IR 05000338/1992028

Insp Repts 50-338/92-28 & 50-339/92-28 on 921116-20.No Violations or Deviations Noted.Major Areas Inspected:To Observe Certain Activities in Preparation for SG Replacement Project in Unit 1 & to Review Approved Welding Procedures

ML20126E408
Person / Time
Site:	North Anna
Issue date:	12/15/1992
From:	Blake J, Economos N NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
To:
Shared Package
ML20126E401	List: IR 05000338/1992028 ML20126E397
References
50-338-92-28, 50-339-92-28, NUDOCS 9212290122
Download: ML20126E408 (7)

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UNITED STATES jog NUCLEAR REGULATORY COMMisslON

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Report Nos.: 50-338/92-28 and 50-339/92-28 Licensee: Virginia Electric and Power Company Glen Allen, VA 23060 Docket Nos.: 50-338 and 50-339 License Nos.: NPF-4 and NPF-7 Facility Name: North Anna 1 and 2 Inspection Conducted" November 16-20, 1992 I

Inspectar:.N.Ecohoiitos(F scr>u rwt gd _8/)/ /L Q4te#ig~ned Approved by: * , 7 J. .plake, Chief Date Signed M ted als Process Section

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ngineering Branch Division of Reactor Safety- '

SUMMARY Scope:

This routine, unannounced inspection was conducted in order to observe certain activities _in preparation for the Steam Generator Replacement Project (SGRP)

in Unit 1 and, to review approved qualified welding procedures, quality records of fabricated components and other project related work procedure Results:

The hydrocaps on the steam generator primary nozzles were being removed by'

machining, and preparations were underway to machine the weld preps-on the hot and cold leg nozzles. Qualification of welders was beginning to get underwa On the S/G mockup, practice runs with a track mounted torch were in progress

.to prepare for making the girth weld cut on _the old steam generators. The new upper restraint ring assemblies were . undergoing final field preparatio Inspector concerns discussed in Report 92-20 have been addressed satisfactoril The temporary resident inspector assigned to this project, Dr. S. S. Lee visited the site on November 16 and 17, 1992. He was introduced to project management and participated in the inspection of field activitie Within the areas inspected violations or deviations were net identifie q a -

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_ REPORT DETAILS _ Persons Contacted Licensee Employees

• R. Bayer, Engineering Supervisor

• R. Carroll, Jr., Administrative Services Supervisor

• L. Carter, QA Coordinator

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• R. Enfinger,' Assistant Station Manager

• M. Gettler, Project Manager, SGRP

• L. Hartz, Manager Corporate QA J. Jones, Quality Control SGRP

• G. Kane, Station Manager

• P. Kemp, Supervisor - Licensing

• J. Leberstein, Staff Engineer - Licensing

• P. Quales, Supervisor QA

• J. Smith, Manager, QA L, Spain, Materials Engineer SGRP J. Stall, Assistant Station Manager Other licensee employees contacted during this inspection included technical support, QA and administrative. personne Other Organizations ,

Bechtel Group Inc. (Bechtel)

L. Bennet,. Welding Engineer

• R. Miller, Project Manager

• B. Reilly, Asst. Project Manager T. Sarma, Project QA Manager L. Smith, Welding _ Test Shop Supervisor NRC Resident Inspectors

• Lesser Senior Resident Inspector

• D. Taylor, Resident Inspector

• Attended exit _ meeting Facility Modification (37700)-

Steam Generator Replacement Project,.(SGRP),= Unit 1 This-inspection is a followup to that documented-in Report 92-20 and was-conducted for the purpose of observing ongoing SGRP activities, review:-

welding procedure specifications and associated procedure qualification records, work plan procedures, fabrication records of selected components and quality records as ' applicable.

