ML20134E523
| ML20134E523 | |
| Person / Time | |
|---|---|
| Site: | Millstone  |
| Issue date: | 08/05/1985 |
| From: | Campbell R, Harris R, Kerch H, Wiggins J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML20134E493 | List: |
| References | |
| 50-423-85-22, NUDOCS 8508200303 | |
| Download: ML20134E523 (24) | |
See also: IR 05000423/1985022
Text
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U.S. NUCLEAR REGULATORY COMMISSION
REGION I
Report No.
50-423/85-22
Docket No.
50-423
License No.
CPPR-113
Priority --
Category C
Licensee:
Northeast Nuclear Energy Company
P. O. Box 270
Hartford, Connecticut 06101
Facility Name: Millstone Unit 3
Inspection At: Waterford, Connecticut
Inspection Conducted: May 20 - June 14, 1985
Inspectors:
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Harry W. Terch,
'.ead Reactor Engineer
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Ri
ard H. Harris, NDE Techniciao
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RandyM.jampbell,NDETechnician
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Approved by:
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Jame)[ialsandT. Niggi .
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Mat r
'ocesses Section
Inspection Summary:
Inspection on May 20 - June 14, 1985 (Report No. 50-423/85-22)
Areas Inspected: A routine, announced, NRC independent measurements inspection
conducted at the utility construction site using the NRC Mobile Nondestructive
Examination (NDE) laboratory consisting of examinations of selected safety
related piping, fabricated to ASME Code,Section III, Classes 1, 2 and 3.
Three regional based inspection personnel assisted by two contracted NDE
personnel were utilized during this inspection.
The inspection involved 440
onsite hours and 135 hours0.00156 days <br />0.0375 hours <br />2.232143e-4 weeks <br />5.13675e-5 months <br /> in the Region I office.
Results: One violation was identified concerning unacceptable radiographic
indications (Paragraph 2.2) and one violation was identified concerning control
of unique identification No. and drawing changes.
(Paragraph 2.2)
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DETAILS
1.
Persons Contacted
NUSC0/NNECO
R. E. Busch, Project Manager
J. O. Crockett, MP3 Unit Superintendent
K. W. Gray, Jr. , Staff Assistant, NCQA
E. J. LaWare, Engineering Technologist
R. E. Lefebvre, Senior Engineer
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D. M. Miller, Jr. , Startup Manager
L. J. Nadeau, Assistant Project Engineer
S. Orefice, Project Engineer
E. J. Peckham, CQA Specialist
R. W. Pritchard, PSI Project Engineer
S. L. Sikorski, NDE Level III
A. J. Silvia, Senior Engineer, Welding
W. R. Sullivan, Startup Engineer
Stone & Webster
M. R. Matthews, Assistant Superintendent, FQC
L. Peterson, Senior Engineer, FQC
L. D. Nace, Project Manager
R. J. Rudis, EA Program Manager
R. J. Scannell, QA Program Administrator
C. B. Sprouse, Supt. of Construction
G. G. Turner, Resident FQC Manager
W. H. Vos, Senior Engineer, FQC
NRC
4
M. Gaudino, Reactor Engineer
R. H. Harris, Engineering Tech
H. W. Kerch, Reactor Engineer
A. Kortas, Reactor Engineer
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T. Rebelowski, Senior Resident Inspector
R. J. Summers, Project Engineer
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1
J. T. Wiggins, Section Chief, Materials & Processes
2.
Independent Measurements - NRC Nondestructive Examination
and Quality Records Review of Safety Related Systems
'
During the period May 20 through 31, 1985, quality records received from
Millstone Nuclear Plant were reviewed in the regional office for complete-
ness and compliance to the licensee's FSAR commitments, applicable codes,
standards and specifications. Subsequently, an on-site independent
verification inspection was conducted during the weeks of
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June 3 through June 14, 1985, using the NRC Mobile Nondestructive
Examination (NDE) Laboratory. This inspection was conducted by
Regionally 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
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I
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 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 licensee, based on
vendor shop and on site QA/QC records.
2.1 Quality Documents Review
Forty 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 commit-
ments.
Personnel properly qualified.
Appropriate examinations performed.
Fabrication Records
A review of fabricator's traveler and
fabrication records was performed and
compared against other corresponding
records and sign off sheets.
Drawings (isometrics)
Drawings were reviewed for proper
designation of weldments, location and
classification.
