ML20206F956
| ML20206F956 | |
| Person / Time | |
|---|---|
| Site: | Crystal River  |
| Issue date: | 04/08/1987 |
| From: | FLORIDA POWER CORP. |
| To: | |
| Shared Package | |
| ML20206F931 | List: |
| References | |
| PROC-870408, NUDOCS 8704140406 | |
| Download: ML20206F956 (25) | |
Text
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INSERVICE INSPECTION l
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REPAIR AND REPLACDENT PROGRAN Crystal River Unit 3
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IlEPAIR MC llEPLACBENT Pll0GRMt i
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/q Review By:
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ISI Section
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Approved By:
7u uc1 ar Techn cal pport Superintendent Approved By:
16ptger, Nuclear Technical Support 8704140406 870408 PDR ADOCK 05000302 O
INSERVICE INSPECTION Florida REPAIR AND REPLACEMENT PROGRAM
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0 1.0 PURPOSE 1.1 This program defines the scope and content of ASME Section XI repair and replacement activities to ASME defined Class 1,
2, 3, and MC components and component supports at Crystal River Unit 3.
1.2 To adequately define the scope and content this program includes subparts on references, and definitions.
2.0 SCOPE 2.1 10 CFR 50.55a requires use of ASME Section XI ru'es to develop a
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program detailing requirements of the complete repair cycle for all repairs to the pressure retaining boundary of ASME Code Class 1, 2, 3, and MC components and their supports.
This program sets forth' the requirements for all Section XI repair and replacement activi-ties.
2.2 Repairs and replacements performed in accordance with this program i
will implement the requirements of ASME Section XI, 1983 Edition through Summer 1983 Addenda.
3.0 REFERENCES
3.1 ASME Section XI, Rules for Inservice Inspection of Nuclear Power Plant Components, 1983 Edition through Summer 1983 Addenda
INSERVICE INSPECTION
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REPAIR AND REPLACDIENT PROGRAM
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3.2 ASME Section IX, Welding and Brazing Qualifications 3.3 ASME Section V, Nondestructive Examinations 3.4 ASME Section III, Nuclear, Power Plant Components, as accepted by the NRC as listed in 10 CFR 50.55a(b)(1).
3.5 ASNT-TC-1A, 1980, Recommended Practice 3.6 ANSI-N45. 2. 6 - 1973, Qualifications of Inspection, Examination and Testing Personnel for Nuclear Power Plants 3.7 MTAP-06, certification of NDE Personnel, Procedures, and Contractors in Accordance with ASNT-TC-1A and AWS 3.8 MTAP-07, certifications of NDE Personnel, Procedures and Contractors in Accordance with ANSI N45.2.6 and Section XI 3.9 Nuclear Operations Welding (NOW) Manual
.e 3.10 NOD-05
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!9 Florida INSERVICE INSPECTION REPAIR AND REPI.ACDIENT PROGRAN
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4.0 DEFINITIONS
4.1 Appurtenance
a subassembly or subordinate part, accessory object.
4.2 Authorized Nuclear Inspector ANI:
an inspector employed by an Authorized Inspection Agency who is qualified for Division 1 or Division 2 construction inspection by ANSI N626.0 - 1974 or ANSI N626.2 - 1976 respectively.
4.3 Authorized Nuclear Inservice Inspector (ANII):
an inspector employed by an Authorized Inspection Agency who is qualified to monitor activities for Compliance with ASME Section XI by ANSI
~ l N626.1 - 1975.
4.4 Code-Stamoed
The presence of a physical stamp (N, NA, NPT, NV, or U) which indicates that a component or part has been constructed to the requirements of Section III or Section VIII.
4.5 Component
An item in a nuclear power plant including vessels, piping systems, pumps, valves, heat exchangers, tanks, and component 4
supports.
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REPAIR AND REPMCDUT PRMAM r
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n 4.6 component Support:
Those metal supports that are designed to trans-
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mit loads from the component and piping to the load carrying building or foundation structures.
This shall include the attach-ment portion of intervening element (s) to pressure retaining components, integral and non-integral attachments of pressure retaining components, and integral and non-integral supports.
Component supports encompass those structural elements relied upon to either support the weight of or provide structural stability to components and piping.
4.7 pipine System: A functional nuclear power plant system with bounda-ries defined by a plant Design Specification, and/or System Flow Diagrams.
4.8 Flaw Indication:
The evidence or signal resulting from nondestruc-tive examination of a component that may reveal the presence of a flaw, or surface degradation.
Flaws include cracks, inclusions, aligned or clustered rounded indications, lack of weld penetration or fusion, and laminations, etc.
