IR 05000277/1983008
| ML20023B520 | |
| Person / Time | |
|---|---|
| Site: | Peach Bottom  |
| Issue date: | 04/21/1983 |
| From: | Durr J, Reynolds S NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML20023B511 | List: |
| References | |
| 50-277-83-08, 50-277-83-8, 50-278-83-08, 50-278-83-8, NUDOCS 8305050147 | |
| Download: ML20023B520 (8) | |
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U.S. NUCLEAR REGULATORY COMMISSION
REGION I
50-277/83-08 Report Nos.
50-278/83-08 50-277 Docket Nos.
50-278 DPR-44 License Nos.
DPR-56 Priority Category C
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Licensee:
Philadelphia Electric Company 2301 Market Street Philadelphia, PA 19101 Facility Name: Peach Bottom Atomic Power Station, Units 2 and 3 Inspection At: Delta, Pennsylvania Inspection Conducted:
March 7-9, 1 83 Inspector:
46/
[b
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S. D. Reynolds, Jr.
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Lead eactor Engi _er Approved by:
'66N CMW
.h J. Durr, Chief, Materials and Process Section Emergency Preparedness Branch, DETP Inspection Summary:
Inspection on March 7-9, 1983 (Report No. 50-277/83-06 and 50-278/83-09)
Areas Inspected:
Routine announced inspection of induction heating stress improvement (IHSI) procedures utilized to mitigate intergranular stress corrosion cracking (IGSCC) of sensitized austenitic stainless steel weld heat affected zones (HAZ) in delected welds in the unit 3 residual heat removal (RHR) suction and return lines and recirculation lines.
The inspector reviewed procedures, sample IHSI setups, and equipment for recording and controlling the procedure.
The inspection involved a total of 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> onsite and 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> at the regional office by the inspector.
Results:
No violations were identified.
8305050147 030421 PDR ADOCK 05000277 O
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DETAILS
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I 1.
Persons Contacted Philadelphia Electric Company (PECO)
- R. Fleischmann II, Station Superintendent l
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- F. Gloeckler, Mechanical Engineer E&R Dept.
R. Zong, Senior Engineer, E&R Dept.
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General Electric Corp., A&ES0 (GE)
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- K. Grayson, QC Supervisor
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A. Barbaretta, Project Manager
E. Reczek, Level III
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- Indicates those present at the exit interview
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2.0 Background
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The sensitization and subject intergranular-stress corrosion cracking (IGSCC) of regular carbon stainless steel.weldments'has been an industry
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problem. Those welds with sensitized heat affected zone (HAZ)
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concomitant with ID tensile stress have failed in boiling water reactor (BWR) oxygenated water as described in NRC Bulletin 82-03, Rev. I and NUREG-0313. The induction heating stress improvement (IHSI) process was
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developed to produce ID surface compressive stress patterns to mitigate
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IGSCC. This process was initially developed by the Japanese ard has been
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evaluated and developed by GE and the Electric Power Resesrch Institute
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(EPRI) and reported in proprietary or limited distribution documents
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(e.g., GE NEDE25394, EPRI NP-2527-LD, EPRI NP-81-4-LD, EPRI NP-2662-LD).
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The licensee initially determined that IHSI would be beneficial for
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j specific welds in the Unit 3 A & B RHR suction and return lines and the A & B Loop recirculation lines.
It was the GE initial recommendation to
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heat treat (IHSI) those welds that had a stress rule index (SRI)-
(engineering summation of weld joint ID surface tensile stresses) of equal to or greater than 1.2.
The licensee initially determined that the
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f-IHSI be limited to welds in non-isolatable portions of the aforementioned piping systems which for plant reliability, safety and extended outage
reasons would cause the major plant perturbations if leakage occurred.
This decision was made without the known existence or absence cf IGSCC in
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these welds.
The welds included in this list are as follows: 2-AS-2 to i-8, 10-0-1 to -7, 10-0-1A, 10-0-1B,.10-0-10 to -12, 2-BS-2 to -7.
All welds are P-8 to P-8 except 10-0-7, -10 and -12 which are P-1 to P-8 dissimilar welds.