Procedures
Procedures were reviewed for
completeness, and to verify the
implementation of the licensee's
commitments to Code requirements.
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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 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 of these examinations was to duplicate,
to the extent practicable, the techniques and methods of the original
examinations.
The following NDE examinations were performed:
Radiographic Examination:
Thirty-four safety related pipe weldments were radiographed using an
Iridium-192 source per NRC procedure NDE-5-Rev. O addenda MS-1-5-1.
Class 1 and 2 weldments were examined. The resulting radiographs were
evaluated per applicable Code requirements and compared to the licensee's
radiographs.
Results:
The NRC reviewers rejected weld RSS-9-FW2 because of an elongated
indication approximately 1 inch in length, located at station 7-14. Weld
RSS-7-3-4-2-SWB was also rejected because of an elongated indication at
station 26.
The inspectors determined that the indications noted in the above weldment
did not meet the acceptance criteria of ASME Code section III, Article
NB/NC5320.
Further, these indications had not been previously identified
and dispositioned per Article N8/NC5310 of the Code by the licensee.
Failure to identify and disposition these indications is considered a
violation (423/85-22-01). As a result of this violation, Nonconform-
ance and Disposition (N&D) reports, 13387 and 13533 have been issued by
the site and the weldments have been re-radiographed and properly inter-
preted.
The dispositions for the N&Ds were to repair the welds.
Weld MSS-32-SWC was radiographed by the NRC and the film was compared to
the site radiographs. The NRC radiographic film and the site film did not
match. The inspector learned that the site control drawing 2179-C.1-MSS-32
Rev. 2, dated 08/30/84, identified two vendor shop welds fabricated by
TUBECO as SWIC and SWID. The weld identified on the drawing as MSS-32-SWC
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was also identified as TUBECO SWIC.
These welds no longer exist in this
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pipe spool because they have been cut out and replaced by another offsite
vendor (Southwest Fabrication).
Southwest used different unique numbers
(i.e. SW2 and SW3) to identify these new welds.
The pipe spool control
drawing had not been revised to show the change to these welds. Conse-
quently, the inspector initially attempted to compare a NRC radiograph of
SW2 with a TUBECo radiograph of SWIC. Additionally, the inspector learned
that SWIC was one of a number of welds that had been similarly removed and
replaced by Southwest Fabrication when it assumed the pipe contract from
TUBECO. The licensee stated that they were aware of this condition;
however, no documentation was presented to support this statement.
In
this specific case, no direct safety implications were identified.
The
concern lies in the fact that during the transition from TUBECO to South-
west Fab ather singular misidentified or unidentified welds might exist
which do not appear on controlled drawings. The licensee stated that
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a decision was made not to update the cito eawings until the completion
!
of the code-stamping process.
The inspector informed the licensee that this decision was not consistent
with the requirements of site quality procedures for piping fabrication
which require that vendor-supplied items be uniquely identified on site
isometrics. Not updating the drawings was identified as a violation.
,
(423/85-22-02)
Penetrant Examination:
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Twenty-eight safety related pipe weldments and adjacent base material
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(h" either side of weld) were examined using liquid penetrant techniques
per NRC procedure NDE-9, Rev. O addenda MS-1-9-1.
Samples examined included ASME class 1 and 2 piping.
Results: No violations were identified.
Magnetic Particle Examination: (MT):
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Four ASME Class 3 safety related pipe weldments and adjacent base material
(h" either side of weld) were MT examined per NRC procedure NDE-6 Rev. O
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addenda MS-1-6-1.
Results: No violations were identified.
Thickness Measurements:
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Twenty-nine safety related pipe weldments and adjacent base material (2'
'
either side of weld) were examined to determine minimum wall thickness per
NRC procedure NDE 11, Rev. O.
Measurements were performed using a
NOVA-0100 thickness gage. Minimum wall thickness was determined using an
ASTM standard pipe size and noninal thickness chart.
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Results:
No violations were identified.
Ferrite Measurements
Nineteen pipe weldments were checked for Delta Ferrite content using a
type II Ferrite Indicator (Severn Gauge). This test was performed to
verify that the weld filler metal deposited had a composition of suffi-
cient delta ferrite to prevent weld metal solidification cracking. The
Severn Gauge was checked against a coded calibration standard traceable to
the National Bureau of Standards.
