IR 05000352/1981016
| ML20039E438 | |
| Person / Time | |
|---|---|
| Site: | Limerick  |
| Issue date: | 12/07/1981 |
| From: | Durr J, Mccabe E, Varela A NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML20039E431 | List: |
| References | |
| 50-352-81-16, 50-353-81-14, NUDOCS 8201070291 | |
| Download: ML20039E438 (10) | |
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U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT Region I 50-352/ 81I16l4 B
Report No. 50-353/
50-352 Docket No.
50-3'53 CPPR-106
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License No.
CPPR-107 Priority
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Category A
Licensee:
Philadelphia Electric Cmoany 2301 Market Street Philadelphia, Pennsylvania 19101 Facility Name: Limerick Generating Station, Unit Nos.1 and 2 Inspection at: Limerick, Pennsylvania Inspection conducted:
October 1 through November 30, 1981 Inspectors:
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f/J D r n% r Resident Inspector
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Varela, Reactor Inspector date signed
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date signed Approved by: _ k U
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L. nctace, Uniet, Keactor date sioned Projects Section 2B
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Inspection Summary:
Report 50-352/81-16 and 50-353/81 14 performed on October 1 through November 30, 1981.
Areas: A routine, unannounced inspection by the Senior Resident and one Regional based inspector of the spray pond activities, pipe installation and welding, safety related equipment installation, structural steel welding, plant tours, and closecut of unresolved items. The inspection involved 90 inspector-hours at Unit No. 1 and 33.5 inspector-hours at Unit No. 2.
Results: No items of noncompliance were identified in the six areas examined.
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$?0$bo$$$h PDR Region I Form 12 (Rev. April 77)
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DETAILS 1.
Persons Contacted Philadelphia Electric Company (a-b)
J. M. Corcoran, Field Q.A. Branch Head (b)
D. T. Clohecy, QAE (a)
J. J. Fedick, Construction Engineer -
(a)
E. C. Gibson, QAE (b)
A. C. McLean, Construction Engineer
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P. K. Pavlides, Manager, QA (b)
H. R. Walters, QA Bechtel Power Corporation (a)
T. Altum, Assistant Project Field Engineer (APFE)
(a)
P. J. Alverson, Field Procurement (b)
R. D. Bryan, Project Field Superintendent (a)
G. E. Fissel, APFE (a-b)
H. D. Foster, Project Field QCE (PFQCE)
(b)
M. G. Held, Lead Civil QCE (a)
A. Hill, Office Engineer (a-b)
E. R. Klouin, Project (AE (b)
G. Koch, Subcontract Engineer (a)
R. Lamley, Long Term Maintenance (LTM) Engineer (a)
D. Lerch, LTM Engineer (a-b)
J. L. Martin, Lead Site QAE (a)
K. L. Quinter, Assistant PFQCE (b)
N. Shah, Resident Engineer (b)
W. J. Tate, Lead Staff Civil Engineer (a-b)
D. C. Thompson, Assistant PFQCE
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(a)
R. E. Weaver, Lead Site Mechanical Engineer (b)
A. G. Weedman, Project Field Engineer (b)
S. A. Wybranski, Senior Lead Subcontracts Engineer t
General Electric Company (a)
W. J. Neal, Resident Site Manager (a) Attended-ll/25/81 Exit Interview (b) Attended 10/8/81 Exit Interview-The above listed personnel attended fomal Exit Interviews on the dates indicated.
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Other craftsmen, engineers, quality control technicians, and supervisors were contacted and interviewed as the inspection interfaced with their-
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work activity.
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2.. Plant Tours (Unit Nos. 1 & 2)
Periodically during the inspection, tours were made of the Unit Nos.1 and 2 primary reactor containments, the reactor buildings, the control structure, and surrounding yards and shops. The inspector examined completed work, work in-progress, quality control activities, and equip-ment storage, handling, and maintenance.
He discussed the technical aspects of the work with craftsmen, supervisors, and engineers to assure work was baing perfomed in-accordance with requirements.
On November 19, 1981, the Senior Resident Inspector conducted a tour of the facility for two members from the Office of the Executive Legal Director.
The inspector observed the ultrasonic testing of a structural beam splice weld, No. 5B6, in the fabrication shop.
He verified that the test was performed in accordance with the procedure No. UT-PE-1, 2, Revision 1.
He discussed the technical aspects of the test with the technicians and confimed the test results.
