IR 05000443/1985019

Insp Rept 50-443/85-19 on 850701-26.No Violations Noted. Major Areas inspected:safety-related Piping,Structural & Support Weldments Fabricated to ASME Code,Section III, Classes 1-3 & Aws Code D1.1 Requirements

ML20132E863
Person / Time
Site:	Seabrook
Issue date:	09/03/1985
From:	Campbell R, Harris R, Kerch H, Wiggins J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I)
To:
Shared Package
ML20132E833	List: IR 05000443/1985019 ML20132E829
References
50-443-85-19, NUDOCS 8510010185
Download: ML20132E863 (24)

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U.S. NUCLEAR REGULATORY COMMISSION

REGION I

Report N Docket N License N CPPR-135 Priority -

Category C Licensee: Public Service of New Hampshire 1000 Elm Street Manchesi.er, New Hampshire 03105 Facility Name: .Seabrook Unit 1 Inspection At: Seabrook New Hampshire Inspection Conducted: July 1 thru 26, 1985 Inspectors:

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d o. k W. Khrch,' Lead ea'ctor Engineer 9 9

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DE Technician

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'M7 Camptpil, NDE Technician P/.2tlf[

da Approved by: l/ Ix4% ~ 3b f TTWiggfrjA Chief, Materials and ' date '

U ProcessMMection, DRS Inspection Summary: Inspection on July 1 Thru 26, 1985 (Inspection Report No. 50-443/85-19)

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, structural and support weldments fabricated to ASME Code,Section III, Classes 1, 2 and 3 and American Welding Society (AWS) Code D1.1 requirements were in-spected. Three regional based inspection personnel assisted by two contracted NDE personnel were utilized during this inspection. The inspection involved 497 onsite hours and 157 offsite hour Results: No violations were identifie yC BW 5000443 POR ADO PDR G

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DETAILS 1.0 Person's Contacted New Hamsshire Yankee (NHY)

• J. W. Singleton, Assistant QA Manager

• G. F. Mcdonald, Construction QA Manager

• J. G. Tefft, Start-up Engineer

• C, M. Wiley, Manager, Owners Construction Department

• J. A. Vail, PSI Start-up Coordinator

• J. Marchi, Site QC Manager

• B. Sanchez, Licensing Engineer #

• W. Middleton, QA Staff Engineer R. Anderson, Start-up Engineer Yankee Atomic Electric Company (YAEC)

R. A. Jeffrey, PSI Supervisor R. C. Julian, NDE Supervisor B. J. McNeal, Jr. , QA Inspector R. P. Grippardi, Asst. QA Manager R. White, QA Auditor P. A. Oikle, Audit Manager Pullman-Higgins Company (PH)

R. G. Davis, QA Manager D. Clark, NDE Supervisor

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U.S. Nuclear Regulatory Commission (US NRC)

J. M. Grant, Reactor Engineer r *R. S. Barkley, Reactor Engineer

• A. C. Cerne, Senior Resident Inspector

• 0. G. Ruscitto, Resident Inspector 2.0 Independent Measurements - NRC Nondestructive Examination and Quality Records Review of Safety Related Systems During the period July 1 through 12, 1985, quality records received from Seabrook Unit I were reviewed in the regional office for completeness and compliance to the licensee's FSAR commitments to applicable codes, stan-dards and specifications. Subsequently, an onsite independent verifica-tion inspection was conducted during the weeks of July 15, through July 26, 1985 using the NRC Mobile Nondestructive Examination (NDE) Laborator This inspection was conducted by region based personnel in conjunction with NRC contracted personne The-purpo'se of this examination was to verify the adequacy of the licensee's welding and nondestructive examination quality control pro-

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gram This examination was accomplished by duplicating as close as pos-sible those examinations required of the licensee and by then evaluating the results. In addition to the required examinations, several other con-firmatory examinations designed to verify conformance with material speci-fications were performed and compared to quality assurance record An NRC inspector made a random selection of shop and field weldments fabricated to AWS D1.1 and to ASME Class 1, 2 and 3 codes. These weldments were intended to provide a representative sample of piping systems, components, and pipe size. Fabrication of the items selected had been previously accepted by the licensee based on vendor shop and onsite QA/QC record .1 Quality Documents Review Fifty 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:

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Document Attributes Reviewed '

