Text

Insp Rept 50-354/85-08 on 850408-0503.No Violation Noted. Major Areas Inspected:Selected safety-related Piping, Weldments Fabricated to ASME Code,Section III & Class 1,2 & 3 Preservice Requirements
	ML20129G023
Person / Time
Site:	Hope Creek
Issue date:	06/20/1985
From:	Campbell R, Harris R, Kerch H, Wiggins J; NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I)
To:	;
Shared Package
ML20129G000	List: IR 05000354/1985008; ML20129F996;
References
	50-354-85-08, 50-354-85-8, NUDOCS 8507170512
	Download: ML20129G023 (27)
	v • d • e

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U. S. NUCLEAR REGULATORY COMMISSION

REGION I

Report No. 85-08 Docket No.

50-354 License No. CPPR-120 Priority Catergory C

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Licensee:

Public Service Electric & Gas Company 80 Park Plaza - 17C Newark, New Jersey 07101-Facility Name: Hope Creek Unit 1 Inspection At: Hancocks Bridge, N. J.

Inspection Conduc d: April 8 thru May 3, 1985 Inspectors:

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H. W. Kerch, Lhad Reactor Engineer

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. Harri's, ADE Technician

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Approved by:

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'Wiggins,{4%cessesSection,DRS J.

fief, Materials and

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date Inspection Summary:

Inspection on April 8 thru May 3,1985 (Report No.

50-354/85-08)

Areas Inspected: A routine, announced NRC independent measurements inspection was conducted at the utility construction site using the NRC Mobile Non-destructive Examination (NDE) laboratory.

Selected safety related piping, weldments fabricated to ASME Code,Section III, Classes 1,2 and 3 and ASME Code Section XI pre-service requirements were inspected.

Three regional based inspection personnel assisted by two contracted NDE personnel were utilized during this inspection. The inspection involved 473 onsite hours and 168 offsite hours.

Results: No violations were identified.

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DETAILS 1.

Persons Contacted Public Service Electric & Gas Company (PSE & G)

A. E. Giardinao,. Quality Assurance Manager

A. D. Barnabet, Quality Assurance Engineer

R. T. ' Griffith,- Quality Assurance Engineer i

R. Donges, Lead Quality Assurance Engineer

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S. LaBruna, Assistant General Manager

G. D. Owen, Principal Site Construction Engineer

J. Nichols, Technical Manager

C.'W. Lambert, Supervising Engineer

G. S. Daves,. Senior Operations Engineer

P. Kudless, Maintenance Manager

E. C. Logan, Site Manager

T. G. Busch, Technical Engineer

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M. F. Metcalf, QA Startup Engineer

R. F. Brandt, Plant Engineer

G. L. Duncan, Senior ISI Supervisor V. J. Bleux, Construction Manager V. Bloemer, Construction Engineer K. McJunkin, Construction Engineer

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G. Morrill,_ Radiation Protection Supervisor

R. P. Inversa, Construction Contract Supervisor Bechtel Construction Company

W. Goebel,-Quality Assurance Engineer

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B. Cole, Site Quality Assurance Engineer

S. L. Vezendy, Assistant Quality Control Engineer

C. D. Headrick, Quality Control Engineer

M. J. Dutra, NDE Level III

G. Moulton, Quality Assurance Engineer

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~*W. E. Mouer, Manager Site Construction-

W. D. Griffin, Project Field Engineer A. J. Peter, Senior Safety Representative E. Steiner,- Quality Control

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R. C. Hanselman, Weld Engineer-N. Wypyck,-Lead NDE C. H. Cecil, Lead Contract Engineer General Electric Company C. T. Brinson, Quality Assurance Engineer U. S. Nuclear Regulatory Commission

S. D. Ebneter,_ Director, Division of Reactor. Safety

A. Kortas, Reactor Engineer

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M. Dev,, Reactor Engineer

N. Blumberg, Lead Reactor Engineer

H. I. Gregg, Lead Reactor Engineer S. K. Chaudhary, Senior Resident Inspector A. R. Blough, Senior Resident Inspector J. J. Lyash, Resident Inspector 2.

Independent Measurements - NRC Nondestructive Examination and Quality Records Review of Safety Related Systems During the period April 8 through 18, 1985, quality records received from Hope Creek Nuclear Plant #1 were reviewed in the regional office for completeness and compliance to the licensee's FSAR commitments to applicable codes, standards and specifications.

