IR 05000265/1982004
| ML20050B467 | |
| Person / Time | |
|---|---|
| Site: | Quad Cities  |
| Issue date: | 03/08/1982 |
| From: | Ward K NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML20050B463 | List: |
| References | |
| 50-265-82-04, 50-265-82-4, IEB-81-01, IEB-81-1, NUDOCS 8204050360 | |
| Download: ML20050B467 (13) | |
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U.S. NUCLEAR REGULATORY COMMISSION
REGION III
Report No. 50-265/82-04(DETP)
Docket No. 50-265 License No. DPR-30 Licensee: Commonwealth Edison Company Post Office Box 767 Chicago, IL 60690 Facility Name: Quad-Cities Station, Unit 2 Inspection At: Quad-Cities Site, Cordova, IL Inspection Conducted: January 18-21, 26, 29 and 30, February 2-4, 6 and 7,
,9 and 10, 16 and 17, 1982 j/f/b. wth ~
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Inspector:
K. D. Ward Accompanied By:
D. H. Danielson (February 16 and 17, 1982)
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O,/E Approved By:
D. H. Danielson, Chief
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Materials and Processes Section Inspection Summary In pection on January 18-21, 26, 29 and 30, February 2-4, 6 and 7, 9 and 10, 6 t.nd 17, 1982 (Report No. 50-265/82-04(DETP))
Areas Inspected: Replacement, repair, welding and nondestructive examinations of the reactor water cleanup system piping; IE Bulletin No. 81-01 activities.
The inspection involved a total of 95 inspector-hours onsite by one NRC inspector.
Results: No items of noncompliance or deviations were identified.
8204050360 820319 PDR ADOCK 05000265 G
DETAILS Persons Attending the Quad-Cities Station, Unit 2, Reactor Water Cleanup System Temporary Repair of Nonisolable IGSCC Meeting January 26, 1982, in RegionIII, NRC Commonwealth Edison Company (CECO)
F Palmer, Division Vice President, Nuclear Stations W. Stiede, Assistant Vice President, Nuclear Operations N. Kalivianakis, Station Superintendent L. Gerner, Assistant Superintendent, Administrative Support and Service R. Bax, Assistant Superintendent of Maintenance W. Shewski, Manager QA D. Galle, Operations Manager E. Hemzy, Construction Manager, Mechanical W. Burkamper, QC Supervisor S. Gaitonde, General Supervisor, Engineering W. Kiefer, Supervisor of Offsite Review J. Abel, SNED M. Strait, SNED T. Rausch, Nuclear Licensing W. Witt, Deputy, Level III, NDE E. Potter, Chief, Level III, NDE Examiner R. Tamminga, ISI Administrator E. Schulte, Maintenance Staff, Nuclear Division, General Office E. Budzichowki, Of fsite Review NUTECH P. Riccardella, Engineering Director, Nutech D. Pitcairn, Engineering Director, Nutech J. Gavula, Engineering Manager, Nutech A. Higginbotham, General Manager of Engineering, Nutech G. Edwards, General Manager, Projects, Nutech NRC J. Keppler, Regional Administrator, RIII A. Davis, Deputy Regional Administrator, RIII C. Norelius, Division Director, DETP, RIII R. Knop, Branch Chief, Projects, RIII W. Little, Branch Chief, Engineering, RIII D. Dar.ielsen, Section Chief, Materials and Processes, RIII C. Williams, Section Chief, Plant Systems, RIII W. Key, Reactor Inspector, RIII K. Ward, Reactor Inspector, RIII W. Hazelton, MTED, NRR D. Smith, MTED, NRR R. Devin, ORB, NRR i
J. Collins, Engineering, IE Headquarters
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Persons Contacted for Other Than Meeting Above Commonwealth Edison Company (CECO)
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Kalivianakis, Station Superintendent
- R. Bax, Assistant Superintendent of Maintenance
- W. Burkamper, QC Supervisor
- L. Williams, QA Supervisor Great Atlantic and Pacific Pipe Welding and Construction Company, Inc. (GAPCO)
D. Antoine, Welder Foreman
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NUTECH D. Pitcairn, Engineering Director J._Gavula, Engineering Manager Hartford team Boiler Inspection and Insurance Company P. Fisher, Region Manager R. Notquin, ANII The inspector also contacted and interviewed other licensee and contractor employees.
- Denotes those present at the final exit interview on February 17, 1982.
Licensee Action on IE Bulletin Ref:
a.
NRC memorandum dated January 27, 1981, IE Bulletin No. 81-01, titled, " Surveillance of Mechanical Snubbers," Units 1 and 2 and Revision 1, dated April 5,1981.
b.
