ML20041A173
| ML20041A173 | |
| Person / Time | |
|---|---|
| Site: | Limerick  |
| Issue date: | 01/18/1982 |
| From: | Durr J, Mccabe E NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML20041A170 | List: |
| References | |
| 50-352-81-17, 50-353-81-15, NUDOCS 8202190215 | |
| Download: ML20041A173 (8) | |
See also: IR 05000352/1981017
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U.S. NUCLEAR REGULATORY COMMISSION
OFFICE OF INSPECTION AND ENFORCEMENT
Region I
50-352/81-17
Report No. 50-353/81 15
50-352.'
Docket No.
50-353
CPPR-106
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License No.
CPPR-107
Priority
-
Category
A
Licensee:
Philadelphia Electric Company
2301 Market Street
Philadelphia, Pennsylvania 19101
Facility Name:
Limerick Generating Station. Unit Nos. 1 and 2
Inspection at:
Limerick, Pennsylvania
Inspection conducted: December 1,1981 - January 8,1982
Inspectors:
nAL)
/
r/s2
P. Durr~, Senior Resident Inspector
/ date/ sig~ned
.
date signed
date signed
Nb
Approved by: _
/ b8 IBZ
t.
L. Nctace, tniet, Keactor
date signed
Projects Section 2B
Inspection Summary: Report 50-352/81-17 and 50-353/81-15 performed on December 1, 1981
through January 8,1982.
Areas: A routine, unannounced inspection by the Senior Resident Inspector of pipe
welding, piping documentation, safety related structures, electrical separation,
plant tours, and licensee action on open items. The . inspection involved 64.5
inspector-hours at Unit 1 and 10 inspector-hours at Unit 2.
Results:
One violation was identified in the six areas examined (violation of
minimum pipe wall, para. 5 ).
Region I Form 12
(Rev. April 77)
8202190215 820204
PD9 ADOCK 05000352
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DETAILS
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Persons Contacted
Philadelphia Electric Company
D. T. Clohecy, Quality Assurance Engineer (QAE)
J. M. Corcoran, Field QA Branch Head
F. J. Coyle, QAE
M. J. McGill, QAE
G. J. Moffitt, Construction Engineer
P. K. Pavlides, Manager, QA
R. T. Scott, Lead Construction Engineer
Bechtel Power Corporation
G. D. Abbey, Subcontracts Engineer (SCE)
T. Altum, Assistant Project Field Engineer (APFE)
M. J. Baron, Lead Field Welding Engineer
R. D. Bryan, Project Field Superintendent
H. D. Foster, Project Field Quality Control Engineer (QCE)
H. E. Gilbert, Lead Mechanical QCE
J. J. Honer, SCE
G. C. Kelly, QAE
E. R. Klossin, Project QAE
D. F. Lerch, Long Term Maintenance Engineer
J. L. Martin, Lead Site QAE
A. Molinaro, Project Superintendent
.K. L. Quinter, Assistant Project Field QCE (APFQCE)
D. C. Thompson, APFQCE
Schneider, Inc.
T. M. Carroll, Project Manager
G. Heindrichs, Q.C. Manager
The above listed personnel attended exit interviews on December 10 or 23,
1981.
Other craftsmen, engineers, quality control technicians, and
supervisors were contacted and interviewed as the inspection interfaced
with their work.
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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
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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 wo,k with craftsmen, supervisors, and engineers to assure
work was being perfomed in accordance with requirements.
The inspector witnessed the vacuum box testing and magnetic particle
examination of the spacer to quencher weld FPGW-F on drawing C-263,
in Unit #1 containment.
He reviewed the procedures 25.A.2, Leak Testing
of Welds, and 3.21. A.3, Dry Particle Yoke Method, and verified that the
work was perfomed in accordance with the procedures.
Ventilation dampers BPD-203-38A and BPD-203-39A were observed to be
temporarily stored at elevation 217', area 16, without the proper coverings
to protect them from construction activities. Further investigation
disclosed that the licensee has a similar audit finding, Finding Reports
M-520 and M-536.
Corrective actions are being teken by the licensee and
will be examined during a future inspection. This item is unresolved
pending completion of the licensee's actions.
(352/81-17-01)
3.
Previous Inspection Findings
(Closed) Unresolved Item (352/76-07-4b)
The licensee stored carbon steel pipe spools outside without protective
covers. The storage practice was reviewed by NRR (Memorandum A. Schwencer
to R. Keimig, November 27,1981) and found to be acceptable.
This item
is closed.
(Closed) Unresolved Item (352/79-11-03)
The welding details for drawing C-956 were not adequately prescribed.
Full penetration groove welds were being made, in see cases, with a
fillet weld covering. The inspector viewed this as added reinforcement.
The licensee clarified the drawing by adding note 3, Revision 6, which
pemits fillet welds to be used in cabination with groove welds. This
is consistent with the AWS Code D 1.1, figure 2.9.1.b, note 3.
This item
is closed.
