IR 05000261/1988014
| ML14191B045 | |
| Person / Time | |
|---|---|
| Site: | Robinson  |
| Issue date: | 12/21/1988 |
| From: | Blake J, Economos N NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML14191B043 | List: |
| References | |
| 50-261-88-14-01, 50-261-88-14-1, NUDOCS 8901090277 | |
| Download: ML14191B045 (12) | |
Text
pfk REG, UNITED STATES NUCLEAR REGULATORY COMMISSION o
REGION II
101 MARIETTA ST., ATLANTA, GEORGIA 30323 Report No.:
50-261/88-14 Licensee:
Carolina Power and Light Company P. 0. Box 1551 Raleigh, NC 27602 Docket No.:
50-261 License No.:
DPR-23 Facility Name: H. B. Robinson Inspection Conducted:
N vember 28 -fDecember 2, 1988 Inspector:
C
Ni ck ono, D) eigied Approved by:
S ak Chie Signed mate ial and Processes Section Eng nee ing Branch Di is ion of Reactor Safety SUMMARY Scope:
This routine unannounced inspection was conducted in the areas of resistance temperature detector (RTD) bypass elimination and service water system piping replacement modification Results:
In the areas inspected, no violations or deviations were identifie Both modifications are being implemented by vendor, e.g. Westinghouse and PCI, respectivel The licensee has dedicated adequate resources/manpower for engineering work monitoring and liaison between the licensee and the vendor Work quality, material control, training and qualification were found to be consistent with Code and regulatory requirement REPORT DETAILS 1. Persons Contacted Licensee Employees S. B. Clark, Project Engineer Configuration Control R. Cox, Modification Project Liaison Engineer
- J. M. Curley, Director, Regulatory Compliance
- R. H. Dufresne, Project Engineering Supervisor, Civil Engineering W. Farmer, System Supervisor Technical Support B. Harward, Principal Engineer Modification Projects 3. Latimer, Welding Engineer
- R. E. Morgan, General Manager R. Munday, Engineering Technician I, Modifications Projects
- S. M. Pruitt, Inservice Inspection (ISI) Coordinator
- D. Sayer, Senior Specialist Regulatory Compliance
- H. J. Young, Director, Quality Assurance (QA)
Other licensee employees contacted during this inspection included craftsmen, engineers, operators, mechanics, security force members, technicians, and administrative personne Westinghouse Energy Systems Services Division R. Bialecki, Project Manager, Mechanical J. Marburger, QA Lead Engineer W. Rice, Manager, Fluid Systems
- Attended exit intervie.
Design, Design Changes and Modifications (37700) RTD Bypass Piping Elimination Westinghouse (W) has been contracted by the licensee to remove the existing RDT bypass piping system and replace this hot leg -and cold led temperature measurement method with fast response thermowell mounted RTDs installed in the reactor coolant loop pipin The licensee stated that the reasons for this modification was to eliminate the outage maintenance and the corresponding radiation exposure associated with periodic replacement and response time testing of the RTDs installed in the bypass manifolds and connecting piping to the reactor coolant syste By review of non-proprietary WCA-11890, the inspector ascertained the following information:
(1) The hot leg temperature measurement on each loop will be accomplished with three fast response, narrow range, dual element RTDs mounted in thermowell One element of the RTD
will be considered active and the other element will be held in reserve as a spar To accomplish the sampling function of the RTD bypass manifold system and minimize the need for additional hot leg piping penetrations, the thermowells will be located within the three existing RTD bypass manifold scoops wherever possible. A hole will be drilled through the end of each scoop so that water will flow in through the existing holes in the leading edge of the scoop, past the RTD, and out through.the new hol Because of structural interferences on Loops A and B, one thermowell on each loop cannot be installed in the existing scoop locatio These thermowells will, instead, be mounted in independent bosses and relocated downstream from the existing scoo The resulting unused hot leg scoops will be cappe These three RTDs will measure the hot leg temperature which is used to calculate the reactor coolant loop differential temperature (WT) and average temperature (T avg (2) On the cold leg side of the coolant loop, One fast response, narrow range, dual-element RTD will be located in each cold leg at.the discharge of the Reactor Coolant Pump (RCP)
(as replace ment for the cold leg RTDs.located in the bypass manifold).
