ML20204H311
| ML20204H311 | |
| Person / Time | |
|---|---|
| Site: | Beaver Valley |
| Issue date: | 07/30/1986 |
| From: | Harris R, Kerch H, Wiggins J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML20204H285 | List: |
| References | |
| 50-412-86-13, NUDOCS 8608080076 | |
| Download: ML20204H311 (13) | |
See also: IR 05000412/1986013
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U.S. NUCLEAR REGULATORY COMMISSION
REGION I
Report No. 50-412/86-13
Docket No. 50-412
License No.
CPPR-105
Category A
Licensee: Duquesene Light Company
Robinson Plaza Building No.2
Suite No.210 Pa. Route 60
Facility Name: Beaver Valley Power Station, Unit 2.
Inspection At: Shippingport, PA
Inspection Conducted: June 9-20, 1986
Inspectors:
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Inspection Summary:
Inspection on June 9-20, 1986 (Inspection Report No.
50-412/86-13)
Areas Inspected: A routine, announced NRC independent measurements inspection was
conducted at the utility construction site using the NRC Mobile Nondestructive
Examination (NDE) Laboratory.
Selected structural supports, fuel racks and pre-
service inspection weldments were inspected, by a team of two regional based
inspectors assisted by two contracted NDE personnel.
Results: One violation was observed concerning an unacceptable indication in
base material (86-13-01) and one violation was identified concerning liquid
penetrant indications in weldments.
(86-13-02)
8608080076 860001
ADOCK 00000412
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DETAILS
1.0 Persons Contacted
Duquesne Light Company
J. M. Jaworski, Senior Engineer, Mechanical and Welding
D. K. Rohm, Assistant Director Quality Control
R. M. Reba, Principal Engineer
L. M. Rabenau, Compliance Engineer
W. H. Sikorski, Director In-Service Inspection
J. B. Andrews, In-Service Inspection Program Coordinator
T. Heimel, Non-Destructive Examination Specialist
R. Coupland, Director Quality Control
J. R. Houghton, Duquesne Light Company Engineering Department
M. Zaki, Duquesne Light Company Engineering Department
C. R. Davis, Director Quality Assurance
H. T. Schob1, Start-up
D. W. Dreams, Assistant Director, Quality Assurance
L. P. Williams, Director Start-up
A. F. Mosso, Quality Assurance Non-Destructive Examination
Stone and Webster Engineering Co. (SWEC)
G. Orr, Senior Training Supervisor
D. P. Lessard, Assistant Superintendent
K. Kirkman, Assistant Superintendent Construction
J. R. Hurley, Contract Manager
R. C. Wittschen, Licensing Engineer
J. J. Purcell, Assistant Project Manager
H. W. Durkin, Supervisor of Engineering
Nuclear Energy Service (NES)
M. Shallis, Site Supervisor
T. J. Koch, Project Manager
G. Griffith, Director Plant Operations
C. D. Cowfer, Director of In-Service Inspection
Nuclear Regulatory Commission
L. J. Prividy, Resident Inspector
All of the above were present at the June 20, 1986 Exit Meeting.
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2.0 Purpose of the Inspection
2.1 An onsite independent verification inspection was conducted during
June 9 through 20, 1986, using the NRC Mobile Nondestructive Exam-
ination NDE Laboratory. This inspection was performed by NRC Region
I personnel in conjunction with NRC contractor NDE personnel.
The purpose of this inspection was to perform an independent exam-
ination of selected piping weldments that were previously inspected
and accepted under the licensee's Preservice Inspection Program.
Also examined were structural steel weldments, piping supports and
cable tray support weldments to ascertain the adequacy of construc-
tion fabrication and of the welding quality control program to assure
safety and reliability during plant operation. QC/QA records were
reviewed to ascertain compliance to governing codes, standards and
regulations.
3.0 Independent Measurements
The purpose of this independent examination of weldments was to verify the
adequacy of the licensee's welding Quality Control Program applicable to
ASME Class 1, 2 and 3 components. This was accomplished by duplicating
those examinations required of the licensee by regulations and codes, and
evaluating the results.
In addition to those examinations, several other
confirmatory examinations designed to verify conformance with material
specifications were performed and compared to quality assurance records.
The NRC inspectors performed the examinations on randomly selected weld-
ments that had been previously inspected and accepted by the licensee, as
indicated by vendor shop and on-site QA/QC records.
3.1 New Fuel Racks
This inspection included the visual and liquid penetrant examination
of forty fuel rack assemblies.
Examinations were performed using NRC
procedure NDE-9 Revision 0 and the licensee's detailed drawings,
procedures, standards and specifications.
Results: During this inspection it was noted that weld symbols shown
on SWEC drawings 12241-RV-20A indicated that welds were to be ground
flush.
The inspect]r found that the majority of these welds were in
the as-welded condition.
Subsequently, the licensee issued a Non-
conformance and Disposition Report (N&D 33538) which was disposit-
ioned use as is.