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Material Certifications Material chemical and physical properties J (Base) compared to standards and Code require- 1 ment NDE Records Examinations met codes and standards, licensee procedures and other commitment Personnel properly qualified. Appropriate examinations performe Fabrication Records A review of fabricator's traveler and fabrication record was performed and compared against other corresponding records and sign off sheet Drawings (isometrics) Drawings were reviewed for proper designation of weldments, location and classificatio Procedures Procedures were reviewed for completeness, and to verify the implementation of the

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licensee's commitments to Code requirement Welding Material Material certifications for welding materials were reviewed to determine if physical and chemical properties were as required by licensee's commitments to Code and Industry Standard .

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Results: No violations were identifie .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 examination The following examinations were performed:

Radiographic Examination Thirty-seven pipe weldments were radiographed using an Iridium-192 source per NRC procedure NDE-5-Rev.0 addenda SB-1-5- The weldments examined were ASME class 1, 2, and 3. The resulting radiographs were evaluated per applicable Code requirements and compared to the licensee's radiograph Results: No violations were identified.'

Socket Welds Twenty-four socket welds were visually examined and radiographed to ascertain minimum. gap required during-fit-up prior to weldin Results: No violations were identifie Penetrant Examination Thirty-two safety related pipe weldments and adjacent base material (h" either side of weld) were examined using liquid penetrant techniques per NRC procedure NDE-9, Rev. O addenda SB-1-9- Samples included ASME Class 1 and 2 weldment Results: No violations were identifie Visual Examination Sixty-eight weldments and adjacent base material (h" either side of weld)

were visually inspected for weld reinforcement, rejectable visual indications, surface condition and overall workmanship per NRC procedure l NDE 14, Rev. Results: No violations were identified.

Magnetic Particle Examination

' Twenty-three safety related pipe weldments and adjacent base material (h" either side of weld) were examined by the magnetic particle method per NRC

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procedure NDE 6 Rev. O addenda SB-1-6- Samples included ASME Class 1, 2, and 3 material Results: No violations were identifie Ultrasonic Examination Six ASME Class 1 austenitic stainless steel weldments were ultrasonically inspected using a Sonic Mark I ultrasonic flaw detecto Equipment calf-bration was performed per NRC procedure NDE-1 Rev. O and site procedure 80A6462 Rev. A distance amplitude curve (DAC) was constructed using Calibration Block Nos. SB-4-160-SS and SB-8-160-SS. Instrument settings, transducers and DAC were made to reflect as close as possible the original examination performed by site personne Five weldments examined could not be properly evaluated due to the dif-ferent transducers used by the site and the NRC. One weldment identified as RC-21-1 weld 7'was inspected and indications confirmed by the inspec-tor. Confirmed were two indications numbered 1 and 2 as geometric re-flectors due to the below described conditio Sometimes, because of grain growth in austenitic stainless steel-weld-ments, ultrasonic sound waves may be redirected along grain boundaries which act as a wave guide. To confirm that this condition resulted in the identified geometric reflectors, the NRC inspector placed the transducer on the weld crown to obtain maximum indication then turned the transducer 180 from the original directio .The same indication appeared, therefore, the inspector determined that

'the indications achieved using the above technique were generally consis-tent with difficulties that restit from the transmission of ultrasonic wares in austenitic material Results: No violations were identifie Hardness Measurements Eleven weldments and adjacent base metal were checked for hardness using the Equo-tip hardness tester per NRC procedure NDE-12, Rev. O. Hardness numbers were converted to Brinnell values and approximate tensile strength was determined by use of conversion table Results: No violations were identifie Thickness Measurements Forty-four weldments and adjacent pipe material were examined to determine minimum wall thickness per NRC procedure NDE-11, Rev. O. Measurements were performed using a NOVA-D 100 thickness gauge. Minimum wall thickness

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was determined by use of ASTM standard pipe size and nominal thickness char Results: No violations were identifie '