Temperature-streaming in the cold leg is not a concern due to the mixing action of the RC For this -reason, only one RTD is require This RTD will measure the cold leg temperature which is used to calculate reactor coolant loop WT and T
.
The existing cold leg RTD bypass penetration nozzle willap modified to accept the RTD thermowel One element of the RTD will be considered active and the other element will be held in reserve as a spar This modification will not affect the single wide range RTD currently installed near the entrance of each steam generator and in each cold leg at the discharge of the RC Changes required by this modification will involve the hot leg scoops, the hot leg piping, the cross-over leg bypass return nozzle, and the cold leg bypass manifold connection All welding will be Gas Tungsten Arc Weld (GTAW)'or Shielded Metal Arc Weld (SMAW)
per ASME Code,Section IX. This welding will be examined using nondestructive methods (liquid penetrant or radiography where applicable) per ASME Code,Section XI, 1977 Edition through Summer 1978 Addendu As required by Article IWA-4000 of Section XI, a hydrostatic test will be performed following completion of the modificatio Other codes, standards, and regulatory requirements applicable to this modification were as follows:
ASME Boiler and Pressure Vessel,Section III, 1983 Edition ANSI B31.1-1967, "Code for Power Piping"
ANSI N45.2.2-1972, "Packages, Shipping, Storage, and Handling of Items for Nuclear Power Plants" RG 1.33
.
-
"Quality Assurance Program Requirements (Operation)," November 1972 [references ANSI Standard N18.7-1976, "Administra tive Controls. and Quality Assurance Requirements for the Operating Phase of Nuclear Power Plants"]
-
"Quality Assurance Requirements for Cleaning of Fluid -Systems and Associated Components of Water-Cooled Nuclear Power Plants," March 1973 RG 1.38
.
-
"Quality Assurance Requirements for Packaging, Shipping, Receiving,.
Storage, and Handling of Items for Water-Cooled Nuclear Plants," March 1973 RG 1.39
-
"Housekeeping Requirements for Water Cooled Nuclear Power Plants,"
March 1973 RG 1.58
-
"Qualification of Nuclear Power Plant Inspection, Examination, and Testing Personnel," September 1980 The scope of work either planned or in progress on the hot legs, cold leg and crossover legs were as follows:
Hot Legs The existing hot leg bosses were being cut to allow for the removal of the Schedule 160 bypass piping. The severance cut on the existing bosses was being made just below the socket at predetermined dimensions to allow for removal of the pipin The existing hot leg scoops were being modified to allow the addition of a flow hole in the bottom of the scoo This flow hole was formed by utilizing the Metal Disintegration Machining (MDM) Proces The debris produced was an insignificant benign talc-like powdery material which was determined to be harmless to the RCS. Due to interferences, Loop A hot legs scoops cannot be utilize These scoops were to be capped and new penetra tions and bosses would be installed approximately 24 inches from the existing scoops towards the steam generato These scoops will be located in approximately the same plane at 0, 120 and 240 degree A hydraulic boring machine, mounted on the hot leg piping will perform the machining on the scoops to allow for thermowell installation. Prior to installing the thermowells, the machined surfaces will be-deburred and the weld preps and surface conditions will be verifie Dimensional checks will be performed on the the hot leg scoops to verify proper thermowell fit-u The thermowells will be screwed into place with a seal ring and then seal welded to the hot leg bosses. A dam will be used during the external machining process to control debri This pressure boundary code weld will be radiographe Cold Legs The existing cold leg nozzles will be cut the same as the hot leg bosse A cut will be made in the 2" Schedule 160 bypass piping with a port-a-band saw at a location to allow for removal of the pipin Upon completion of the cut, a hydraulic boring machine will be mounted on the cold leg.to machine the nozzl Crossover Legs The existing crossover leg bosses will be cut using a split OD machining too The cutting tool bit used for this operation is designed to machine a specific weld prep while -the severance cut is being made. A cut will made in the 3" Schedule 160 bypass piping with a port-a-band saw at a location to allow for removal of the piping. A pipe cap will be welded to the crossover leg boss to complete the modificatio This pressure boundary ccde weld will be radiographe Replacement materials specified for this modification were as follows:
(a) Thermowells. and crossover line caps are made from Class 1 SA-182 F316 or equivalent stainless steel materia Valves installed as Reactor Vessel Level Indication System (RVLIS), root valves shall be "zero-leak" type metal diaphragm packless globe valve The valve body shall b austenitic stainless steel (ASTM SA182, Alloy Types 316 or F316, or equivalent).
