IR 05000338/1993004
| ML20034F197 | |
| Person / Time | |
|---|---|
| Site: | North Anna  |
| Issue date: | 02/23/1993 |
| From: | Blake J, Economos N, Samson Lee NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML20034F194 | List: |
| References | |
| 50-338-93-04, 50-338-93-4, 50-339-93-04, 50-339-93-4, NUDOCS 9303020383 | |
| Download: ML20034F197 (18) | |
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UMTED STATES i
.[( '.k NUCLEAR REGULATORY COMMISSION
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o REGION il
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101 MARIETTA STREET,N.W.
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t ATLANTA, GEORGI A 30323
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FEB 2 3 m3
Report Nos. :
50-338/9304 and 50-339/93-04 i
Licensee:
Virginia Electric and Power Company.
Glen Allen, VA 23060
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Docket Nos.:
50-338 and 50-339 License Nos.:
NPF-4 and NPF-7 Facility Name:
North Anna 1 and 2 Inspection Conducted: January 11-15, and January 25-29, 1993 Inspector:
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o s Date Signed
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Dhte Si ned Approved y: -
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J f (B1ake, Chief Date ' Signed aterials Process Section
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Engineering Branch Division of Reactor Safety
SUMMARY Scope:
This routine announced inspection was conducted in order to observe certain steam _
generator replacement project (SGRP), activities in Unit 1, including severing of piping attached to the SG's, severing of SG shell at the transition, lifting of the SG dome (s), weld preparation machining, welding of replacement piping and review of fabrication and qualitj records as applicable.
Information contained in this report includes input from S. S. Lee on temporary assignment while SGRP is in progress. His input covers the time period between December 14,.1992, until January 29, 1993.
Results:
Severing of the SC's at the predetermined location of the transition cone and'of;
'the reactor coolant system (RCS), piping was-in progress.
Lifting of the upper SG-sections (domes), and transporting them with-the polar crane to their respective
storage locations inside containment was performed satisfactorily and-in'a. safe i
manner.
i 9303020383 930223 PDR ADOCK 05000338 G
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Welding procedures and welders to be used on this project have been, for the most part, qualified; preheat and post weld heat treat procedures have been reviewed; and most components i.e., upper SG restraints and wrapper plates which were fabricated / assembled on site were being preassembled and checked for tolerances before installation.
The licensee is monitoring the work effort through the use of knowledgeable engineering staff and well trained QA/QC personnel.
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A sample of work plan and inspection records (WP&IR), were reviewed and found to lack certain signoffs in some instances. This and another example of weakness maintaining complete and accurate records (See paragraph 5 and 6), were' brought to licensee managements attention, who took immediate corrective measures to prevent recurrence.
Feedwater nozzle to pipe welds in SGs "A" and "C" exhibited linear indications with a maximum depth of approximately 1/10 inches at one location in SG "A".
The licensee is conducting a metallurgical failure analysis investigation to ascertain the root cause of these indications.
Preliminary results suggest a fatigue / corrosion mechanism which may be related to thermal stratification commonly associated with feedwater lines.
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Within the area inspected violations or deviations were not identified.
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REPORT DETAILS
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Persons Contacted Licensee Employees
- R. Bayer, Engineering Supervisor, SGRP l
- R. Carroll, Jr., Administrative Services Supervisor
- L. Carter, OA Coordinator
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- G. Clark,. Manager, QA
- G. Kane, Station Manager
- P. Kemp, Supervisor - Licensing
- J. Leberstein, Staff Engineer - Licensing
- P. Quales, Supervisor QA
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- B. Shriver, Acting Assistant Station Manager
- J. Smith, Manager, QA
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L. Spain, Materials Engineer SGRP
- J. Stall, Acting Assistant Station Manager Other licensee employees contacted during this inspection included technical!
support, QA and administrative personnel.
Other organizations Bechtel Group Inc. (Bechtel)
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A. Bryant, SGRP QC-Engineer
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L. Bennet, Welding Engineer R. Miller, Project Manager B. Reilly, Asst. Project Manager T. Sarma, Project QA Manager J. Senecal, Welding / Mechanical QC Engineer -
J. Sesson, Welding Coordinator NRC Resident Inspectors
- M. Lesser, Senior Resident Inspector
- D. Taylor, Resident Inspectoc i
- Attended Exit Meeting 2.