Ferrite Measurements Twenty-four pipe welds were checked for delta. ferrite content using a Type II Ferrite Indicator (Severn Gauge). This test was to verify that welding filler metal compositions achieved as deposited microstructures with delta ferrite content adequate to eliminate possible hot crackin Results: No v.iolations were identifie Alloy Analyzers Five stainless steel pipe welds and adjacent base materials were examined using a Texas Nuclear Alloy Analyzer. The alloy analyzer is capable of making selected quantitative and qualitative nondestructive analysis of metal alloys and verifying material type Results: No violations were identifie .3 Review of Procedures The following procedures were reviewed for compliance with NRC and industry Code requirements. They also provided the basic acceptance criteria and background information for this inspectio NONDESTRUCTIVE EXAMINATION PROCEDURES PULLMAN HIGGINS Magnetic Particle 1X-MT3-W77 Rev. 0 IX-MT4-AWS76 Rev. 03 1X-MT5-AWS77 Rev. 02 Liquid Penetrent IX-PT-1-W77 Rev. 07 1X-LP-3-AWS76 Rev. 02 Radiographic IX-RT-1-W77/R7-1 Rev. 07-IX-RT-6-W77 Rev. 03 IX-RT-7-AWS-76 Rev. 01 Ultrasonic IX-UT-1-W77 Rev. O Visual X 11 Rev. 03 In process X9 Rev. 15

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7 PERINI POWER Magnetic Particle MT-QCP- Rev. A DRAVO Magnetic Particle ASME-III-MP Rev. 06 Liquid Penetrent ASME-III-DP Rev. 05 Radiographic ASME-III RT Rev. 10 Ultrasonic ESM-UT-4 Rev. 01 ESM-UT-1 Rev. 06 Visual ES-VE-1 Rev. 01 Results: No violations were identifie .0 Radiographic Review A sampling of the licensee's radiographs were reviewed to verify compli-ance of.the nondestructive examination program to ASME III Code require-ments. The inspector reviewed seventeen field welds and one hundred, thirty-nine shop welds to verify the adequacy of the licensee's radio-graphic program. Also twenty-five welds were re-radiographed by the NRC and these radiographs were compared to site file films in order to inde-pendently verify the correct radioigraphic file film was on han Results: No violations were identifie .0 Preservice Inspection (PSI) Program During this inspection a review of PSI data was performed and the fol-lowing items were identified by the inspector as concerns:

(a) As reported by the site PSI contractor, weld surface preparations do not provide for ratisfactory transducer contac Example: see ul-trasonic data sheets 6462-61, 6462-62, 6462-76, 6462-72, 6422-74, 6462-63, 6462-7 _(b) Main reactor coolant cast elbow welds have not been ultrasonically examined and it was not clear as to what the licensee intended to do regarding these welds. No calibration block existed for the exami-nation of these cast elbows at the sit (c) The in.spector could not determine if the calibration block for the main reactor coolant piping welds (material ASME SA 376-TYP 304) met ASME Section XI requirement l l

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(d) Site PSI ultrasonic data did not cross-reference previous ultrasoni examinations of the same wel (e) Ultrasonic data for weld 1-RH-158-5-6 indicated a support obstruction and prevented full examination of this weld. A walkdown of this piping weld revealed no obstruction existe (f) A reverification of the as-built weld seam location on the reactor, using as built drawing 10873-161-003-03 was compared against the location shown on Nuclear Energy Service (NES) Preservice Inspection (PSI) document 80A6401 reactor weld seam location. A discrepancy of 45 was revealed as to the long seam locations for the reactor closure hea (g) A review of the PSI ultrasonic procedure for the reactor vessel revealed an inconsistency between site vessel procedures. For example, reactor-procedure 80A6483 references several documents and applicable drawings. However, the weld seam as-built drawing E-10873-161-003 Rev. 3 was not included within these reference Additionally, other PSI ultrasonic vessel procedures 80A6965, 80A6466 reference 80A6461, the general ultrasonic requirements and the PSI program, but neither weld seam as-built drawings nor any other ap-plicable drawings were listed in these procedure (h) Document YA-SB1S1-1 Rev. 2 states that the contractor will advise the Engineering Supervisor of interferences created by construction as they are determined. Notifications have been accomplished verball No formal system existed to assure customer notification for the

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report of limitations to the examinations, surface problems and ob-structions, as they are encountered in the field and subsequently referenced on the applicable ultrasonic examination report (1) Preservice Inspection Document 80A8984, page 12, Figure D-02, " System Line Nes.155 and 162 Weld and hanger Map" had erroneous elevation data for weld RH 155-5. The inspector reviewed site' con-trol drawing 9763-800155 Rev. 18 and observed that this drawing con-tained the correct informatio (j) Preservice Ultrasonic data sheet 6462-171 indicated that the site was experiencing difficulty in the ultrasonic examination of 6" diameter stainless steel welds. Also the valve sides of the 6" piping welds were not being examine It was not clear to the inspector as '

to what type of examination the licensee plans for these weld Results: The above items are considered unresolved pending licensee action and NRC review (UNR 50-443/85-19-01).