Thermowell Bosses, RTD Thermowells, and other weld fittings are made of austenitic stainless steel material per ASTM A182, Alloy Types 316, 316L, 316N, F316, or F316L or equivalen Welding rods used on stainless steel piping or fittings were made from material compatible with the respective base meta Engineering and/or design documents applicable to this modification that were provided by the licensee for review were as follows:
M-959:
Design Change Notice Plant Modification Safety Evaluation, Attachment 2, M-959-2, Rev. 0, Design Basis, Attachment 4, M-959-4, Rev. 0 Implementing Procedure, Attachment 8, Rev. 0 WCAP-11889 Response to NRC Question on RTD Bypass Elimination Licensing Report for H. B. Robinson -
2, June, 1988 WCAP-11889 Response to NRC Questions on RTD Bypass Elimination LicensingReport, October, 1988 Westinghouse Field Change Notice (WFCN)
RTD Bypass Elimination CPLO 40519A R87-048/00-01 Design Basis Document, Rev. 2 RCS Bypass RTDs Plant Modification Manual M-959, 9/25/88 MPII 2.7.2 CPL-1 Re, RTD Bypass Elimination for H. B. Robinson Replacement materials required for this modification were procured by W under requirements of their Q progra Those materials included couplings, nozzle caps, fast response dual elements, thermowells and bosses and filler meta For these items, the inspector reviewed quality records including certified material test reports, W quality release reports, certificates of compliance, Nondestructive Examination (NDE)
reports, and receipt inspection reports as applicabl Replacement material of particular interest selected for a review of quality records were as follows:
Fast Reponse Dual Elements, Model N9004E-2B PO
- 85140-D, Quality Release (QR)#N-101981, Rev. O (W)
SPIN QAELRT o
Thermowells and Bosses (W) SPIN # RCPCTW QR #N-101982, Rev. 0 o
Couplings (RVLIS Welded Fittings)
PO# MA 00973D o
3" Schedule 160 Nozzle Caps (W) SPIN # RCPCFB QR #N-102613, Rev. 0 o
1" Schedule 160 Nozzle Caps QR N-102612, Rev. 0 (W) SPIN #RCPCFB o
Weld Filler Metal PO #PCP-88-150 In addition to the quality records, the inspector reviewed the following special process procedures:
Nondestructive Examinations NDE-240, Rev. 0 (W) Liquid Penetrant Procedure NDEP-101, Rev. 11 CP&L Radiographic Examination Weld Procedures (W)
WPS 50800, Rev. 3 Manual Gas Tungsten Arc WPS 10800, Rev. 1 Manual Shielded Metal Arc Completed welds examined for workmanship and appearance were as follows W-1-2A 1"d x.250 Hot Leg Loop A Acceptable Cap to Pipe nipple @1200 W-1-1A 1"d x.250 Hot Leg Loop A Acceptable Cap to Pipe nipple @ 00 W-1-3A
.1"d x.250 Hot Leg Loop A Acceptable Cap to Pipe nipple @2400
These welds were radiographed with the aforementioned procedure to verify weld integrity. The inspector reviewed the films to verify that the welds and technique used met applicable code requirements and determined them satis factor Difficulties draining the primarly loops to satisfactory levels caused a delay in the start-up of the modificatio That and the need to wear respirator protection precluded the inspector from observing cutting and MDM activities which commenced on December 1, 198 Within the areas inspected, no deviations or violations were identifie b) Service Water System Piping Replacement Modificatio This inspection effort was.performed as a followup to that documented in Inspection Report No. 50-261/88-1 This plant modification serves to replace a portion of service water supply and return piping. inside the Reactor Building including the supply and return lines to the Containment Fan Coolers HVH-1, -2, -3, and -4.