At' this junction, the licensee planned to perform a pre-IHSI ultrasonic l
examination (UT) on all those welds of the aforementioned group with an l
SRI > 1.2 (a total of 13 welds).
A' change was then instituted by the licensee to extend the scope of the IHSI to include as'many sensitized i
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welds with potential IGSCC as was possible without extending the outage.
Following further review of current IGSCC data, a change in the pre-IHSI
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UT program was then made to limit this examination to welds in these
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systems known to be generic IGSCC problems rather than using an SRI
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criterion.
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The change in the hojenecessitatedthedeselopmentofaprioritylist
as follows:
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1.
_Theoriginalscope(non-dolatablejoints).
c.
2.
Other wejds in.these systems that have proven to be generic IGSCC
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l prohlems.
3)
Those welds in these systems with knowri higher carbon contents.
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As'many other welds as possible during the outage.
The licensee stated th'at if nre-IHSI UT indicated the actual presence of significant IGSCC, the scope of the IHSI program will be reviewed and modified as-applicable.
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Itshould3e'poiste'doutthatthePeachBottomUnit#3IHSIprogramis the first applic-atiUn of the Japanese-developed process attempted by GE.
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3.0' Review of Applicable IHSI Documents
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The following GE IHSI documents were reviewed:
a.
PB 83-1.0 (UT)
paragraph 4.1.3 recommends use of known IGSCC
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sample for training.
GE at site has EPRI IGSCC sample.
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b.
PB 83-2.0 (VT) - document states personnel qualified to ASME SCIII, i
V and XI requirements. Discussions with GE QC Supervisor (and VT
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Level III) indicates personnel also q'ialified to GE P28A-AE-1001.
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PB 83-3.0 (PT) - GE utilizes Sonics Systems International PT Level
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II personnel.
Records of qualification of personnel not reviewed at
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this time.
d'. ~ PB b3-410-(Etching) - Procedure not used to date.
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PB 83-50-(Materials and Processes).
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PB 83-6.0 (Arc Strike Removal) - not used to date.
g.
PB 83-7.0 (general welding procedure) - not used to date.
h.
PB 83-8~.8.1 (Detailed Welding Procedure P8 to P8) - not used to t
date.
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PB 83-9.0 (Hanger removal and installation).
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PB 83-10.0 (temporary pipe supports).
k.
PB IHSI-1.0 through -5.0.
1.
PB IHSI-6.0 IHSI Treatment - 4.11 permits aborting the heat
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treatment during cycle on lack of flow.
4.17 permits multicycle IHSI, but does not indicate limit on number of cycles.
There is no provision for aborting cycle due to water hose failure on coils which would water quench OD surface.
Consideration should be given to including these items on the procedure.
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PB IHSI 7.0/IHSI Implementation Procedure:
This prcedure is PORC
approved.
This procedure references all other applicable IHSI i
procedures.
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PB IHSI 8.0.
Only GE PB IHSI 7.0 (the implementation procedure) is PORC approved.
This procedure references the other procedures.
All of the above procedures have been approved by the licensee's Engineering and Research
Department.
- Review of other applicable. documents:
a.
(PECO) Diederich to (GE) Davis letter dated 3/2/83 indicating approval of' procedures 1-18.
b.
GE Standard IHSI Travelers for Project 320N6500:
(1)
2.0-T-1 Rev 0 1/18/83 (2)
3.0-T-1 Rev 1 2/7/83 (3) Sample Coil Fit Up and T/C Layout
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(4)
3.0-T-2 Rev 1 2/7/83 (5)
Fine Coil Adjustment Data Sheet (6)
6.0-T-1 Rev 0 1/18/83 i
c.
F. C. Gloeckler isometric sketches and weld / SRI / coil. number tables (4 sheets dated 2/15/83).
d.
GE NEDE-25394 "IHSI for SS Piping"
e.
PECO Engineering and Research Department Quality Assurance Major
Activities Schedule dated March 1.1983 for activities through May i
1983.
This document indicates an internal audit of MOD 945 (IHSI) on page 2.
