IR 05000354/1980005
| ML19330A461 | |
| Person / Time | |
|---|---|
| Site: | Hope Creek  |
| Issue date: | 06/12/1980 |
| From: | Reynolds S, Lester Tripp NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML19330A460 | List: |
| References | |
| 50-354-80-05, 50-354-80-5, 50-355-80-05, 50-355-80-5, NUDOCS 8007280246 | |
| Download: ML19330A461 (5) | |
Text
__
-
.
U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT Region 1
'
50-354/80-05 Report No.
50-355/80-05
'50-354 Docket No.
50-355 CPPR-120
License No. CPPR-121 Priority Category
__
--
Licensee:
Public Service Electric & Gas Company 80 Park Place
'
Newark, New Jersey 07101 Facility Name: Hope Creek Generating Station, Units 1 & 2 Inspection at: Hancocks Bridge, New Jersey Inspection conducted: April 21-25, 1980 Inspectors:
k
%W m
o
$.D.Reynol{s,Jr.,'ReactorInspector date signed
'
date signed date signed Approved by: 4.b.
th0
$//4/fd l
t. E. Trtyp, Chief, Engineering Support date signed
- 1, RC&ES Branch Insoection Summary:
Inspection on April 21-25, 1980 (Combined Report Nos. 50-354/80-05; 50-355/80-05)
Areas Inspected:
Unannounced inspection by a regional based inspector to witness reactor vessel nozzle safe end field changes and welding of safety related piping.
~
Inspection involved 33 hours3.819444e-4 days <br />0.00917 hours <br />5.456349e-5 weeks <br />1.25565e-5 months <br /> on-site by one NRC regional based inspector.
Results: No areas of noncompliance were identified.
Region I Form 12 (Rev. April 77)
8007280 /YC
.
-
--
-
.
_
_.
--
_ -
.
.
D_ETAILS 1.
Persons Contacted Public Service Electric & Gas (PSE&G)
- A. Barnabei, QA Engineer
- A. Giardino, Project QA Engineer Bechtel Power Corporation (Bechtel)
- J. Gatewood, Head Site QA Engineer
- R. Hanks, Project Construction QC Engineer
- R. McKinnan, Assistant Project Field Engineer General Electric Installation and Service Engineering Division (GE I& SED)
- R. Burke, Site Project Manager
- F. Eaton, QA Manager
- V. Kenney, QC Supervisor (Acting)
C. Clarke, Field Engineer D. George, Welding Engineer
- Denotes those present at exit interview.
2.
Plant Tour (Units 1 & 2)
A general tour of Units 1 and 2 was made to determine areas where pipe welding activities were underway and to observe the operations and preparation for field weld replacement of reactor (s) nozzle safe ends.
Areas observed included: Portable machining removal of reactor nozzles, automatic weld perfonnance test assembly welding of recirculation nozzle test assembly, joint fit up of I-P-EG-020-FW9, and welding of torus shaped suppression chamber.
..
-.
~
.
3.
Reactor Vessel Nozzle Replacement (Units 1 & 2) - Review of Procedures The recirculation nozzles, feedwater nozzles, CRD return nozzles and core spray nozzles for Units 1 and 2 are undergoing a field change where the original safe ends are being removed by portable machining by Power Cutting, Inc. in preparation for rewelding of new safe ends.
The rec.irculation nozzle assemblies (F-43 buttered, P-8 safe end to F-43 buttered, P-3 nozzle), core spray nozzle assemblies (P-43 safe end to F-43 buttered, P-3 nozzle) and Unit #2 feedwater nozzle assembly (F-43 buttered, P-1 safe end to F-43 buttered, P-3 nozzle) will be welded automatically with an Arcos Type K F-43 consumable insert root using Dimetrics Gold Trac II welding equipment.
The welding will be conducted with welding supervision by GAPCO, Inc.
The Unit 1 feedwater nozzle assembly (P-1 safe end to P-1 nozzle) and CRD return nozzle assembly (P-43 safe end to F-43 buttered. P-3 nozzle will be welded manually with E70S-2 and F-43 filler metals respectively)
using Arcos Type K consumable inserts, manual GTAW additional passes and SMAW for the remainder of the joint.
The welding will be under the overall technical and QA supervision and welding procedures of GE. The welding technique' and procedures utilized will be similar to that used for reactor nozzle replacement at Susquehanna by GE I&SE.
The following GE documents were reviewed.
(GE I&SE)
HSCE 1-7, Rev. 1, dated 3/19/80, General Welding Procedure for
--
Nuclear Service Field Installation.
HSCE 79-1-7D (Rev. 2), HSCE 79-1-2D (Rev. 4), and HSCE 79-1-40
--
(Rev. 2), Detailed Welding Procedures (DWP).
HSCE 79-1-7W (Rev. 1), HSCE 79-1-2W (Rev. 1), and HSC 79-1-4W
--
(Rev.1), welding performance qualifications (WQ) for the above Detailed Welding Procedures.
PQR(s) 1, 3, 418 (Part 2/3) 102, and 503 for the above detailed
--
welding procedures.