Facility Modificatior. (37700)
Steam Generctor Replacement Project, (SGRP), Unit 1 This inspection is a followup to that documented in ~ Report-
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No. 92-28 and was conducted for the purpose of' observing ongoing SGRP l
activities, including severing of SGs at the transition cone,.RCS piping, main steam (MS) piping, and 'feedwater piping; lifts of SG. steam domes and:
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lower assemblies; welding, NDE and review of welding procedure specifications
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and associated procedures, fabrication records of selected components and quality records as applicable.
Work in Progress:
Load Test of Outside l'ft System at Equipment Hatch.
An outside lift system (gantry crane) has been installed at the equipment hatch. This lift system will be used to lift the old steam generator from the equipment hatch platform, and lower it onto the trailer for removal to storage. This lift system will also be used to move the new steam generator onto the platform, from where it will be moved
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into containment.
l On December 15, 1992, the outside lift system was load tested.
The weight of the new steam generator lower assembly is 470 kips. The weight of the old steam generator lower assembly with cover plates, water, and sludge is estimated to be 494 kips.
Thus, the outside lift system has to lift 494. kips. The load test of the outside lift system was performed at 543.5 kips which is 10 percent over the heaviest anticipated load.
On December 14, 1992, the test load, consisting of concrete blocks weighing 543.5 kips, was placed on a trailer near the new steam generator storage facility (NSGSF) and moved by a prime mnver to the equipment hatch beneath the outside lift system. On December 15, 1992, the lift system raised the test load approximately 20 feet and moved it from the trailer over the equipment hatch platform.. The test load a
was not lowered onto the platform. Then the test load was returned back onto the trailer and subsequently back to the old steam generator storage facility (OSGSF). The inspector observed portions of the activities on December 14-15, 1992.
The work was performed under Bechtel Work Plan and Inspection Record (WP&lR) No. WR-05.05.00-12, " Load Test of the Outside lift System, the Hydraulic Platform Trailer and the Haul Route from Equipment Hatch to OSGSF." After completion of the load test, the licensee requested the rigging contractor, Rigging International, to finalize i
drawings to incorporate the actual value of the test load.
e Rigging of Steam Generator Lower Assembly Out of D
Containment j
After the old steam generator is severed at the transition i
cone, the old steam generator lower assembly is to be rigged out of containment onto the equipment hatch pl atform. WP&lR No. WR-05.05.00-03, " Rigging of the 'A'
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S/G Lower Assembly Out of Containment Including.
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Installation of RCS Nozzle Shield Covers," contains procedures for the rigging effort.
Similar WP& irs are provided for steam generators B and C.
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The steam generator lower assembly is lifted and down-ended into a horizontal position on a carriage. The carriage is supported by two sets of hydraulic jacks. The lower assembly will be moved out of the containment on rollers riding on runway beams.
Because of interference with the containment wall at the equipment hatch, the lower assembly will be supported at different jack locations both, inside and outside containment.
The jack locations are such that the center of gravity (C.G.) of the lower' assembly will be close to one of the jack supports, both inside and outside
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containment.
In order to ensure that the C.G. of the lower assembly was between the two sets of Jacks the inspectors reviewed the basis for placing the jacks at the designated location of the steam generator (s).
Because the location of the C.G.
of the old steam generator (s) was not known precisely, Bechtel made a number of assumptions including, old steam.
generator design and amount of water and sludge that it may contain at the time of removal.
Bechtel Calculation Number.
C-15, Revision 0 (Job Number 21809) contains the analysis.
The rigging procedure was based on this C.G. estimation and is limited to checking the' load at a single jack location.
Because of the close proximity of the C.G. relative to the jack support, the many assumptions in the C.G. estimation,
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and the importance of rigging stability, the inspectors discussed with the licensee the potential need for enhancements in the 3rocedure. To provide added assurance that the C.G. would ye located between the jacks, an option was incorporated in the procedure allowing for the use of the existing gauges on the jacks to determine the actual weight and location of the C.G. during rigging.
The licensee incorporated the inspector's comments, as appropriate, in WP&IR Change Notice (WCN) No.
WR-05.05.00-03-01 for steam generator A.
Similar WCNs were provided for steam generators B and C.
e Planning for Inspection of Existing Feedwater Nozzle Weld The piping welded to the feedwater nozzle will be replaced with erosion / corrosion resistant chrome-moly material.