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,1 e 2 Work In Progress

• Cutting of Hydrocaps from Primary Nozzles At the time of this inspection, the hydro caps' welded to the primary nozzles for hydrostatic testing the primary side.of the lower assemblies were being removed by mechanical _ mean The work was being done under work plan and inspection record (WPIR) No. WR-06.02.00-14. Cut line locations and optical templating was performed in accordance with-instructions delineated in procedure 21809-SC-001-001.- This-procedure was developed by Siemens, contracted to obtain critical measurements throughout the project. The cut line was located a minimum of 1/2- inch in from the hydrocap wel The procedure called for making a face cut followed by machining the weld prep on the arimary nozzles. The inspector noted that hydrocaps aad been successfully removed from two of the three lower S/G assemblies and work was underway on the third. The aforementioned WPIR was. reviewed-to verify that line item activities including inspections were performed and signed by appropriate personnel as require *

Steam Generator' Upper Restraint Ring Assembly The existing upper lateral restraint (s) will be cut,- removed <

and replaced with newly designed and fabricated restraint ~

These replacements were manufactured by Newport News Industrial Corp. under-purchase order, (P0), number-BNT367162 and the licensee's specification, NAP-0033 Rev. 3,.

S/G Upper Restraint Replacement Ring Assembly. ASME Code Section III, Division, NF, was used for guidance in~ desig The controlling industry standard-was the-American Institute for Steel Construction-(AISC). Requirements for materials, fabrication and testing were delineated .in the subject'

specification. Article NF-5000 of the ASME Code Section III -

was invoked for nondestructive' examination requirements. By-review of the subject specification and fabrication records the inspector ascertained that the four-(4")' inch plata-material used, was produced from AS43 Class 2 low alloy steel, while the' pins and/or studs used were made from the following bar stock material; P0 #2697-A-13 2"O A193-90,GR-87/4140 Ht #50788 P0 #2697-A-3 5 1/4"O A322/4340 Ht #11965 P0 #2697-A-4 3 3/4"O A194-90/1045 Ht-#61885 Certified material test reports were reviewed for the'above bar stock and for the weld filler metal used during fabrication. A certificate of conformance which was

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required by the subject specification was included in the-data package. At the time of this inspection, all three assemblies were on site and were undergoing adjustments including installation of shims on the IDl surface to meet design clearance requirement *

Mockup Activities Severence of both the steam generator shell and the wrapper plate will be accomplished with the use of a track-mounted, tractor-driven, oxygen-fuel cutting torch. Two circumferential cuts will be made in the-S/G shell, resulting in a band appro.ximately 2" wide of shell material that will be removed as part of the construction activit Removal of this band will provide an access for the cut to be performed on the wrapper plate. The inspector observed-the cutting apparatus mounted on the mockup and discussed plans for a practice cut which was made at a later time on November 17, 199 Within the areas inspected violations or deviations-were not identified, Procedure Review Following is a list of procedures reviewed for technical- content, completeness and compliance with applicable regulatory requirements and industry standards as applicable'.

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Bechtel: -Work Plan / Procedures (WP/P(s))

WP/P-1- Rev. 1 Establishment, Control-and Implementation of the WP/P Program WP/P-4 Rev. 2 Document Control  ;

WP/P-5 Rev. 1 Construction Change Request Notic WP/P-6 Rev. O Field Sketch Preparation -

L WP/P-7 Rev. 1 Deviation Control

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WP/P-9- Rev. 1 Material Requisition WP/P-10 Re Housekeeping L

l WP/P-12 Rev 0 Control of Temporarily removed Permanent l Plant Material-

! WP/P-16 Rev. 0 l Field. Fabrication

j- WP/P-20 Rev. O Inspection Teiting of Hoisting, Rigging and Transporting Equipment L

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Siemens Procedures:

SNPS 0T-02 Rev. 1 Optical Templating of Existing Steam Generators (Two Cut Methodology)

SNPS-0T-01 Rev. 2 Optical Templating of New Steam Generators

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Review of Special Process Procedures - Bechtel GWS-1 Rev. 2, Am. 3 Bechtel General Welding Standard

WFMC-1 Rev. 5 Welding Filler Metal Control WQ-1 Rev. 2, Am. 2 Welding Qualification Performance Specification GPS-1 Rev. 1, Am. 1 General Purging Qualification RT-ASME Rev. 3 Nondestructive Examination Standard Radiography PiiT-1 Rev. 3 Postweld Heat Treatment of Field Welds WD-1 Rev. 2 Documentation of Welds During the previous inspection, documented in Ril, Report No. 92-20, the inspector identified and documented in paragraph 2.0. several concerns over matters which were not fully addressed in Bechtel's General Welding Standard GWS-1 Rev. 2-Amendment These matters involved applicable codes and standards, cold springing of piping, weld bead size limits, weld joint offset and/or misalignment limits, using the GTA processes without: filler metal and specific controls on the amount of the heat input when making stainless steel welds. Each of these areas were revisited-during this inspection and through review of new procedures and/or procedural revisions made to address these concerns and through discussions with cognizant technical personnel the inspector was satisfied that each of the concerns were addressed satisfactoril The inspector suggested that the licensee conduct heat input calculations on a periodic basis during welding of the primary loop piping in order to assure that energy input is maintained within acceptable limits and thereby minimize the potential for partial or local severe sensitizatior,.

