ML20235L662
| ML20235L662 | |
| Person / Time | |
|---|---|
| Issue date: | 09/30/1987 |
| From: | Shaaban H, Wu P Office of Nuclear Reactor Regulation |
| To: | |
| References | |
| NUREG-1194, NUDOCS 8710050558 | |
| Download: ML20235L662 (57) | |
Text
{{#Wiki_filter:, NUREG-1194 s i i i Construction Appraisal Team Inspection Results on Welding and Nondestructive Examination Activities 4 I { U.S. Nuclear Regulatory Commission Office of Nuclear Reactor Regulation P. C. S. Wu, H. I, Shaaban porcoq f'.t.jq 5 %4 i;p,/ i \\,,,;, I l "M E82n "7 ' 1194 R PDR I
1 NOTICE q Availability of Reference Materials Cited in NRC Publications Most documents cited in NRC publications will be available from one of the following sources:
- 1. The NRC Public Document Room,1717 H Street, N.W.i 1
Washington, DC 20555 I 1
- 2. The Superintendent of Documents, U.S. Government Printing Office, Post Office Box 37082, l
Washington, DC 20013 7082
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It is not intended to be exhaustive. i Referenced documents available for inspection and copying for a fee from the NRC Public Docu-ment Room include NRC correspondence and internal NRC memoranda; NRC Office of Inspection and Enforcement bulletins, circulars, information notices, inspection and investigation notices; Licensee Event Reports; vendor reports and correspondence; Commission papers; and applicant and j licensee documents and correspondence. The following documents in the NUREG series are available for purchase from the GPO Sales l Program: formal NRC staff and contractor reports, NRC-sponsored conference proceedings, and NRC booklets and brochures. Also available are Regulatory Guides, NRC regulations in the Code of Federal Regulations, and Nuclear Regulatory Commission Issuances. Documents available from the National Technical Information Service include NUREG series reports and technical reports prepared by other federal agencies and reports prepared by the Atomic Energy Commission, forerunner agency to the Nuclear Regulatory Commission. Documents available from public and special technical libraries include all open literature items, such as books, journal and periodical articles, and transactions. Federal Register notices, federal and state legislation, and congressional reports can usually be obtained from these libraries. Documents such as theses, dissertations, foreign reports and translations,and non NRC conference proceedings are available for purchase from the organization sponsoring the publication cited. Single copies of NRC draf t reports are available free, to the extent of supply, upon written request to the Division of Information Support Services, Distribution Section, U.S. Nuclear Regulatory Commission, Washington, DC 20555. Copies of industry codes and standards used in a substantive manner in the NRC regulatory process are maintained at the NRC Library, 7920 Norfolk Avenue, Bethesda, Maryland, and are available there for reference use by the public. Codes and standards are usually copyrighted and may be purchased from the originating organization or, if they are American National Standards, from the American National Standards institute,1430 Broadway, New York, NY 10018.