The remaining piping, including that in the Auxiliary Building, will be replaced by a later Plant Modification. The replacement material is a stainless steel alloy which contains.6% molybdenum and additional amounts of nitrogen and nickel to achieve maximum corrosion resistanc The new *piping was fabricated from Allegheny Ludlum AL6XN material, Alloy N UNS N08367 manufactured/supplied in accordance with ASME Code Case N-43 The replacement pipe, which has the same diameter and schedule as the original was procured under purchase order number 545681M-AR-02 from Connex Pipe Systems Inc.,
The chemical analysis and mechanical properties of one of the heatnumbers supplied, HT# 838907, was as follows:
Element
%Content Mechanical Properties Carbon
.018 Tensile 113,700 psi Manganese
.
0.36 Yield 58,000 Nickel 23.82
%Elongation 44%
Chromium 20.28 Hardness RB83 Molybdenum 6.28 Copper
.30 Nitrogen
.230 Corrosion tests were performed on the material per ASTM A-262 Practice E, to determine its resistance to crevice pitting and intergranular corrosion attack. Results showed no evidence of pitting, intergranular corrosion and the degree of. crevice corrosion attack experienced measured
1.5 mills in dept The licensee found these results to meet the acceptance. criteria of Specification HBR2-M-027, Rev. 1. The licensee stated that this type material was used by other licensees including Public Service Electri and Gas Company, Salem Plant, for a similar service water pipe proble The licensee indicated that all existing pipe supports are to be revised as well as anynew ones which may be required will be designed in accordance with applicable sections of ANSI B31.1 and AISC Code ASME,Section IX (86S88), was the governing code for qualification of weld procedures and welders, inspection and testing of welds was being performed in accordance with ASME Section XI, 1977 Edition and Addenda through Summer 197 A review of the Safety Evaluation Report M-858-2, Re, revealed that the subject modification generated no unreviewed safety question Following is a list of procedures relative to this modification that were reviewed for content and compliance to code and regulatory requirements:
WP-502, Rev. 15 Weld Rod Control WP-503, Rev. 11 Qualification of Welders and Welding Operators WP-500, Rev. 11 General Welding Procedures WP-504 Processing of Weld Documentation WP-506, Rev. 2.Welding Procedure Specification Welding Specifications (WPS)
Filler Procedure Metal Qualification Thickness Type/
WPS Process Records Range Size 45-4-01 GT (machine)
181 1/16 -
17/64 ERN1CrMo-3 0.035" 45-4-30 GT (machine) -182 1/16 -
17/64 ERNlCrMo-3 0.035" 45-2-04 GT (manual)
181 1/16 -
17/64 ERNlCr Mo-3 3/32, 1/8, 0.035 45-2-31 GT (manual).
182 1/16 -
17/64 ERNlCr Mo-3 3/32, 1/8, 0.035
- GT -Gas tungsten arc welding
The above WPSs and their supporting Procedure Qualification Records (PQRs) were reviewed to ascertain whether essential, supplementary and/or nonessential variables, were consistent with Code requirements; whether the WPSs were properly qualified and their supporting PQRs were accurate and retrievable; whether all mechanical tests had been performed and the results met the minimum require ments; whether the PQRs had been reviewed and certified by appropriate personnel; and whether any revisions and/or changes to nonessential variables were note Completed welds and others being fabricated were observed to ascertain whether appearance and workmanship require ments imposed by the aforementioned code and procedures were being followe For the most part, pipe welds were being fabricated with a combination manual/machine GT procedur The welding was being performed by CPI, In under contract with the licensee. Following is a list of welds examined as part of.this work effort:
Weld Size
.