4.9 Repair Orcanization:
An organization that repairs or replaces components or systems under the provisions of this program.
Either FPC or an outside vendor may be the repair organization.
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0 4.10 Repair:
The activity in which unacceptable flaw indications are removed or reduced to an acceptable limit by thermal cutting, or mechanical methods (machining or grinding) and/or replacing removed metal, if required, with weld metal according to the rules of Sec-tion XI.
There may be repairs where no material is removed.
A repair does not necessarily require the addition of weld metal.
Repair may involve plugging heat exchanger tubes.
4.11 Replacement:
The activity in which a component, appurtenance, or pressure-retaining subassembly or part of a component or system is removed and replaced by an identical or substitute item or the same is added or modified according to the rules of Section XI.
Instal-
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lation of new parts or components to existing systems where there is no pre-existing part is considered a replacement (this includes attachment of nonpressure retaining parts welded to the pressure boundary of components).
It also includes system changes such as rerouting of piping within the scope of Section XI.
It does not include the addition of complete new systems.
(New systems are addressed by Section III.)
4.12 Oricinal Construction Code:
The original Code (s) Edition and Addenda under which the component was constructed and installed.
Use of the words " construction" and " constructed" include rules for materials, design, fabrication, examination, and testing. More than one Code may be applicable to the " construction" of the system or component.
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4.13 Repair / Replacement Construction Code:
The Code (s) Edition and Addenda to be used for the repair or for the construction of the replacement component / subassembly /part. This may be the same as the Original Construction Code or it may be a later Edition and Addenda, in part or whole.
It may also be Section III of the ASME Code, in part or in whole.
This is the Code identified on line Sa of form NIS-2.
All Code cases used in conjunction with that repair or replacement must also be identified on form NIS-2.
4.14 Examination:
Shall denote the performance of nondestructive testing and visual observation such as volumetric examinations (radiography, ultrasonic and eddy current), surface examinations (liquid penetrant or magnetic particle), and visual examinations (VT1, VT2, VT3, and
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VT4).
5.0 ADMINISTRATIVE CONTROLS 5.1 The Repair and Replacement Program Document will be administratively controlled by the Nuclear Technical Support Group.
The Nuclear Technical Support Group will provide the interpretation of the document for FPC.
5.2 The individual requirements will be implemented by the procedures referenced in Attachment 2 " Implementing Procedure Cross Reference."
The administrative control of these procedures must not deviate from the system established for that class of document because of the interface with this program.
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0 5.3 Annually, the Nuclear Technical Support Group will provide an update
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package to Nuclear Document Control so that all of the controlled copies of the program document can be updated.
The program update package will consist of a listing of all changes to Attachment 2 caused by procedure changes during the past year.
This package will be processed in accordance with NOD-05.
6.0 GENERAL PROGRAM REOUIREMENTS 6.1 All Section XI relief requests must be reviewed and approved by the Nuclear Inservice Inspection Section, prior to submission to the Nuclear Licensing Section for transmittal to the NRC.
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6.2 The ANII shall be notified prior to starting any welded repair or replacement and shall be kept informed of the progress of work so that necessary inspections can be performed.
6.3 ASME Section XI Code Cases used in conjunction with repairs or j
replacements will be noted on the NIS-2 Form, Attachment 1 to this program, which is part of the documentation for the repair.
Only Code Cases which have been approved for FPC by the NRC and shown in Regulatory Guide 1.147 will be considered.
The use of any other Section XI Code case is prohibited.
6.4 This Repair and Replacement Program shall be subject to review by the NRC and the ANII.
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0 6.5 Nondestructive examinations shall be performed by personnel qualified through Material Technology Administrative Procedures.
6.6 The Construction Codes, including rules for design, materials, fabrication, procurement,
- erection, and installation shall be identified by Nuclear Operations Engineering.
6.7 ASME Section XI allows the use of later editions of the original Code or Section III of the ASME Code, in part or in whole.
7.0 REOUIREMENTS FOR SECTION YI REPATRS f -:..
7.1 This section sets forth the rules and requirements for repair activities, where the word repair is defined in paragraph 4.10.
7.2 The scope of applicability is defined in IWA-4110 as including all ASME code Class 1,
2, 3,
and MC pressure retaining boundaries, components and their supports, including appurtenances and subassem-blies and core support structures.
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7.3 The repairs shall be performed in accordance with the Repair Code, as defined in paragraph 4.12 and 6.6.
If the repair cannot be performed in accordance with these requirements then the following may be used:
a.
IWB-4000 for Class 1 components b.
IWC-4000 for Class 2 components c.
