 | |
| Download: ML20002C355 (11) | |
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U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT
REGION III
Report No. 50-254/80-23; 50-265/80-25 Docket No. Y0-254; 50-265 License No. DPR-29; DPR-30 Licensee:
Commonwealth Edison Company
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1>. O. Box 767 Chicago, IL 60690 Facility Name: Quad-Cities Station, Units 1 and 2 Inspection At: Quad-Cities Site, Cordova, IL Inspection Conducted: September 2 - 3, 18 - 19, October 8, 15 - 16, and November 6, 1980 M
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[o Inspector:
K. D. Ward Accompanied By:
D. H. Danielson (9/18-19 and 10/15-16/80 only)
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Approved By:
D. H. Danielson, Chiet
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/t Engineering Support Section 2 Inspection Summary Inspection on September 2-3, 18-19, October 8, 15-16, and November 6, 1980 Reports No. 50-254/80-23; 50-265/80-25 Areas Inspected: QA/QC program, implementing procedures, work activities, review nondestructive examinations (NDE) data of inservice inspection (ISI) and torus modification; IE Bulletin 79-03A, IE Bulletin 80-08, and IE Bulletin 80-13 activities. This inspection involved a total of 53 onsite inspector hours by one NRC inspector.
Results: No items of noncompliance or deviations were identified.
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DETAILS Persons Contacted Commonwealth Edison Company (Ceco)
N. Kalivianakis, Station Superintendent
- W. Burkamper, QC Supervisor D. Huizenga, QC Inspector J. Ford, QC Inspector D. Schutte, QC Inspector R. Peterson, QC Inspector T. Warner, QC Inspector Graver Energy Service Incorporated GESI)
W. Dumke, Senior QA Engineer Morrison Construction Company (M)
R. Bullock, QC Supervisor Hartford Steam Boiler Inspection and Insurance Company F. Roose, Authorized Nuclear Inspector (ANII)
The inspector also contacted and interviewed other licensee and contractor employees.
- Denotes those present at the final exit interview, November 6, 1980.
Licensee Action on IE Bulletins
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Reference t
NRC memorandum, dated April 7, 1980 to CECO (IE a.
Bulletin 79-03A titled, " Longitudinal Weld Defects in ASME SA-312 Type 304 Stainless Steel Pipe".
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b.
CECO letter, dated August 7, 1980 to Region III.
(Final response to IE Bulletin 79-03A.)
c.
NRC memorandum, dated April 8, 1980 to CECO (IE Bulletin 80-08 titled, " Examination of Containment Liner Penetration Welds")
d.
CECO letter, dated July 9, 1980 to Region III.
(Final response to IE Bulletin 80-08.)
e.
CECO letter, dated August 15, 1980 to Region III (Supplemental response to IE Bulletin 80-08.)
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f.
NRC memorandum dated May 13, 1980 to CECO.
(IE Bulletin 80-13 titled, " Cracking in Core Spray Spargers".)
g.
CECO letter dated September 16, 1980 to Region III.
(Final response to IE Bulletin 80-13.)
(Closed) IE Bulletin 79-03A titled, "Longitidinal Weld Defects in ASME SA-312 type 304 Stainless Steel Pipe".
The inspector reviewed the final response and actions taken for IE Bulletin 79-03A, Units 1 and 2, and has no questions at this time.
(Closed) IE Bulletin 80-08 titled, " Examination of Containment". The inspector reviewed the final response and actions taken for IE Bulletin 80-08, Units 1 and 2, and has no questions at this time.
(Closed) IE Bulletin 80-13 titled, "Crackina in Core Spray Spargers, Units 1 and 2".
The inspector reviewed the final response and actions taken for IE Bulletin 80-08, Units 1 and 2 and has no questions at this time.
Functional or Program Areas Inspected 1.
Torus Modification a.
General References:
(1) Region III Reports No. 50-254/79-19; 50-265/79-16 (Torus Modification)
(2) Region III Reports No. 50-254/79-29; 50-265/79-26 (Torus l
Modification)
(3) Region III Reports No. 50-254/80-03; 50-265/80-05 (Torus Modification)
(4) Region III Reports No. 50-254/80-15; 50-265/80-18 (Torus Modification)
(5) CECO letter to Mr. D. G. Eisenhut, Director, Washington, D. C.
(Revised schedule for Units 1 and 2.)
The external torus welding is completed on both units.
b.
Procedure Review The inspector reviewed the following Morrison new and revised procedures.