3.
Action On Previous Inspection Findings (Closed) Unresolved Item (352/78-12-03)
Evaluation practices for ultrasonic testing indications. The im pector questioned the evaluation practices and disposition for weld RHD-047.
Re-evaluation by the licensee's level III examiner disclosed that the indication was entrapped slag in the weld and not an internal reflector.
The entrapped slag was further evaluated to be ASME Code acceptable on Nonconfomance Report No. 3462. The vendor reviewed all indications-previously evaluated by the individual involved. Further, the licensee is independently reviewing the vendor's work. This' item is closed.
.(Closed) Unresolved Item (352/79-05-01 and 353/79-05-01)
Revision to Site Quality Assurance Audit Procedures. The licensee had established the audit finding report issue time as the time the finding was identified. This appeared to be restrictive and unrealistic. The licensee revised Appendix "S", paragraph S-5.1.2 to allow report issue within 30 days. This item is closed.
(Closed) Unresolved Iten (352/79-06-02)
Bolt hole centers to edge of box beam and plates are less than AISC recommendations. The inspector noted the above condition and requested confimation that this.was the design intent. The-licensee initiated Finding Report N-164 describing the condition and requested an explanation for the deviation from AISC tolerances.
The response to the Findin3 Peport verified that the deviation was the design intent and was supportti by calculations and established practices.
This item is closed.
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(Closed) Unresolved Item (352/79-07-03)
The weld joint configuration on pipe whip restraints, shown on drawing C-938, did not provide access for full penetration welding. The licensee issued Finding Report No. N-166 describing the condition. The corrective actions initiated were as follows:
(1) Field Change Request C-5914 was issued to change drawing C-938 to pemit a is "T" minimum effective throat in the area of concern.
(2) Verification of the k "T" effective throat is
made by a quality control hold point inspection of the weld.
The inspector examined drawing C-938, Revision 7, and verified the addition of note 4, which pemits the k "T" welding. He also reviewed a
the Quality Control Inspection Record, C-932-W17, block 2.1, W-2.00, and verified that the above requirement is a hold point inspection. This item is closed.
(Closed) Unresolved Item (352/79-10-01)
ASME site survey of General Electric Company, I & SE. The inspector verified that the GE-I & SE Company issued the appropriate ASME Certifi-cates of Authorization. This item is closed.
(Closed) Unresolved Item (352/79-10-02)
ASME site survey of Reactor Controls, Inc.
Reactor Controls, Inc. was to be the installer of the reactor vessel internals and the hydraulic control units, however, they have left the site and will not be doing the work.
This item is closed.
(Closed) Unresolved Item (352/79-11-02)
Cracks found in recirculation pipe restraint to bioshield welds. The licensee determined that due to the size of the welds and thickness of material being used that there.was insufficient pre. heat of the base material before weiding.
The inspector reviewed Nonconfomance Report No. 3795 which required the renoval of the cracked weld and replacement. Further, the licensee revised note 6 on drawing C-950, Revision 11, to require a soaking preheat of welds k" thick or larger attaching to the bioshield. The welds are then magnetic 2particle tested not less than 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> after completion. The inspector reviewed QCIR's C-956-W22, W-21, and W-18 and verified that soaking preheat is inspected on a surveillance basis and that a final magnetic particle test is perfomed. This item is closed.
(Closed) Unresolved Item (352/79-11-07)
Welds on the PGCC panels to floor embeds were not clearly specified.
Field Deviation Disposition Report, HH1-1000, Revision 3, was issued listing the panels affected and the details of the weld joints used. The revision was approved on July 21, 1980. The inspector examined the welds on the Unit No.1 control rocra panels and verified that they confom to the FDDR. This item is closed.
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(Closed) Unresolved Item (352/80-12-08)
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Improper copes nn structural beams. The inspector identified repairs to structural beam copes which were not documented and corl.ained flaws.
The licensee examined 374 beams and identified 18 of these as having had repairs. The beams that indicated repairs were radiographically examined for flaws. He also increased the on-site receipt surveillance and vendor site inspection of beam copes. The vendor supplying the beams instituted 100% in-process inspection of beam copes and cope repairs. This item is closed.
(Closed) Unresolved Item (352/81-14-06 & 353/81-12-04)
Spray Pond backfill inconsistencies in documentation of moisture-density test method. The licensee will note on the test fom, QC-G1, the amount of material retained on the 3/4" sieve, thus providing 'ustification for using the alternate test method. This item is closed.
