IR 05000271/1986002

Insp Rept 50-271/86-02 on 860113-17 & 21-31.No Violations Noted.Major Areas Inspected:Ndes on Replacement Piping in Reactor Recirculation Sys.Visual Insp of Pipe Restraints Also Performed

ML20154A366
Person / Time
Site:	Vermont Yankee
Issue date:	02/14/1986
From:	Campbell R, Harris R, Kerch H, Wiggins J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I)
To:
Shared Package
ML20154A363	List: IR 05000271/1986002 ML20154A360
References
50-271-86-02, 50-271-86-2, NUDOCS 8603040003
Download: ML20154A366 (17)

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U.S. NUCLEAR REGULATORY COMMISSION

REGION I

I Report N _50-271/86-02 Docket N ,

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License N OPR-28 Priority -

Category C

, licensee: Vermont Yankee Nuclear Power Corporation l 1671 Worcester Road F Framingnam, Massachuse_tts 01701 Facility Name: Vermont Yankee i

Inspection At: ____Vernon, Vermont  !

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Inspection Conducted: January 21-31, 1986 Inspectors: dlkr Hagr3 ,, -

, Lea @ eactor Ergineer, NDE b/V-(6 date i

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f>V Ric@rd H. Kstis, NOL" Technician l ' I 4 - f (,

date ;

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% * l'l- C&

Ran / M.&Cahyy>

tsef1DE(;fect.nician 3_& date ;

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Approved by: 2 - / t/ -f b kl.fA.ef gins Materials & Processes, cate 7

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Inspection Summary:

Inspection Conducted JanuarL21-31, 1986 (Report No. 50-271/86-02) .

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! Areas Inspected: A special, announced inspection utilizing the NRC Mobile NDE Van to perform nondestructive examinations on replacement piping in the

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reactor recirculation system. A visual inspection of pipe restraints, embed- .

ment plate weldments and other safety related areas was also performe *

Three regional-based inspection personnel assisted by two contracted NDE

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personnel were utilized during this inspection. The inspection involved 422 onsite hours and 64 hours7.407407e-4 days <br />0.0178 hours <br />1.058201e-4 weeks <br />2.4352e-5 months <br /> in Region I office.

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Results: No violations were identified.

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8603040003 060225

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PDR ADOCK 05000271 G PDR

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4 DETAILS 1.0 Persons Contacted

Vermont Yankee

• J. P. Pelletier, Plant Manager

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• 5. A. Vekasy, DSR Supervisor j *B. Wittmer, Project Manager

• J. Gianfrancesco, Construction Superintendent j Yankee Atomic f *L. Mullins, NDE/ISI Supervisor

US Nuclear Reculatory Commission

• Raymond, Senior Resident Inspector

" Denotes those present at Exit Meeting.

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2.0 Independent Measurements - NRC Nondestructive Examination and Quality Records Review of Safety Related Systems 1

During the period of January 13 through 17, quality records received from Vermont Yankee Nuclear Generating Station were reviewed in the regional i office for completeness and compliance to the licensee's FSAR commitment to applicable codes, standards and specifications. Subsequently, an cnsite independent verification inspection was conducted from January 21 .

th*ough January 31, using the NRC Mobile Nondestructive (NDE) Laborator '

This inspection was performed by NRC contracted personnel in conjunction with regional-based NRC personnel. The purpose of this examination was to 4 verify the adequacy of the licensee's welding quality control program  ;

j during replacement of the Reactor Recirculation System piping. This was '

! accomplished by duplicating those examinations required by the regulations and evaluating the results. These test results were then compared to the

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licensee's quality assurance records for completeness, accuracy and correlation. In addition to the above examinations, a visual examination 6

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of other safety-related items including pipe restraints and embedded

plates was performed along with a walkdown of HPCI system piping and j supports, j The NRC Senior Resident Inspector made a selection of pipe weldments which provided a representative sample of the recirculation piping system I replaced by the licensee. The selection made represented various pipe

. sizes and included, shop and field weldments fabricated to ASME Class I component requirements. Also selected were embedded plates mounted on reactor building walls for visual inspection for movement or any areas of