IWD-4000 for class 3 components d.
IWE-4000 for Class MC components 7.4 Flaw indications resulting from ASME Section XI inspection of components or component supports shall be acceptable by one of the four techniques below:
3 a.
Acceptance by Examination b.
Acceptance by Evaluation c.
Acceptance by Repair d.
Acceptance by Replacement 7.5 The rules for items a and b, Acceptance by Examination and by Evalu-ation, are contained in the Examination Program Plan.
If through that program it is determined that a repair is necessary, then the rules of this program apply.
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7.6 The rules for this program apply to welded replacements no matter why the replacement is being made.
The rules for replacements are given in Section 8.0 of this program.
7.7 The Section XI Code repair requirements for Class MC components were in the course of preparation when the 1983 addenda were issued.
If metal removal and welding are required on Class MC components a work package will be prepared that specifies the requirements in accord-ance with the original design and construction codes.
Later editions of the Construction Code or Section III, either in its entirety or portions thereof may be used.
7.8 The Section XI Code repair requirements for Subsection IWF were in
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the course of preparation when the 1983 Edition and Summer 1983 addenda were issued.
The supports shall be repaired in accordance with the requirements of the original design and construction codes.
Later editions of the Construction Code or Section III, either in its entirety or portions thereof, may be issued.
7.9 REPAIRS BY METAL RDIOVAL 7.9.1 Not all repairs require the addition of weld filler metal.
For all repairs the excavation that removed the flaw shall be processed as outlined in the following steps, 7.9.2 through 7.9.7.
7.9.2 A reference point shall be established from which the excavation can be dimensionally located, during and after the repair.
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O 7.9.3 The methods, thermal and/or mechanical, utilized in the flaw excava-tion shall be documented.
7.9.4 The size of the cavity excavated and the method of measurement shall be documented.
7.9.5 Following the final grinding the excavation surface shall be examined by magnetic particle or liquid penetrant method to ensure that the flaw indication does no longer exceed the applicable NDE acceptance standard.
7.9.6 Indications detected as a result of the excavation, per the instruc-tions of 7.9.5 above, that are not associated with the flaw being removed shall be evaluated against the applicable NDE acceptance standard.
7.9.7 For those excavations where no repair welding is planned, ultrasonic or mechanical thickness measurements shall be performed to verify that the required wall thickness has been maintained.
7.10 REPAIRS BY WELDING 7.10.1 Prior to any repairs by welding being authorized, an evaluation of the suitability of the welding procedure to be used shall be performed.
If the repair is due to failure, the cause of the failure should be considered in the evaluation.
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l 7.10.2 All welding procedures shall be qualified in accordance with ASME i
Section IX.
7.10.3 All welders shall be qualified in accordance with ASME Section IX.
7.10.4 Any additional requirements of ASME Section III or XI that impact the qualification of welders or welding procedures shall be identi-fied in the " Nuclear Operations Welding Manual" (NOW, reference 3.9).
7.10.5 Welders need not be employed directly by Repair Organization, whether the Repair Organization is Florida power Corporation or a contracted company, provided that these welders work under the Quality Assurance Program of the Repair Organization.
This program shall include the following:
7.10.5.1 Requirements for the complete and exclusive administration and tech-nical supervision of all welders by the Repair Organization.
7.10.5.2 Requirements for contractual control which provides the necessary
' emove welders at the discretion of the authority to assign and r
Repair Organization.
7.10.5.3 Documentation that the Repair Organizations Quality Assurance Pro-gram is acceptable to Florida Power Corporations ANII.
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7.10.6 The weld repair techniques of Section XI, subarticles IWB-4300, IWC-4300, and IWD-4300 are utilized when Post Weld Heat Treatment is not performed in accordance with the Original Construction Code. Quali-fication of the techniques in accordance with ASME Section IX, as modified in the subarticles IWB-4300, IWC-4300, and IWD-4300, SHALL be performed PRIOR to using them.
1 7.10.7 POST-REPAIR TESTING l
7.10.7.1 Following repairs by welding on the pressure retaining boundary a system hydrostatic test SHALL be performed in accordance with IWA-5000.
This requirement is in addition to all construction code
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requirements for hydrostatic testing.
7.10.7.2 Hydrostatic testing need not be performed on those items that are specifically exempted by Section XI in subarticle IWA-4000 and IWA-5000.
7.10.8 POST-REPAIR EIAMINATION 7.10.8.1 Following repairs, the repaired area SHALL be examined to establish a new preservice record.
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7.10.8.2 The examination SHALL include the method that detected the flaw for repairs to remove or correct flaws.
