IR 05000324/1990022
| ML20055H431 | |
| Person / Time | |
|---|---|
| Site: | Brunswick  |
| Issue date: | 07/10/1990 |
| From: | Blake J, Economos N NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML20055H430 | List: |
| References | |
| 50-324-90-22, 50-325-90-22, GL-84-07, GL-84-7, NUDOCS 9007260198 | |
| Download: ML20055H431 (9) | |
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nn magt, DNITED STATES '
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'o NUCLEAR REGULATORY COMMISSION r
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~ REGION 11 3'
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'101 MARIETTA STREET,N.W.
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ATI.ANTA, GEORGI A 30323
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Report Nos.:
50-325/90-22 Land 50-324/90-22 Licensee:
Carolina-Power and Light Company!
P. 0; Box 1551
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Raleigh, NC 27602-Docket Nos.: 50-325 and 50-324 License Nos.-
' Facility Name:
Brunswick 1 and 2-
Inspectio o u te -
un 11-15, 1950 j
Inspector._
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'Date Signed
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Approved by.
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9v J.
Take, Chief
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M te ials and Processes Section i
ng 'eering Branch
.i Division of Reactor Safety i
l SUMMARY
._i Scope:
This routine, unannounced inspection was performed to provide the inspector the
' opportunity to meet with the ~icensee and discuss planning and technical issues y
associated with the recirculation system' inlet safe-ends, cort-spray - system safe-ends and associated piping. replacement. The modificationiisLscheduled for the upcoming September refueling outage.
Results:
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By document review, and through; discussions"with management.and key. technical
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personnel,- the inspector. ascertained that the : licensee is movi_ng' forward.in-
- 3 this project following the guidelinei ofj Generic -Letter' 84-07. : Accordingly,
the licensee has generated controlling documents which address organization
'i structure / responsibilities; design, radiation. protection,.'and 7 engineering
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specifications for procurement, pipe installation and: testing activities, ~ In'
i the areas' inspected, violations or deviations were not' identified.
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9007260198 900713 PDR ADOCK 05000324
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. REPORT DETAILS-
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Persons Contacted j
h Licensee Employees
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- W.- J. Dorman, QA/QC Manager
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J.:L. Harness, General Ms BNP
- R. E. Helme, Manager, Teci Support.
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- J. R. Holder, Hansger, Outages..ad Modifications
- R. -Johnsen, Project. Manager, Recirculation Piping
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- T. Jones, Regulatory Compliance Specialist
- D E. Moore, 'ricnager, Engineering NED'
t T. Pitchford, Lead Engineer, Recirculation Projects L
- R..M. Poulk, Supervisor Regulatory Programs-
- R. L. Warden, Manager, Maintenance
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Other licensee employees contacted during -this inspection i ncluded engineers, technicians, operators, mechanics, and office personnel.
Other Organizations ~
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General Electric Nuclear Plant Services-R. Markley, Shift Supervisor NRC Resident Inspectors
- W. Le'vis, Resident Inspector
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- D. Naison,. Resident Inspector I
- Attended exit interview l
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Replac c ent of BWR Recirculation Piping-(2512/13)
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Design Changes and Modification Program-Unit-1-(37702)
Replacement of thel Brunswick' Plant Unit-l' Recirculation Systemiinlet
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safe-ends,12-.icch riser piping J and core spray safe-ends : and ' iping p
is :the result of c CP&L 'conmitment to the Commission (NRC) - Letter,
No. NLS-89-192, dated June.28, 1989, from.'R. A. Watson to: the
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Commissiom NUREG 0313,~Rev.~ 2,
" Technical Report : on ~ Material-
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Selection and Processing Guidelines for BWR Coolant Pressure' Boundary Piping" has been evoked for the selection of. replacement materials.
Installation, weiding and nochining requirements are those=
reccmmended by the Electric JPower Research Institute.(EPRI),. and will be adhered to, 'as much ; as possible.