Ferrite numbers ranged from SFN to 8.5FN
Results:
No violations were identified.
Hardness:
Twelve safety related pipe weldments were examined for hardness using an
Equo-tip hardness tester per NRC procedure NDE-12, Rev. O.
Hardness
numbers determined by the use of the Equo-tip tester were converted to
Brinell values and the approximate tensile strength was determined by use
of conversion tables.
Results:
No violations were identified.
Alloy Analysis:
Three safety related pipe weldments and adjacent base material were
examined using a Texas Nuclear Alloy Analyzer.
This examination provides
a qualitative and quantitative analysis of the major elements to assure
the materials meet applicable requirements.
Results:
No violations were identified.
Visual Examination:
Fifty one safety related pipe weldments and adjacent base material
(h" either side of weld) were visually examined for weld reinforcement,
weld size, appearance, surface condition and overall workmanship per NRC
procedure NDE-14 Rev. O.
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Results:
1
No violations were identified.
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Ultrasonic Examination:
An ultrasonic examination was performed on a pipe to reducer weldment,
(licensees identification) FWS-17-FW-7C-M. This was an examination to
confirm indications shown on UT data sheet MP-3-03.
Using a Sonic Mark I
flaw detector, the inspector found geometric reflections intermittently,
!
360 around the pipe, at the root area of the weld. The examination was
performed using a technique as close as practical to the original.
Calibration an1 the Distance Amplitude Curve were performed using site
calibration block No. UT-35.
The instrument setting, gain setting and
search units were essentially the same as those used in the original
examination.
Results:
No violations were identified.
3.
Radiographic Film Review
A sampling of licensee's radiographs were reviewed. The selection was made
from a computer listing.
The purpose of this review was to determine the
compliance of the nondestructive examination program to ASME Section III
Code requirements.
The inspector reviewed 106 field welds and 12 shop
welds to verify the accuracy of the interpretation and the adequacy of the
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licensee's radiographic program (see attachment 2).
Listed below are the
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findings.
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Radiographic reader sheet for weld CP-402700 FW-19-1 did not have
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the interpretation for the film area 2-3 which was reshot on
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03/13/84.
The reader sheet for this area was found to have been
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filed with the original radiographs, dated 0;/09/84
This filing
problem was resolved.
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Weld CHS-9 FWS, film area 4-0, contained a 3" elongated indication
and weld CHS-15-FW8 contained an elongated indication 360* around the
weld. Visual examinations were performed by the licensee and the NRC
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on these welds.
The indications were found to be apparent weld
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undercuts on the 0.D. surface of the weld.
Neither of the above weld
radiographic reader sheets identified or dispositioned the apparent
indications.
The above items are unresolved pending licensee
investigation and NRC review. Unresolved items (423/85-22-03)
j
Pipe to nozzle weld MSS-502-FW1-1 was radiographed by the NRC.
Film
area 62-69 contained an elongated indication 8" in length. A review
of the licensee radiographs did not reveal this indication.
The
,
,!
licensee re-radiographed this weld and the indication was apparent on
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the site film. An attempt to visually examine the weld root was
determined to be impracticable due to limited access to the pipe I.D.
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from the steam generator.
PSI ultrasonic examination data were
reviewed and the data indicated intermittent root geometry reflectors
360 around the weldment.
In order to precisely define this indica-
tion the licensee ultrasonically examined this weld.
This examina-
tion was witnessed by the NRC.
The examination revealed an indica-
tion in the same area as the radiographic film, detectable from the
pipe side only.
The indication appeared to be caused by a size
mismatch between the pipe and the nozzle.
The inspector had no
further concerns with this item.
Results:
No violations were identified.
4.
Previous NRC Inspection Findings
(Closed) Violation (50-423/83-14-01):
Radiographic penetrameters placed
across weld in the area of interest.
This condition was found to be
acceptable under the latest ASME III Code, provided that the lead identi-
fication numbers of the penetrameters do not obscure any part of the weld.
The inspector reviewed the licensee's corrective action, such as re-radio-
graphing where penetrameter lead numbers were placed in the area of
interest. The inspector had no further concerns; this item is closed.
(0 pen) Violation (50-423/83-14-02): ASME Code radiographic film density
problems. The NRC inspector viewed the remaining 50 vendor weld radio-
graphic films and associated documentation.