CECO letter to NRC dated January 14, 1982, Final response to IE Bulletin No. 81-01, Unit 2 and interim response for Unit 1.
(Closed) IE Bulletin No. 81-01: The inspector reviewed the final response for Unit 2 and the visual inspection and manual test reports.
A total of 33 mechanical snubbers were inspected and tested. A report for Unit 1 will be submitted within 60 days of completion of the in-spection and testing. The inspection is scheduled for September 1982.
Functional or Program Areas Inspected 1.
General a.
During a drywell entry to check oil levet on the recirculation pump, January 15, 1982, a leak was disco;ered in a 6-inch reactor water cleanup (RWCU) pipe, weld No. S-14, in the heat affected
zone (HAZ) pipe side. The leak was between two valves and was isolatable. Unit 2 was placed in cold shutdown in anticipation of repairs. The leak rate was approximately 2 gallons per minute (gpm). The Technical Specification for unidentified leakage is 5 gpm.
Following discovery of the throughwall crack, the licensee began to ultrasonically examine (UT) all 6-inch RWCU butt welds and HAZ approximately 6 inches adjacent to each side of the weld, between the 20 inch shutdown cooling suction header to the outboard isolation valve, including four welds outside the containment.
The licensee also contracted CONAM and GE to perform UT in accordance with ASME,Section V, 1974 Edition, Summer 1975 Addenda and CECO Ultrasonic Inspection Procedure of Pipe Welds, NDT-C-2, Revision 12.
Inservice inspection had been performed on welds No. F-1 and No. F-3 in 1978 and 1982, weld No. F-4 in 1976 and weld No. F-5 in 1981. The welds were all found to be acceptable.
The elbows in the RWCU system were manufacturud by " Flow Line,"
HT No. 10897 and the pipe was manufactured by Babcox & Wilcox, HT No. 1345-4-2, HT No. 20626, HT No. M-2092, HT No, M-1602 and HT No. M-1456. The elbows and pipe HT No. M2092, HT No. 20626, HT No. 1602 and HT No. 1345-4-2 had crack-like indications.
b.
On January 26, 1982, a meeting was held in Glen Ellyn, Illinois with CECO representatives to discuss a proposed temporary repair to the nonisolable section of the RWCU piping system on Unit 2.
CECO summarized their repair which included the history of the problem, inspection and flaw characterization, design of the repair and repair procedures, technical evaluations for the repair, the safety evaluations that were performed, and the quality assurance program that would be in effect for-the repair.
(See Attachment i for summary of the meeting and subsequent telephone discussions with the NRC.)
The following identifies actions which received licensee and NRR concurrence on February 1, 1982, which were completed prior to proceeding with the RWCU System repairs to the nonisolable side and actions which will be taken following the repairs.
Prior to starting sockolet weld repair, install mechanical
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restraint on 2" line. Verify accessibility and clearance for welding truncated cone sleeve in place.
Recognizing space limitations, demonstrate capability to minimize leak, should one develop, during the repair of the sockolet.
Establish and maintain a freeze plug during the first 1/8"
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thickness of weld overlay on the flaw repairs for weld joint S-9, S-10, and F-12.
Maintain the equipment in place for the remainder of the weld repair such that the freeze plug could be reestablished.
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Personnel designated to install the three types of mechanical
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clamping devices are to be familiar with and instructed in the installation of the devices.
Prepare, review, and approve all procedures to be used during
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the RWCU line repair prior to the start of work. This in-cludes all Quad-Cities procedures included and referenced in the handout given to NRC at Region III on January 26, 1982.
Welding procedures and welders are to be qualified in
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accordance with ASME Section IX prior to start of work.
Mock-up studies, metallurgical examinations and evaluations
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included in the handout for the January 26, 1982, meeting will be completed prior to start of work on the weld overlays.
Establish ANI concurrence and ASME Code acceptability of all
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parameters of this repair. Also, assure all ANI hold points are established.
Establish by use of instrumentation or mechanical devices the
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extent of distortion of each point of repair. Acceptability of any distortion will be evaluation prior to startup.
Mechanical clamping devices will be available at the work
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place. At least one supervisor shall be available in the repair area (may be outside of drywell) ready to install the clamp should a leak develop.
The capability to provide fuel storage rocks shall be arranged
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for, such that, if needed, the racks can be installed onsite such that removal of fuel from the core can commence following removal of the reactor head.
Ultrasonically examine weld joint F-11 af ter the repair of
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weld joint F-12.
A complete summary of stress analyses performed will be avail-
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able early during the morning of February 1, 1982. The summary will include as a minimum, a description of the methods and analysis being done, the load combinations used, and the results of the analysis.