Followint completion of. the~
L recirculation pi.pe replacement modifit.3 tion.of Unit-2, in-February'of i1990, the licensee began preparations for the same modification in Unit-1.
As in Unit-2, _ the primary purpoce for the recirculation
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system and core spray system safe-end/ riser pipe replacement plant modification (PM), is to replace existing intergranular stress corrosion cracking (IGSCC) susceptible material,.within the reactor coolant rtcirculation piping system, with ~1ow carbon, corrosion resistant austenitic stainless steel type 316 NG material-and thereby mitigate the main cause for IGSCC-on this system.. The project is
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essentially a direct replacement effort of, existing; components withL the exception of using scamless, ~ induction bent risers and. an improved -design safe-end ' which eliminates the. thermal sleeve attachment weld.
.The controlling documents for_ the subject.
modifications are PM_ #89-092, Core Spray- (CS),;-Safe-End Replacement; and PM #89-095, Reactor Coolant Recirculation -(RCR), System Inlet
Safe-Ends / Riser Replacement.
More specifically, the scopegof_these-j modifications will require the following activities:,(A) removal, by j
machining, of weld overlays on seven safe-end to recirculation-inlet j
nozzle (RPV Nozzle N2)- welds and two safe-endLto core spray inlet
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nozzle (RPV nozzle NS) welds (nine - nozzle.. overlays : total);
~(B) removal and replacement of recirculation system-N2 nozzle safe-ends and twelve inch inlet piping; (C) removal' and replacement of core spray system NS nozzle safe-ends and _ a portion of the piping.
(piping will be replaced with a forged. carbon: steel transition piece).
tnis 'will standardize. the-design with-Unit-2;. (D) removal,. by
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machining, of the original Inconel ' 182 RPV nozzle cladding and butter, including removal of: the flaws and. repair, :if required. of
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the low alloy steel:(LAS),. nozzle base material, with replacement of
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the cladding and butter with stainless steel (309L) weld material.
. A'pplicable ASME/ ANSI codes and standards including = code [ case (s)
invoked for these modifications are as follows:
ASME B&PV Cede,Section II, 1986 Edition with 1988 Addenda --
I ASME B&PV Code, Section. IX, Latest. Edition _ and. Addenda, at time of. procedure and performance qualification.-
ASME B&PV Code,Section XI,1980- through W81 Addend. Code Case N-432 ASME B&PV Code,Section V, 1986 Edition I
a AWS D1.1 - 1988 Edition.
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ANSI N45.2.1-1980 Cleaning of Fluid Systems and L Associated -
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Components for Nuclear Power Plants Licensee issued specifications; applicable to this modif,1 cations -are
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a 248-153 CP&L-Specification for Precurement of ASME III, CL'1'
Stainless Steel. Pipe & _ Fittings
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ze8-156
" Design Spbcification for LReactor _ Coolant
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Recirculation System N2 Nozzles, Safe Ends and --
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Thermal Sleeves."
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248-157 Design Specification for ' Core : Spray : System N5 -
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Nozzles, Safe-Ends Thermal ~ Sleeves and Transition
Pieces..
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248-158 CP&L-Specification for - Field Replacement of j
Reactor' Coolant-Recirculation' System Inlet
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Safe-Ends and Piping i
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CPL-XXX-W-01~
. elding Filter Metals for NuclearL Power
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Following is a tabulation _ and a. summary of exis' ting. materials. and replacements for the subject. modification (s)r Comy w t Existing Material-Replacement Material Saft~u ' (core Typec316L-
' Type 316L NG.SS i
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N5 Nozzle Cladding Inconel 82'and 182 Type 309L SS
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Transition Piece (Pipe) SA-333 Gr. 6-SA-350 Grade LF2'
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Discharge Riser Type 304 Stainless
~ Type 316 NG SS-Steel-(SS)-
Safe-ends Inconel.600 Type 316 NG:SS (recirculation)
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a Thermal' Sleeve Inconel 600
. Type.316 NG SS'
Extensions N2 Nozzle Cladding - Inconel 82 and 182-Type 309L SS-Weld Metal Inconel.Inconel 82:ano 182,--
. Type 308L SS Type:308L SS,,308'LSS
' and Incone1~82 (Th'ermal-Sleeve'
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t ER705-2'or'E7019-ER705-2, ER705-3.or E7018 CS-b.