However, because of industry concerns about the potential for cracking of the feedwater nozzle weld due to thermal q
stratification, the licensee performed NDE inspections on
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the existing nozzle weld to determine its as-found condition.
It was noted that on prior inspections the i
licensee had not found such cracking at North Anna. The licensee's interest in assessing the cracking potential is a strong point.
The licensee's staff performed ultrasonic testing (UT) on the feedwater nozzle weld before making the cut.
The piping was cut by the contractor at a location one inch away from the nozzle weld on the pipe side.
Then the licensee's staff performed MT on the inside surface of the nozzle weld. The contractor will remove the old weld and attach the new feedwater piping with a new weld. This work involves an interface between the licensee's staff who performed the UT and MT and the contractor who will perform the cutting and welding. The inspector requested information on the licensee / contractor interface to ensure that the inspection would be performed as planned.
The licensee indicated that appropriate procedures would incorporate clear interface requirements.
- Severance of Feedwater Line A portion of the feedwater line had to be removed to allow for the replacement of the steam generator.
The feedwater line was severed near the feedwater nozzle and near the crane wall. This portion of piping contains a U-shaped loop seal.
The p,iping will be replaced with piping of the same configu Aafter the new steam generator is installed.
roc'F6 pres for cutting the feedwater line are contained. n WP&IR No. WR-07.03.00-01,
" Removal / Installation of Steam Generator ' A' Feedwater and Chemical Feed Piping." Similar WP& irs are provided for feedwater loops B and C.
The inspectors observed the severance of the B loop feedwater line on January 17, 1993. The B loop feedwater line was the first feedwater line to be removed.
The feedwater line was drained and blocked to prevent pipe movement.
Before making the cut, the line was supported by rigging and torch cut.
The first cut started from the bottom of the loop seal.
However, after cutting through the pipe wall, several gallons of water spilled out from the cut hole. The hole was immediately plugged and cutting ceased. After it was determined that the water was trapped in the loop seal because the loop seal drain valve was clogged, the water was allowed to drain from the cut hole.
The loop seal drain valves for feedwater loops B and C were inspected and fcund clear.
e Inspection Results for Existing Feedwater Nozzle Weld As stated above, the licensee performed UT on all three feedwater nozzle welds from the outer surface of the pipe
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and found no recordable indications per ASME Section XI requirements. However, the licensee performed MT on the-inside surfaces of the feedwater nozzles and-found linear indications in nozzles A and C.
As described in the licensee's Deviation Report Number N-93-107, two linear indications were found in the C
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feedwater nozzle. One indication was at the'12 o' clock position on the pipe side of the pipe-to-nozzle weld and
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was approximately 6 inches long. The other indication is at the 7 o' clock position on the nozzle side of the pipe-to-nozzle weld and was approximately 3 inches long.
As described in the licensee's Deviation Report Number N-93-120, two linear indications were found in the A feedwater nozzle. One indication was at the 12 o' clock position and was approximately 3.5 inches long.
The other indication was at the 4 o' clock position and was approximately 4 inches long. 'The indications for the A
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feedwater nozzle were on the pipe side of the pipe-to-nozzle weld.
The licensee is currently evaluating these linear indications.
For the C feedwater nozzle, the original construction radiograph and the inside surface visual appearance of the weld suggest that a portion of'the linear indication at the 12 o' clock position may correspond to a weld undercut or root geometry condition due to fabrication. A subsequent review of the UT records
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recordable level were detected for the A' and C feedwater nozzles at the locations corresponding to the linear indications at the 12 o' clock position.
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Because of the similarity of the locations of the linear
indications between the A and C feedwater nozzles, the licensee believes that they may be caused by a common mechanism.
Because the MT appearance of the linear indications in the C feedwater nozzle suggests deeper flaws in the A nozzle than in the C nozzle, the licensee cut out the A fecowater nozzle weld for metallurgical examination to determine its root cause.
A ring of piping material from the A feedwater line was cut to capture the-linear indications. The material was decontaminated prior to sendinb to the laboratory for analysis.
The inspectors observed the initial metallurgical examination of the linear indications on the A feedwater nozzle at the licensee's Innsbrook Technical Center on January 23,.1993.
Preliminary pht ;omicrographs show the presence. of cracks along the linear indications. The deepest crack'is approximately 0.1 inch in depth and is at
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the 12 o' clock position at the weld counterbore. The pipe wall is approximately 7/8 inch thick.
Preliminary analysis suggests the cracking is due to a combination of fatigue and corrosion. The licensee is continuing the technical evaluation.