4.
Safety Related Components - Observation of Work The main steam isolatien valve, B21-F0220, and the high pressure coolant injection pump turbine were selected for review of installation, storage, and maintenance practices.
The main steam isolation valve (MSIV) was visually examined to assure it was properly stored and sensitive components protected. The weld records for connecting the valve to its piping were examined for use of correct procedures, qualified welders, and appropriate nondestructive tests. The weld radio-graphs, BWRPD-lMS1-D6 and BWRPD-lMSl-07, were reviewed for compliance with ASME Code requirements.
The valve quality records were reviewed for compliance with the Draft ASME Code for Pumps and Valves (DCPV). The inspector had the following findings:
-- Sequence af manufacture:
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12/20/.i Nomalize valve casting at 1700 F l
1/18/72 100% Radiography perfomed 2/9/72 Repair welding perfomed 2/11/72 Re-radiograph of weld repairs
2/12/72 Post weld / Temper Heat Treat at 1340 F (1) The DCPV, Section 515.3.5(b) and (e) requires thag for post weld heat treatment (PWHT), at temperatures above 600 F, a heating rate of not greater than 400 F per hour per inch of thickness be permitted U
and a cooling rate of 500 F per hour per inch of thickness. During the PWHT/ temper perfomed on 2/12/72, these heating and cooling rates were exceeded.
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'(2) The DCPV, Section 314.1.6(c)- requires that repair welding procedures be qualified in accordance with the ASME IX Code.
The ASME IX Code, Section Q-ll, paragraph V-6, requires that the welding procedure be requalified if there is, "a change in the heat treating temperature..." The Quaker Alloy Procedure, QAP-49D,
for repair welding was qualified for a PWHT temperature of 1100 F.
The valve casting repair welds were PWHT/ tempered at 1340 F.
(3) The DCPV, Section 314, requires, "Non-destructive examinations...shall be perfomed after any heat treatments required by the material specification." The valve was nomalized on 12/20/71, radiographed on 1/18/72, and tenpered on 2/12/72.
(4) The DCPV, Section 314.1.6, Repair of Defects, paragraph (b), requires that repair excavations be magnetic particle or liquid penetrant-tested before repair welding. The casting was-repair welded on 1/22/72, 2/1/72, 2/4/72, 2/7/72, and 2/9/72. The excavations ranged from the repair of surface defects to indications up to 3" deep.
There are no records to indicate that the repair excavations were nondestructively examined.
(5) Quaker Alloy Procedure QAP-49, Revision D, paragraph 2.3, requires that welding be perfomed after nomalizing and temper treatnient. The casting was nomalized on 12/20/71, repair welded on 2/9/72, and tempered on 2/12/72.
(6) The valve castings were made by the Quaker Alloy Casting Company for the Atwood Morrill Company, the manufacturer of the valve. Atwood Morrill Company supplied the valve to the General Electric Company, the nuclear steam system supplier. The Atwood Morrill Company provided a " Certificate of Compliance", dated October 9,1973, certifying that the valve meets all specifications. Also, the General Electric Company supplied a " Product Quality Check List" certifying that items 1 through 4 above were satisfactorily completed and reviewed.
The licensee stated'that there appears to be further, mitigating documentation available at the vendor's facility. These items are unresolved pending review of this information (352/91-16-01).
The high pressure coolant injection (HPCI) turbine was examined for storage, installation, and maintenance practices. A visual inspection of the turbine disclosed that it is maintained under temporary cover and openings to internal parts are plugged. 'During the inspection, craftsmen were perfoming a preliminary alignment of the turbine to pump coupling. The inspector discussed the technical aspects of the work with the craftsmen and verified that the measured tolerances were consistent with the manufacturer's manual.
A review of the Quality Control Inspection Records M-2.10 and M-2.30 revealed that the levelness of the turbine unit was never verified to the accuracy
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specified in the manufacturer's instruction manual. The manual specifies a levelness of,2 mils per foot. This particular page of the manual. was revised after the turbine was installed and was not available in all copies of the manual. This item is unresolved pending determination of the applicability of the 2 mils per foot levelness to the HPCI turbine and the-cause for the nonuniformity in the manuals.
(352/81-16-02)
It was determined from a review of the storage maintenance records that all scheduled maintenance was being perfonned in a timely manner.