NUREG-1194 Construction Appraisal Team Inspection Results on Welding and Nondestructive Examination l Activities f Manuscript Completed: June 1987 Date Published: September 1987 P. C. S. Wu, H. l. Shaaban' ' Affiliated with International Atomic Energy Agency Division of Reactor inspection and Safeguards Office of Nuclear Reactor Regulation U.S. Nuclear Regulatory Commission Washington, DC 20555 i ) p'> ooy f o 4 l l
' ABSTRACT This report' summarizes data and findings on deficiencies and discrepancies in welding and nondestructive examination (NDE) activities identified by the U.S. Nuclear Regulatory Commission Construction Appraisal Team (CAT) during its inspection of 11 plants. The CAT reviewed selected welds and NDE packages in its inspection of the following plant areas: piping and pipe supports and/or restraints; modification and installation of reactor internals; electrical installations and electrical supports; instrumentation tubing and supports; p heating, ventilation, and' air conditioning (HVAC) systems and supports; fabri-El' cation and erection of structural steel; fabrication of refueling cavity and spent fuel pool liner; containment liner and containment penetrations; and fire protection systems. The CAT inspected both structural welds and pressure-retaining welds and reviewed welder qualification test records and welding pro-cedure documents for code compliance.' The NDE activities that were evaluated included visual examination, magnetic particle examination, liquid penetrant examination, ultrasonic examination, and radiographic examination of welds. i -l j r l NUREG-1194 iii
CONTENTS Page iii ABSTRACT............................................................... ix ACKNOWLEDGMENT........................................................ 1-1 1 INSPECTION DATA AND FINDINGS......................................... 1-1 1.1 Introduction.................................................... 1-1 1.2 Objectives of Appraisal......................................... 1-2 1.3 Appraisal Methodology........................................... 1-2 1.3.1 Welding Activities...................................... 1.3.2 Nondestructive Examinesion Activities..................... 1-3 2 WELDING AND NONDESTRUCTIVE EXAMINATION ACTIVITIES.................... 2-1 2.1 Piping and Pipe Supports or Restraints......................... 2-1 2-1 2.2 Reactor Internals..............................................
- 2. 3 Electrical Installations and Supports..........................
2-2 2.4 Instrumentation Tubing and Supports............................ 2-2 2.5 Heating, Ventilation, and Air Conditioning System.............. 2-3 2.6 Fabrication, Erection, and Modification of 2-3 Structural Steel.............................................. 2.7 Refueling Cavity and Spent Fuel Pool Liner..................... 2-4 2.8 Containment Liner and Penetrations............................. 2-4 2-5 2.9 Fire Protection System......................................... 2.10 Vendor-Fabricated Tanks and Heat Exhangers...................... 2-5 3-1 3 CONCLUSIONS................................... 4-1 4 REFERENCES........................................................ FIGURES 2.1 Types of weld and NDE deficiencies in piping and pipe supports 2-/ or restraints.................................................... 2.2 Number of weld deficiencies in piping and pipe supports or 2-7 restraints...................................................... 2.3 Types of weld deficiencies in electrical installations and 2-0 supports......................................................... 2.4 Number of weld deficiencies in electrical installations and 2-8 supports......................................................... 2-9 l 2.5 Types of weld deficiencies in instrumentation tubing and supports 2.6 Types of weld deficiencies in heating, ventilation, and air 2-9 conditioning systems............................................ 2.7 Number of weld deficiencies in heating, ventilation, and air 2-10 conditioning systems.......................................... 2-10 2.8 Types of weld and NDE deficiencies in structural steel........... 2.9 Number of weld deficiencies in structural steel................ 2-11 NUREG-1194 v
Yt F CONTENTS (Continued) Page 2.10 Number of weld deficiencies in refueling cavity................... 2-11 -2.11 ' Number of weld deficiencies in containment liner and containment penetrations........................................... 2 2.12L Types of weld and NDE deficiencies in vendor-fabricated ~ tanks and. heat exchangers......................................... 2-12 2.13' Number of weld deficiencies in vendor-fabricated tanks and heat.exchangers................................................... 2-13 3.1 Nu'mber of plants found to have welding or NDE deficiencies in a given system or component......................................... 3-2 TABLES 1.1 Plants-inspected by the NRC Construction Appraisal Team and I included in this report........................................... 1-4 1.2 Number of inspected structural welds and deficient welds.......... 1-5 2.1 Number of inspected piping welds and piping spools where welds were located,-inspected support or. restraint (S/R) welds and S/Rs where welds were located, and reviewed welder qualification test records and welding procedures.- welding activities.......... 2-14
