ML20054C193
| ML20054C193 | |
| Person / Time | |
|---|---|
| Site: | Beaver Valley |
| Issue date: | 04/02/1982 |
| From: | Durr J, Mcbrearty R, Reynolds S, Lester Tripp, Walton G NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML20054C186 | List: |
| References | |
| 50-412-82-01, 50-412-82-1, NUDOCS 8204200223 | |
| Download: ML20054C193 (10) | |
See also: IR 05000412/1982004
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U.S. NUCLEAR REGULATORY COMMISSION
REGION I
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Report No.
50-412/82-01
Docket No.
50-412
License No.
CPPR-105
Priority
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Category
A
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Licensee:
Duquesne Light Company
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Robinson Plaza Building No. 2
Suite #210, PA Route 60
Pittsburgh, PA 15205
Facility Name: Beaver Valley Power Station, Unit 2
Inspection at: Shippingport, Pennsylvania
Inspection conduc ed: J nuary 2,1982 to February 26, 1982
Inspectors:
. [ #MV)
2/7' 2 -
. A. Waltdn, Senior Resident Inspector
'da'te signed
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WNYsdbw
4/2//
/;> S. Reyno'lds, Reactor Inspector
date signed
YkbOw
f/2/ &
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6L R
A. McBrearty, Reactor Inspector
date signed
4.6I
d'a#e signed
dd' , DurrQ,7Sr. Resident Inspector - Limerick
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Approved by:
$. h
N
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E. Trlip, Chief, Projects Section 2A
'date signed
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Inspection Summary:
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Inspection on January 2 - February 26, 1982 (Report No. 50-412/82-01)
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Areas Inspected:
Routine, announced inspection by two regional based inspectors
and two resident inspectors of piping installation, storage and direct
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inspection effort by the NRC Mobile NDE Laboratory.
The direct inspection
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effort was performed using NRC contractor personnel. The inspection involved
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668 hours0.00773 days <br />0.186 hours <br />0.0011 weeks <br />2.54174e-4 months <br /> onsite,
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Results: Of the three areas inspected, two violations were identified in one area;
(1) Failure to achieve proper weld control, (2) Failure to assure
control of delta-ferrite in stainless steel welds.
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B204200223 820405
PDR ADOCK 05000412
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DETAILS
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1.
Persons Contacted
Duquesne Light Company
M. L. Carpenter, Construction Engineering - Welding
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- R.
Coupland, Director, Quality Control
- H.
N. Crooks, Assistant Director, Quality Control
- C. R. Davis, Director, Quality Assurance
- C, E. Ewing, Manager, Quality Assurance
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- W. H. Glidden, Senior QA Engineer
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R. M. Kight, Senior Project Engineer
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- E. F. Kurtz, Director, Nuclear Safety and Licensing
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- G. B. Maksin, NDE Supervisor
- G. W. Martin, SQC NDE Level III
Stone and Webster (S&W)
S. T. Adams, Superintendent of Construction
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- C. R. Bishop, Resident Manager
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- M. Damiana, Construction Specialist
- K. G. Fellers, Assistant Superintendent
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R. D. Harris, Material Engineer
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- A. McIntyre, S.E.O.
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- P. Rayfercar, Project Engineer
D. J. Weatrak, Safety Supervisor
Power Piping Company
H. Good, Q.A. Manager
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- L. E. Tripp, Chief, M&PS, EIB
- R. A. McBrearty, Reactor Inspector
- Denotes those present at the exit interview held on February 26, 1982.
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2.
Licensee Action on Previous Inspection Items-
(Closed) Construction Deficiency Report (79-00-05);
(Closed) Construction Deficiency Report (80-00-03);
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(Closed) Part 21 Report (80-88-03)
a.
On December 7,1979 the licensee reported a significant deficiency
(79-00-05) in accordance with 10 CFR 50.55(e), that linear
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indications had been identified in the skirt to base flange weld of
the neutron shield tank.
This information was confirmed by letter
from the licensee dated January 4,1980 and was also reported to IE
Region IV by the vendor in accordance with 10 CFR 21 (80-88-03).
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On July 17, 1980 the licensee reported a second significant deficiency
(80-00-03) for linear indications found by magnetic particle examination
of a weld connecting a gib gusset to the reactor vessel support
structure top plate of the neutron shield tank.
On December 12, 1980 the licensee reported by " Interim Report Number
3," the decision to have the repair work performed offsite. The
facility selected was the Babcock & Wilcox Company, Mt. Vernon,
The neutron shield tank was built at Newport News Industrial
Corporation to the requirements of ASME Section VIII, Division 1.