Communications will be established between the welding
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operator supervisor and the control room during welding operations.
The inboard isolation valve 2-1201-2 will be chain locked
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to prevent inadvertent opening. The valve may be cracked to relieve pressure when the freeze plug is established.
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ALARA evaluation for the repair program has been performed
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prior to start of work.
Perform visual inspection of repaired sections of piping
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when unit is in hot standby.
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Establish temporary procedures to be used during reactor
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operation to require that if the volume pumped from the drywell floor drain sump in a 4-hour period exceeds the previous 4-hour pumpdown by 240 gallons or more, drywell entry will be made to investigate and determine the cause of the increase. The unit will be shut down if the increase is determined to be caused by pipe degradation or if any of the limits in QOS 1600-7 are exceeded.
Update and submit to Region III, the summary of repairs
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document handed out during the January 26, 1987, meeting.
Perform a pump operability test for CS and LPCI prior to
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start of repairs.
During the repairs, the vessel water level will be maintained
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with all four ranges indicating the rormal level.
c.
In the isolable portion of the Rt.
1;au, 8 of 11 butt welds downstream of the inboard isolation valve had UT reflectors, indicative of cracks.
Seven of these 8 welds had circumferential indications on the pipe side in the HAZ. One weld (F17) had an axial indication on the elbow side of the weld.
The 6-inch RWCU, Line No. 2-1202-6A was replaced from the inboard isolation valve, valve No. 2-1201-2, downstream to the drywell
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penetratior,to the insert pipe in accordance with ASME Section XI, 1977 Edition, Summer 1978 Addenda. The original material was ASTM A-312 TP 304 pipe and ASTM A-403, Gr. WP304 fittings.
The new material is ASME SA-312 TP 304L for pipe and ASME SA-403, Gr. WP 304 for fittings.
A system pressure test was performed in accordance with Article IWA-5000 of ASME Section XI.
The test was performed at 1.0 times the operation pressure at 100*F.
d.
In the nonisolable portion of the RWCU line, 4 of 10 butt welds had crack-like indications. A circumferential crack indication approximately 95 percent through wall and 1 1/2 inch in length was found in the HAZ of one side of the pipe to pipe weld No. F6.
Longitudinal crack indications were found in the elbow side of the elbrw to pipe welds No. S9 and No. S10. These indications were approximately 3/4 inch long and 95 percent of wall. Three longitudinal crack indications were found in the elbow side of the elbow to valve weld No. F12. These indications were approx-imately 3/4 inch long and 95 percent of wall. A suspected leak was noted at a 2 inch branch line in sockolet weld No. FIA.
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e.
One mock-up was made of new 304L stainless steel, 6 inch, Sch. 80 pipe welded to an elbow. The test spool was filled with water and then was pad welded to produce a weld pad approximately 6 inches long, 3 inches on either side of the butt weld with a Dimetrics, Inc.
Gold Track II Automatic Welding System, making welds using wire feed, oscillator, and arc voltage with a torch position.
The pad welded mock-up was visually examined (VT), liquid penetrant examined, (PT), and radiographed (RT) in accordance with ASME Section III, 1980 Edition, Winter 1980 Addenda. A test sample was then sectioned for metallurgical examination. The heat affected zone, quality of weld deposit, and the band along the fusion line was investigated.
Microstructure in the HAZ was evaluated using ASTM A262, practice A.
The degree of sensitiza-tion (DOS) observed was compared with DOS generally observed in a typical butt welded sample. The final results from Station Operations Analysis Department (SOAD) was that there were no evidences of adverse effects.
The second mock-up was made from an elbow to pipe joint No. F-17 removed from service and radiographed to locate the crack. The pipe was then filled with water and pad welded on the outside diameter (OD) to produce a 6 inch long, 1/2 inch thick pad by the automatic welding system. After the first layer was laid down, the weld layer was PT and found to be acceptable. The completed weld repair was RT, compared with the original radioagraph and found that the crack was not visible because of the additional material to radiograph through.
f.
The 6 inch RWCU line No. 2-1202-6A was repaired between the tie-in to the 20 inch recirculation line and the inboard isolation valve No. 2-1201-2 in accordance with ASME Section XI, 1977 Edition, Summer 1978 Addenda.
The pipe to pipe joint No. F6, containing the circumferential indication was repaired using a sleeve.