- 2. 2 '
Number of inspected-shop-fabricated and field-fabricated welds, reviewed radiographic films, reviewed NDE inspector qualification records and NDE procedures, and NDE and quality control inspectors whose inspection activities were observed - NDE activities........ 2-18 2.3 Field-fabricated piping and pipe support vendors.................. 2-21 2.4 Shop-fabricated piping and pipe support vendors................... 2-22
- 2. 5 Number of inspected welds, reviewed welding procedures and welder qualification test records, and reviewed NDE inspection
. qualification records and NDE inspectors whose inspection activities were observed - reactor internals...................... 2-23 2.6 Number of. inspected field-and shop-fabricated welds, reviewed welding procedures and welder qualification test records, and reviewed NDE inspector qualification records and NDE inspectors whose inspection activities were observed - electrical installa- .tions and supports................................................ 2-24 2.7 Number of inspected welds and supports, reviewed we'iding procedures and welder qualification test records, and reviewed NDE inspector qualification records and NDE inspectors whose inspection activities were observed - instrumentation tubing and' supports.... 2-26 2.8 Number of inspected field-and shop-fabricated welds, reviewed welding procedures and welder qualification test records, and reviewed NDE inspector qualification records and NDE inspectors whose inspection activities were observed - heating, ventilation, and ai r condi ti oni ng sys tems...................................... 2-28 2.9 Number of inspected field-and shop-fabricated welds, reviewed welding' procedures and welder qualification test records, and reviewed.NDE inspector qualification records and NDE inspectors whose inspection activities were observed - structural steel...... 2-30 NUREG-1194 vi
CONTENTS (Continued) Page ) I 2.10 Length of inspected seam welds (in feet) and number of inspected films, inspected welds in brackets and other components, reviewed welding procedures and welder qualification test records, and reviewed NDE procedures or records and NDE inspectors whose inspection activities were observed - refueling cavity and spent f u el. pool l i n e r.................................................... 2-32 i 2.11 Number of visually inspected seam welds and reviewed radiographs; inspected mechanical and electrical penetrations; inspected plugs, i 1 openings, hatches, etc.; and reviewed welding procedures and welder qualification test records - containment liner and penetrations...................................................... 2-33 j 2.12 Number of inspected support and pipe welds, reviewed welding procedures, and reviewed welder qualification test records - fi re p ro tec ti on sy s tems........................................... 2-35 2.13 Number of evaluated vendors or items and reviewed radiographs of seam and other welds and of valves, pumps, and castings - tanks and heat exchangers............................................... 2-36 I l l l l l l i NUREG-1194 vii j l I
h i i ACKNOWLEDGMENT j ~ The authors wish to express their appreciation to G.- B. Georgiev, R. F. Heishman, and-J. E. Konklin.of the. Reactor Construction Program Branch, Office of Inspec-tion and Enforcement, for their valuable guidance and encouragement. Addition- - ally, H. I. Shaaban wishes to thank the International Atomic Energy Agency for the. fellowship that was offered to him. I i l NUREG-1194 ix
m, [ {l' 1 "I'NSPECTION DATA'AND; FINDINGS
- 1. 11 Introduction Jihe U.S.1 Nuclear Regulatory Commission (NRC), Office of Inspection and Enforce -