Description Comments HBR2-CW-276 6"d x.134" Pipe to Pipe Complete/
Accept HBR2-CW-27 "d x.134" Pipe to Reducer
"/"
HBR2-CW-272 3"d x.134" Reducer to Pipe HBR2-CW-271 3"d x.134" Pipe to Ell HBR2-CW-519 6"d x.134" Pipe to Tee
"/"
HBR2-CW-521 6"d x.134" Pipe to Pipe HBR2-CW-527 6"d x.134" Pipe to Pipe HBR2-CW-656 6"d x.134" Pipe to Pipe I/it HBR2-CW-212 6"d x.134" Pipe to Pipe HBR2-CW-203 6"d x.134" Pipe to Pipe HBR2-CW-285 6"d x.134" Pipe to Tee Tacking/
Accept By walk-through inspections, drawing and other related document reviews, the inspector ascertained that the majority of the piping was being routed in the same location as the existing pipe, using the existing pipe supports. Design variances from the existing configuration
were:
1) Tie-in of motor cooler outlet piping in HVH unit outlet piping inside containment, thereby relocating the motor cooler isolation valve to inside containment and eliminating the motor cooler containment penetrations; 2) Reduction in diameter of the motor cooler outlet piping from 2" to 1-1/2" between the motor cooler discharge and the new tie-in with the HVH discharge valves; and 3) Addition of flanges on the inlets and outlets of.the HVH units and their motor cooler As required by the applicable code, pipe welds are liquid penetrant examined and upon completion of the modification will be hydrostatically tested prior to plant start-u Also as a control tool used to monitor microbiological corrosion (MIC) attack on the new material, the licensee is radiographing selected weld The procedure used to radiograph these welds does not meet code requirements in that no penetrameter is used to monitor qualit Instead the licensee uses lead shot at predetermined locations/
intervals along the weld whose image will be used as the standard to check against possible MIC attack in the futur The inspector selected at random the following radiographs to ascertain the type of film-and weld image that was produced by this procedur The welds selected were as follows:
Weld Size
.
Loop W-034 6 "x 0.134" HVH-1 W-044
.6 "x 0.134" HVH-1 W-203 6 "x 0.134" HVH-2 W-212 6 "x 0.134" HVH-2 W-441 6 "x 0.134" HVH-3 W-442 6 "x 0.134" HVH-3 W-521 6-"x 0.134" HVH-3 W-527 6 "x 0.134"
.
HVH-3 W-656 6 "x 0.134 HVH-4 W-665 6 "x 0.134" HVH-4 W-751 6 "x 0.134 *
HVH-4 Welders whose stencils appeared next to completed pipe welds were noted and their qualification records were reviewed to verify that they had been and are currently qualified to weld under the respective procedures abov Welders selected for this evaluation were identified by the following stencils; TC, through TI and T Filler Metal Control Filler metal used on this modification is purchased and controlled/issued to the field by the license Accordingly, the inspector reviewed the licensee's applicable procedure, documented earlier in this report, inspected warehouse storage, issuing stations and field locations where the material wasbeing used/consumed. The material checked had been purchased from Techalloy under purchase order PO #472598A It was produced under SFA 5.14 requirements, type ERNiCrMo-3. For Heat Nos. VX0582AK and VXO389AK; purchase, receiving and rod issue records, were reviewed to verify that these activities were consistent with approved procedures and that the material met specification requirements. -In the field the inspector verified that cleanliness and identification was being maintained up to consumption, and that unused material was being controlled and/or returned as appropriat Within the areas inspected, no deviations or violations were identifie.
Exit Interview The inspection scope and results were summarized on December 2, 1988, with those persons indicated in paragraph 1. The inspector described the areas inspected and discussed in detail the inspection results listed belo Although reviewed during this inspection, proprietary information is not contained in this report. Dissenting comments were not received from the licensee