Pipi_ng Configuration
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.(1) Reactor Coolant Recirculation System Piping'
Ic The - RCR system pl. ping configuration wi.11 ' remain essentia11y'
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unchanged as.a tesult of PM #89-095; However,la few minor i
details will change and are discussed below.
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L The replacement-safe-ends will include an integrally forged
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thermal sleeve extension : which _ will improve the stress profile in the:" tuning fork" region.
The new design will.
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also eliminate the existing creviced condition. which has contributed to cracking 'at the thermal sleeve 1 attachment
weld.-
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The ten (10)' existing risers will be replaced with
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induction, bent seamless piping, thus. eliminating l ten (10)-
welded elbows' and, ; correspondingly,-
twenty.. (20)
L circumferential welds. - The: replacement risers will 'also. be -
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l slightly longer in the-horizontal plane. than the existing.
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risers and will eliminateL the " safe-end"' extension"i spool pieces in the' existing system.
Since the replacement l
risers are seamless, the number of longitudinal weld seams l
in the RCS system will also be reduced.
- A summary of welds that will-be eliminated by this project is as follows (excluding differentia 1' pressure tap welds):
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l l DESCRIPTION OF WELDS TO BE ELIMINATED INUMBERll
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! Circumferential:
Riser to Elbow l
20. l l
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Safe-End to, Safe-End Extens-l = 10 l
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Thermal Sleeve to Safe-End:
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.10- -l:
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Pipe
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Elbows l
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TOTAL-1.-80 -l
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A decrease in' total '. number -" welds.is: a design improvement
since weld joints (including heat-afft :ts zones) L are more.
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E susceptible toIGSCC -than other aren n no sensitized-
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austenitic ~ stainless-steel; and Inconel piping systems.
Therefore,.this change improvesElong ter
' liability of the CS
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system.
The existing RCR system discharge risers have differentia 1'
L pressure -instrument taps which were-cut, capped and-abandoned. in place by a previous plant. modification.
The replacement ~ risers ; do : net' include instrument -taps. - Thi s -
change does-not-degrade RCR system design or function since L
the existing taps are --abandoned ' ands are not described in L
the-FSAR. Additionally, removal. of the taps will' eliminate '
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the possibility of a ' small-bore =line break caused by failure of the abandoned pipe stubs or-caps.
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-N2 nozzles will be slightly shortened to elitdnate existing.-
i flaws'and some may require localized repair. :In all cases,
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the modified configuration will be analyzed to establish the original design criteria have been met.
(2) Core Spray, System Piping
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The primary change instituted by Plant Mod. No.89-092 is a-J material upgrade to mitigate tintergranular-stress - corrosion
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cracking (IGSCC) of ' replaced components.. The original 304 stainless steel safe ends ;were replaced in 1979 'with 316L'
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stainless steel safe-ends._ The purpose of ~this project is to
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replace the 316L-stainless steel-safe ends vith 316NG stainless-
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steel safe-ends and to replace. the existing Inconel weld butter and cladding on the nozzles with: Type : 309L stainless steel.
Portions-of. the original piping were also replaced ~ in 1979.
These portions will be replaced with carbon = steel transition.
pieces. The " transition piece" is a' carbon' steel forging.and forms the interface between the safe-end and the first CS elbow.
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The transition-piece configuration is ' essentially identical to Unit-2 and will, therefore, eliminate one circumferential weld per loop or a total of two joints.