. ment (IE),L Construction Appraisal Team (CAT) = conducted a series of inspections to verify theLquality of construction at nuclear power plants. The NRC CAT was composed of IE staff, NRC regional staff, and several-consultants. The effort ' consisted of a detailed inspection of selected. hardware that had been through ? previous quality control inspections, a review of. selected portions of the quality assurance program,' examination'of procedures and records, and observation -of work' activities. 'The inspected areas included electrical and instrumentation control, mechanical construction, welding and nondestructive examination, civil and structural construction, material traceability and control, design change control, and, corrective action procedures and activities. Under the.NRC CAT program, 15 inspections have been completed. A CAT. inspection report was issued af ter each' inspection to identify deficiencies and construc-tion program. weaknesses that. required corrective actions and additional manage-E ment attention..In some instances, enforcement actions were taken' against the subject plants. nThis. report summarizes the CAT inspection results on welding and nondestruc-tive examination activities in 11 plants. The results from the first four CAT inspections are not' included because the extent of inspection was not the same as.that of all subsequent inspections. In addition, the reactor internals and ' fire' protection systems were not inspected in all plants. Table 1.1 identifies the'11 plants for which the results are included in this . report and.the' dates of the CAT inspections as well as the architect-engineer / constructor of each plant and the type of reactor (boiling-water reactor (BWR) or. pressurized-water. reactor (PWR)) at each plant. 1.2 Objectives of Appraisal The primary objective of the appraisal of welding and nondestructive examination (NDE) activities was to determine if these activities, which have been accepted by; quality control personnel, were controlled and performed in accordance with design requirements, Safety Analysis Report commitments, and applicable codes and' specifications. 'Another objective was to determine whether personnel involved in welding and NDE activities were trained and qualified in accordance with established per-formance standards and applicable code requirements. To accomplish the above objectives, the CAT inspected welds and welding details i for. piping and pipe supports or restraints; field-and shop-fabricated tanks; structural steel installations; heating, ventilation, and air conditioning (HVAC) installations; electrical supports; and instrumentation and control tubing and supports. The' inspected welds were selected to provide a representative sample of the welding activities of the licensee's contractor in terms of welding NUREG-1194 1-1 i _ _ _ - _. _ _____.________________j
o ' processes used, materia'ls welded, and existing weld-joint configurations. Physical location, difficulty'of. welding, and limited accessibility also were considered in selecting the samples. Design changes related to welding such as the increase or. decrease of weld size and a change-from one welding process or procedure to another also were reviewed for technical adequacy. j NDE activities were appraised through the review of radiographs of field-and I shop-fabricated welds, the review of NDE procedures and personnel qualifications, the evaluation of the calibration status of NDE equipment, and the observation of. in process NDE activities. 1.3. Appraisal Methodology 1.3.1 Welding Activities The NRC CAT inspectors divided the welding activities into two major categories: j those pertaining to structural welds and those pertaining to pressure-retaining ] welds. ..These two categories were subdivided into two subcategories depending i on whether the welds were field-fabricated welds or shop-fabricated welds. The f main method used by the CAT inspectors was the visual inspection of welds. .l ( In the structural weld category, various areas were covered as shown in Table 1.2. These areas included pipe supports; electrical and instrumentation supports; heating, ventilation, and air conditioning supports; structural steel; and reactor internal, spent fuel pool, and refueling cavity liner welds. Most 'of the' structural welding was performed in.accordance with the: requirements of the American Welding Society, Structural Welding Code D.1.1 (AWS D.I.1). Some pipe' supports were fabricated in accordance with the requirements of the American i Society of Mechanical Engineers Boiler and Pressure Vessel Code (ASME Code), Section III, subsection NF. As shown in Table 1.2,,the total number of struc-tural welds in-the 11 inspected nuclear power plants was 20,933. Weld defi-ciencies were noted in 465 welds, which represented 2.2% of the total inspected welds. The main deficiency identified'was undersized welds. This represented 83% of all reported deficiencies. The next highest deficiency was the substi-tution of seal welds for fillet welds; 17 cases were reported, which accounted for 3.7% of'the total weld deficiencies. Twelve welds with insut ficient length accounted for 2.6%. All other types of weld deficiencies, such as porosity, unacceptable weld contour, insufficient wraparound, undercut, and lack of fusion, represented 