ML20085C276

Field Weld Radiography Review, Final Rept

ML20085C276
Person / Time
Site:	Seabrook
Issue date:	08/31/1991
From:	NUCLEAR ENERGY SERVICES, INC.
To:
Shared Package
ML20085C274	List: ML20085C271 ML20085C276
References
NUDOCS 9109040219
Download: ML20085C276 (15)

Text

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119.E l FINAL REPORT NES PROJECT 2007 FIELD WELD RADIOGRAPilY REVIEW AUGUST 1991 l

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l Nuclear Energy Services,inc. 44 Shelter Rock Road. Danbury, CT 06810 9109040219 910330 PDR ADOCK 05000443 l R PDR k _ _ __. ._ _

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l EXECUTIVE SUhth1ARY As pan of the New Hampshire Yankee (NHY) program to verify required radiographic records of f

field welds at the Seabrook Power Station, Nuclear Energy Services (NES) conducted an in <iepth I review of both the design requirements for radiography and the actual radiographic film and data i packages.

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These reviews were conducted in accordance with detailed procedures and subjected to multiple i checks to assure accuracy. The design packages were reviewed for the AShtE and B31.1 code i piping systems, AShiE Class 1 supports, AShtE vessel repairs and AShtE hietal Containment

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Welds made by Pullman-Higgins. During these reviews, field welds were identified and those i requiring radiography in accordance with code requirements were listed. The review involved  !

1 2,2% isometric piping drawings,454 support drawings and 21 vessel repairs. As pan of this work, t more than 6650 design change packages were reviewed for impact on the specified field welds or i the requirements forradiography. Th .eview enumerated 19,410 piping field welds and more than 11,359 support welds. Of these,2,669 required radiographic inspections in accordance with design f code requirements.

The film review was to determine which t.ield welds had completed radiographic packages in the k records vault and to verify the required acceptance approvals. During the review process,4,096 l weld packages were examined, which contained nearly 41,000 individual pieces of film. The data

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review involved 4 pieces of information on each film and 15 to 20 data entries for each package. [

Hence, over 235,000 data items were checked during the film review task.

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RESULTS: Of the 2,669 field welds which required radiographic inspection,4 sets of radiographs were found to be missing. One of these missing radiograph packages had been identified by NHY e in December,1990. All of the radiograph packages, which were revicwed by NES, had the required approvals. The administrative enurs noted during the review were corrected by NHY personnel.

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1. INTRODUCTION l

The Nuclear Regulatory Commission (NRC) and New Hampshire Yankee (NHY) nave conducted several studies of the programs and processes that assured the welding and nondestructive eumination processes at the Seabrook Station. In December,1990, NHY determined that one radiograph package for a field weld was missing from their records.

This was reported to the NRC and following subsequent communications and correspondence, the NRC requested NHY to:

1. Re-review the Seabrook as-built isometric drawings and identify all Pullman-Higgins field welds for which radiography was a requirement established by code (e.g., ASME, B31.D.

2. Determine whether New Hampshire Yankee has the required radiographs and RIRs for all welds identified by the above review, and whether those records attest to independent YAEC (Yankee Atomic Electric Company) determination of acceptability, if they do not, please explain why not.

3. Dunng the above review and determination,if any additionalincomplete records are noted, assess the individual and generic causes and safety implications, and take appropriate compensatory and/or corrective actions.

4. Report the results of this effort to the NRC within about one week of its completion, retaining auditable records of the effort on-site for reference.

NHY determined that the basic data review should be conducted by a qualified third party to assure independence of the process. Hence in early April,1991, Nuclear Energy Services (NES) was centracted to develop the basic information required in items 1 and 2 of the NRC's request. Dispositioning irregularities, determination of cause, corrective actions and reporting the results to the Commission were performed by NHY. The following sections detail the scope of NES' work, the process employed to perform the reviews, and the results.

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11. SCOPE OF WORK

!!.1 Using esisting NHY engineering records NES was to develop a list of field welds for ASS 1E Section ill pipirig systems: ASSIE Section 111.Clast I supports; AShtE Section Vill vessel base metal repairs; and ANSI B31.1 power piping systems, and to detenmne whether those field welds required radiography. The applicable codes are:

• American Society of hiechanical Engineer's (AShtE) Code,1977 Edition, Winter 1977 Addenda.

• American National Standards Institute ( ANSI),031.1 Power Piping Code, 1977 Edition, with addenda up to Winter 1977.