The technical justification was that the intent of
requiring that the welds be ground was to provide a smooth surface
for liquid penetrant testing.
The inspector noted that the as welded
surfaces met the 250 rms requirement specified in the drawing and
were acceptable in the as-welded condition.
No violations were identified.
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3.2 Spent Fuel Racks (SFR)
This inspection included examination of three (3) 8x8 fuel storage rack
arrays and consisted of visual and liquid penetrant examinations.
These items were previously inspected and accepted by the licensee,
as indicated by vendor shop and onsite QA/QC records. The inspectors
examined 75% of all welds denoted as critical in accordance with NES
drawing 80E7653. Attributes examined during the visual inspection,
were weld size, length, location and overall workmanship.
Liquid
penetrant inspection was performed to determine if any indications
existed which were unacceptable or detrimental to the service of the
component.
The inspection of the spent fuel racks wac performed using NRC proce-
dures NDE-14, Revision 0, NDE-9, Revision 1 and Addendas BV-2-9-1 and
BV2-14 in conjunction with licensee detail drawings and site procedures,
standards and specifications.
Results:
During liquid penetrant examination of a sample of critical
welds denoted on detail drawing NES 80E7653, linear indications were
found in two fillet welds on fuel bundle #16. As a result of the NRC
finding, DLC/SQC NDE laboratory reexamined those welds with identi-
fied linear indications.
The results of the reexamination, substan-
tiated the indications found by the NRC. The indication were
dispositioned on Noncomformance and Disposition Report No. 32471
(DLC-SQC). Supplemental NDE and liquid penetrant records confirmed
that unsatisfactory indications such as star cracks and linear
indications were present.
Based on the above, the inspector considered the existence of SFR
weld indications a violation of 10 CFR 50 Appendix B requirements
(412/86-13-02).
3.3 Cable Tray Supports and Conduit Supports
A random sample of cable tray supports located inside the Service
building and the Main Steam Building were inspected. This inspection
was performed using NRC procedure NDE-18, Rev. O in conjunction with
site procedures and specifications. The attributes examined during
this inspection were dimensional checks and checks for support lo-
cation, support welding, and loose or broken support members. Also,
the size and location of the Hilti conrete anchor bolts were compared
<
to drawing requirements.
See Attachment 2 for specific items inspected.
Results: No violations were identified.
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3.4 Pipe Supports
A sample of pipe supports located inside the primary containment and
auxiliary building were examined. Attributes examined during this
inspection, were dimensional checks and checks for support location,
support welding and loose or broken support members. Measurements
were compared with detailed isometrics / drawings indicating support
location and orientation, support types and field weld requirements.
Results: During this inspection the inspector identified that draw-
ing BZ-1078-331-0A did not conform to the actual pipe support install-
ation. A further investigation revealed that E&DCR #2PA-M-1189 had
been issued to modify the support.
Reinspection with the correct
information was performed by the inspector and no further questions
developed.
See Attachment #3 for specific items inspected.
Results: No violations were identified.
3.5 Steam Generator Support
A visual and dimensional inspection of Steam Generator lower support
assemblies
A, B and C, located in the reactor containment building,
was performed.
The visual examination consisted of weld inspections
and surface material examinations. Dimensions were taken and com-
,
pared to as-built dimensions shown on Steam Generator lower support
drawings.
Results: A base metal linear defect was detected by visual inspec-
tion of the lower horizontal beam member on the steam generator C
lower support assembly. The indication was open to the surface and
approximately 6" long.
The inspector determined that this item had
been previously inspected and accepted by the licensee with this
defect not being identified.
The licensee issued Noncenformance and Disposition Report No. 32812.
The final indication size was 18 inches in length and 3/16 in depth.
The failure to identify and disposition this indication is a viola-
tion of 10 CFR 50.55a requirements (412/86-13-01).
3.6 Pressurizer Support
The inspectors conducted an ultrasonic examination of 16 full pene-
tration weldments on the Pressurizer component support. The ob-
jectives of this inspection were to verify weld integrity and to
assess the adequacy of previous ultrasonic examinations performed by
the fabricator. The examination was performed using NRC procedure
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NDE-1, Revision 0, Addenda BV2-1-1, in conjuction with site proce-
dures, specifications and as-built drawings. Weldments were randomly
selected by a region- based NRC Nondestructive Examination (NDE)
Specialist, based on weld accessibility.
Results: No violations were identified.
3.7 Windsor Probe
The compressive strength of concrete poured around the reactor contain-
ment was examined using the Windsor Probe test kit.
Three probe results
were averaged and a compressive strength was determined using standard
conversion tables.
Results: No violations were identified. The examination indicated that
the concrete compressive strength exceeded the 6000 psi required by
the governing site specification.
3.8 Ultrasonic Examination (UT)
Ten pipe weldments were ultrasonically examined to verify the adequacy
of the licensee's PSI program.