10.7% (50 welds) of all the reported deficiencies. The pressure-retaining-weld category included welds in all classes of piping, 1 that is, ASME Code Classes 1, 2, and 3 and power piping fabricated under the rules of American National Standards Institute Standard ANSI B31.1. This cate-gory also included the containment liner and containment penetration welds. The number of pressure retaining welds inspected by the CAT was 12,511. Total deficiencies reported as a result of visual inspection were 24 defective welds (0.2% of the total inspected sample). The main types of deficiencies were im-proper weld profile (50% of the deficient welds), underfilled welds (33%), and other types (17%) such as arc strikes, undercut, and porosity. The vendor welds fabricated off site included those on tanks, pressure vessels, and heat exchangers. A total of 97 items were visually inspected. The main deficiency found was the undersized welds of nozzles and manways. This type of deficiency represented more than half of the inspected sample (56%), which is a NUREG-1194 1-2
very high frequency. In addition, in some cases (5 plants out of 11), under-sized welds were identified on some of the tank supports. The NRC has issued ~ Information Notice 85-33, which discusses undersized weld reinforcement in ASME Code nozzle-to-shell joints. In the final step of its appraisci of welding activities, the CAT inspectors reviewed 776 welder qualification test records and 295 welding procedures. The reported deficiencies included 6 welder qualification test records and 10 welding procedures that did not meet code specification requirements. These reported deficiencies represented 0.8% of the sample welder qualification test records and 3. G of the cample v. tiding procedures. 1.3.2 Nondestructive Examination Activities The CAT inspectors appraised'the ongoing NDE activities at the inspected construction sites. The NDE activities included visual examination, magnetic particle examination,' liquid penetrant examination, ultrasonic examination, and radiographic examination of welds. The data show that radiographic examination of welds accounted for most of the 'I CAT review. This NDE method generates a permanent record, that is, the radio-graphic film can be read and interpreted at any time. The rest of the NDE methods such as ultrasonic, liquid penetrant, and magnetic particle examinations ( do not generate such records; therefore, the reviews were limited to the actual observation of the performance by NDE inspectors of some of those' examinations. The CAT also evaluated a sample of NDE records to verify the adequacy.of NDE documentation, and reviewed HDE procedures, personnel qualifications, and the calibration status of.the NDE equipment. The CAT inspectors reviewed 44,254 radiographs, 85 NDE procedures, and 301 inspector qualification records, and i observed 146 NDE inspectors while they were performing inspections. The CAT findings were related mainly to radiographic examination of welds, and the deficiencies were divided into the following two categories: (1) Quality of welds: The deficiencies indicated on the radiographic film f included porosity, cracks, lack of penetration, and slag. A total of ( 51 radiographs showed weld defects. This represented 0.11% of all radio-graphic samples reviewed by the CAT. j ) (2) Film quality or radiographic technique used: The deficiencies involved q low-or high-density film, incomplete radiographic coverage, film artifacts, missing station marks, and missing or insufficient documentation of film. A total of 70 films were found to have technique-related deficiencies. This represented 0.16% of the total reviewed sample, NUREG-1194 1-3
L Table:1.1 Plants inspected by~the NRC Construction Appraisal: Team and. included in this' report l Architect-engineer /- Reactor 1 Inspection Dates Plant constructor type Nov. 7-19, 1983 Nine Mile Point Unit 2 Stone & Webster BWR Nov.'28-Dec.' 9. 1983 Engineering Co. [ l 'Feb. 13-25, 1984 Waterford Unit 3 Ebasco Services Inc. PWR. i ~ Mar. 12-23, 1984-l 'f Apr. 23-May 4, 1984 Seabrook-United Engineers PWR May 14-25, 1984 & Constructors July 30-Aug. 10, 1984 River Bend Unit 1 Stone & Webster BWR l Aug. 20-31, 1984-Engineering Co. 'Oct. 1-12, 1984 Shearon Harris Unit 1 Ebasco Services Inc./ PWR Oct. 22-Nov. 2, 1984 Daniels Interna-tional Corp. Dec. 10-20, 1984 Braidwood Sargent & Lundy-PWR. Jan. 7-18, 1985 Engineers Feb. 19-Mar 1, 1985 Millstone Unit 3 Stone & Webster PWR Mar. 11-22, 1985 Engineering Co. May 20-31,~1985 Clinton Power Station Sargent & Lundy BWR June 10-21, 1985 Engineers -Aug. 19-30, 1985 Byron' unit'2 Sargent & Lundy. PWR Sept. 9-20, 1985 Engineers Oct. 21-Nov. 1, 1985 South Texas Project Brown & Root / PWR Nov. 12-22, 1985 Ebasco Services Inc. Jan. 13-24, 1986 Palo Verde Unit 3 Bechtel Power PWR Feb. 3-14, 1986 Corporation l L 1 NUREG-1194 1-4 1