The bat.e engineering documents consisted of the:

• Piping and Instrumentation Drawings (P&!D) for each AShtE system and the listed isometric drawings

. AShtE Class I suppon drawings

. Code Data Repons for base metal repairs to AShtE Section VIII vessels

. Isometric drawings for B31.1 Power Piping

• Containment penetration drawings for the AShtE Section 111, htC Class in addition, NES was to review design change documents which are applicable to the above engineering data, but not yet incorporated in the base documents. These unincorporated change documents were l'"ad in the N-5 data repons and the Change Document Tracking (CDT) Syst. ..i. When necessary to revolve specific conditions, the field weld process sheet was to be reviewed.

The review was to be accomplished on a system basis and the applicable P&lD annotated to verify complete review of all system isometrics.

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. 112 5 For each base engineering document, NES was to record periment information on a Data Sheet. All field welds within the applicab!c code boundaries w ere to be listed, those specified as requinng radiographic inspection noted, and the code basis verified if no radiography w as required.

Design anomalies were to be submitted to NilY using the site Request for  :

Engineering Services (RES) procedure. N11Y was responsible for dispositions.

11 2 in the same system priority basis, NES was to develop a list of field weld radiographic packages which are stored in the N11Y records vault. The Radiograph Irispection Reports (RIR) were to be reviewed for proper approvals, particularly that of Yankee Atomic Electne Company for all accepted film. Peninent data from the RIR was to be recorded aad the individual radiographic film reviewed to venfy consistency with the RIR. This task did not involve any re-interpretation of the radiographic film.

Anomalies in the radiographic records were to be recorded using NHY's Corrective Action Request (CAR) system. NilY was responsible for resolving CAR's and providing a copy to NES for inclusion of the disposition in the data base. ,

11.3 The lists of welds requiring radiography (from 11.1 above) and the lists of welds with accepted radiographs (from 11.2 above) were to be compared. Any discrepancies were to be reported to NHY using the NHY Corrective Action Request. NHY was responsible for resolving these discrepancies and providing a written response to NTS.

Interim reports were to be submitted to NHY for each system companson or combination of systems where efficient. These reports contained copies of the weld lists, discrepancies, NES data sheets and the marked up P&lD.

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11.4 NES was to submit a final repon to NiiY, documenting the work performed.

11.5 The work was to be perfonned under MiY's Quality Assurance System. NES was to prepare procedures to control each phase of the work. These were approved by N1lY and ',1corporated in their records management system. As indicated above, discrepancies in the design or radiographic data were documented using the CAR or RES systems, and NiiY was responsible for determining the dispositions. NES was to incorporate the CAR or RES disposition in the accumulated data.

11.6 NiiY was responsible for preparing the licensee response to the NRC's .\tarch 19, 1991.'equest. The NilY response will use the pertinent parts of NES' report as the basis for the repon to the NRC. NiiY was responsible for assessing the individual and generic causes and safety implications for any anomalies, or deficiencies identified through the NES' efforts. N11Y was responsible for taking the appropriate compensatory and/or corrective actions associated with the anomalies or deficiencies. NiiY prepared copies of the design documents, including engineering changes, and assembled them into packages for NES, who remained responsible for verifying completeness.

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III. DESCRIITON OF WORK & RESULTS Ill.1 The NES Project $1anager and one Field Engineer arnved on site April 8,1991 to stan work. The first task was to prepare procedures for the conduct of the project.

Thase procedures were:

" Procedure for the Review of Radiographic Records", NES Procedure 83ASMI -

This procedure covered the activities of the Project Stanager which included the comparison of the list of welds for which radiographs exist with the list of welds for which radiography is required. It also prescribed the preparation of System Reports and a Final Repon, as well as integrating the activities under the other two procedures. Figure 1 provides a flow chart for the overall process.

" Procedure for the Review of Raulographs", NES Procedure 83ASM2 - This procedure covered the review of radiographs and the recording of data from both the reader sheets and the film.

" Procedure for the Review of Drrwings", NES Procedure 83ASM3 - This procedure covered the work of the Field Engineers in the review of drawings and outstanding change documents to develop a list of field w elds and their requirement for radiography.

111.2 The review of both the drawings and the radiographs was completed in an order such that systems with ASME Class I components were completed first, followed by systems with ASME Class 2 components and then systems with ash 1E Class 3 components. Next were ANSI B31.1 piping systems, suppons for ASME Class 1

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systems, ASME Section VIII vessels and finally ASME Section 111, Class MC penetrations.