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(1)
M, General Procedure for Welding of Carbon Steel Piping, Pressure Vessels and Structural Materials, PC-901, Revision 1, October 1979.
(2)
M, Procedure Specification for Shielded Metal Arc Welding of Carbon Steel Materials According to ASME Section IX, CS-1, Revision 5, January 1980.
(3)
M, Procedure Specificatic, for Gas Tungsten Arc Welding (GTAW) of Carbon Steel (AsME P-1) Materials According to ASME Section IX, CS-4, Revision 3, December 1979.
(4)
M, Procedure Specification for Shield Arc Welding (SMAW)
of Carbon Steel (ASME P-1) Material According to ASME Section IX, GS-11, Revision 3, October 1979.
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(5)
M, Qualification and Certification of Nondestructive Examination Personnel NDE/PQC-2, Revision 4, October 1979 (1975 Edition).
(6)
M, Magnetic Particle Examination, ASME Section V, NDE/MT-2, Revision 5, June 1980.
(7)
M, Qualification and Certification of Nondestructive Examination Personnel, NDE/PQC-1, Revision 4, October 1979.
(8)
M, Visual Inspection of Welds to AWS DI.1 Structural Welding Code, NDE-VE-3, Revision 4, June 1980.
(9)
M, Process Controls, QSPC-18, Revision 3, November 1979.
(10) M, Bolt-Up Procedure, QSPC-33, Revision 3, December 1979.
(11) M, Process Control; Groove Fillet or Socket Welds, QSPC-37, Revision 4, November 1979.
(12) M, Torus Coating, QSPC-38, Revision 1, November 1979.
(13) M, Welding Material Control, QSPC-2, Revision 2, November 1979.
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(14) M, Qualification of Welders, QSPC-4, Revision 1, November 1979.
l (15) M, ASME Welder Performance Test, QSPC-4A, Revision 1, November 1979.
(16) M, Material Handling, Scaffolding and Rigging, QSPC-9, Revision 1, November 1979.
(17) M, Use of Weld Data Report for Piping Subassemblies for Sizes 2-1/2" 0.D. and Larger, QSPC-17, Revision 0, September 1979.
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(18) H, Procedure Specification for Shield Arc Welding (SMAW)
of Carbon Steel (ASME P-1, Group 2) Haterial According to ASME Section IX, CS-16, Revision 3, January 1980.
(19) M, Procedure Specification for Shield Arc Welding (SMAW)
of Carbon Steel (ASME P-1) Materials According to ASME Section IX, CS-17, Revision 2, November 1979.
(20) M, Material Control - Receiving of Materials, QSMC-1, Revision 1, November 1979.
(21) M, Storage of Materials and Items, QSMC-5, Revision 1, November 1979.
(22) M, Utilization of Mechanical Revision Directive, OSPC-23, November 1979.
(23) M, General Repair Procedure, QSPC-30A, September 1979.
c.
NDE Personnel Certifications The inspector reviewed the following NDE certifications in accordance with SNT-TC-1A, 1975 Edition.
Morrison Name E PT g IE R. Bullock II II II II F. Abrigo II T.e welder certifications were reviewed in accordance with ASME Section IX, 1977 Edition, Summer 1977 Addenda.
Graver Welders Morrison Welders Name Name R. Breton F. Bishop R. Sibila B. Calhdon J. Ferguson J. Keefer
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M. Costabile N. Rash D. Leven M. Tripp d.
Material and Equipment Certifications The following material certifications were reviewed:
Electrodes:
Graver E7018, 1/8" HT #21612-5-
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Morrison E7018, 1/8" HT #401K7251 E7018, 3/32" HT #42K1061 E7018, 5/32" HT #659H075 e.
Observation of Work The inspector observed the following:
(1) Graver, Unit 1, column 1 painted gray and all other columns were primed.
(2) Graver, Unit 1, visually examined several welds.
(3) Graver, Unit 2, magnetic pargicle examination performed on Column 12, Weld E60.
(4) Graver, Unit 2, pulling of bolts on Column 11 due to water in holes because of drain back up.
(5) Morrison, Unit 1, welding on bay 16, Weld 3.
(6) Morrison, Unit 1, fit up on bay 15, #QC1238.
(7) Morrison, Unit 1, the welding of deflector piping, downcomer braces, T quencher supports and SRV supports, f.
Review of NCRs, Surveillance and Data Reports A review of data reports for the torus activity demonstrated that the QA/QC commitments had been complied with.