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cracked concrete around the embedded plates. The items selected were previously accepted by the licensee based on vendor shop and onsite QA/QC record ;

i 2.1 Quality Documents Review

Nineteen safety related piping system document packages were reviewed for compliance with licensee procedures, applicable codes ,

and standards and regulatory requirements. The following types of  :

documents were reviewed, Document Att*fbutes Reviewed

Material Certification Material chemical and (Bcse)

physical properties compared to

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standards and code requirenent NDE Records Examinations meet codes and stand-ards, licensee procedures and other

, commitments; personnel properly qualified; appropriate examinations performe Fabrication Records Fabrication travelers and records I

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were reviewed and compared against other corresponding records and sign-off sheet Drawings (Isometrics) Drawings were reviewed for proper designation of weldments, location '

and classification.

Procedures Precedures were reviewed for com-pleteness, and licensee's commitment to Code requirement i Welding Material Material certifications for welding ,

materials were reviewed for physical and chemical properties as required

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by licensee's commitment to Code and

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industry standard ;

These documents were reviewed to verify compliance to NRC require-  !

ments and licensee's commitments to industry codes and standard ;

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The document packages reviewed are listed in Attachment # t

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Results: No violations were identified, i

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i 2.2 Nondestructive Examinations  ;

Examinations were performed using NRC procedures with addenda written specifically for coepliance to the Itcensee's FSAR commitments. The ',

intent was to duplicate, to the extent possible, the techniques and

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estbods used during the original examinatio '

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The following examinations were performed:

Radicarachic Examination

Eighteen pipe weldoents were radiographically examined per NRC ;

procedure ADE-5, Revision 0, Addenda VY-1-5-1. These weldments were ;

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located in the RHR and Reactor Pecirculation system ,

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Results: No violations were identifie '

l Liguid_ Penetrant Examination

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Fourteen pipe veldcents and adfacent base metals were examined per NRC procedure NDE 9. Revision 0, and addenda VY-1-9-1. Samples exanined were ASME Class ! pip ,

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! Results: No violations were identifie i Visual Examination

, Nineteen pipe weldments and acjacent base materials were examined for

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weld reinfcrcement, surface condition and overall workmanship per NRC ,

. procedure NDE-14, Revision 0.

l Results: No violations were identified.

Thickness Measurements  !

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! Seven weldments and adjacent pipe material were erasined per NRC l procedure NDE-11, Revision 0, using a Nova 0-100 thickness gauge, i

Minimum wall thickness was determined by using ASTM standard pipe -

size and nominal thickness char t i

Results: No violat. ions were identified, i  !

2.3 Other Confirmatory Examinations

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2. Walkdown (HPCI) High _ Pressure Coolant Injection System ;

The inspectors performed a walkdown inspection of the High Pressure Coolant Injection system, utilizing site drawing PI-1062. The walkdown inspection involved a visual and 4 physical inspection of piping and pipe supports identified en the aforementioned site drawing.

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Aspects of the walkdown inspection included the following:

a pipe geometry, dimensions, angles and orientation; a pipe support location;

• pipe-to pipe and pipe-to-equipreent welds; and a support dimensions and weldin See Attachment #4 for specific supports inspecte Results: No violations were identifie .3.2 Whip Restraints The inspectors performed a visual examination of (10) ten large bore pipe restraints on the Reactor Recirculation syste Inspection was performed on the whip restraint fillet weld mounting plates of Loops A and 8. The licensee had previously completed an inspection and evaluation of all the recirculation system whip restraints (total of 32)

in accordance with the original construction drawing G-191711, Revision The licensee's examination indicated that the original installation of the component fillet

welds was not in accordance with the design drowing for some restraints. The licensee has developed a corrective I

action program to restore the required restraints to oper-able cor.ditions during the piping replacement progra The NRC inspectors performed an overview weld inspection and compared the results with the licensee's findings and evaluation (Document #006820 MEM-PT-MIS, Appendix 2). See Attachment #4 for specific restraints inspecte Results: No violations were identifie .3.3 Embeded Plates and penetrations The inspectors performed a visual examination of selected areas around embedded plates and penetrations to identify indications of plate moverrent or other unusual condition Inese inspections were undertaken as a result of the licensee's findings that a high pressure coolant injection system pipe support plate had not been properly installed during plant construction, f