After arrival onsite, visual inspection performed by the licensee
revealed weld overlap at the toe of certain welds which was ultimately
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removed by grinding to a depth of 1/2 inch.
Repairs were made
onsite of the defective weld which is behind 1-3/4 inch thick
reinforcing gusset plates located every 9 inches along the length of
the weld. An analysis made by the licensee and reported to the NRC
on June 16, 1980 discussed their justification for leaving the defects
behind the gusset plates in the skirt to base flange weld.
Further
inspection of other welds by the licensee disclosed extensive
rejectable defects in the welds connecting the gib gusset to the
reactor vessel support structure top plate. A program for replacement
of all forty gib and gib gussets was initiated and repairs are now
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complete.
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In addition, extensive additional nondestructive tests were performed
on the repaired welds and other welds to assure other defective
areas did not exist.
The following additional tests were performed.
(1)
100 percent of all. accessible welds were magnetic particle
inspected after the final post weld heat treatment.
(2)
100 percent ultrasonic examination of the bottom skirt to base
flange weld and approximately 5 percent of all welds previously
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UT inspected by the vendor.
(3)
100 percent review of all radiographic film generated by the
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vendor was made by the licensee.
This review produced 27 films
that were difficult to interpret.
These areas were
re-radiographed and repaired where necessary.
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The NRC inspector reviewed the metallurgical information contained
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in licensee's " Final Report on Weld Discrepancies in Reactor Vessel
Structural Supports (Neutron Shield Tank) at BV 2" forwarded to the
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NRC on 6/16/80. The report indicates that the gussets change the
load path such that the area of concern is not in the load path,
there are negligible load cycles in the fatigue life of the unit,
the lowest service temperature is +60 F (more probably 75 F), the
LOF defects are bounded by E7018 deposits at their terminal ends and
normalized and PWHT SA 516, grade 70 for the remainder of the defect.
Review of Newport News Shipbuilding PQR P01.4-3N(M-445) dated 12/16/77
indicates that the weld metal and base metal HAZ toughness properties
(tested at -30 F) meet the requirements of the applicable edition of
Review of NUREG 0577 indicates that the expected
NDT of a normalized and PWHT C-Mn steel of the SA 516 type is 60 F
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below the lowest service temperature.
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No violations were identified.
The inspector had no further questions
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in this matter.
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b.
(1) (Closed) IE Bulletin 79-3A
It has been determined that no systems which use SA 312, Type
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300 series pipe are subject to design stresses greater than 85
percent of the code allowable stress at the system design
temperature and pressure.
(2) (Closed) IE Bulletin 80-21
It has been determined that no valve components manufactured by
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Malcolm Foundry Company, Inc., were supplied to_ Beaver Valley
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Unit 2.
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(3) (Closed) IE Bulletin 80-23
It has been determined that no Valcor valves were supplied to
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Beaver Valley Unit 2.
3.
Unresolved Items
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During this inspection period, four unresolved items were found.
Listed
below are the items and basis for being unresolved.
a.
Dent In Service Water Line
(1) The inspector noted several dents in a 24 inch service water
line 2-SWS-66-2 located in the Safeguards Building at elevation
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730.
It was supplied by Power Piping in compliance with ASME
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Section III, Class 3.
The dents were dispositioned as acceptable on Nonconformance
and Disposition (N&D) number 6450.
The inspector questioned the acceptance of this condition based
on a visual inspection of the dented a-
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The licensee has
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agreed to re-measure the suspect areas, get exact readings, and
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if any significant differences are found perform a finite
analysis on the areas. This is unresolved (82-01-02).
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(2) The inspector asked for a recheck of the measurements for the
ovality acceptance on the same dents described above. The
original data from Power Piping showed a 3.89 percent maximum
ovality. Maximum allowed ovality is 8 percent. A recheck
performed February 25, 1982 by Power Piping inspectors showed
5.2. percent ovality on the same area.
It was explained that
the measurement techniques would account for these changes.
However, if measurements can vary by 1.3 percent, a 7 percent
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ovality could exceed 8 percent. The licensee agreed and has
committed to recheck those which exceed the condition found on
2-SWS-66-2.
This is unresolved (82-01-03).
b.
Heating, Ventilating and Air Conditioning System, (HVAC)
On January 6, 1982 the inspector found cracked tack welds on two
uninstalled HVAC ducts, number 773-45-13, piece 1 and 1A. The ducts
are category 1 and are part of the leak collection filtration
system. The cracked tack welds were made on square butt joints of
galvanized 10 gauge sheet metal.
A review of weld procedure SPBV-200 only addresses tack welds which
are to be incorporated into the final weld. The inspector was
informed that the tack welds in question were used for temporary
erection purposes to handle the sheet metal. They stated that all
tack welds would be removed prior to welding.