The sleeve was material 304L stainless steel with less than 0.035 percent max carbon and having mechanical properties of type 304. The longitudinal crack indications in the elbows at joints No. S9, No. S10, and No. F12 were repaired by depositing weld metal 360* around and to either side of the existing welds. The weld deposited bands approx-imately 4 inches long and 1/2 inches thick. CECO requested to make 4 inch pads instead of 6 inch pads because of time end an analyses made. The NRC agreed this was acceptable. The suspected leak in the 2 inch side of the sockolet was repaired with a sleeve. This sleeve, similar to a standard type sockolet was welded to the 6 inch RWCU line and to the 2 inch drain line.
The repairs to the nonisolable portion of the RWCU line are temporary and the line will be replaced at the next refueling outage planned for the spring of 1983. The leak test was per-formed in accordance with CECO Procedure QOS 201-4, Revision 7.
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2.
Program and Procedures Review The inspector reviewed the following programs and procedures:
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10 CFR 50.59 - Safety Evaluation of Proposed Repair Program for
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Unit 2 Reactor Water Cleanup System Pipe Cracks in the Drywell.
CECO Repair Program - Reactor Water Cleanup Line, COM-3402-002,
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Revision 1.
CECO, Repair Program - Nonisolable Portion of Reactor Water Cleanup
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Line, COM-3402-003, Revision 0.
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CECO Quality Assurance Manual No. 164.
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CECO, Certification of Inspection and NDE Personnel, Procedure
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No. 1-1-0, Revision 15.
CECO Administrative Procedure for Unit 2 Reactor Water Cleanup
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Pipe Repair Upstream of 170-2-1201-2, Revision 6.
CECO, Radiographic Examination, NDT-A, Revision 8.
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CECO, Magnetic Particle Examination, NDT-B, Revision 5.
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CECO, Ultrasonic Examination, NDT-C, Revision 8.
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CECO, Ultrasonic Inspection of Pipe Weld., NDT-C-2, Revision 12.
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CECO, Ultrasonic Examination of Weld Build Up, NDT-C-33, Revision 0.
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CECO, Liquid Penetrant Examination, NDT-D, Revision 9.
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CECO, Visual Examination, DNT-V1, Revision 1.
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CECO, Loss of Coolent (Fast Leak:
Large or Small Line Break Inside
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Containment) QGA-1, Revision 15.
CECO, On-Site Review Report, QAP 1400-T2, Revision 2 and No. 82-05.
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CECO, Loss of Coolent (Slow Leak) QGA-2, Revision 4.
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CECO, Loss of Feedwater QGA-18, Revision 5.
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CECO, Freeze Seal Data Sheet, QMP 800-54, Revision 1.
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CECO, Freeze Seal Log, QMP 800-55, Revision 1.
CECO, Freeze Seal Procedure Using Jackets, QMP 800-8, Revision 1.
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CECO, Table for Freeze Seals, QMP 800-T1, Revision 2.
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CECO, Shutdown Cooling Start-up and Operation, QOP 100-5, Revision 9.
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CECO, Suppression Pool Water Transfer to the Main Condenser,
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l QOP 100-12, Revision 5.
CECO, Weekly Summary of Daily Surveillance, QOS 005-S1, Revision 20.
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CECO, Operating Surveillance Procedures, QOS 005-2, Revision 5.
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CECO, Reactor Coolant Leakage in the Drywell, QOS 1600-7, Revision 3.
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CECO, Welding Procedure Qualification Record, QE-483.
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CECO, Axial Seam Welds using Mechanical Incorporated Procedure,
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WPS-800A.
CECO, Circumferential Welds Using Mechanical Incorporated
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Procedure, WPS-800A, Revision 3.
CEC, GTA/ Automatic Multi or Single Pass Thickness Qualified 1/16
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inch to 0.686, WPS-8-8-DA, Revision 0.
Mechanical Incorporated (MI) QA Manual.
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MI, P-8, to P-8 GTAW 0.0625 inch Wall to 0.674 inch Wall, WP8-800A,
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Revision 3.
MI, Weld Repair Procedure, WPS-903, Revision 1.
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No items of noncompliance or deviations were identified.
3.
Material and Equipment Certifications and Purchase Orders (PO)
a.
The inspector reviewed the certification documents, relative to the folicwing items:
Ultrasonic instruments, calibration blocks, transducers and
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couplant.
Liquid penetrant materials.
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Stainless steel (S/S) A 312 type 304L, Sch. 80, 6 inch pipe.
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S/S Type 304L, Sch. 80, long radius 90* elbows, 6 inct. diameter.
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S/S Type 308L S/S, 6 inch, Consumable Inserts,
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b.
The inspector also reviewed PO's on 6 inch pipe, elbows, consumable inserts, bar-stock for sleeves and welding wire.
No items of noncompliance or deviations were identified.