(Closed) Unresolved Item (352/79-11-04)
Welding rod fra GE-I&SE was found to be improperly stored. The licensee
had a similar finding the preceding day and initiated corrective actions.
The inspector reviewed a letter fr m Philadelphia Electric to GE-I&SE,
dated March 20, 1980, which documented the corrective actions. GE-I&SE
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has cmpleted their contract for the reactor pressure vessel nozzle safe
ends and left the site. This item is closed.
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(Closed) Unresolved Item (352/80-02-02)
There was a disparity in the quality documentation for pipe spools in
the recirculation loop. The documentation showed that the pipe spools
were fabricated in accordance with the ASME III Code, Summer 1978
edition; while the purchase order specified the Summer 1977 edition.
The inspector examined Revision 2 of the purchase order, 205-AL852
and found that the latest Revision specified ASME III Code, Winter 1977
edition.
However,10CFR50.55(a) pemits the use of ASME III Codes,1977
edition, including addenda through Summer 1979. This item is closed.
(Closed) Unresolved Item (352/81-05-01)
The inspector noted electronic trip units loosely secured in their panels.
No documentation was available to indicate that authorized work was perfomed.
The licensee has located infomation which indicates that these trip units
were removed and inspected as part of GE's Field Disposition Instruction
TNEJ and Field Deviation Disposition Request 1068. The licensee has
recalibrated the units and verified reinstallation. This item is closed.
(Closed) Unresolved Item (352/81-01-07)
The licensee used the calculated minimum pipe wall thickness on the welding
documents. This resulted in welders being assigned to weld pipe walls
beyond their qualified thickness range.
The licensee revised Job Rule
JR-G-16, paragraph 16.3.1, to require the field to make measurements of the
pipe wall when only the minimum wall thickness values are supplied. Further,
the licensee issued a Nonconfomance Report NCR4585, which identifies the
welders who welded beyond their qualified thickness range. This item is
closed.
(0 pen) Unresolved Item (352/81-16-01)
The castings for the main steam isolation valves do not appear to satisfy
the ASME Draft Pump and Valve Code. The issues involved and updated
information are summarized as follows:
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(1) The body castings appear to have exceeded the allowed heatup
and cooldown rates on heat treatment. Further review by the
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inspector disclosed that the heatup and cooldown rates for
postweld heat treatment do not apply to the materials manu-
facturer. This is supported by later editions of the ASME III
Code, paragraphs NB-2975.5. This item is resolved.
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(2) The welding procedure was not qualified for the post weld heat
treatment (PWHT) temperature.
The licensee has stated that
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there is reason to believe that a Procedure Qualification Record
exists which will support the PWHT used. This item remains
open.
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(3) Nondestructive testing was perfomed before heat treatment.
The licensee maintains that the 13400F' heat treatment was a
post weld heat treatment and not a tempering operation perfomed
under-the material specification. Documentation will be provided
to substantiate this position. This item remains open.
(4) Repair excavations were not nondestructively tested before
rewelding. The licensee presented documentation'which indicates
that nondestructive examinations were perfomed prior to rewelding
excavations. This_ item is resolved.,
(5) Repairs and heat treatments. were not performed sequentially
in accordance with the procedure. The licensee has presented
infomation which shows that the General Electric Company did not
approve the revision of the procedure supplied in the quality
documentation until circa 1973. This implies that an earlier
version of the procedure was being used at the time of the
casting manufacture.
The May 7,1971 revision states that, " Welding shall be performed
on castings which have been nomalized or nomalized and tempered."
The October 26, 1971 version states, in part, "have been nomalized
and tempered."
In addition, the Procedure Qualification Record, dated February 1,
1965, which supports the May 7,1971 version is not qualified
for the thickness ranges welded. The Procedure Qualification
Record was retested on October 26, 1971 to upgrade the thickness
range to 8 inches, which qualifies the welding on the casting.
This coincides with the date of the later procedure revision.
Furthermore, the May 7,1971 version limits post weld heat
treatment temperatures to 1300 F.
This item remains open.
(6) Because of the foregoing items, it appears there was a breakdown
in the quality assurance program. This item remains open
pending the resolution of the other items.
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(0 pen) Unresolved Item (352/81-16-02)
The high pressure coolant injection (HPCI) turbine manual specifies a
levelness of 2 mils per foot. This levelness value was established
after the turbine was installed. The licensee presented a telephone
conversation report with the nuclear steam system supplier which
indicates that they feel the 2 mils per foot is not a requirement.
This has not been verified with the turbine manufacturer. This item
remains unresolved pending verification by the turbine manufacturer.
(Closed) Construction Deficiency Report (352/80-00-03)
An improper application of brass lock washers allowed the loosening
of operating linkage nuts on 4 KV switchgear. Testing revealed a design
deficiency within the linkage itself and corrective actions consisted of
replacing the linkage. The inspector reviewed the completed Nonconformance
Report, No. 4143, which documented the repairs and the PEC0 Audit Report,
No. E-088 which verified the corrective actions.