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Welding (55050)
By : specification review and discussions-with cognizant personnel, tne j
inspector ascertained the following regarding welding activities. ; Welding
- 3 heat treatment and cutting processes and equipment.will be demonstrated as being suitable for the application on mock-ups and, for welding and post.
weld heat treatment, per applicable ASME Sections.II, IX andLXI require-
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ments.
Welding will.be performed-using Diametric ;or Arc Machines-Inc.
automatic orbital Gas Tungsten Arc - Welding' (GTAW).. equipment with remote -
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control aided by video equipment.
Weld joints will be made usingL "K" type consumable; inserts',1/8" x 5/32"..
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This includes the thermal sleeve weld.
Welding procedures will' be qualified using a 50/50:(t 5%) Argon-Helium-sh%idihg gas mixture. The backing gas shall be 99.9's high purity' argon.
i The shielding gas mixture willLbe. welding grade.or better.
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Heat'. input for the mixed gas: welding 'of butt weided joints shall: have La
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maximum energy density of.1.7 megajoules, per cubic ; inch with a. primary.
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voltage of_9.S maximum except.for root passes and cap passes.
Increasing s
heati. input beyond 1.7 megajoules l is permitted only. by variations - of
. primary: voltage ; input. No other changes are permitted which could result in a higher megajoule output.
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Shielding and b6cking gasses willL be filtered and. dried as necessary to L
provide a maximum dewpoint at the weld of -45'.
Welding operators will be qualifie at the site using 316 NG or 316L, 0.02% maximum rarbon: material.
Completed welds will be nondestructively
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examined in accordance with ASME Sections III, V, and XI requirements as-applicable.
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' Post-medification -hydrostatic testing will be -performed per the L
requirementsaof'ASME Section XI.
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Preservice-and Inservice examinations will be conducted in accordance with L
ASME; Section' XI requirements.
This area will be-addressed in ~ subsequent.
inspections. Other areas 1 reviewed during thi; inspection included quality-
, assurance requirements, piping analysis, design reports, and justification.
.for continued operation. Because these areas were reviewed and discussed in detail in Report 89-35, they wi.ll not be addressed in this report'since
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they apply to this modification also;
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Piping Procedure and-Specifications (49051)
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. Work procedures reviewed for technical content and for compliance _with
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l applicable codes, standardsLand regulatory requirements were as follows:
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L CPL-1.0 Rev. 1
. General Rigging.
L CPL-2.0 Rev. 1
' Material and Processes L
CPL-3.0 Rev. 1 Arc Strike Removal
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= CPL-4.0 Rev.'1 Etching Procedure CPL-5.0 Rev. 1 Cleanliness Control Proc.
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CPL-8.0 Rev. 1-Material Handling and Storage
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CPL-9.0 Rev. 1 Control of' Measuring and Testing Equipment
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CPL-10.0-Rev. 2:
Thermal Cutting l
CPL-29.0 Rev. 2 Purging of Piping Joints and-Controllof Gasses CPL-30 Rev~. 2
' Cal /on of. Meas;/g and Testing Equipment 5.
Procurement, Receiving'and Storage - 35065 a.
Filler Metal Material'
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Welding materials 1needed for this PM were procured by;the' licensee l'
from a-previously approved vendor. ' The procuring document,-was CP&Ls '
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L Specification, CPL-XXXX-W-01 Rev 4 Welding Filler-Metals ~ and(
L Materials Procurement for Nuclear Power Plants.
Additional ~
procurement requirements for chromium-nickel steel welding materials,-
i specific to this EPM,, were added as Supplementary ;. Requirements,-
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L Part 1, We?d Procurement -- ASME Section III Class 1.
Purchase y
Vendor Order Size Type-Heat Sandvik 685724 1/8" (
ER308-L S19068
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Purchase-Vendor Order Sizei
~ Type Heat Sandvik 685724 3/32" 4.
ER308-L-S12613 Sandvik 685724 0.035" 4.' ER309-L S22366 i
The inspectnr-noted the material had been receipt inspected by the licensee-and in process _of being - stored.