5.0 NDE Personnel Qualifications NDE qualification and certification records for seven Pullman Higgins (site NDE contractor) personnel, and_eight Nuclear Energy Service (site

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preservice contractor) personnel were reviewed for compliance to ASNT-TC-1A and ASME criteri The inspector noted that records for two Pullman Higgins corporate NDE level III personnel reflected .their NDE certification had expired. Pullman Higgins site personnel contacted their corporate office and a current copy of their NDE certifications were faxed to the site. The inspector reviewed the faxed copies and had no further concern with site NDE qualification and certification record Results: No violations were identifie .0 Other Confirmatory Examinations 6.1 Ultrasonic Examination (Anchor Bolts)

Fifty-six anchor bolts for installations in the Reactor Buildin Unit 1, Elevation O' level were randomly selected and ultrasonically examined for length using NRC Procedure NDE-18, Rev. Results: No violations were identifie .2 Visual Examination ("J" TUBE WELDMENTS)

The NRC inspector completed visual examinations on eight "J" Tube weldments replaced on Westinghouse Steam Generator "A", per Westinghouse visual procedure D11 Results: No violations were identifie .3 Confirmatory Coatings Inspection A confirmatory inspection was performed on the containment liner in the Reactor Building for coating thickness requirements. Readings were taken at three locations, ten readings at each location. The inspection was performed using site procedure, IP-103 Rev. O. A Zormco 2002 paint thickness gauge was used to perform the inspection utilizing the dry film thickness method (DFT). On average, the-results indicated thicknesses in the 15 to 25 mil rang Results: No violations were identifie .0 Attachments Attachment No. 1 is a tabulation of the specific items examined and the result Attachment No. 2 is a list of specific radiographs reviewe Attachment No. 3 is a list of specific documentation packages reviewe .

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8.0 Unresolved Items An Unresolved Item is that for which more information is necessary for the NRC to determine whether the item is acceptable or a violation or deviation. An unresolved item is contained in paragraph .0 Exit Interview An exit interview was held on July 26, 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 the course of inspectio .

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C - CRACK LF - LACK FUSION A - ARTIFACTS

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[T23-02-0006 lB-C l/l l l' l l l l l l l l l l l l 1 I I I I I I I I I I I I I I I I I IT23-02-0006 IC-D l/l l l l l l l l l l l l l l l l l l ! l l l l l l l l I l I l l l lT23-02-0006 lC-F l/l l l l l l [ t l l l l l l l l l l 1 1 I I I I I I I I I I I l1-RH-159-1-601-8-2 12408 l/l l l l l l l Dl Rl Al VI 01 l l l 1 I I I I I I I I I I I I I I I I I l1-RH-159-1-601-8-2 l2400 l/l l l l l l l l l l l l l l l l l l l l 1 1 I ! I I I I I I I I i l1-CS-360-1-2501-3-3 1831C .l / l l l l l l l l l l l l l l l l l l l l l 1 l l I I I I I I l l I l1-CS-360-1-2501-3-3 l8310 l/l l l l l l l l l l l l l l l 1 l l l l 1 I l I l i L l I l l i I l1-CS-360-1-2501-3-3 1831E l/l l l l l l l l l l l l l l l l 1 I I l i I I I I fll I l I i l Attachment #2

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l 1 1 I I I I I i 1 I I I I I I I l1-CS-360-1-2501-3-3 l831H I/l l j l l l l l l l l l l l l l 1 ~l i I I I l l I I I I I I I I I l1-CS-360-4-601-3-1 l832A i/l l l l l l l l l l l l l l l l 1 I I I I I I I I I I I I I I I l1-CS-360-4-601-3-1 l832B l/l l l l l l l l l l l l l l l l l l l I I I I I I I I I I I I I I l1-CS-360-4-601-3-1 18320 l/[ [ l l l l l l l 1 l l l l l l l 1 I I I I I I I I l I I I I I I l1-CS-360-4-601-3-1 l832E l/l l l l l l l l l l l l l l [