Subsequently, an on-site independent verification inspection was conducted during the weeks of April 22 through May 3, 1985 using the NRC Mobile Nondestructive Examination (NDE) Laboratory. This inspection was conducted by region based personnel in conjunction with NRC contracted personnel.

The purpose of this examination was to verify the adequacy of the licensee's welding and nondestructive examination quality control programs.

This was accomplished by duplicating those examinations required of the licensee and evaluating the results.

In addition to the required examinations, several other confirmatory examinations designed to verify conformance with material specifications were performed and compared to. quality assurance records.

An NRC inspector made a random selection of shop and field weldments fabricated to AWS and ASME Class 1, 2 and 3 codes. These were intended to provide a representative sample of piping systems, components, and pipe size.

The items selected had been previously accepted by the ifcensee based on vendor shop and on site QA/QC records.

2.1 Quality Decuments Review Forty-eight safety related piping system document packages covering the items shown~in attachment 3 were reviewed for compliance with licensee procedures, applicable codes, standards and regulatory requirements. The following documents were reviewed:

Document Attributes Reviewed Material Certifications Material chemical and physical (Base)

properties compared to standards and Code requirements.

NDE Records Examinations meet codes and standards, licensee procedures and other commitments. Personnel properly qualified. Appropriate examinations performed.

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Fabrication Records A. review of fabricators traveler and fabrication record was reviewed and

compared against other corresponding

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records and sign off sheets.

Drawings (isometrics)

Drawings were reviewed for proper

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designation of weldments, location and classification.

Procedures Procedures were reviewed for

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I completeness, and to verify the implementation of the licensee's commitments to Code requirements.

Welding Material Material certifications for welding d

materials were reviewed to determine if physical and chemical properties were as required by licensee's commit-ments to Code and Industry Standards.

Results: No violations were identified.

2.2 Nondestructive Examinations:

Nondestructive examinations were performed using NRC procedures with addenda written specifically to comply with the licensee's PSAR commitment to the ASME B&PV Code. The intent was to duplicate, to the extent practicable, the techniques and methods of the original

examinations.

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The following examinations were performed:

Radiographic Examination:

1 Thirty-nine pipe weldments were radiographed using an Iridium-192 source per NRC procedure NDE-5-Rev,0 addenda HC-1-5-1.

The weldments examined were ASME class 1 and 2.

The resulting radiographs were eval'ated per u

applicable Code requirements and compared to the licensee's radiographs.

Results: No violations were identified.

Socket Welds:

Eighteen socket welds were visually examined and radiographed to ascertain minimum gap required during fit-up prior to welding.

Results: No violations were identified.

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Penetrant Examination:

Thirty-one safety related pipe weldments and adjacent base material

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.(h"either side of weld) were examined using liquid penetrant techniques

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per NRC procedure h0E-9, Rev.0 addenda HC-1-9-1.

Samples included ASME Class 1 and 2.

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Results: No violations were identified.

Visual Examination:

Eighty-nine weldment and adjacent base material ( " either side of weld)

were visually inspected for weld reinforcement, rejectable visual

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indications, surface condition and overall workmanship per NRC procedure-

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NDE 14, Rev.0.

Results: No violations were identified, j

Magnetic Particle Examination:

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i Twenty-four safety related pipe weldments and adjacent base material-( " either side of weld) were methods examined by magnetic particle per

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NRC procedure NDE 6 Rev.0 addenda HC-1-6-1.

Samples included ASME class 1 and 2.

- Results: No violations were identified.

Utrasonic Examination:

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Two (2) safety related pipe weldments were examined using a Sonic Mark I ultrasonic flaw detector per NRC procedure NDE-Rev.0 and Southwest

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Research Institute procedure, SWRI-600-41-Rev.9. Weldments examined were

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identified on SWRI ultrasonic examination records as line 1-BC-18GBB-063A, 10-12 and 10-8.

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i Instrument Calibration was performed-using NRC procedure NDE-2,

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Instrument linearity verification. Distance Amplitude Correction (DAC)

was constructed using SWRI calibration block 18-CS-XS-500-22-HpC.

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Instrument settings and the search unit were matched as close as possible to those for the origin'al examinations in order to duplicate the original

examinations.

- Results: No violations were identified, i

t Hardness Measurements:

Twenty-three weldments and adjacent' base metal were checked for hardness

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using the Equo-tip hardness tester per NRC. procedure NDE-12, Rev.0.

' Hardness. numbers were converted to Brinnell values and approximate tensile

strength was determined by use of conversion tables.

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,Results: No violations were identified.