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l DEVELOP WORK CONTROL

PROCEDURES REVIEW OF m

_ m REVIEW OF

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RADIOGRAPHS DRAWINGS 1

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DATA DATA OVER 4ECK i

1 SYSTEM LISTS 1

OF FIELD WELDS

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, II ir.m SYSTEM REPORTS

! M 1r FINAL

, REPORT t

FIGURE 1 j FLOW CliART J

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111.3 Radiographic Film Review To identify deld weld radiographs in the N1W Records Vault, NES signed out the boxes identified as containing neld weld film, and moved them to a review room set up with tables and film viewers for this purpose. The review of the udiographs was 1

accomplished by pulling a film package for one weld from the file and recording the following information from the reader sheet (RIR) on the NES data sheet: I

. Full weld identification  !

. Exposure date

. Applicable code

. Views and acceptance or rejection

. Approvals After recording the information from the RIR, each Glm was viewed and the data from the identification block, date exposed, and the station numbers were recorded on the data sheet. Since an average radiograph package contains 4-5 views and

, most were double loaded, there are usually 8-10 individual films in each package.

The film reviewer completed a findings box, signed and dated the data sheet. This process was completed for each film package.

Ftrquently, the weld package will contain multiple reader sheets and film sets due to repairs, reshoots or other causes. NES prepared a separate data sheet for each RIR and checked the film and RIR required approvals on each set.

l At the end of each day, the data sheets were turned over to the Project Manager w ho reviewed them for completeness and legibility, signed and dated each data sheet.

The field weld radiograph data was then input to a computer data base which assembled the list of welds for which radiographs exists and permitted compatison

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to the data developed during the drawing review task. Any missing information or discrepancies were reported to NilY using NilY Procedure 12720 " Corrective Action Request" Dunng the course of this activity, radiographs for 4.096 welds were reviev ed. This involved the viewing of approximately 41.000 pieces of illm and the recording of over 23$,000 pieces of infom1ation. As a resul: of this review,18 CAR's were generated by NES identifying potential weld record anomalies. These anomalies involve legibility of radiographic film data, minor data mismatches betw een the RIR and the radiographic film and questions regarding required approvals on RIR's. In addition for 2 welds, some of the views (3 of 4 for one and 1 of 2 for the other) were missing weld identification information contained in the " Identification block".

Resolution and corrective action for these conditions were handled by NHY.

111.4 Drawing Reviews The review of design documents to identifying field welds requiring radiography was perfomted by a team of NES Field Engineers. The following paragraphs desenbe the process for each set of welds.

A. hQing The review of ASME Section 111 piping was initiated by NHY assembling document packages. A document package contains the isometric drawing and any unincorporated change documents applicable to the drawing. The isometric drawing has extensive information on a section of a piping system, including identification of field welds, the NDE requirements and essential data to establish the type and size of the field weld. The unincorporated change documents contain changes to the system since the last revision to the isometric, and were determined 9-

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by listing those in the N-5 data packages, as w ell as those listed in the NHY Change Document Tracking System (CDT). The N-5 data repon is prepared by the ASME approved piping installer and verifies completion of code requirements. Later in the process, the list of piping isometrics for a system was checked by NES against the P&ID's to ensure that all line segments were included.

For ANSI B31.1 piping, the list of drawings to be reviewed was developed by NilY based on B31.1 code requirements, specifically; design temperature between 350'-

750*F, a design pressure over 1025 psi and a wall thickness over 3/4 inch.

Separately, all line segments with a design temperature over 750' were identified.

In addition to the piping welds, NES reviewed the drawings containing metal containment (ASME Section III, Class MC) welds performed by Pullman-Higgins.

These were identified by NilY fmm welding and film records.

In performing the drawing teviews, the Field Engineer would review each document package and complete the NES data sheet. The information recorded included the identification of the drawing, applicable code and a listing of field welds. Each field weld specified as requiring radiognphy was noted on the data sheet. Those that did not require iediography were also noted with the addition of the reason why radiography was not required. The reason for exempting radiography was based on the NDE requirements in the applicable code. These were contained in the Procedure for Review of Drawings. Change documents which effected the status of a weld were also noted on the data sheet. After completing a drawing package, the Field Engineer reviewed the data, signed and dated the sheet.

in the course of this task,2,206 drawing packages were reviewed. The review HEM identified 19,410 piping welds of which 2,650 required radiography. Seven Requests for Engineering Services (RES) were generated by NES and answered, providing guidance in the use of the NHY doeuraent system. Not alldrawing review issues were resolved for the Class 3 drawings since these welds do not require radiography by the code.