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PEC0 Modification 83-007 (E&R MOD 945) Package. This document indicates PORC approval, NDE requirements before and after IHSI, safety evaluation, 10 CFR 50.59a discussion, and indicates the modification does not involve changes to safety related equipment, does not involve an unreviewed safety question and does not require a change in the Technical Specifications nor an amendment to the licensee.
g.
PECO (Gloeckler) list of carbon contents on applicable weldment base metals.
No violations were identified.
4.0 Observation of IHSI Setup The inspector witnessed a typical heat treatment set up with thermocouples, coils and with water cooling circuits for equipment and
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instrumentation installed.
The joint was a 22" diameter 1.5 nominal wall joint using a sample (non production) coil. The instrumentation signals are recorded on cassette tape and are displayed on a CRT. The inspector
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witnessed the re-run of an IHSI program (File Name NFF07, Date 11/12,
-Time 13:50:09). The re-run included running a trial (or idle) program as a proof test of coil concentricity and thermocouple (T/C) operation.
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Printout tapes were obtained for a special checkout trial run and T/C
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readings for T/C 01 during the 148 second IHSI thermal cycle.
A calcomp
temperature vs time plot was obtained for the trial run and for 7 of the T/C outputs for the IHSI.
- During the witnessing of the heat treatment setup, the inspector observed loose stainless steel electrodes and two unlocked unheated electro'de ovens in the trailer used for the training of personnel in IHSI.
This trailer was behind the' power plant buildings.
The inspector requested the licensee to review the GE General Welding Procedure to determine if the handling of these electrodes meets GE and licensee requirements.
- This item is considered unresolved until addressed by the licensee and the answer reviewed by the NRC.
(278/83-08-01)
5.0 Review of GE IHSI QC Records Although most of the GE IHSI QC packages were not complete the following items and discrepancies were noted:
a.
2-BS-10/ pump to elbow:
Noted apparent absence of trial run calculations (trial run conducted).
b.
2-BS-9/ pipe to elbow:
Trial run did not produce desired results.
IHSI had I low T/C reading on elbow side apparently past the point of tangency.
FRR IHSI 6.4.1 issued.
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2-BS-7/ attachment to valve:
IHSI had 1 T/C reading which missed range (low).
d.
2-BS-6/ pipe to elbow:
IHSI had one low T/C reading.
Post IHSI UT conducted, but results not given final dispostion. No apparent
indicate of IGSCC.
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e.
~2-BS-5/p.ipe to pipe:
QC package complete.
Good IHSI run.
Post IHSI UT conducted which reports root indications believed to be weld root contour not IGSCC.
Final PECO review of UT not complete.
f.
2-BS-4/ pipe to elbow:
IHSI had 3 T/C miss the desired temperature band on low side and one T/C miss on high side.
FRR IHSI 6.4.2
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issued.
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2-BS-3/ pipe to elbow:
IHSI indicates 5 T/C temperatures missed on j
low side and one T/C missed on high side.
h.
2-BS-2/ pipe to sweepolet: QC package not complete due to unanswered NCR on PT results following T/C removal.
PT produced an indication
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most probably not related to T/C attachment or IHSI.
IHSI had good
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T/C readings.
Post IHSI UT completed and reviewed by PECO.
No indication of IGSCC.
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2/AS-2/ pipe to sweepolet (similar joint to 2-BS-2 which had good T/C readings):
IHSI had 4 low T/C readings.
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.The review of the QC documents indicates that the IHSI cannot be reliably controlled within the parameters specified in the GE procedures; however, it may be controlled within GE San Jose engineering requirement limits.
This means that either the procedure limits are excessively tight or the
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execution of the procedures is inadequate. The former is most likely
correct. The possible technical problems are addressed in paragraph 6.0.
The Travelers have provision for ANI and licensee to sign off an approval of individual travelers and for individual sign off of line items.