The potential for thermal fatigue of the feedwater piping is known and has been addressed in NRC Bulletin 79-13,
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" Cracking in Feedwater System Piping," and in NRC Information-Notice 91-28, " Cracking in Feedwater System Piping." As discussed earlier, the licensee's interest in assessing the cracking potential of the feedwater nozzle is a strong point. The inspectors find the licensee's efforts in evaluating the linear indications adequate.
o Pipe Whip Restraint Damage on Feedwater Piping In an effort to establish the as-found condition of piping supports prior to cutting the feedwater line for steam generator replacement, the licensee examined the supports for the feedwater line near the steam generators. The licensee found that several of the pipe whip restraints were damaged due to excessive movement of the feedwater piping.
(See the licensee's Deviation Report Number N-93-125) There are three damaged pipe whip restraints.
One of the damaged restraints is in feedwater loop A.
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other two are in feedwater loop C.
The damaged restraint in feedwater A is the first restraint away from the
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feedwater nozzle.
The damaged restraints in feedwater C are the third and fourth restraints away from the feedwater
nozzle.
Excessive movement of feedwater piping was discussed in NRC Information Notice 91-38, " Thermal Stratification in Feedwater System Piping," dated June 13, 1991.
Because the damaged pipe whip restraints are in feedwater loops A and C, which are the same feedwater loops with linear indications in the feedwater nozzle welds, the inspectors suspect that there may be a common root cause.
The inspectors observed the damage sustained by the identified pipe whip restraints and will follow the licensee's effort to resolve Deviation Report N-93-125 as part of the routine inspection effort associated with this project.
- Cutting of Reactor Coolant System (RCS) Piping The RCS piping was cut at the steam generator' nozzles to facilitate steam generator replacement. The RCS piping will be rewelded after the new lower assemblies are installed.
The work will be performed under WP&lR No.
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WR-07.01.00-01, " Cut / Reweld RCS Piping Loop 'A' to Allow Removal / Installation of Steam Generator." Similar WP&lRs are available for loops B and C.
The licens w 's contractor, Siemens, is performing surveys of the existing steam generators and loop piping, using the
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optical templating method to identify exact dimensions of
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piping layout. The optical templating method consists of establishing fixed reference points on walls or supports
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near the channel head; measuring the locations from the fixed reference to punched marks on the pipe near the nozzle weld using a land survey instrument called
"theodolite;" photographing the channel head which is covered with many target stickers; and analyzing the photographic negatives and survey data to establish channel head and nozzle weld locations and geometry. The cut location and weld prep will be based on the optical templating data.
The inspectors reviewed the WP&IR and provided comments to the licensee for the purpose of enhancing procedure clarity. The comments generally related to the weld prep for fit up, contingency for replacing a crossover leg elbow, and_ verification of debris dam removal after work completion.
The licensee incorporated the inspectors comments, as appropriate, in WCN No. WR-07.01.00-01-01 for loop A and in Construction Change Request (CCR) No. CCR-M-024.
Similar WCNs were provided for loops B and C.
Craft assigned to this work effort were given classroom training on technical issues, ALARA and health physics on
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January 7, 1993. Mockup training on machining practices and technique for cutting the RCS piping were given on November 18-24, 1992.
The inspectors observed the cutting of the B loop primary piping on January 24, 1993, on closed-circuit television.
The B loop RCS was the first RCS line to be cut.
The RCS line was blocked to prevent pipe movement.
The RCS was cut at the steam generator nozzles by machining. The nozzles were cut to approximately 90-percent through wall. Then, suction was taken from a 3 inch line in the crossover leg to create a negative pressure inside the RCS piping for radiation protection. The RCS was severed at the hot leg side first and then, at the crossover leg side. After piping severance, preliminary observations showed that the hot leg pipe end did not move and the crossover leg pipe end moved down approximately 3/8 inch away from the steam generator nozzle.
- The RCS loops A and C were subsequently severed.
The inspectors observed cutting of the A loop in the pump motor
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cubicle.
Preliminary reports indicated that the pipe ends for loops A and C' moved less than 1/8 inch after cutting.
- Severance of Main Steam Line A portion of the main steam line was removed to facilitate
- replacement of the steam generators. The main steam line was severed near the main steam nozzle and at a point approximately 10 feet downsteam to provide clearance for the steam generator. This portion of piping will be rewelded back after the new steam generators are installed.