The inspector reviewed Graver NCRs of Graver and the following Graver surveillance reports of Graver:
l (1) Document Control (2) Welder Performance Qualification (3) Production Welding
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(4) Weld Material Control The in.spector also reviewed CECO surveillance reports of Graver and Mortison.
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No items of noncompliance or deviations were identified.
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2.
Preservice Inspection a.
General CONAM personnel were on site approximately one week in September and were replaced by the personnel of CONAM's parent company, Nuclear Energy Services, Inc. (NES).
b.
Program and Procedures CECO developed the ISI program and procedures and Nuclear Energy Services, Inc. (NES) performed the ISI.
The inspector reviewed the following procedures.
ft) Procedure for Certifying Nondestructive Examination Personnel, No. CNTP-1, January 1969, 1968 Edition.
(2) Procedure for Certifying Nondestructive Test Personnel 99-CNTP-001, Revision 1, August 18, 1978, 1975 Edition.
(3) Procedure for Certifying Visual Examination Personnel for Preservice/ Inservice Examination, 96-VT-001, Revision 0, October 24, 1978.
(4) Visual Examination of Nuclear Reactor Coolant System Components, NDT-V-1, Revision 3, September 1979.
(5) Ultrasonic Inspection of Pipe Welds, NDT-C-2, Revision 11, February 1979.
(6) Ultrasonic of Pressure Retaining Bolting from 2" to, and including, 4" in diameter, NDT-C-1, Revision 4, December 21, 1974.
(7) Ultrasonic of Inner Radius of Nozzle-to-Vessel Junction, NDT-C-10, Revision 6, February 1979.
(8) Flourescent Magnetic Particle Examination, NDR-B-1, Revision 1, May 22, 1974.
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(9) Ultrasonic Flange Ligaments Between Threaded Bolt Holes, NDE-C-11, Revision 8, February 1979.
(10) Ultrasonic of Reactor Vessel Head Welds, NDE-C-12, Revision 6, March 1979.
(11) Ultrasonic of Pressure Retaining Bolting over 4" in Diameter, NDT-C-14, Revision 5, February 1979.
(12) Ultrasonic of Ferritic Safe End to Nozzle Welds and Safe Ends, NDT-C-15, Revision 3, February 1979.
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(13) Ultrasonic of Disimilar Metal Pipe Welds, NDT-C-16, Revision 3, February 1979.
(14) Ultrasonic Inspection of Control Rod Drive Thimble Welds NDT-C-3, Revision 1.
(15) Magnetic Particle Examination of Turbine Components, NDT-B-2, Revision 1, March 1, 1979.
(16) Ultrasonic Inspection of Control Rod Drive Return Line
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Nozzle, NDT-C-26, Revision 0, September 15, 1977.
(17) Ultrasonic Inspection of De-clad Feedwater Nozzle Inner Bore and Radius of Boiling Water Reactors, NDT-C-27, Revision 0, November 30, 1979.
(18) Ultrasonic Inspection of Feedwater Nozzle Inner Bore, NDT-C-25, Revision 1, March 3, 1977.
(19) J1trasonic Inspection Feedwater Nozzle Inner Radii, NDT-C-24, Revision 3, February 18, 1977.
(20) U1 transonic Examination of Stainless Steel Clad Forgings, NDT-C-24, Revision 0, April 12, 1976.
(21) Ultrasonic Inspection of Cylindrical Forgings, NDT-C-22, Revision 0, April 8, 1976.
(22) Ultrasonic Examination Procedure for the Detection of Intergranular Stress Corrosion Cracking, 80A3592, Revision 2, August 1979.
(23) Ultrasonic Instrument Linearity Verification 80A9053, Revision 1, September 1978.
(24) Procedure for Non-Aqueous Red Dye Liquid Examination, NDR-D-2, Revision 3, February 1979.
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(25) Procedure for Non-Aqueous Red Dye Liquid Penetrant c
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Examination. of Reactor Vessel Safe-Ends, NDT-D-1, Revision 2 February 1979.
(26) Ultrasonic of External Support Attachment Weld Areas on Piping, NDT-C-4, Revision 9, February 1979.
(27) Ultrasonic of Reactor Vessel Welds, NDT-C-5, Revision 8, March 1979.
c.
Personnel Certification l
The inspector reviewed the following NDE personnel certifications
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in accordance with SNT-TC-1A 1975 Edition.