l 1 Table 1.2 Humber of inspected structural welds and deficient welds Welds of Other Inspected Undersized insufficient deficient Area of welding welds welds length welds Pipe supports. 10,850 309 10 8 Electrical and instrumentation supports 4,504 20 2 18 Heating, ventila-tion, and air con ~ ditioning supports 1,830 34 7 24* Structural steel 1,928 20 i Reactor internal, l spent fuel pool, and refueling cavity liner welds 1,821 3 10 Total 20,933 386 12 67
- 0f the 24 defective welds, 17 were identified as seal welds that i
were used instead of fillet welds. I 1 NUREG-1194 1-5 i
4I. 2fWELDING'ANDNONDESTRUC1IVEEXAMINATIONACTIVITIES 2.1 ' Piping and Pipe Supports or Restraints Welding Activities The CAT.' inspectors evaluated piping system welds, support or restraint welds, welding procedures, and weld and welder qualifications, and observed welder in process field performance. Representative piping and pipe support or restraint samples were select'ed from-systems such as.the' primary coolant system, various safety injection systems, the feedwater system, and the main steamline. Table 2.1 indicates the number of samples in each category and the. inspection findings for each plant. In general,:the welding activities were found to comply with the requirements of the applicable codes and specifications. Of.all the weld deficiencies iden- - tified during the CAT inspections, undersized welds, as shown in Figure 2.1, appear-to be the most prevalent. problem. Four or more types of weld deficien-I cies were identified in five plants,'as shown in Figure 2.2, and among all the plants nine different types of weld deficiencies were identified. L Nondestructive Examination Activities The CAT inspectors reviewed selected shop-and field-fabricated welds with all pertinent radiographic film.. In addition, they reviewed NDE procedures and NDE personnel qualification records to verify compliance with the governing codes and' specifications. Table 2.2 indicates the number of samples inspected in each category for a given plant and the number of NDE inspectors whose perfor-mance was observed by the CAT inspectors. In addition, inspection findings pertaining to NDE activities for each plant are given. In general, the NDE activities were found to comply with the requirements of j the' governing codes and specifications. However, unlike the welding activi-ties.there was no_ specific deficiency that appeared to be the most common problem at most plants. The vendors supplying field-and shop-fabricated piping and pipe supports for the plants reviewed in this report are listed in Tables 2.3 and 2.4, respec-tively. In general, minor welding irregularities or NDE deficiencies were identified on products of each vendor. However, none of these vendors were identified as having significant problems in their welding and NDE activities associated with both field-and shop-fabricated piping and pipe supports. 2.2 Reactor-Internals Objectives. The primary objective of the CAT appraisal of welding and NDE activities was to determine if the reactor internals were installed in accordance with applicable NUREG-1194' 2-1 1
.l specification'and design requirements and Safety Analysis Report commitments. Another objective was to determine whether the personnel involved in welding and NDE activities were trained and qualified in accordance with established -performance standards and applicable code requirements. ~ l To accomplish these objectives, the CAT inspectors reviewed a sample of docu-I mentation packages and visually examined a sample of welds to determine their quality. In addition,.they reviewed welding and inspection procedures and cer-tification and qualification records of selected welders and inspectors. The sample selected from each plant and the results are given in Table 2.5. Inspection Findings. Of the nine plants inspected,' seven plants did not have any problems. At the i other two plants, only one or two minor weld discrepancies were identified. 2.3 Electrical Installations and Supports Objectives The primary objective of the CAT inspection was to determine if welding and NDE activities performed on electrical installations and electrical supports were carried out in accordance'with applicable codes, specifications, design re-quirements, and Safety Analysis Report commitments. Another objective was to determine whether the personnel involved in welding and NDE activities were . trained and qualified in accordance with established performance standards and applicable code requirements. 