However, the manufacturer's manual, Standard Practice Specification, SP-ll, requires that extensive pieventive measures be performed at three year intervals. The records indicate that the SP-ll maintenance was not performed during the 1972 to 1979 interval. The maintenance was performed in 1979, but this activity is not' listed in the In-Storage Maintenance Computer Program which determines the frequency at which maintenance is performed. This activity is in the computer for Unit No. 2.
This item is unresolved pending correction of the computer listing.
(352/81-16-03)
A review of Field Deviation Disposition Report No. HH1-442 disclosed that ASTM material A-108-GR-C1018 was' used in the HPCI pump drain nipples.
This material is not recognized by the ASME Code and requires further qualification of any weld procedure used on it. The disposition of the FDDR was to upgrade the material to A-105 which is reccgnized by the ASME Code. This practice was reviewed internally by the NRC and found to be acceptable in this case. The inspector had no further questions concerning this matter.
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5.
Observation of Welding Activities Reactor coolant pressure boundary (ASME III, Class I)' and other safety related pipe welds (ASME III, Class II and III) were selected for document review and observation of welding activities. The document reviews verified the welder's qualifications, proper welding procedures were employed, required nondestructive tests specified, appropriate quality control inspection points.specified and signed off, and proper preheat and postweld heat treatments were required. The observation of welding consists of, where-applicable, examination of the cleanliness, fitup, and alignment of the parts; proper welding equipment; purge and cover gas flow rates, electrodes and filler materials; appearance of the weld deposit; evidence of quality control activities; and proper documentation. The following welds were examined:
Weld No.
Class System Status-DCA-204-FW 2
RHR(pene)
I DBA-206-FW 2
HPCI F,A,R HBC-139-FW 63
OnergSvcWater F,A,R BWRPD-lREC-1/6WA33
Recirc/RHR F.A R BURPD-lREC-1/5WB1
Recirc FC DCA-318-03-FW 3 RHR I
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Status Code:
I - Intermediate weld pass; F - fitup; A - alignment; R - root pass; FC - final cover pass
No items of noncompliance were identified.
6.
Safety Related Structures Observed the fitup and welding of the containnent seal plate as shown on
drawing C-290/12 at elevation 327', azimuth 33. The inspector verified that the welder was qualified, the proper filler metal was being deposited, and the correct welding procedure was specified.
He also observed the welding of the feedwater restraint, C-842/5, WR F-1115.
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He observed the final weld pass, verified that the proper preheat was
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used and that the welder was' qualified.
No items of noncanpliance were identified.
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7.
Spray Pond (Ultimate Heat Sink)
Observation of Construction Activities The following activities were observed by the inspector in construction of the spray pond:
Rock excavation by mobile power equipment of the
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south easterly area.
-- Clean-up of rock in second spray net area in prepar-ation for unreinforced concrete fill.
Geologist inspection and approval of rock
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excavation in spray net area "A".
Unreinforcement concrete placement
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in area "A".
Preparation and placement of reinforced concrete
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in pipe column foundations for spray net area "C".
-- Concrete batching, mixing, delivery, and testing at the laboratory and at truck-discharge.
Quality control inspection and documentation.
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No items of noncanpliance.were identified.
Review of Construction / Inspection Criteria The inspector reviewed the following construction and inspection requirements for the spray pond:
-- C 94, Specification for Spray Pond Earthwork C 61, Specification for Furnishing-and Delivery
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of On-Site Concrete i
C 36, Specification for Placing Reinforced i
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Concrete C ll, Specification for Placing Unreinforced
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Concrete LGS, FSAR Sections 2.5, 3.8 and 9.2
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-- Drawings C-1101.1102,1103,1106 and 112B No items of noncanpliance were identified.
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Review of Batch Plant and Test Laboratory Qualifications-The inspector verified that the batch plant and test laboratory activities conformed to ACI 318. The batch plant was certified in accordance with requirement of the National Ready Mix Concrete Association. The concrete test. laboratory was inspected and i
found satisfactory by the National Bureau of Standards, as required by ASTM E 329.
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Unresolved Items Unresolved items are matters about which more information is needed to determine whether it is acceptable, a noncompliance, or a deviation.
Unresolved items are discussed in paragraph 4.
9.
Exit Interview The inspector held exit interviews on October 8 and November 25, 1981,
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with members of the licensee's staff. He discussed the scope and findings 1'
of_the inspection.
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