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Thickness Measurements:

i Fifty-oneweldmentsand'adjacentpipematerialwereexaminedtodetermine

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..mi.nimum wall thickness per NRC procedure NDE-11, Rev.0. Measurements were i

performed using a NOVA-D 100 thickness. gauge. Minimum wall thickness was determined by use of ASTM standard pipe size and nominal thickness chart.

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Results: No violations were identified.

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Ferrite Measurements:

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Nine pipe welds were checked for delta ferrite content using a Type II

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Ferrite Indicator _(Severn Gauge). This test was to verify that welding r

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. delta ferrite content adequate to eliminate possible hot cracking

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Results: No violations were 1dentified.

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3.

Radiographic Review

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A sampling of the licensee's radiographs were reviewed to verify compliance of the nondestructive examination program to.ASME III Code

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requirements. The inspector reviewed nineteen field welds and ninety-two

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j shop welds to verify the. accuracy of interpretation and the adequacy of i

the licensee's radiographic program. Also thirty-seven of the above welds were

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re-radiographed by-the NRC and these re-radiographed welds were compared i

_to site file films in order to irdependently verify the' correct radio-

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F graphic. file film was on hand. During this review the following shop i

welds required surface checks in order to resolve indications not properly j

documented on radiographic reader sheets.

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1-BE-050-512-D, 1-BD-003-508-G, 1-BE-022-504-A

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1-BE-066-501-F, 1-BC-075-509-0, - 1-BC-072-506-E

Results: Although no violations were identified, the following were

noted:

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During NRC review of radiographic film for weld 1-AP-003-502-H, the

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inspectors noted that the film contained an apparent indication which was

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not properly documented on the licensee's radiographic reader sheet.

In

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response to this finding, the licensee re-radiographed and properly

reviewed the film for this weld. The weld was found to be acceptable.

The inspector reviewed the radiographs and reader sheets and concurred

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with the licensee's data.

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The radiographic reader _ sheet for weld 'l-BC-072-505-233-0, dated'

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4 January 78, did not reflect the fact that~ film area.3-4 was radiographed

at_a different time, using a different technique than the remainder of the

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weld.

This item remains unresolved pending completion of the licensee's evaluation and NRC review (unresolved item 50-354/85-08-01).

4.

Followup On Items From A Previous Inspection The inspector reviewed previous NDE van inspection concerns, such as archive quality checks on radiographic film.

Review of documented records indicates archive quality checks have been performed.

The inspector requested a archive quality check to be performed. Different speed films were selected and the archive quality check of the fixer removal was satisfactory.

Radiographic procedure RT-HC-77-9-12-2 required two technical changes to address the use of non-standard RT techniques.

These changes were subsequently incorporated in the licensee's radiographic procedure revision RT-HC-77-9-12-3.

The inspector had no further concerns with the above items.

5.

Preservice Inspection (PSI) Program The inspection selected ultrasonic calibration block 14-CS-STD-375-16-HPC to verify that the right calibration block was used for weld examination.

He verified the dimension of the calibration block were adequate and that the dimensions were traceable to the National Bureau of Standards (NBS).

Material Certification and documentation of the calibration block was also verified.

The inspector also reviewed fourteen ultrasonic and magnetic particle data reports for the following welds: 1-AE-24DLA-035-1 thru 13 and 15.

No problems were found.

In the case of weld 1-AE-24DLA-035-6, Southwest Research Institute (SWRI) ultrasonic data record sheet 890027 indicated an examination limitation due to weld spatter. The UT record was accepted by all concerned. Southwest Research Institute procedure NQAP-13-1 requires customer notification (CNF) when an examination limitation is encountered. This should have been reported to the licensee and the weld spatter removed and the weld re-examined.

This matter remains unresolved pending completion of the licensee's evaluation to determine if it was an isolated case or indicative of a more widespread problem.

(unresolved 50-354/85-08-02)

6.

Review of NDE Procedures The following NDE procedures were reviewed to verify their technical adequacy and their conformance to Code requirements:

Branch Radiographic Lab Inc Magnetic Particle

- MT-HC-77-9-12-3

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Liquid Penetrant

- PT-HC-77-9-12-3 Radiography

- RT-(ASME)-HC-77-9-12-3 Southwest Research Institute Ultrasonic

- SWRI-NDT-600-41-Rev.9

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Magnetic Particle

- SWRI-NDT-300-1 Rev.23 Liquid Penetrant

- SWRI-NDT-200-1 Rev.55 Visual

- SWRI-NDT-900-7-Rev.3 Dravo Corporation i

Magnetic Particle

- ASME-III-MP Rev.7-Radiography

- ASME-III-RT Rev.0 Liquid Penetrant

- ASME-III-DP Rev.6

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Results: No violations were identified i

7.