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The procedures for cutting the feedwater line are contained in WP&IR No. WR-07.02.00-01, " Removal / Installation of Steam Generator 'A' Main Steam Piping." Similar WP& irs are provided for steam generators B and C.
The inspector observed the severance of the B loop main steam line on January 20-21, 1993, on closed-circuit television. The B loop main steam line was the first main steam line to be removed. The main steam line was blocked to prevent pipe movement. Acid etching was used to identify the location of existing welds. The main steam line was cut by machining. The nozzle cut was stopped at approximately 90-percent through the pipe wall. The other cut was stopped at approximately half-way through the pipe wall.
Then, the piping was rigged to the polar crane before completing the cut.
The nozzle cut proceeded by hand grinding to minimize the amount of potential debris entering the steam dome. The other cut proceeded by continuing the machine cut. After the pipe section was severed, the piping was rigged out using the polar crane.
The main steam lines for loops A and C were subsequently severed.
The removed piping will be reinstalled after the new steam generators are in place.
e Inspection of Steam Dome Lifting Lugs and Steam Generator Trunnions The old steam dome lifting lugs and steam generator trunnions were inspected prior to the lift using magnetic particle testing (MT). WP&lR No. WR-06.01.00-01, "SG 'A'
Steam Dome Assembly Removal / Reinstallation" and WR-05.05.00-03, " Rig Out Old S/G ' A' Lower Assembly &
Removal from Containment," provides acceptance criteria for indications revealed by MT for steam generator A.
The same criteria were used for steam generators B and C.
The licensee indicated that the criteria were selected by Bechtel and were. essentially those in Section III of the
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ASME Code, subparagraph NB 2545.3, which is applicable to the examination of forgings and bars during construction..
The licensee examined the steam dome lifting lugs and found
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unacceptable linear indications approximately an inch long on the A and B steam generators.
The indications were removed by grinding and subsequent UT thickness measurements indicated that the remaining thickness exceeded the minimum required by the ASME Code and was acceptable.
The licensee also examined the steam generator trunnions and found them acceptable.
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Welding (IP55050)
Fabrication of Radial Plates for Steam Generator Wrapper
Radial plates will be welded between the wrapper plates of the new steam generator lower assemblies and the old steam domes. The radial plates consist of four curved plates for each steam generator. The
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inspectors observed the fabrication of the radial plates in the weld shop / mock-up facility. At the time, welders were fabricating.the~
wrapper plates for S/G "A" which appeared on ISO W-9013-1-M-405'Rev 4.
The inspectors reviewed fabrication records at the work-station i.e.,
rod issue slips and the aforementioned IS0; observed weld fitup, ~ joint configuration, weld bead size and appearance; and welder identification. Base material and the filler metal used was noted for a review of quality records. Material used for these wrapper plates was made from A285 Grade C type carbon steel plate, produced from Heat
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- 7416170 and procured under purchase order (P0), #NT-400250.
Filler metal was identified as E7018 low hydrogen rod,1/8 inch diameter.
produced on heat No 90824, Lot, 3K114B01.
Chicago Bridge and Iron
(CBI); welder C01 and C14 were responsible for welding the subject wrapper plate.
I A subsequent record review disclosed the required quality records and welder qualifications were in order.
In discussing this work effort with the licensee, the inspectors suggested that it may be desirable to verify the fit up of the radial plates outside containment during fabrication and thereby minimize work inside the steam generator. The licensee incorporated the inspectors comments, as appropriate, in WCN No. WR-06.02.00-22-01.
Fabrication of Feedwater Replacement Piping e
In addition to the work effort pertaining to the wrapper plates described earlier, the inspectors observed welding on-feedwater replacement piping. The applica"e code for this activity was identified in the previous paragraph of this section. Welds' observed for weld appearance and workmanship were:
FW-55, - 56 and - 57 on
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drawing number FSK-M-115 in loop "B".
Elbows and piping used to.
fabricate this were made from SA-234 grade, WP22 and A335 grade P22, 16
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inch schedule 80 seamless chrome-moly material.