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C - CRACK LF - LACK FUSION A - ARTIFACTS

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l LINE N I WELD N I REVIEW I COMMENTS I l RC-49 l F103 l ACCEPT l ITEM # 1 l l l l s l~ I l SI-201 .l F0201 l ) l ITEM # 2 l l I I I I l SI-201 l SW-8 l l ITEM # 3 l l l l l 1 l SI-251 l F1202 l l ITEM # 4 l l l l 1 1 I l RC-13 l F0605 l / l ITEM # 5 l 1 I I l i I

.l RC-13 l SW-D l f l ITEM # 6 l l 1 1 1 1 I l RC-48 l F0401 l / l ITEM # 7 l l l 1 I I l l RC-48 l SW-F l l ITEM # 8 l l l 1 1 I l CS-365 l F0401 l l ITEM # 9 l 1 I I I I l RH-155 l F0601 l l ITEM # 10 l l l l [ l I l RH-155 l SW-J l \ l ~ ITEM # 11 l l l 1 \ l !

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1 1 I I l l CS-360 l- F0805 l l ITEM # 13 l l l I I I l CS-360 l SW- l l ITEM # 14 l l l l l l l- RC-121 l F0301 l -l ITEM # 15 l l l I I I l RC-121 l F0302 l l ITEM # 16 l l l l l l l RC-121 l SW-W l l ITEM # 17 l l 1 1 I I l CC-742 l F013 l l ITEM # 18 l l l 1 I I

.l CC-742 l SW-E l l ITEM # 19 l l 1 1 I I l- CC-817 l F012 l l ITEM # 20 l l l l l . l l CC-798 l F0315 l l ITEM # 21 l l l l l 1 l CC-798- l F0516 l l ITEM # 22 l l l 1 l l l FW-4614 l F0201 l l ITEM # 23 l l 1 1 I I l FW-4614 l SW-B l l ITEM # 24 l l 1 l Y l l l .RH-155 l F0313 l ACCEPT l ITEM # 25 l l l 1 l l Attachment #3

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l LINE N I WELD N I REVIEW l COMMENTS I l SI-244 l F0203 l ACCEPT l ITEM # 26 l

'l l I \ l .I l CS-353 l F0104 l \ l ITEM # 27 l l 1 l \ l l l CS-465 l F0101 l

l ITEM # 28 l l l l l l l CS-0541 l F0921 l s l ITEM # 29 l l l l I I l DG-4419 l F0307 l l ITEM # 30 l

.I l l I l l DG-4421 l F0406 l j l ~ ITEM # 31 l-l l i I l l l DG-4405 F0113 ITEM # 32 l l f l l l 1 I l l I l RH-160 l F0408 l / l ITEM # 33 l l l 1 I I I l RH-160 l SW-F l / l ITEM # 34 l 1 I I I I l l RH-160 l SW-E l f

l ITEM # 35 l l l l l 1 l .RH-159 l SW-E l l ITEM # 36 l l- I l I I l RH-159 l SW-F l [ ITEM # 37 l l 1 l I _ _ __1

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l S L-X13-01 l F0101 l [ l ITEM # 38 l l l . I \ l l l SL-X35-01 l F011 l \ l ITEM # 39 l l l 1 \ l I l SI-248 l F0107 l \ l ITEM # 40 l l l l T l l l- MS-4000 l F0502 l t l ITEM # 41 l

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l l 1 I l l MS-4000 l SW-F l ( l ITEM # 42 l l l l \ l l l FW-4609 l F1802 l 1 l ITEM # 43 l l 1 I I I l FW-4609 l SW-C l l ITEM # 44 1 I I I I RH-158 l F0301 l l ITEM # 45 l l l l l l l RH-158 l SW-D l l ITEM # 46 l l l l l l l 3C2998 l BM3C2998 l l ITEM # 47 l l l l l l l 40168B l BM4D168B l l ITEM # 48 l l l l 1 l l 203-RM-9 FILLET WELDS l ITEM # 49 l l M/S-1808-RG-02 l FILLET WELDS l ACCEPT l ITEM # 50 l l 1 I I I Attachment #3

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