Information given to the NRC inspector indicated that to date the ANI and
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licensee have waived all approvals on IHSI weld joint operations to date.
l 6.0 Discussion of Quality and Technical Aspects of PEC0/GE IHSI Activities The inspector held a discussion with Messrs. Gloeckler and Zong of the
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i PECO Engineering and Research Department on the IHSI activities.
l Questions were raised by the inspector as a result of review of the i
procedures and work in progress.
a.
The appropriate level of PECO quality assurance / quality control
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coverage for the GE IHSI program was discussed.
The licensee has
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approved the GE QA program and delegated quality aspects of the IHSI
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program to GE. The licensee program provides for only QA auditing of the Modification (MOD 945) program and no QC surveillance. Based on the current difficulties in meeting the procedure requirements (T/C readings meeting heat band requirements), the inspector questioned the overall acceptability of the procedures as written to provide " measures to control a special process." This is considered an unresolved item.
(278/83-08-02)
b.
The inspector questioned the adequacy of engineering control of the IHSI process by GE PB IHSI-6.0 which permits aborting of the process during the heating cycle, permits unlimited number of IHSI cycles on a specific weldment, and does not cover a potential cooling coil hose failure (water quenching of the OD surface during the thermal cycle).
c.
Although the GE travelers provide opportunities for the licensee and ANI to review the travelers and indicate (licensee and ANI)
mandatory hold points or checks, to date this quality aspect has been waived by both parties. The inspector questioned if waiving this quality aspect was prudent.
d.
The inspector requested information on what GE engineering assumptions were made for the determination of "R" and "t" in the formulas for calculating heat band width and heating element width.
3.
The inspector requested information on whether any of the circumferential welds in the subject RHR and recirculations lines were shop welded with the' submerged arc welding (SAW) process or welded in the field in the down hand, rotated position.
If these processes were used, does this affect the selection of welds to be given IHSI treatment.
f.
The inspector pointed out that the blank GE travelers did not indicate the latest revisions of procedures.
This was rectified during the inspection period.
g.
The inspector requested clarification of the assumed ID surface temperature, where the GE NEDE-25394 document indicates 100 C is adequate, but the procedure does not permit heat treatment unless there is water circulation. Water circulation would essentially produce a maximum ID surface temperature of 50 C.
h.
The GE fine coil adjustment data sheet requires a calculation to prove the adequacy of the trial heating operation and also permits
"the Engineer" to disregard the results of the test. The inspector questioned if this method provided adequate quality control of the process.
1.
To date, the UT examinations have indicated that there is no indication of IGSCC.
The inspector requested that the licensee inform Region I if welds witn known IGSCC were being heat treated,
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as the process is then being used as a repair technique.
The inspector also asked if the licensee planned to the use the ALN-4060 (black box) to resolve UT interpretations, if difficulties in interpretation of the extent of IGSCC was a problem.
During the inspection the Senior Metallurgical Engineer indicated that consideration had been given to this technique, but if it were used it wouid only be used to assist in interpretation, not as a final disposition method.
j.
The inspector asked if any sensitization tests (ASTM:A262 or EPR)
were planned to provide information on the degree of sensitization in the subject weldments. The licensee indicated none were planned.
k.
The inspector requested the formula used by GE to determine the Stress Rule Index (SRI).
1.
The inspector asked if the strain hardening and attendant increase in yield strength caused by multiple heat treatment was considered in the engineering decision to permit multiple heat treatments using the same AT parameters.
m.
The inspector requested the licensee's criterion for determining the IGSCC crack size (% of wall) which is to be permitted for IHSI treatment.
Items b to e, g to 1, and k to m in the above list are considered Inspector Information Items.
The licensee is requested to provide technical answers to these questions.
(278/83-08-03)
7.0 Unresolved Items Unresolved items are matters about which more information is required in order to ascertain whether they are acceptable items, items of noncompliance or deviations.
Unresolved items disclosed during this inspection are discussed in paragraphs 4 and 6 of this report.
8.0 Exit Interview The inspector met with licensee representatives (denoted in Paragraph 1)
at the conclusion of the inspection on March 9, 1983.
The inspector summarized the scope and findings of the inspection.
In addition, the NRC Resident Inspector, Mr. A. R. Blough attended the meeting.
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