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4.
Personnel Certifications a.
The inspector reviewed the following NDE personnot certifications in accordance with SNT-TC-1A, 1975 Edition.
CECO contracted CONAM and GE; and GE contracted Trans-Eastern Inspection, Inc. and Barclay International Ltd.
CECO'
Trans-Eastern Inspection, Inc.
Name UT Name UT W. Witt III W. Barr-II B. Wilson II R. Heller II CONAM Name UT RT MT PT VT R. Lachermeier II II II A. Dukhorn II II T. Randle III III III III III Barclay International Ltd.
Name UT RT MT PT VT D. Gross II j
J. Decker III II II II II l
b.
The inspector reviewed the following welder certifications in accordance with ASME Section IX, 1977 Edition, Summer 1977 Addenda.
GAPCO Mechanical, Inc.
Name Name D. Antoine N. Hall R. Brannon J. House J. Rouse M. Goering M. Holmes No items of noncompliance or deviations were identified.
5.
Observation of Work Activities The inspector observed work and had discussions with personnel during review of the following activities: These observations included per-formance of welding, work examinations and the related documentation.
It was determined that applicable welding and NDE procedures and materials were used and the appearance of the weld surfaces were acceptable.
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Visual examination of the 6 inch RWCU piping system in the drywell
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prior to replacement and repair.
Visual examination of guided bend test coupons and reviewing the
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radiographs for welder qualifications.
Fabrication of new spools, pipe and elbows.
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Mechanical clamping devices were viewed outside of drywell
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including pipe clamp and stainless steel braided cable for repair of sockolet.
Freeze plug equipment in place and operating. There were T.V.
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cameras mounted at various angles viewing the freeze. The T.V.
monitors were located outside of the drywell.
Automatic welding of the mock-ups, welding of pads on welds No. S9,
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and No. S10, and the welding of the sleeve support adjacent to weld No. F6.
There were T.V. cameras mounted at various angles on the automatic welding machine observing the welding. The T.V. monitors were located outside of the drywell.
Manual welding on sleeve over No. F6, pad over weld No. F12, and
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sockolet in drywell.
No items of noncompliance or deviations were identified.
6.
Review of Data Reports, Drawings and Audits The inspector reviewed travelers, welding, and NDE reports including the following:
Ultrasonic reports on the original piping. The following non-
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isolable welds No. F1 to and including weld No. F13 remain in the system. The following isolable welds No. S14 to and including weld No. S23 were replaced.
Weld No.
Circumferential Crack Longitudinal Crack F1 None None S2 None None F3 None None F4 None None F5 None None F6 Pipe Side, 1 1/2" None Long 95% of wall F7 None None S9 None Elbow Side, axial, 1/2" - 3/4" long, 50% of wall S10 None Elbow Side, axial, 1/2" - 3/4" long, 95% of wall
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S11 None None F12 None Elbow Side, axial, 3 indications, 1/2" - 3/4" long, 95% of wall F13 None None S14 Pipe Side, leaker None S15 Pipe Side None S16 Pipe Side None S17 None Elbow Side, axial indications S18 Pipe Side None
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S19 Pipe Side None S20 Pipe Side None S21 None None S22 None None S23 Pipe Side None Reviewed several " CECO Damage Control Personnel Training for Nonisolable Unit 2 RWCU Pipe Repair" Forms.
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Reviewed Drawings:
MI. DWG. 2-1202-6 - ISO No. 3, Revision 0, Unit 2 Drywell Pipe Repair.
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S&L DWG. No. 151-119, Revision A
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Grinnel DWG. No. 2-1202-ED-1 and No. 2-1202-ED-2, Revision
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November 2, 1971, RWCU Piping.
Review reports and radiographs of the following welds which
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were replaced on the isolable side of the RWCU piping system.
Weld No.
Weld No.
FW1 FW6 FW2 FW8 FW3 FW9 FW4 FW10 FW5 FW11
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Reviewed CECO QA Surveillance Reports on activities of
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l General Electric Company (Trans-Eastern Inspection Company and Barclay International Ltd.) and CONAM Inspection Company.
Reviewed CECO QC Surveillance Report on Mechanical Inc. work
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on isolable side of RWCU piping system.
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Reviewed CECO audit of RWCU repair.
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All NDE performed of the isolable and the nonisolable side welds
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were all found to be acceptable.
No items of noncompliance or deviations were identified.
Exit Interview The inspector met with site representatives (denoted in Persons Contacted paragraph) at the conclusion of the inspection. The inspector summarized the scope and findings of the inspection noted in this report.
Attachment 1: February 3, 1982, Memo Danielson to Files 13