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The practice of using tack welds for temp'rary alignment is rot
covered in weld procedure SPBV-200 and no provisions are made to
assure removal.
This item is unresolved until procedure changes are
made to SPBV-200 which addresses temporary tacks and their removal
(82-01-05).
c.
Marks on Outside of Class 1 Pipe
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When the independent examination was performed on a 6 inch pipe,
SIS-269-2, surface damage was noted on the outside surface which
appeared to be caused by handling.
To determine acceptance of the
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condition, the licensee performed depth measurements, acid etch for
ferrite contamination, light grinding to remove contamination, and
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thickness examination to assure minimum wall.
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No surface examination has yet been performed after the grinding and
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no cause for the damage was found.
This item is unresolved pending
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review of the surface examination report and further observations of
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other pipe and handling practices (82-01-06).
4.
Welding - Inadequate Taper
Service water system, Class 3 piping field weld number 25WS-066-F08 was
inspected with respect to requirements of NB 4000,Section III of the
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ASME B&PV Code, 1971 Edition through Winter 1972 Addenda.
Section III
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provides acceptance limits for butt weld alignment and acceptable slopes
for unequal I.D. and 0.D. conditions.
ASME Section III requires that any allowable offset have a minimum 3 to 1
taper over the width of the finished weld.
The inspector's examination of weld 2 SWS-066-F08 revealed that the
required minimum 3 to 1 taper was not provided over the width of the
weld.
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This is a violation (82-01-01).
5.
Delta-Ferrite in Stainless Steel Welds
The inspector reviewed Power Piping Company specification N-1141-P-1,
revision 3, dated October 20, 1974, Delta Ferrite Control of Austenitic
Stainless Steel Welding, with respect to Regulatory Guide 1.31, revision
1 and Duquesne Light Company specification 2 BVS-58, dated December 31,
1973.
Revision 3 of N-1141-P-1 was approved on January 27, 1975 by Stone
& Webster for use at Beaver Valley, Unit 2.
Compliance with revision 1
of the Regulatory Guide is required by the licensee's specification.
The inspector found that N-1141-P-1, revision 3, permits less than 1
percent delta-ferrite in production welds.
This does not agree with the
Regulatory Guide which requires a minimum of 3 percent delta-ferrite in
production welds.
This is considered a violation (82-01-04).
6.
Acceptable Items
a.
In-Plant Storage
During a walk-through inspection of the service building, the inspector
observed electrical panels which were uncovered.
There was no work
being performed on the panels and it appeared to the inspector that
they should have been protected to prevent dirt and debris from
entering the panels.
Further inquiry by the inspector found that
Specification 2 BVS-981 and SQC-5.2 " Storage Inspection Program" and
SQC 1P-5.2.1 " Storage Inspection" was written to cover equipment
in yard storage but did not clearly address in plant storage.
The licensee agreed to revise the procedure to be more specific in
addressing in plant storage inspection requirements, and issued a
revision dated 1-19-82 to Inspection Plan IP-5.2.1.
This revision
was reviewed by the inspector and found acceptable.
In addition,
the electrical paneh described above were cleaned, openings sealed,
and placed on a monthly inspection program. The inspector had no
further questions in this area.
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b.
Nonconformance and Disposition Report N&D
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The inspector performed detailed review of N&D's 6203A and 6200 to
ascertain compliance with commitments and code requirements. A
review of engineering disposition was also made. No violations were
identified.
c.
Nondestructive Examination Procedures
The inspector audited the below listed nondestructive examination
procedures to ascertain compliance with ASME, B&PV Code Section III,
Winter 72 Addenda.
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(1) MT-10
Magnetic Particle Examination, Revision dated 9-23-80.
(2) MT-ll
Magnetic Particle Examination, Revision dated 10-17-80
(3) PT-10
Solvent Removable Visible Dye, Revision dated 12-02-80
(4) RT-4
Radiographic Film Processing, Revision dated 2-15-82
(5) RT-10
Radiographic Examination, Revision dated 9-23-80
(6)
UT-2, 3, 6 UT Thickness, Revision dated 1-25-82
No violations were identified.
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7.
Site Tour
Routine tours of the site were made to observe the status of work and
construction activities in progress. Work items were examined for
defects or noncompliance with regulatory requirements.
No violations were identified.
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8.
Independent Measurements - Independent Inspection of Fabrication / Construction
Quality and Verification of Licensee's Nondestructive Examination (NDE) Records
This independent verification inspection was conducted February 16, 1982
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through February 26, 1982 using the Region I Mobile NDE Laboratory. This
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was the first inspection of this type to be done on a routine basis
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(i.e. , not as part of an investigative effort 'r as the result of allegations
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concerning quality).