7.10.8.3 The preservice record SHALL include the preservice examination j
requirements of IWA-2000.
This requirement SUPERSEDES the construction code NDE requirement where Section XI requirements are more restrictive.
7.10.8.4 If the repair includes the complete isolation of the item bearing the flaw, such as heat exchanger tube plugging, then the require-ments of step 7.10.8.1 above SHALL NOT APPLY.
7.10.9 REPAIR RECORDS 7.10.9.1 A copy of form NIS-2, Attachment 1 to this program, SHALL be completed for every repair.
8.0 REOUTRFMENTS FOR SECTION II REPLAcisu.rus 8.1 This section sets forth the rules and requirements for replacements, where the word replacement is defined in paragraph 4.11.
8.2 Replacements may meet all or portions of the requirements of later editions of the Construction Code, provided that the following requirements are met.
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8.2.1 The requirements affecting the design, fabrication, and examination of the replacement are reconciled with the owner's Specification.
8.2.2 Mechanical interfaces, fits and tolerances that provide satisfactory performance are not changed by the later edit! ion of the Construction Code.
8.2.3 Modified or altered designs are reconciled with the owner's Specifi-cation through the Stress Analysis Report, Design Report, or other suitable method which demonstrates the satisfactory use for the specified design and operating conditions, whichever is applicable.
8.2.4 Materials are compatible with the installation and system require-
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ments.
8.3 Prior to authorizing the installation of a replacement an evaluation of the suitability shall be performed.
8.3.1 If the replacement is due to failure, the evaluation shall consider cause(s) of failure to ensure that the selected replacement is suit-able.
8.3.2 The replacement evaluation report shall be transmitted to Nuclear Plant Quality Document Files.
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l 8.4 All replacements involving welding shall comply with the Repair i
l Program requirements, Section 7.0 of this document.
8.5 The following items shall be exempt from the replacement program requirements:
l a.
gaskets b.
instruments c.
electrical conductors and insulators d.
piping, valves and fittings that are 1 inch nominal pipe size or less l
e.
nonstructural pump and valve internals, except when the original l
l equipment was constructed in accordance with a Construction Code l
or Code Case.
f.
pump seal package and valve packing l
8.6 A copy of form NIS-2, Attachment 1 to this program, shall be completed for each item replaced by this program.
l 8.7 Prior to return of the plant to service, a preservice inspection j
l shall be made in accordanc'e with IWA-2000.
9.0 REOUIRDIENTS FOR RECORDS AND REPORTS l
l 9.1 A copy of form NIS-2, Attachment 1 to this program, SHALL be completed for every repair and replacement.
9.2 The following steps are instructions for completing the form NIS-2:
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9.2.1 Line 1 is completed by the planner as follows:
FLORIDA POWER CORPORATION P.O. Box 14042 St. Petersburg, FL 33733 9.2.2 Line 2 is completed by the planner as follows:
CRYSTAL RIVER UNIT 3 P.O. Box 1240 Crystal River, FL 32629 9.2.3 Line 3 is completed by the planner with the name and address of the repair organization, the purchase order number, job number, work request number, et cetera, as appropriate.
9.2.4 Line 4 is completed by the planner with the system identification.
9.2.5 a.
Line Sa is completed by SNES with the Repair / Replacement construction code edition, addenda, and the code cases utilized.
p b.
Line 5b is completed by the ISI Specialist.
9.2.6 Line 6 is completed by Nuclear Operations Engineering.
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9.2.7 Line 7 is completed by the work package originator.
9.2.8 Line 8 is completed by the ISI Specialist.
9.2.9 Line 9 is completed by Nuclear Operations Engineering and QCIs attached to the work package by shop planners.
9.3 It shall be the responsibility of the ISI Specialists to sign the
' Certificate of Compliance
- section of form NIS-2 and the then main-tain the form until the ANII has signed it.
9.4 The ISI Specialists shall review the work packages sufficiently to attest that the repair complies with Section XI.
9.5 Form NIS-2 for all repairs performed since the previous refueling, shall be submitted with the Summary Report and form NIS-1 that is filed after the next scheduled refueling outage.
9.6 A copy of the Summary Report Submission is transmitted to Nuclear Plant Quality Document Files.
No other copy of form NIS-2 need be transmitted.
10.0 ATTACHm.n r5 10.1 ATTACHMENT 1, FORM NIS-2 10.2 ATTACHMENT 2, Procedure Cross Reference List
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""c" ATTACHMENT 1 FORM NIS-2 OWNER'S REPORT OF REPAIR OR REPLACEMENT AS REQUIRED BY THE PROVISIONS OF ASME CODE SECTION XI 1.