The radiographic film quality
was poor in that the films were scratched and crimped, and showed evidence
of finger prints, dirt and smudges on all the radiographs viewed.
The
above conditions have caused loss of radiographic detail.
Film density
still remains a problem.
The licensee and the NRC agreed to the resolutions for 50 vendor welds.
Since the initial NRC Van inspection of August 1983, the licensee has
performed several radiographic film viewing sample plans that ultimately
ended up with a 100*.' radiographic film viewing of Tubeco's shop welds.
The licensee identified and re-radiographed some 600-700 welds due to ASME
radiographic film problems.
These radiographs are considered ASME site
final films. However, the inspector noted that the licensee did not have
the re-radiographs reviewed by the independent ANI. The licensee dis-
cussed this problem with the ANI and a comprehensive radiographic
review by the ANI is now in progress.
This item remains open pending completion of the film reviews.
5.
Ultrasonic Demonstration
The utility performed an ultrasonic test demonstration that was witnessed
by the NRC.
The purpose of this demonstration was to address the follow-
ing concerns:
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9
(1) The ability of ultrasonic waves to penetrate cast stainless steel
material.
(2) The adequacy of the ultrasonic calibration block for ultrasonic
testing of cast stainless steel material.
Three representative samples of Millstone centrifugally cast piping
containing 15% through wall depth fatigue cracks were UT examined with
defects verified. Another UT demonstration on weld LP-EC2-SWB was per-
formed with results as follows:
ID reflectors were detected inter-
mittently, 360 , adjacent to the weld.
The reflector (indication)
appeared to be a counterbore condition. A geometric plot of this
reflector was made, and the reflector was found to be approximately 1
1/4" from the weld root area.
The ID of the counterbore was previously
blended smooth, with the machine edges rounded out. The inspector
believes that due to transducer wobble, beam spread and, redirection of
the beam in the cast stainless steel material, this reflector was
incorrectly reported off location by 9 .
It appeared that the recorded
reflector was probably due to ID surface irregularities originating at the
weld root.
The 9* shift represented a difference of 1 1/2" from the
actual area (weld root) to the recorded reflector, causing problems with
reported information.
However, the inspector felt that a significant
indication could have been detected using the licensee's method of ultra-
sonic examination.
Exact sizing and location of indications still would
remain a problem when performing UT on this type of material.
A single calibration block, identified as UT-7 (3.28" thickness), was used
for all main coolant loop ultrasonic examinations.
The test block
material is SA-351, grade CF8A, and was manufactured from a cast elbow. A
surface check was performed on the calibration block (125 RMS) and also on
the required examination area of the piping (32RMS). An attenuation com-
parison was performed by the licensee between the calibration block and a
pipe section. A similar comparison between the block and a pipe elbow
section showed that the attenuation was essentially equal.
The centri-
fugally cast pipe attenuation was 6 db greater than the calibration block
(cast elbow material) thus in this case providing less sensitivity to
detecting indications in the pipe. The range of thickness for all com-
ponents examined was 2.1" to 3.81", as reported on the licensee's ultra-
sonic examinations records. Because of the difference between the thick-
ness of the calibration block and the pipes examined, it appeared that the
thickness requirement of ASME section XI Appendix III, Paragraph III -
3410 had not been met.
This problem is unresolved pending a review of the
licensee's basis for use of the calibration block.
(423/85-22-04)
6.
Review of NDE Procedures:
The following NDE procedures were reviewed to verify their technical
adequacy and conformance to industry Codes and Standards.
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STONE & WEBSTER
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QAD-9.32 Rev. A
Liquid f enetrant Examination
QAD-9.41 Rev. B
Radiographfe Examination
QAD-9.52 Rev. C
Ultrasonic thickness measurement
TUBECO INC.
T-405 Rev. 2
No violations were identified.
7.
Attachments:
Attachment No. 1 is a tabulation of specific iter.s examined and results.
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Attachment No. 2 is a list of specific radiographs reviewed and results.
Attachment No. 3 is a list of specific documentation packages reviewed.
Attachment No. 4 is a list of TUBECO Radiograph Resolutions.
8.
Unresolved Items
l
Unresolved items are matters about which more information is necessary to
determine whether it is a' violation, a deviation, or acceptable.
Unresolved
items are discussed in paragraphs 3 and 5.
9.