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The inspectors performed a visual inspection on tne following embed -

plates for additional instances of improperly installed support plates:

Reference Area Embed Plates Inspected Penetration x 39A 2 plates Results: No violations were identifie .4 Review of QA/QC Procedures i

The following procedures were reviewed for compliance with NRC j regulations and applicable code requirements, j (NDE) Nondestructive Examination Procedures J

Morrison and Knudson f

Document Title Rev.

FQP-09-01 Visual Inspection 2 l

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FQP-09-02 Liquid Penetrant 2 .

FQP-09-03 Magnetic Particle 1 FQP-09-04 Radiographic 2 t

' t FQP-09-06 Ultrasonic Thickness Examination 2 l

, FQP-02-03 Qualification and Certification of Audit

] Personnel 0

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! FQP-02-02 Qualification and Certification of

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Inspection Personnel 0 j FWP-04-01 Control of Welding 3

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Hitachi Lt VY-IP-001 Liquid Penetrant 3 Results: No violations were identified.

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3.0 Radiographic Review 4 The inspector reviewed the site radiograph data packages for twenty-nine (29) vendor shop welds and six (6) field welds. Of the thirty-five (35)

sets of radiographic data packages reviewed, thirteen (13) were compared -

to NRC radiographic data packages. This comparison of radiographs was performed to verify the adequacy and completeness of the licensee's

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record < See Attachment #2 for specific radiographs reviewe .

Results: No violations were identified. The inspector found the

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contractor's radiographic program to be very goo .0 Infrared Demonstration Background During the recirculation piping replacement activities, an embedded plate used as an anchor point for high pressure coolant injection (HPCI) system piping was discovered pulled from the wall. The problem with this plate was traced to original plant construction, wherein the required plate anchors and shear lugs had apparently been removed. Visual inspection of

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this and similar embedded plates was made by the licensee. The attributes verified were size of plate, location and evidence of plate movement or 1 evidence of cracking of the concrete around the embedded plates; shear

lugs and anchors were not initially verifiable. To address the shear lugs and anchors, the utility has developed a NDE Infrared (IR) technique using i heat flow analysis to determine if the lugs and anchors are attache The utility performed an infrared test demonstration that was witnessed by the inspector to show that the IR technique was able to verify the proper 4 installation of the embedments. As a result of the demonstration, the  :

l inspector agreed that lugs and anchors near the edges of the embedments could be positively identified using the IR techniqu '

The utility has written a preliminary procedure 85-03 for IR testing and for a pull test of embedded plates. Since only a portion of the embed-

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ments can be positively verified by IR, a sample of the embedment plates that were IR-tested will also be subjected to a pull test. The test will apply a 10,000 lb. load; this load exceeds any load currently applied to embedded plates of the type in questio The inspector concluded that af ter the licensee completes the qualifica-tion of the IR technique and completes the pull test, the test results obtained should adequately resolve the issue of improper installation of existing embedded plates.

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5.0 Welding Problems Encountered During the course of this inspection, the inspector examined certain problems which had been previously identified by the licensee. The inspector sought to assess the adequacy of the licensee's proposed corrective action "

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5.1 Safe Ends

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During the course of the recirculation piping replacement, the licensee identified several welding problems. The inspector looked into the welding problems associated with safe end N2H-SE reported on

! OIR #046. This safe end was welded up to h" weld thickness, then I radiographed. Radiographs of areas 0-10 and 20-30 were rejected by the contractor for incomplete fusio Both affected weld areas were repaired; repairs were radiographed and subsequently rejected for ID root problems as reported on OIR #06 !

Site engineering disposition was to remove and reweld safe end

, N2H-SE. This disposition was based on Vermont Yankee Welding Specification EDCR 85-1(E), paragraph 6.5.5. This section dealt with repairs and the control of sensitization of stainless steel face mate ri al . Also, the inspector noted that Morrison Knudsen Welding Procedure FWP-9.1, Revision 3, paragraph 4.4.2.9, limited the maximum i allowed weld repairs to three repairs within the same area. All repairs were required to be reported on the back of the weld data

card for licensee engineering review.