Rod Issue Forms (WR-6), and Field Weld Checklists (WR-5) were_ reviewed for accuracy pertaining to documentation of welders,' weld procedures and material (s)
used. Qualification records of welders with stencil number C-03, - 06 and - 10 identified as having welded on the subject welds were reviewed and found to be acceptable. Materials used to fabricate this spool piece included the following:
Filler Metal Type Size Lot #
Heat #
E9018-B3 3/32" O 2H105Q04 90298 E9018-B3 1/8" O 3C220Q03 91148 ER90S-B3 1/8" O 236605-11-0 F5797 ER905-B3 3/32" O 236590-6-0 F4545 Pipe & Fittings Size Heat #
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90*, ELL 16" Osch.80 76522 SNS316794 Several
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Pipe 16" Osch.80 75640 SNS316856 Several
This inspectors reviewed material certifications and receipt inspections for completeness and accuracy.
The subject quality records were found to be in order. Within the areas inspected, violations or deviations were not identified.
4.
Review of Welding Procedures As stated in earlier reports, the steam generator replacement project (SGRP)
is under the requirements of'ASME Code Section XI (83S83) and' III, 1986 Edition. As required by these codes, qualification of welding procedures and welders / operators is controlled by the requirements of the subject codes, the inspectors reviewed the following welding specifications and supporting procedure qualification records (PQR(s)) to ascertain whether required mechanical tests, applicable essential and nonessential variables were in compliance with requirements of the subject codes.
These WPS(s) and PQR(s)
pertain to the replacement feedwater nozzle to pipe welds:
Welding Supporting Process Thermal Range Specification PQR #
Treatment Thickness P4, P3-AT
- 1042 GTA/SMA Preheat:
3/16" to 8" SA38F GRII 250 F to SA302 GRB Postweld:
1100 F 6 hrs.
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- 177 GTA/SMA Preheat:
3/16 to
A335, GR P22 300 F 1.812 to A335 GRPll
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- 931 GTA/SMA Preheat:
3/16" to 8" A387 GR22 GTA 250 F to A387 GRll SMA 450 F Postweld:
1375 F 6 hrs.
- Review of Welder Performance Qualification Records.
Welding responsibilities for the SGRP have been assigned to three subcontractors. As discussed in earlier reports, PCI will weld the RCS piping, Chicago bridge and Iron (CBI) will weld the girth weld, main steam and feedwater piping and Becon Construction (Becon),will handle
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the balance of welding needs.
As such, the inspectors picked at random a sample of welders performance records from each of the three organizations for a review to determine completeness, accuracy and compliance with applicable code requirements.
See previous paragraph for applicable code.
Welder records selected for this review were as follows:
PI-T Pl-A-LH PI-A-LH P8-T-AG P8-T-RA P8-A 2" pipe 1" plate 2" pipe 2" pipe 10" pipe 2" pipe sch 80 sch 80 sch 80 sch 140 sch 80 BECON A-1
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A-2
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A-7 failed P-8-T-AG, root unsatisfactory 12-1-92 A-4
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A-11
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A-15
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A-20
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A-36
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A-37
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PCI B-02
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B-10
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B-14
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B-19
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B-32
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C-02
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A514, PX-A (F43) 2" pipe sch 80 C-03 10" pipe sch 140 C-06
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C-10
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C-17 1" plate
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Within these areas, the inspectors noted that the welder performance qualification record, showed a discrepancy in the minimum qualifying diameter.
For example, testing on a two inch diameter pipe, limits the range
of qualification to a minimum of one inch outside diameter pipe and above.
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However, the information entered into the welder performance qualification
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record was inconsistent in that the pipe size for the lower end of the
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qualification limit was expressed in some instances as one inch nominal pipe size (NPS), and in others as % inch NPS. Through procedure review and by
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discussion with cognizant welding personnel, the inspectors ascertained that the interest was to limit the pipe size to one inch outside diameter as L
permitted by the ASME Code,Section IX. However, tha problem was created during documentation, when the individual in charge of completing the forms
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mistakenly entered the lower limit of the qualifying range as one inch' NPS
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instead of one inch OD.
A small bore pipe with a one inch NPS OD, has an
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actual OD of 1.315 inches. The % inch NPS pipe has an actual OD of 1.05
inches which compares favorably with the one inch limit stipulated by code.
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In order to correct this discrepancy Bechtel issued NCR-0C19, " Welder Qualification Test records WR-1."
The corrective action (s) taken, corrected
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the pipe diameter entry in this form, to show the size of the coupons as
% inches diameter NPS in lieu of the one inch NPS previously entered on the Form (WR-1).
Existing test records were corrected to reflect actual pipe size dimensions, i.e., % inches NPS. This finding was regarded as a weakness in the review process and an apparent lack in attention to details.