Exit:
An exit interview was held on June 14, 1985, with members of the
licensee's staff.
The scope and findings of this. inspection were
summarized.
No written material was provided to the licensee during this
inspection.
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ATTACHMENT #2
PAGE 1 of 6
C - CRACK
LF - LACK FUSION
A - ARTIFACTS
SL - SLAG
IP - INADEQUATE PENETRATION
S - SURFACE
P - POROSITY
LI - LINEAR INDICATION
CC - CONCAVITY
T - TUNGSTEN
VI - UNFUSED INSERT
CV - CONVEXITY
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PAGE 2 of 6
C - CRACK
LF - LACK FUSION
A - ARTIFACTS
SL - SLAG
IP - INADEQUATE PENETRATION
S - SURFACE
P - POROSITY
LI - LINEAR INDICATION
CC - CONCAVITY
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ATTACHMENT #2
PAGE 3 of 6
C - CRACK
LF - LACK FUSION
A - ARTIFACTS
SL - SLAG
IP - INADEQUATE PENETRATION
S - SURFACE
P - POROSITY
LI - LINEAR INDICATION
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ATTACHMENT #2
PAGE 4 of 6
C - CRACK
LF - LACK FUSION
A - ARTIFACTS
SL - SLAG
IP - INADEQUATE PENETRATION
S - SURFACE
P - POROSITY
LI - LINEAR INDICATION
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ATTACHMENT #4
PAGE 1 of 2
SUMMARY OF TUBECO SUPPLIED RADIOGRAPHS WHERE WELD DENSITY
EXCEEDS PENETRAMETER DENSITY BY MORE THAN 30%
SHOP
PIPE SP0OL NUMBER
RESOLUTION
3 MSS-25-1-5-2
0
Reshoot
32-1-5-2
C
Reshoot completed
35-2-5-2
A
End prep now MSS-35 FW-1
35-1-5-2A
B
NRC review and accepted
25-1-5-2
E
Reshoot completed
30-1-5-2
C
Reshoot
31-1-5-2
C
Reshoot
32-1-5-2
E
Reshoot
25-1-5-2
B
Reshoot
3 FWS-13-7-4-2
H
Reshoot completed
15-7-4-2
H
Reshoot
17-6-4-2
H
Reshoot
22-6-1-2
D
Re-examined to meet code
compliance
3 SIH-4-6-2-2
K
Weld deleted per EDCR
P-P-3070
3 RHS-4-2-4-2
D
Reshoot
4-2-4-2
E
Reshoot
7-4-4-2
J
Reshoot
7-6-4-2
C
Reshoot
3 FWA-9-3-4-2
Class 3 - MP inspect
13-4-4-2
H
Class 3 - MP inspect
14-1-4-3
D
Weld deleted per CRN 019
3 CHS-10-3-2-2
8
Not required - Typo on N&D
10450
57-1-2-2
B
Reshoot
9-2-2-2
0
Reshoot
44-1-2-2
C
Reshoot completed
44-1-2-2
B
Reshoot
15-3-1-1
B
Weld deleted per Iso
3 QSS-3-3-4-
0
Reshoot
3 RSS-10-3-4-2
0
Reshoot
12-1-4-2
E
Reshoot
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ATTACHMENT #4
PAGE 2 of 2
l
PIPE SPOOL NUMBER
RESOLUTION
3 SIL-2-2-3-2
C
Reshoot
2-4-2-2
D
Joint was reshot - Sat. by
TUBEC0
7-1-1-2
B
Reshoot
8-2-4-2
K
Reshoot
8-2-4-2
M
Reshoot
8-3-4-2
G
Reshoot
10-3-4-2
H
Reshoot
12-1-4-2
J
Reshoot
3 CCP-1-4-3-3
D
Class 3 - MP inspect
5-6-2-3
8
Class 3 - MP inspect
6-1-2-2
C
Reshoot
7-3-2-3
G
Class 3- MP inspect
8-1-2-3
C
Class 3 - MP inspect
8-3-2-3
E
Class 3 - MP inspect
8-3-2-3
F
Class 3 - MP inspect
3 RCS-SL3
E
NRC reviewed and accepted
3 RCS-SL3
H
NRC reviewed and accepted
LP1-CL2
F
NRC reviewed and accepted
LP2-CL2
F
NRC reviewed and accepted
LP4-CL2
E
NRC reviewed and accepted
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