The inspection was conducted by the NRC Senior Resident Inspector and one
Region I Reactor Inspector. The NDE was performed by two technicians
from Wisconsin Industrial Testing under the supervision of the NRC
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inspectors.
The selection of the inspection sample was made by the NRC inspectors and
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was intended to provide a representative sample of piping systems, components,
pipe sizes, materials, shop and field welds and Class 1, 2 and 3 welds.
All of the selected items were previously accepted by the licensee based
on vendor NDE records, or on-site NDE by licensee contractors.
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The examinations were performed using NRC detailed procedures and addenda
specifically written for compliance with the licensee's PSAR commitments
to the ASME Boiler and Pressure Vessel Code, 1971 Edition through Winter
1972 Addenda.
The intent was to duplicate, to the extent practicable,
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the techniques and methods of the original acceptance examinations.
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a.
Material Traceability
Twenty-five docunientation packages were reviewed for the following:
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Material certification records including weld wirei
NDE results.
Fabrication records - shop and field.
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Drawings
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The following examinations were performed:
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Radiography - Eighteen welds were radiographed using an
Iridium 192 source.
These included Class 1, 2 and 3 welds
fabricated from stainless steel and from carbon steel. -The
technique and evaluation of results was performed in accorrance
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with NRC procedure NDE-5, revision 0, and procedure addendum
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BV-2-5-2, revision 0.
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Magnetic Particle - Five welds were examined using a magnetic
yoke and the dry powder method.
The technique and evaluation of
results was performed in accordance with NRC procedure NDE-6,
revision 0.
The sample included restraints and Class 3 welds.
(Weld number CCP-326-9 weld A was examined by the magnetic
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particle method in lieu of the liquid penetrant method due to
the presence of paint on the test surface).
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Liquid Penetrant - Six welds were examined using the color
contrast, visible dye, solvent removable penetrant method.
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tehnique and evaluation of results was performed in accordance
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with NRC procedure NDE-9, revision 0, and procedure addendum
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BV-2-9-1, revision 0.
The sample included restraints and Class
1, 2 and 3 welds.
Thickness Measurements - Twenty-six areas were measured
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including welds and base materials using an ultrasonic digital
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readout instrument. ~The measurements were made in accordance
with NRC procedure NDE-11, revision 0.
The minimum wall
thickness was determined by using the pipe wall thickness
specified in the piping design tables minus the 12.5 percent
mill tolerance.
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Hardness Checks - Twenty-six areas (base materials adjacent
to welds) were checked using an Equo-Tip hardness tester in
accordance with NRC procedure NDE-12, revision 0.
Hardness
values were converted to Brinnell hardness and approximate
ultimate tensile strength by the use of conversi:n tables'.
Ferrite Measurements - Seventeen stainless steel welds were
measured using a Type II Ferrite Indicator (Severn Gauge).
Visual Examination
Twenty-two welds were examined for weld
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reinforcement.
Alloy Analysis - Fourteen areas of stainless steel base
material were examined for material composition using a Texas
Nuclear Alloy Analyzer.
The examination included material
identification and chemical analysis.
The results were
compared with vendor material certification records.
Thickness Measurements - Twenty-six areas were measured
including welds and base materials using an ultrasonic digital
readout instrument.
The measurements were made in accordance
with NRC procedure NDE-ll, revision 0.
The minimum wall
thickness was determined by using the pipe wall thickness
specified in the piping design tables minus the 12.5 percent
mill tolerance.
c.
Findings
Materials Traceability - All the requested documentation was
readily retrievable and was found to be complete.
Radiography - All areas were found acceptable and correlation
with original tests results was good.
Magnetic Particle - All areas were found acceptable and
correlation with original test results was good.
Lisuid Penetrant - All areas were found acceptable and
correlation with original test results was good.
Thickness Measurements - All areas equalled or exceeded the
minimum thickness requirements.
Hardness Checks - No unacceptable readings were found.
Ferrite Measurements - Good correlation with the original
results was found.
(See 82-01-04)
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Visual Examination - All examined weld reinforcements were
found to be acceptable.
A1_loy Analysis - All tests confirmed the material test report.
Chemistry analysis values were within 2 percent of the results
recorded on mill test reports.
9.
Unresolved Items
Unresolved items are matters about which more information is required to
ascertain whether they are acceptable items, items of noncompliance or
deviations.
Unresolved items identified during this inspection are
discussed in Paragraph 3.
10.
Exit Interviev
The inspectors met with licensee representatives (denoted in Paragraph 1)
at the conclusion of the inspection on February 26, 1982.
The inspectors
summarized the scope and findings of the inspection.