5.
Review of Radiographs Replacement Feedwater Piping, (IP57C90).
The replacement feedw ter line spools were fabricated in sets by Bechtel in accordance with ANSI B31.7 Code Edition 1969 requirements including _1970 Addendum.
Radiography is performed in accordance with licensee approved
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Bechtel procedure RT-Asme III Rev. 3 written to comply with ASME. Code Section III 1986 Edition. The reason for this pipe replacement was discussed earlier in this report.
Welds selected for this radiograph film review were as follows:
Weld Dwa#
Size Comment FW-41 C1 FSK-M-Il6 Loop C 16" dia x %"
acceptable FW-43 Cl FSK-M-115 Loop C 16" dia x %"
acceptable
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FW-57 C1 FSK-M-114 Loop A 16" dia x %"
acceptable
FW-55 FSK-M-115 Loop B 16" dia x %"
acceptable FW-56*
FSK-M-115 Loop B 16" dia x 1.1 see below FW-57 FSk-M-115 Loop B 16" dia x %"
acceptable
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- This weld was initially rejected by the licensee because the film radiograph (s), did not display adequate sensitivity i.e.,
the licensee i
ascertained that the 2T hole of the penetrameter could not be readily discerned on both films in the cassette (s) used to radiograph the weld.
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After the close of this inspection the inspector ascertained that for this reason and for fabrication related rejectable indications the weld was
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repaired three times. Through discussions with cognizant licensee personnel,
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the inspector ascertained that following the last repair (R3), the film i
showed evidence of root concavity which was measured by the licensee with UT.
These measurements showed the weld thickness at the deepest concavity
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condition met or exceeded minimum code allowable wall thickness requirements and the weld was accepted.
Within the areas inspected violations or deviations were not identified.
6.
Review of Preheat and Postweld Thermal Treatment Procedures.
Cooperheat Inc. has been contracted to perform all the thermal treatment necessary for this project.
This activity is controlled by the Cooperheat, QA Manual Rev. 3, October 1991, and procedures written to cover specific tasks i.e., preheat and postweld heat treatment of welds.
Before use, the procedures are reviewed and approved by the licensee.
The governing codes which control this activity were identified earlier in this report. Within these areas the inspectors reviewed the following approved procedures for technical content, adequacy and consistency with applicable code requirements.
Procedures reviewed were as follows:
33411-CHP -001 Preheat and Intermediate Post Weld Heat Treatment, Upper Girth Seam Weld.
33411-CHP -005-2 Rev.1 Upper Girth Rough Cut Preheat-005-3 Rev.1 Upper Shield Plate Cover, Preheat and Intermediate Postheat-005-4 Rev.1 Upper Girth Precision Cut, Preheat-005-7 Rev.1 Main Steam Flow Limiter, Preheat and Intermediate Postheat-005-7 Rev.1 Main Steam Nozzle to Pipe Preheat and Intermediate Postheat
,
-005-8 Rev.1 Main Steam Nozzle to Pipe and Flow limiter Postweld Heat Treatment-005-10 Rev.1 Main Steam Pipe to Pipe Preheat-005-13 Rev.1 feedwater Nozzle to Pipe Preheat and Intermediate Postheat 33411-CHP-005-14 Rev.2 Feedwater Pipe to Fitting and Fitting to Fitting Preheat and Intermediate Postheat.
33411-CHP-012 Rev.2 Feedwater Pipe to Fitting and Fitting to Fitting Postweld heat Treatment.
33411-CHP-013 Rev.1 Main Steam Pipe to Pipe Postweld Heat Treatment Observation of Work in Progress - Thermal Treatment.
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During this inspection period, the inspectors performed several field inspections, to observe equipment (temperature recorders, power sources cables) and installation of heat elements,. thermocouple and thermal insulation on SG(s) in preparation for thermal cutting of the SG domes. The
- inspectors observed thermal cutting of the girth seam in SG "B", checked the temperature recorder charts to verify that minimum preheat temperatures were being maintained, reviewed applicable WP&lR(s) to ascertain if sign-offs were kept up-to-date with on going activities and checked calibration stickers on selected temperature records. In addition to these efforts, the inspectors reviewed certain quality records for equipment and consumables i.e.,
thermocouple wire, insulation putty.