'To accomplish these objectives, the CAT inspectors evaluated sample welds from i cable tray supports, junction box supports, and conduit supports and the instal-lation welds for electrical panels. They also reviewed welding procedures and qualification' records of welders and weld inspectors. In addition, they ob-served and evaluated the performance of weld inspectors to determine their ability to follow the visual inspection procedures. The sample selected from each of the 11 plants and the results are given in Table 2.6. Inspection Findings The inspection findings on electrical installations and electrical supports are shown in Figure 2.3. Of the 11 plants inspected, 4 were in accordance with requirements. At the remaining plants, undersized welds were found to be the most common problem. At two plants four or more weld deficiencies were identi-fied. At five plants two or more different types of weld defects were identi-fied as shown in Figure 2.4. 2.4 Instrumentation Tubing and Supports Objectives The primary objective of the CAT inspection was to determine if welding and NDE activities performed on instrumentation tubing and supports were carried out in accordance with applicable codes, specifications, design requirements, and Safety Analysis Report commitments. Another objective was to determine whether personnel involved in welding and NDE activities were trained and qualified i NUREG-1194 2-2
in accordance with established performance standards and. applicable code requirements. To accomplish these' objectives, the CAT inspectors visually inspected sample welds from instrument panels and racks. The sample selected'from each plant and-the-' inspection results are given in Table 2.7. Inspec' tion Findings As shown in~ Figure 2.5, of the 11 plants inspected, 5 did not have any report-able weld defects. At three plants undersized welds were reported, at two plants' undercut welds were reported, and at three plants defects other than undercut and undersized welds were reported. 2.5 Heating, Ventilation, and Air Conditioning System Objectises I The primary objective of the CAT inspection was to determine if welding and NDE activities performed on the heating, ventilation, and air conditioning (HVAC) system components such as supports, ducts, dampers, and air filters were carried l l out in accordance with applicable codes, specifications, design requirements, l and, Safety. Analysis Report commitments. Another objective was to determine whether the personnel involved in welding.and NDE activities were trained and qualified in accordance with established performance standards and applicable i code. requirements. To accomplish these objectives, the CAT inspectors visually inspected approxi-mately.120 to 200 support welds and welds on selected duct pieces, air blowers, dampers,'and air filter frames at each plant. Furthermore, they reviewed weld-ing procedures and qualification records for welders and inspectors and observed 4 and evaluated selected welding inspectors to determine their ability to follow the visual inspection procedures. The sample selected from each plant and the results are given in Table 2.8. Inspection Findings As shown in Figure 2.6, 6 of the 11 inspected plants did not have any type of significant weld defects. At the other five plants undersized welds, burned- - through welds, and other kinds of weld deficiencies were identified. Fig-ure 2.7 shows the number of deficiencies that were identified for the plants inspected, j 2.6 Fabrication, Erection, and Modification of Structural Steel Objectives The primary objective of the CAT appraisal of welding and NDE activities was to determine if the structural steel was fabricated, erected, and repaired in accordance with applicable codes, specifications, design requirements, and Safety Analysis Report commitments. Another objective was to determine whether the personnel involved in welding and NDE activities were trained and qualified in accordance with established performance standards and applicable code requirements. l l NUREG-1194 2-3 )
i To accomplish these' objectives, the CAT inspectors evaluated samples of shop-and field-fabricated welds, welding procedures, welder qualification test records, and NDE inspector qualification records. At most plants they observed ) and evaluated NDE inspectors while they performed an inspection. In 2 plants (of 11), they reviewed the radiographic films.for some welds. The sample from each plant and the results are given in Table 2.9. Inspection Findings Figure 2.8 summarizes the types of welding and NDE deficiencies in structural steel. reported. Reportable deficiencies were found in 10 of 11 plants. In six-plants, the' CAT inspectors found that seal welds were used instead of fillet welds as required by specifications. At five plants undersized welds were
- reported, Other weld deficiencies including unacceptable contour, undercut, and lack of fusion were reported in four plants.