Material Certifications for the Johnson Stainless 0.035" diameter
--
Type) Cr-3 (F-43) filler metal for automatic welding and Arcos ERN K ERN - Cr-3 (F-43) and E705-2 (A-I, F-3) consumable inserts.
{
l
__
.
.
In the process of the review it was determined that DWP 79-1-70 contained no welding information concerning the tack welding of the consumable insert to meet the requirements of Section III NB-4231.1. This was determined ta be an unresolved item pending(action by the licensee and review by NRC for inclusion of this data.
50-354/80-05-01,50-355/80-05-01)
In the review of DWP 79-1-70 and supporting PQR documentation it was determined that the classification of P# and F# for the buttered joints is inconsistent with the field weld application.
The field welding documents previously referenced indicate that the field weld safe end to nozzle joints for the recirculation nozzles, feedwater nozzles for Unit #2, CRD nozzles and core spray nozzles are P43 to P43 weld joints.
These weld joints are actually joints between F43 buttered materials (P8, P3, P1) or F43 buttered materisis to P43.
The ASME Code in Section IX QW-403.11 does not directly acknowledge the substitution of F43 buttered base metal for P43 wrought material. This was deter M ed to be an unresolved item pending clarification and resolution of the inconsistencies by the licensee and review by NRC.
(50-354/ 80-05-02, 50-355/80-05-02)
In the review of PQR-1 it was determined that there was insufficient documentation of the parameters utilized in the special weld test assembly to meet the supplementary essential variable requirements for notch toughness qualification (QW 403.5, QW 403.6, and QW 405.2).
The dimensions of the test assembly and welding position for the special SA 537, Class 1 weldment are not adequately indicated on the PQR-1 document.
This lack of documentation was determined to be an unresolved item pending clarification by the licensee and review by NRC. (50-354/80-05-03,50-355/80-05-03)
4.
Safety Related Piping - Observation of Work and Review of Quality Records The inspector determined the status of recently completed and ongoing safety related pipe welding operations.
The flat top grinding of 1-P-BJ-001, FW8 was observed as was the preparation for joint fit up)
examination of 1-P-EG-020, FW9.
(Safety and Turbine Aux" cooling The SA216 valve to SA155 carbon steel pipe joint 1-P-EG-020, FW9 welded to P1-AT-Lh could not be fit up to meet the welding procedure specification fit up requirements. Tnis is a 30" OD x 0.375" wall GTAW/SMAW open root joint.
The material specification tolerances of +
0.150" (00) plus 1% out of roundness for the large diameter thin wall--
pipe and unflex Sle heavy wall valve joint dimensions increase the probability for joint fit up problems.
The joint fit was not signed off by QC. The Bechtel welding procedures provide specific solutions to joint dimensions outside the specification range encountered in repair welding operations, but in the case of out of specif9.ation initial weld joint fit up there is no definitive procedure, however, the QA procedures could permit the use of an NCR,- FCR or FER for this situation.
The specific approach to this problem was not clearly indicated to the NRC inspector.
It was determined that this problem is unresolved pending review of the procedural requirements for documentation of out f specification weld joints by the licensee and review by NRC.
(50-35 08-05-04)
~s
.
.
The inspector reviewed Bechtel specification (awg) P0570 which specifies the General Welding Procedures and Welding Technique Sheets for all safety related piping welds.
During this review it was found that recently aded Note 28 indicated that welds indicated on the isometric drawing as Code Class boundaries should meet the requirements of the lesser class.
Bechtel has indicated in supporting documentation that they have applied for a Code Inquiry to support this position. The inspector questioned the rationale used by Bechtc1 to make the specific decision to utilize the lower class acceptance criteria as the ASME Code Section III does not specifically address this subject.
The use of the lower class requireinents at code boundaries is unresolved pending further information from the licensee on a response to the Bechtel Code Inquiry and review of the response by the NRC.
(50-354/08-05-05.
50-355/80-05- 04)
An audit of weld history records and supporting documentation was made of recently completed welds as follows:
1-P-BE-004, FW14 (CoreSpray)
1-P-BE-004, FW14R1 1-P-BE-004, FW14R2 1-P-BJ-003, FW8 (HPSI)
1-P-BJ-004, FWS 1-P-BJ-001, FW8 1-P-AP-002, FW7 (Coordinate Transfer Storage)
These welds were also visually inspected.
The audit and inspection indicated that the welds were made in accordance with the traveler requirements, were properly identified and located, the welding pro-cedures utilized were properly qualified, welding conducted in accordance with the proper WPS with the proper filler metals, welders were properly qualified and the weld history records were complete.
No items of noncompliance were identified.
5.
Unresolved Items Unresolved items are matters about which more information is required in order to ascertain whether they are acceptable items, items of noncompliance or deviations.
Unresolved items disclosed during this inspection are
,
discussed in paragraphs 3 and 4 of this report.
l 6.
Exit Interview l
The inspector met with licensee representatives (denoted in Paragraph 1) at the conclusion of the inspection on April 25, 1980.
The inspector summarized the scope and findings of the inspection.
In addition, the NRC Resident Inspector, Mr. W. H. Bateman, attended the meeting.