Within the areas inspected violations or deviations were not identifie :

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, Review of Welding Procedures (IP55050)

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As stated in earlier reports, the steam generator replacement project (SGRP) is under the requirements of ASME Code Sections XI (83S83) and III, 1986 Edition. As required by these codes, qualification of welding procedures and welders / operators is controlled by the requirements of ASME Code Section IX, latest Edition in effect. Within-the requirements of the subject codes, the inspector reviewed the following welding specifications and supporting procedures qualification records (PQR(s))

to ascertain whether required mechanical tests, applicable essential and nonessential variables were in compliance with requirements of the subject codes:

Welding Specification Supporting Process Range PQR P8-T (RA) Rev. 2 1041 GTAW Machine 3/16" to 8.00" P8-P8 Pulse Mode P3, Pl-AT-LH 61,203,660 GTAW/SMA- 1/16" to 1.686" P3-P1 Manual Pl-AT-LH 695,696 GTAW/SMA 1/16" to 8.00" Pl-P1 Manual P5A, P3-AT-LH(A4) 1036 GTAW/SMA 3/16" --8.00" P5A-P3 Manual P5A-AT(A4) 43,45,45A GTAW/SMA As Welded 1/16" --0.474" P5-AT-Ag(A4) PS-P5 Manual With PWHT 3/16" - 8.00" P5-Pl-AT(A4) 43,45,45A GTAW/SMA As Welded 3/8" - 0.474" P5-P1 With PWHT 3/16" --8.00" P5-Pl-ATg(A4) 43,45,45A .GTAW/SMA As Welded 3/8" - 0.474*

P5-P1 With PWHT 3/16" - 8,00" P8-AT-Ag-1 629,630 GTAW/iMA 1/16"'-'1.00" P8-P1 Manual P8-T-Ag-1 636 GTAW 3/16" - 8.00" i P8-P8 Manual

- P8-P5-T-Ag(F43) 89 _GTAW- 1/16" - 1/2" P8-PS- Manual P8-Pl-T-Ag -629,630 GTAW 1/16" - 1.00" P8-P5 Manual i

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The inspector observed the qualification of welding specification P8-T(RA) scheduled to be used for the welding of the primary loop piping to the steam generator nozzles. A discussion of this activity was included in Report 92-2 Review of Weld Filler Metal In addition to welding procedure qualification records the inspector reviewed the following certified material test reports (CMTR(s)) to ascertain compliance with the aforementioned code Material Size Heat / Lot PO# Atom Arc-8018M 3/16" 91304/3H224G08 SNS405638 Stress Relief for 16 hrs. O ll50*F Arcos-ENiCrfe-3 3/32" 2GlC-1A SNS405638 Arcos-ENICrfe-3 1/8" 2E17E-17A SNS405638 Arcos-309 0.035" XI6386 SNS400155 Acros-308L 0.035" XT6385 SNS400155 Acros-7018SR* 1/8" 92084/3H212A01 SNS400735 Acros-7018SR* 3/16" 90258/3S104A05 SNS400735 Acros-7018SR* 5/32" 90917/3B224C05 SNS400735

• Stress Relief for 8 trs. O ll50*F Within the areas inspected, violations or deviations were not identifie . Exit Interview The inspection scope and results were summarized on November 20, 1992, with those persons indicated in paragraph 1. The inspector described the areas inspected and discussed in detail the inspection result Although reviewed during this inspection, proprietary information is not contained in this repor Dissenting comments were not received from the license _ _ _ _ _ - _ _ _ _ _ _ _ _ _ _ _ _ _ _ - _ - _ _ _ _ _ ____ _ __ __ -