Quality record were reviewed' to ascertain whether ^ chemical analysis and mechan _ical-properties were. in accordance with applicable code and subject-specification requirements'.
Within the areas inspected,.no -violation or deviation -were identified.
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Core Spray Transition-Pieces The control _ ling document for the core spray transition-pieces is the licensee's specification No. -248-123 Rev. 4.
By reference _ this specification invokes ASME' Section 'III' 1986 Edition.
Material for the subject componentsTwas produced per_ ASME: Specification SA-350, _
Grade LF2, which: applies to carbon and low-alloy steel forging i
intended primarily-for low temperature service and requires noted toughness testing. The subject transition = pieces.were purchased from WFI Nuclear Products-Inc. of Houston. Texas ' under. CP&L's purchase
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order #565674. They were manufactured to meet requirements on CP&L's
sketch #M-P753-04 Rev. C, from material produced from heat number-
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667SNB. At the time of this inspection, the subject components had q
been received and receipt inspected in1:accordance with site -QA
procedures. The inspector found that the,three ordered transition
pieces identified by serial. number N5361A-1 thru 3, had been properly identified inspected and stored, while-the: quality re' cords. indicated'
-that all specification requirements had beenfmet.
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Action on Previous Inspection Findings (92701).
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i (Closed) NOV 325,324/09-35-01, Failure to Review Changes to Procurement-Documents / Specifications-The licenseefs letters' of. response.' dated i
January 5 and - April 5,1990, were reviewed and determined acceptable' by-
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the Region II staff.
The inspector.had ' discussions with the _ cognizant.
Project Engineer and, examined the corrective actions: as' stated in the letters of response.
The inspector concluded _ that the licensee hadi j'
determined the full extent of the subject noncompliance, performed the
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necessary follow-up actions-to correct the present.-conditions and
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developed the necessary corrective actions to preclude conditions of this:
problem. The corrective actions :1dentified in the letter'of-. response.have been implemented.
(Closed)- IFI, - 325,325/88-25-02, Implementation of Permanent Program for
i Repetitive Failure Identification,
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I This : item was' identified for the' purpose' of tracking the licensee's l
development tf a trending program, to detect repetit_ive failures of key
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plant equipment. Plant program procedure, PLP-05, April '1,,1989 has been.
f implemented and is currently used for.this purpose. The subject procedure-
- defines the criteria 'for determining repetitive component failures, root'
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I cause. analysis. and problem resolution.
However, = this-procedure:;is:
presently undergoing revis ten so as to change the method of component'
. identification from the use of tag number (s) to that of-component model
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By this change, the licensee hopes to ascertain whether -
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repetitive problems-can be. related to specific manut.acterers rather than the ~ severity of application and/or service life. limitations. -The
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inspector reviewed
'a' print out Lof approximately. one - hundred. (100)
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equipment. failures designated as _ repetitive failures to determine 4the
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identification and: disposition of those' types-failures and found that the program now in place, address the inspectors concerns ecd,.therefore, any-
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further inspection effort in. this area. should be.licited to program-monitoring.
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Exit Interview l
The inspection scope and results were summarized on-June -15,.1990, with i
those persons indicated in paragraph 1.
The-' inspectors described the
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areas inspected and discussed. in-detail the inspection-results-. listed.
below.
I The licensee was commended for doing an outstanding. job in. thab vendor 4 surveillance efforts as evidenced by visits to contractor / vendor plants in'
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Osaka, Japan; Houston;. Texas and Wayne,cPennsylvania.
These inspections-
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were performed by highly competent personnel whose1 efforts identified and j
corrected problems with materials and processes which if leftl undetected j
would have disrupted the work effort..The licensee'was!also/ commended:for a.significant improvement in' planning for this project las evidenced by'a chango in project management, increased site facil.ities, -improved vendor surveillance and process-controls; The licensee did :not' identify as proprietary'any of.-the material provided to or reviewed by-the inspectors-during this inspection.
Dissenting comments were: not received from. the.
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