, Site welding engineering has reviewed these welding problems and has corrected or improved the following welding practices:

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(a) use of purging dams;

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(b) control of weld wire feed; and

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l (c) specification of the angle of electrode for each pass in the i welding procedur ;

With the above changes, site welding engineering believes that the

safe end problems will be eliminated. The inspector concurred with

! this positio l 5.2 Thermal Sleeve

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During the removal of safe end N2H-SE, it was necessary to remove the

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thermal sleeve-to piping wold. The licensee performed a visual inspection of the previously inaccessible weld side and found that the consumable insert was not completely consumed f or a length in

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excess of 8". This welding defect was reported on MR 074. To address this problem site engineering changed the weld design from a

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consumable insert to a weld with a backing strip. This weld is to be made by a remote control operator using a TV camera. The nozzle opening was noted to be approximately 10" 10 and the weld to be made would be 30" inside of this 10" ID nozzle. The site examination

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requirements for this weld were specified as a solvent-removable liquid penetrant examinatic'n. Also used would be a small diameter boroscope to view the liquid penetrant results and to perform a visual inspection. Other licensee considerations were that ten of these welds are to be made and there would be a radiation problem related to the nozzle shin The inspector had several concerns regarding the examination of thermal sleeves. The inspector noted that the solvent removable penetrant method presents a problem with the remote removal of pene-trant from as-welded surfaces. He furtner noted that other penetrant test methods may reduce personnel radiation exposures. Lastly, a concern was expressed regarding tne qualification and use of a bore-scope for the visual acceptance of the penetrant examination results because of the limited field of view presented and the difficulty of interpretating the result The adequacy of the licensee's proposed examination techniques is considered unresolved pending further evaluation by the licensee and review by the NRC. (50-271/86-02-01).

5.3 Weldine Material Control The licensee's contractor found that carbon steel (705-3) welding rods were issued to a welder for repairs on the weld prep of an N2F nozzle. This was not discovered until the welder returned two welding stubs to the welding wire room and the attendant noticed that the returned stubs were carbon steel and not stainless steel as required by the withdrawal slip. TFe discovery was reported on NCR #058. The inspector vi:ited the welding rod rooms and verified that blank filler material withdrawal slip forms have been removed. The inspector and contractor discussed a plastic hinged cover to be placed on half of the walding wire control storage box, so that carbon steel is' segregated from the stainless steel welding wir A review of NCR 6058, under the section dealing with actions to prevent recurrence, revealed to the inspector that there was docu-mentation for the training of welders and weld wire attendants, but none for the Quality Control personnel, regarding weld wire issuance procedures. The inspector also reviewed the changes made to proce-dure FQP-10-1, Revisior 4, which provided guidance'for the OC personnel regarding welding material controls. This procedure had not been approved or issued, however, it was the inspector's under-standing that when it was implemented, all personnel concerned would be trained. The inspector had no further question .

6.0 Quality Conteo1 Interfaces In the process of inspecting the licensee's radiographic program, vendor (Hitachi) radiographic film for the recirculation piping replacement were reviewed by the NRC. Several deficiencies were identified with the radio-graphic film and reader sheets. Further inspection revealed that Yankee site quality personnel had previously identified the same problems with the radiographic film and reader sheets, and had addressed the deficien-cies by requiring re-reviews and additional radiographic examinations onsite. These actions were documented on report MSG 5/86 W.0. #486 No violations were identifie .0 Attachments Attachment No. 1 is a tabulation of the specific walds examined and the result Attachment No. 2 is a list of specific radiographs reviewea and the result Attachment No. 3 is a list of specific documentation packages reviewe Attachment No. 4 is a list of specific hanger supports and restraints examined and results.

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8.0 Exit Intervies The inspector e.et with the licensee representatives (denoted in paragraph 1) at the conclusion of the inspection. The inspector summar-ized the scope and applicable findings of this inspection. No written informaticn was given to the licensee by the inspector during the course

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