Owner Florida Power Corporation Date P.O. Box 14042 St. Petersburo. FL 33733 Sheet of (Address) 2.
Plant crystal River Unit 3
P.O. Box 1240 crystal River. FL 32629 (Address) 3.
Work Performed By (Name)
(Repair Org. P.O. No.,
Job No., etc.)
(Address) 4.
Identification of System 5.
(a) Applicable Construction Code 19
- Edition, Addenda Code Cases (b) Applicable Edition of Section XI Utilized for Repairs or Replacements 19, Addenda, code Cases
- 6. Identification of Components Repairs or Replaced and Replacement Components.
Name of Name of Mfrs. Ser.
Nat'l Other Year Repaired ASME Code i
Component Mfr.
No.
Bd.No.
Identi-Built Replaced Stamped fication or (Yes or No)
Replacement
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ATTACHMENT 1 (Continued)
FORM NIS Continuation 7.
Description of Work 8.
Tests Conducted:
Hydrostatic Pneumatic Nominal Operating Pressure Other Pressure psi Tests Temp.
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Remarks (Applicable Manufacturer's Data Reports to be attached)
CERTIFICATE OF COMPLIANCE i
We certify that the statements made in this report are correct and this i
conforms to Section XI of the ASME Code.
(repair or replacement)
Signed
_, 19 (Owner or Owner's Designee)
Title Date CERTIFICATE OF INSPECTION I, the undersigned, holding a valid commission issued by the National Board of Boiler and Pressure Vessel Inspectors and the State or Province of employed by of have inspected the (Repairs or Replacements) described in this Report on 19
, and state that to the best of my knowledge and belief, this repair or replacement has been constructed in accordance with section XI of the ASME Code.
By signing this certificate, neither the Inspector nor his employer makes any warranty, expressed or implied, concerning the repair or replacement in this Report.
Furthermore, neither the Inspector nor his employer shall be liable in any manner for any personal injury or property damage or a loss of any kind arising from or connected with this inspection.
Date Commissions (State or Province, National Board) s e
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ATTACHMENT 1 (Continued)
NOTE: Supplemental sheets in form of lists, sketches, or drawings may be used provided (1) size is 8-in. x 11 in.(2) information in Items 1 through 6 on this data report is included on each sheet and (3) each sheet is numbered and the number of sheets is recorded at the top of this form.
Owner or Owner's designee and the ANII shall sign at the bottom of each supplemental sheet.
INSTRUCTIONS The item numbers below correspond to the block numbers on the " Form NIS-2, Owner's Report of Repair or Replacement," Attachment 1.
- 1) Enter Owner's name and address:
Florida Power Corporation' P.O. Box 14042 St. Petersburg, FL 33733
- 2) Enter Plant name and address:
Crystal River Unit 3 P.O. Box 1240 Crystal River, FL 32629
- 3) Enter the name and address of who performed the work, Florida Power Corporation, P.O. Box 14042, St. Petersburg, FL 33733, and the Purchase Order, Job Number, Work Request Number, etc.
- 4) Enter identification of system (e.g., Chemical and Volume Control System).
- 5) a) Enter applicable Construction Code (e.g.,
Section III, 74 Edition, S'75 Addenda, N/A for not applicable, or the number of the Code Case (s) used.)
b) Enter applicable Edition of Section XI Utilized for Repairs or Replacements (e.g., 83 Addenda S83 and any Code cases used).
- 6) Enter identification of components repaired or replaced and replacement components.
Examples are as follows:
Name of Components:
2*S.S. Globe Valve Name of Manufacturers:
Kerotest Mfrs. Serial Number:
CAQ 12-4 National Board Numbers:
N/A for not applicable or the desig-nated National Board Number if assigned.
Other Identification:
(Valve ID Number)
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Year Built:
1974 Repaired, Replaced, or Replacement:
Repaired ASME Code Stamped (Yes or No):
Yes 0
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7)
Enter description of work (e.g., drilled eight (8) holes through lip of valve to facilitate installation of limit switch and locking device).
- 8) Enter tests conducted (e.g., mark the appropriate block, " Hydrostatic",
" Pneumatic *, " Nominal Operating Pressure", or "Other'.
Include the test pressure and temperature; in the case of "Other" being marked, specify the test, like PT for liquid penetrant testing, etc.)
- 9) Enter remarks (e.g., See attached NPV-1 form).
In the " Certificate of Compliance" section, enter the work repair if a repair was done, or replacement if the item was replaced.
This section will be signed by the owner or his designee along with title and date.
In the " Certificate of Inspection" section, will complete this part of the form.
the designated inspection agency 1