Work Observation and Interview Two (2) ultrasonic technicians (SWRI) were interviewed and their work activities observed during pipe weld UT examination..This examination

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was part of site preservice examination as required by ASME Section XI.

The inspector noted that the ultrasonic examination was being performed

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by an ASNT-Level II examiner and recorded by an ASNT-Level I.

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j Results: No violations were identified.

8.

NDE Personnel Qualifications NDE qualification and certification records of six Branch Radiographic Laboratories (site NDE contractor) personnel, and six Southwest Research Institute (site preservice contractor) personnel were reviewed for compliance to SWT-TC-IA, ASME and ANSI-N45-2-9 criteria.

Branch

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personnel qualification records were found to contain several corrections which had been made using white out.

The inspector was satisfied that the changes made by white out were merely editorial in nature and not indicative of a problem with personnel qualifications. However, to address the inspector's concern, the licensee took corrective actions while the inspector was at the site which included:

a)

issuance of an interim letter dated April 26, 1985 to establish the appropriate method to correct quality records; j

b)

issuance of a revision to Branch Quality Manual QAM-2 Rev.0 to establish a uniform method of documenting how corrections are made

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to gaality related documentation.

(c) conduct of a 100% review of personnel records with all records containing white outs being retyped and signed.

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The inspector had no further concerns with this item.

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i 9.

Other Confirmatory Examinations 9.1 The following welds and spool pieces on drawing, FSK p-1-AB-616 Rev.6 were examined visually and by the dye penetrant method:

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LINE WELD NO SPOOL PIECE SIZE ASME CLASS

1-AB-075-DBA-2 FW 1 1-AB-616-2 2"

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1-AB-075-DBA-2 FW 2 1-AB-616-2 2"

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1-AB-075-DBA-2 FW 3 1-AB-616-2 2"

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1-AB-075-DBA-2 FW 4 1-AB-616-2 2"

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1-AB-075-DBA-2 FW 5 1-AB-616-2 2"

1-AB-075-DBA-2 FW 6 1-AB-616-2 2"

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j 1-AB-075-DBA-2 FW 7 1-AB-616-2 2"

4 1-AB-075-DBA-2 FW 8 1-AB-616-2 2"

1 1-AB-075-DBA-2 FW 9 1-AB-616-2 2"

1 1-AB-075-DBA-2 FW 11 1-AB-616-2 2"

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1-AB-075-DBA-2 FW 12 1-AB-616-2 2"

I l-1-AB-075-DBA-2 FW 14 1-AB-616-2 2"

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1-AB-075-DBA-2 FW 15 1-AB-616-2 2"

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i 1-AB-075-DBA-1 FW 23 1-AB-22c 1"

1-AB-075-DBA-1 Rd 24 1-AB-22a an 1"

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1-AB-075-DBA-1 FW 25 1-AB-225-5A 1"

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1-AB-075-DBA-1 FW 37 1-AB-225-5A 1"

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i 1-AB-075-DBA-1 FW 38 1-AB-225-5B 1"

The results of this examination found no apparent indications.

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9.2 The following weldments and spool pieces were visually inspected during

a walkdown inspection of approximately 560 feet of 28 inch diameter r

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LINE WELD NO.

SIZE ASME CLASS

' DRAWING

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003-DBC FW 4 28"

1-P-AB-01

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004-DBC N/A 28"

1-P-AB-01 001-DBC FW 4 28"

1-P-AB-01

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002-DBC

.N/A 28"

1-P-AB-01

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Thickness measurements were also taken at various spots on each spool

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piece.

In addition to the visual inspections, field welds FW 4 on line

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003-DBC and on FW 4 on line 001-DBC were magnetic particle examined.

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The results of these examinations were acceptable with no apparent indications.

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10 10. Attachments

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-Attachment No. 1 is a tabulation of the specific items examined and the

results achieved. Attachment No. 2 is a list of specific radiographs reviewed.

Attachment No. 3 is a list of specific document packages reviewed.

11. Unresolved Items

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An Unresolved Item is that for which more information is necessary for

. the NRC to determine whether the item is acceptab'ie or a violation or deviation. Unresolved Items are contais,ed in paragraphs 3 and 5.

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- 12. Exit Interview

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An exit interview was held on May' 3, 1985 with members of the licensee's

staff. -The inspector summarized the scope and findings of this

inspection. No written material was provided to the licensee during this inspection.

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