He discussed the repairs
with the responsible inspector and examined a completed installation.
This item is closed.
(0 pen) Construction Deficiency Report (352 and 353/80-00-04)
The mounting feet of the emergency diesel generator heat exchangers were
not properly mating on the outer edges. This invalidated the seismic
analysis. The repair consisted of inserting shims to compensate for the gap
and welding the shims in place. The inspector reviewed Nonconformance
Report, No. 4308, which directed the repairs and examined the 4 Unit No. 1-
heat exchangers that are installed. He noted that the shim packs were
added to the outer edges of the heat exchanger feet to correct for gaps at
those locations.
However, . in doing so, gaps have been introduced between
the bolts. The licensee has been asked to verify that this was the intent
of the modification. This item remains open.
(0 pen) Part 21 Report (H06000516)
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Bergen Patterson reported potential interferences between the strut assembly
and certain models of Pacific Scientific shock arrestors. This was reported
in IE Circular No. 79-25.
The licensee has listed the circular in his
computer tracking system and currently shows this item open.
The inspector examined site documentation for the status of corrective actions
and found the following:
(1) Quality Control inspected the equipment in the warehouse.
The problem only manifests itself when the equipment is
assembled and installed.
(2) Subsequent to the inspection, engineering issued a Field
Material Requisition to return the equipment to the
manufacturer for modification. Quality Control was unaware
of these actions. Further, the current status of the modi-
fication could not be readily ascertained. This was the result
of not tracking the activity in a fonnal document system.
This item remains open pending completion of the modification.
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4.
Containment Structural Steel Welding
Recirculation pump restraint, B32-G003-Cl.7, and ventilation cooler supports,
1BV212 and 1FV212, were selected for welding document review and weld
examination. The document review verified welding, nondestructive testing
(where applicable), and inspection activities. The weld examination
consisted of visual and dimensional checks of the welds and structural
components.
It was noted during the review of Quality Control Inspection Record
C-1415-W-1 that hold point inspections of full penetration groove weld
preheat and interpass temperatures, paragraph 2.4.a, had not been performed.
The affected welds are C-1415, FPGW 17-19, 32, 33, 36-38, and 43-47.
This item is unresolved pending verification of weld oint status and a
detennination for the cause of omission (352/81-17-02
Further, during the inspection of support 1BV212, it was noted that a
column base plate to tube steel weld was only made on three sides.' The
drawing required welding on four sides. The drawing series had an FCR
for a similar weld which allowed welding on three sides but it did not
reference this particular detail. The licensee issued FCR C8934F which
corrected this deficiency. Also, detail 6 was missing a weld size symbol.
This was identified on PEC0 Finding Report N-296.
The inspector had no further questions concerning these matters.
5.
Reactor Coolant Pressure Boundary Piping
The accessible portions of the high pressure coolant injection (HPCI) steam
supply line and the core spray (CS) cooling line were selected for a
"walkdown" inspection. The HPCI piping examined is depicted on isometric
drawings DBA-106-1 and DBA-106-2. The CS piping is shown on isometric
drawing DCA-319-1. The inspection verified the location and configuration
of the piping and welds, rough measurements of design lengths were made,
and surface appearance of the pipe and welds was examined.
What appeared to be seams were identified in the flow element, serial
number 50517-1, located in the HPCI steam line. The applicable material
specification SA-1068 permits seams up to 5% of the wall thickness, in this
case .029".
The seams were measured to be less than 1/32" and acceptable.
A ground area was noted on HPCI pipe spool DBA-106-1.
Ultrasonic pipe wall
measurements determined the pipe wall to be approximately .500" thick in
the ground area. The material specification SA-106B, paragraph 18.3,
pennits wall thinning up to 12.5% of the nominal value. The Bechtel
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Specification, P-300, requires schedule 80 pipe to be used for 10"
diameter "DBA" class pipe. Specification SA-106, table A2, for .593"
nominal wall pipe permits a minimum thickness of .519".
The failure of
pipe spool DBA-106-1 to meet minimum wall requirements is a violation of
(352/81-17-03)
The inspector selected eight additional pipe spools, varied by system,
size, and pipe class, for ultrasonic pipe wall thickness measurement. The
following pipe spools were examined:
PIPE SPOOL
SIZE
SYSTEM
GBC-101-7
12"
Main steam relief
DLA-108-1-5
12"
DLA-108-1-1
20"
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DLA-ll2-3-3
12"
DLA-107-1
12"
DLA-112-1
12"
EBB-129-1-6
14"
HPCI pump discharge
GBB-101-1-4
18"
No further violations were identified.
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 equipuent; 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
BWRPD-lRECl-WB41
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RHR Supply
F, R
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WB33
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RHR Return
F,R,C
WB3
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Recirc Valve
D
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"
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WA6
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Recirc Pump
D
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"
WBil
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Header Riser
D
"
1MSl WC2
I
D
"
"
WC15
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HPCI Connection
D
Status Code: F - fitup, R - root pass, C - cover pass, D - document review
No violations were identified.
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