The ultrasonic parameters used during
this inspection were matched as closely as possible to those used during
the original examination performed by the licensee's UT personnel. The
instrument used was calibrated using NRC procedure NDE-2, Revision 0,
and licensee's calibration blocks.
See Attachment 1 for specific weldments examined.
.
Results: Three (3) geometric reflectors, two (2) indications veri-
fied as redirected sound path in austenitic stainless steel weldments
and one (1) planer indication were identified.
These results matched
those previously identified by the licensee during its examination.
No violations were identified.
4.0 Preservice Inspection (PSI) Data Review
Selected PSI data for the RCS System were reviewed to verify that exami-
nations were done in compliance with the governing procedure and that
applicable ASME Code and Regulatory requirements were met. The review
also was undertaken to verify that the licensee had properly recorded
ultrasonic evaluations.
A review of PSI /ISI procedure A 3.6, Revision 3, paragraph 2.93, indicated
that the Supervisor of NDE Services or his designee shall review and
accept the ultrasonic examination data for the licensee. This inspection
revealed that this individual did not process the requisite ASNT NDE
certifications. The licensee reviewed and changed procedure A 3.6 to
indicate that the contractor's Level III would review and accept the
examination results.
The inspector interviewed the contractor's Level III
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who had reviewed the majority of PSI data for piping and concluded that
his signature on each of the NDE data reports represented acceptance of
those reports.
The inspector thus concluded that the requirements of
Section XI of the ASME code regarding acceptance of data had been met.
The inspector noted during the review of data reports, that the examin-
ation record did not clearly state whether the weld was found to be
acceptable or rejectable based on the results of the examination. The
inspector was told that a master tracking list indicated the status of the
welds. The inspector expressed a concern that completed ultrasonic exam-
ination records should stand on their own relative to a statement of the
acceptability of the weld examined. The adequacy of NDE records is
considered unresolved pending licensee review of the inspector's concern
described above (86-13-03).
Overall, the inspector found that the preservice piping inspection at
Beaver Valley 2 and its documentation had been performed professionally
and that a meaningful PSI program had resulted.
Results: No violations were identified.
5.0 Followup on Previously Identified Items
(Closed) Unresolved Item 84-02-01: Technical Justification to waive D1.1 when
using design allowables of AISC
(Closed) Unresolved Item 84-02-02: Method to establish and control ' Engineers"
authority to waive explicit rules of 01.1 not documented
(Closed) Unresolved Item 84-02-03: Engineering justification to use Para A515 in
D1.1 not documented
(Closed) Unresolved Item 84-02-04: Engineering justification to waive 10 mil
undercut rule for D1.1 FAB not documented
(Closed) Unresolved Item 84-02-05: Engineering justification to substitute SWEC
FC P601.8 figure 7 effective throat rules for Para. 61.1 of 01.1 rules
not documented
(Closed) Unresolved Item 84-02-06: Basis for qualification of welding over
galvanized steel unistruts with E6010 not documented
Background: During an earlier field inspection, an NRC inspector
observed that several items had not been properly addressed in
regard to the application of AWS D1.1 at Beaver Valley Unit 2.
During this inspection, the licensee's responses No. 2 NCD-04478 and
2 DLS-23722 and references No. 2 DLS-23064 and 2 DLS-23491 were
reviewed. Procedures No. 2 BVM-7 for Preparation of Specification,
and 2 BVM-102 for Pipe Support Welding Design Guide, were also
reviewed. The inspector verified that the appropriate corrective
action to these items had been taken.
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Based on these reviews, the inspector considers items 84-02-01 through
84-02-06 closed.
(Closed) Unresolved Item 84-15-01: Potential PSI problems due to weld
overlay of piping and lack of vendor as-built drawings and RT maps.
During NRC inspection 85-05, the inspectabililty of the overlay welds
was established. During this inspection, the inspector reviewed the
RT maps and found them to be excellent. Also reviewed, were some of
the required as built drawings (1104552 Revision 4, 1104J50 Revision
2, 1104J51 Revision 4 and 1101J46 Revision 1). The inspector also noted
that in letter ND2 ISI: 0261 the licensee has requested SWEC to obtain
the required as built drawings for the reactor pressure vessel.
Based on this and the previous NRC inspection of this subject, item
84-15-01 is closed.
(Closed) Unresolved Item 86-05-01: Incomplete Transducer Certification
Documentation
The licensee performed calculations and physical measurements to
determine that the transmit and receive crossover point and focal
depth of dual transducers serial numbers J-22462 and J-22463 were
adequate. The transducers were marked. Transducers serial numbers
F-16030 and F-20320 listed in inspection report 86-05-01 as focused
dual element were in fact found to be single element and thus did not
require additional documentation.
This item is therefore closed.
6.0 Unresolved Items
i
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 4.
7.0 Exit Meeting
An exit interview was held on June 20, 1986 with members of the licensee's
staff. The inspector summarized the scope and findings of this inspec-
tion.
No written material was provided to the licensee during the course
of the inspection.
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