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CONAM Name VT PT MT UT RT P. Christensen II II II I I
M. Creech II II II II I A. Dukhorn II II II I I
G. Forster II II II II II R. Guentensberger II II II II II R. Koroska II II R. Lachermeier II II I
R. Pepersen II T. Randle II II II II M. Sippel II II II I II V. Tetrev I
II B. Walsh II II II I R. Wilson II II II II NES Name PT MT UT RT E. Anderson III II II J. Boardman III II F. Carr III III III C. Groski II II S. Dietrich II M. Metcalf, Jr.
II R. Bott II d.
Material and Equipment Certification The inspector examined and verified the adequacy of the ultrasonic calibration standards, preparation of weldments and certification documents relative to the following l
items.
CONAM
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Ultrasonic couplant, Glycerol Analytical Reagent.
Ultrasonic instruments, transducers and calibration blocks.
l Liquid penetrant Magnaflux materials, penetrant cleaner j
and developer.
NES Ultrasonic instruments, transducers, and calibration l
blocks.
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Observation of Work Activities The inspector. observed an ultrasonic examjnation of the reactor prassure vessel vertical seam 339 and had a discussion with NES personnel during review of the ISI activities. These observations included calibrations, preparation of welds, performance of the examinations, and the documentation.
f.
Data Reports The inspector examined and determined that the data reports demonstrated that the QA/QC requirements were met. The required information was available for the ISI.
No items of noncompliance or deviations were identified.
3.
Independent Inspection The licensee performed a visual examination (VT) on the 10" diameter core spray piping inside the drywell on Unit 1.
The VT revealed two welds #P-El 14B-S3 and #El-P 14B-S5 on tha "B" loop as having seepage and one weld #EE 14A-S3A on the "A" loop as having a visible crack approximately 1/4" long. The three defects were in the welds associated with the first elbow upstream of the safe end.
The core spray welds were ultrasonic 1y examined (UT) 100%. The UT disclosed several linear indications in three welds of "A" core spray loop and two welds of "B" core spray loop. The indications were located in the welds and heat-affected zone of the pipe-to-elbow and elbow-to-elbow welds between the reactor vessel penetration and the first manual isolation valve in both loops in the drywell. The section of piping where the indications were found is a normally stagnant line which is exposed to reactor operating pressure and elevated coolant temperatures. The core spray piping is type A-312, grade TP 304, 10 inch, schedule 80 seamless stainless steel pipe.
The elbows are type A403, grade WP 403, 10 inch, schedule 80, seamless stainless steel elbows.
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The 105 elbows were cut out of both core spray loops as well as a short section of pipe on each end of the elbows. The elbows were stored at the station pending future investigations. The elbows and short sections of pipe were replaced with carbon steel piping.
The replacement carbon steel pipe is Type SA-333, grade 6, schedule 80 seamless pipe. The fittings are Type SA-420, grade WPL-6, schedule 80 seamless elbows. NDE following the replacement included 100% radio-graphy and magnetic particle or liquid penetrant examinations of all areas adjacent to the welds and 100% UT of the weld to be used as a baseline for future inspections. Prior to reactor startup,
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the core spray lines will be pressure tested during the reactor
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vessel pressure test.
A re-inspection of the welds for both core spray loops in the drywell will be performed during the next Unit One Refueling Outage.
Mechanical Inc. personnel performed the welding. The inspector reviewed welding procedures GTAW, PI-P8, Consumable Insert WPS905, Revision 1, August 10, 1980 and GTAW and SMAW PI-P1, Consumable Insert Revision 2, September 10, 1980, WPS905, also five welder qualifications of J. Lavis, M. Bukta, D. Morphis, R. Mrotek and C. Fancher.
The inspector reviewed the following radiographs of the new core spray welds.
AFW-7A BFW-12 ASW-8 BFW-13 AFW-2A BFW-2A ASW-4 BFW-11A ASW-3 BSW-3 AFW-9 AFW-10 The inspector observed the following NDE activities.
a.
Visual Examination of core spray welds #P-El 14B-S3,
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Ultrasonic examination (UT) including calibration of core spray welds #SE-P 14A-F2, #P-E 14A-S3, #EE 14A-S3A, #E-P 14A-S4 and SE-P 14B-F2.
c.
Magnetic Particle Examination (MT) of core spray weld
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No items of noncompliance or deviations were identified.
Exit Interview The inspector met with Mr. W. Burkamper at the conclusion of the inspection. The inspector summarized the scope and findings of the
inspection noted in this report.
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