Items selected for this review were as follows:
Thermocouple Purchase wire order P/ALPTW-20-KX SP 05-07863 Thwemosil/Q-20-K 05-09816 Putty-Fiberfiax
- VERPC0 Consumable Material Evaluation
- N92-222, 10-3-92
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Material Safety Data Sheet, Carborundurn, #136/M0105 Temperature Serial No.
Calibration Recorders (S/N)
Date Yokogawa 80826-1-2 1-14-93 Yokogawa 141753B657 12-29-92 Yakogawa 14177KB984 12-29-92 Yakogawa T4176KB604 1-14-93 Cabbrator 110984-19 Expiration 1-10-93 For the above items, the inspector identified certain inaccuracies in the quality records presented for review which were as follows:
l 1.
The certificate of calibration showed that recorder S/N T4176KB604 was calibrated with a Micromite calibrator S/N I 11854-2. However the calibrator with this S/N was a Cooper calibrator and not a Micromite.
Cooperheat had no certificate of calebration on site for the subject calibrator.
2.
Temperature Recorder, S/N T4176JB515.
Same problem as that discussed in item 1. above, expect that the calibrator was a Micromite ani not a
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Cooper as documented in the certificate of calibration.
In thit case the correct calibration sheet was on site.
3.
Quality records showed that, Micromite calibrator S/N 110984-1-9 was due for calibration on January 10, 1993, however there was no record on
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site to show that the calibrator had been recalibrated.
This apparent weakness in verifying completeness and accuracy in quality records discussed with the licensee and Bechtel's on site QA manager who tout immediate steps to correct the problems identified by conducting an in depth audit of all Cooperheat equipment in the field to verify that appropriate quality records were on hand and accurate for equipment designated for service during this project.
Following this discussion, the licensee provided the inspectors a copy of the missing certificate which had been faxed on site and reported that all calibrators referenced in the calibration sheets were at the Cooperheat laboratory and not on site.
Bechtel's audit report was still open at the end of this inspection. This report will be reviewed on a future inspection.
Within the areas inspected violations or deviations were not identified.
7.
Record Review - Work Plan and Inspection Records (WP & IR9S))
A sample of WP & irs were selected at random for a review of line items to ascertain whethe work was being done in an orderly manner with appropriate signoffs entered by designated individuals in a timely manner. WP & irs selected for this work effort were as follows:
WP & IR Title WR-07.01.00-01,-0E-03 Cut / Reweld RCS Piping loop "A", "B",
and
"C" WR--7.02.00-01,-03 Removal / Reinstallation of SG "A",
"C" Main Steam Piping WK-07.03.00-01,-02,-03 Removal / Installation of SG "A",
"B",
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"C" Feedwater and Chemical Feed Piping The review of the above documents at the field office and in Document Control revealed that several line items requiring signoffs had been left blank. A list of the line items in question were given to the licensee for an investigation into this apparent prot,lem. On the following day, January 28, 1993, the inspectors met with the licensee to review the results of their investigation and resolution.
The results showed that out of the 25 items in question, fifteen were monitoring activities which required no signoffs.
Three of the remaining ten items involved a signoff of the same work and of the same activity by individuals in the same organization, i.e., responsible construction engineer (RCE) and the production supervisor (S).
In this case, the licensee provided memorandum dated January 8, 1993, authorizing the RCE to N/A the signoff of the (S) when he, (RCE) performed inspections of the same activity.
Similar authorization had been given to the quality control engineer over the RCE for internal component cleanliness verification and, to the welding coordinator over (S) when inspections for the same activity were required.
The remaining seven line items involved situations where the responsible individuals had
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initialed the field copy, but had neglected to initial the record copy or vice-versa.
In a few cases the licensee acknowledge that the signoffs had been omitted.
This' apparent weakness in assuring that quality control documents are kept complete and accurate was discussed with the licensee's SGRP management. The
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inspectors were assured that steps were underway to impress upon everyone the importance of maintaining complete and accurate documentation of inspections
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and other tasks performed and that it be done in a timely manner.
The inspectors stated that these areas would be revisited during subsequent inspection to evaluate improvements in this area.
Within the areas inspected violations or deviations were not identified.
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8.
Exit Interview The inspection scope and results were summarized on January 15 and 29, 1993, with those persons indicated in paragraph 1.
The inspector' described the
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areas inspected and discussed in detail the inspection results-Although
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reviewed during this inspection, proprietary information is not contained in this report.
Dissenting comments were not received from the licensee.
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