B. ASME Section 111 - Supports The review of supports was accomplished by NHY developing a list of all Class I supports from the N-5 data reports. Copies of the support drawi1gs were acquired from the document records including applicable unincorporated change documents  !

which were identified in the N-5 data reports. These drawings were reviewed and compared to code requirements in a similar manner as dons, for the piping drawings.

Those welds that required radiography were listed on the NES data sheets. 454 support drawings were reviewed, which contained approximately 11,350 field welds. Of these, only 8 welds were identified which requirrd radiography per the ASME code.

C, ASME Section VIII- Unfired Pressure Vessels For ASME Section Vill Unfired Pressure Vessels, since no fabrication or assembly was performed on site, only repairs to Section VIII vessels would involve field welding and potentially radiography. The drawings for twenty-one repair welds on these vessels were reviewed for radiography requirements. These welds were listed on the NES data sheets in the same manner as for the piping welds. One ressure vessel field weld was identified which required radiography.

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D. On a daily basis, the data sheets from the drawing review were turned over to the Project Nianager who reviewed them for completeness and legibility, signed and dated each data sheet. Data for each weld were entered into a data base on a system-by-system basis. The printout from this data base provides the list of field welris requiring radiography.

When a piping system was completed, the system P&lD's were highlighted to now each line segment that was reviewed during the drawing task. This was done as a check to insure that allline segments within t e AShiE Class 1,2 and 3 tvundanes had been reviewed.

111.5 With the drawing review and the radiographic film review completed for a system, a comparison of the list of welds developed in the two reviews was made from the computer data base. Lists were prepared using the several combinations of requirements and film identified.

The database weld lists were submitted to NHY in eleven interim reports, consisting of:

. 6 separate repons for the larger ASME Section III, Class 1 & 2 systems

• A combined interim repon for ANSI B31.1 Power Piping and the Main Steam (MS) and Feed Water (FW) ASME piping systems. Rese were combined because the MS and FW systems contain B31.1 piping as well as ASME Section ill Piping.

• An interim repon for 4 large ASME !!!, Class 3, systems which contained 2255 piping welds, but none requiring radiography since Class 3 was exempt by the code option selected by Seabrook's Construction Specification.

• A " miscellaneous" interim report covering 18 smaller systems.

• A repon on the ASME Section Vill, unfired pressure vessel field welds, a

A repon on the ASME Section Ill, Class I supports.

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Following review by NHY and conection of minor identitication errors, eight CAR's were generated by NES which identified potential radiograph deficiencies.

Engineenng and records review by NHY resolved most of these discrepancies; however,4 welds remain for which film was not located, namely:

1-CS-328-02, F0204 1-CS-360-08 F0801 1-CBS-1201-07, F0701 1-F1-188-01, F0150 In summary, NES identified 2,669 field welds which required radiography in accordance with the codes. Accepted radiographic film was available in the N11Y records vault for 2,665 of these field welds, the above listed 4 were not found.

Additionally,19,410 field welds were identified during the piping system review with only 13.7% requiring radiography. To establish the weld list, approxirnately 9,330 engineering drawings, isometries or change packages were reviewed. In the film review process, 4,096 radiographic packages were reviewed, containing approximately 41,000 separate pieces of film.

Ill.,6 Overchecks During the course of this project, overchecks were performed by the Project Manager or his designee. This was accomplished by taking approximately 5% of both the drawing and radiographic film paclages and completing data sheets for those packages in accordance with the appropriate procedure. These overcheck data sheets were then compared to the actual data sheets. Any differences noted were resolved and if required, the data sheets were corrected. Additionally, NES' Quality Assurance Manager performed an audit of the work on May 16 and 17,1991 to asstue that it was being performed in full compliance with the procedures. Since the oL .

0 task is being perfomied under NilY's Quality Assurance Program, NiiY has  !

conducted surveillances and independent checks of the work. The NiiY findings l

were provided to NES and have been incorporated in the work output.

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These many layers of overchecks were designed and implemented to proside a high level of confidence that the reponed results are accurate. NES is contident that we have provided a highly reliable product.

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