Of the two plants where radiographs were examined, the CAT reported that at one plant an incorrect radiographic technique had been used resulting in inaccurate weld radiographs. Figure 2.9 shows the number of weld deficiencies reported in each plant. At seven plants ~one type'of weld deficiency was reported. At three plants two or more types of deficiencies were reported, and at one plant there were no weld deficiencies. 2.7 Refueling Cavity and Spent Fuel Pool Liner Objectives .The primary objective of the CAT inspection of welding and NDE activities was to determine if the refueling cavity and spent fuel pool' liner were fabricated, erected, and repaired in accordance with the required codes, specifications, design requirements, and Safety Analysis Report commitments. Another objec-tive was to determine whether the personnel involved were trained and quali-fied in accordance with established performance standards and applicable code requirements. To accomplish these objectives, the CAT inspectors visually inspected sample seam welds and welds in plates and brackets and examined some welding procedures and some welder qualification test records. They also reviewed NDE procedures and records and observed a number of the NDE inspectors while they performed inspections. The sample from each plant and the results are given in Table 2.10. Inspection Findings In 8 of 10 plants inspected no problems were reported. In one plant a minor weld defect as shown on one film was reported. In the remaining plant some undersized welds were identified, and fillet welds were used in some cases instead of the required full penetration welds. Figure 2.10 shows the number of weld deficiencies in.the refueling cavity. 2.8 Containment Liner and Penetrations Objectives The primary objective of the CAT inspection was to determine if welding and NDE activities performed on the containment liner and penetrations, such as NUREG-1194 2-4
mechanical or electrical penetrations, openings, and hatches, were carried out in accordance with appl.icable codes, specifications, design requirements, and i Safety Analysis. Report commitments. ' Another objective was to determine if' the personnel involved in. welding and NDE activities were trained and qualified in accordance with established performance standards and applicable code requirements. To accomplish these objectives, the CAT inspectors visually inspected samples of seam welds, mechanical and electrical' penetrations, and welds in plugs, openings, and hatches and examined some welding procedures and some welder -qualification test records. They also reviewed a sample of radiographic films and NDE procedures. The sample from each plant and the results are given in Table 2.11. Inspection Findings In three plants deficient radiographic films were reported. Some weld defects identified on the film were porosity, linear indications, and aligned indica-. l tions. In other cases, poor radiographic techniques were reported, such as the absence of identification labels and nonauthorized corrections. High-density film also was reported. Figure 2.11 shows the number of weld deficiencies in the containment liner and containment penetrations. 2.9 Fire Protection System: Objectives The primary objective of the CAT inspection was to determine if the fire protec-tion. system was fabricated and erected in accordance with the requirements and the Safety Analysis Report commitments. Another objective was to determine if the personnel were trained and qualified in accordance with established perfor-mance standards and applicable code requirements. The CAT inspectors visually inspected a sample of pipe and support welds and reviewed the welding procedures and the qualification test records for some welders. The sample from each plant and the results are given in Table 2.12. Inspection Findings The CAT inspected eight plants. In seven plants, no significant deficiencies were reported. In one plant, a minor deviation from the design in one support was reported. 2.10 Vendor-Fabricated Tanks and Heat Exchangers Objective The objective of the CAT inspection of vendor-fabricated tanks and heat j exchangers was to determine if welding and NDE activities were performed in accordance with applicable codes, specifications, design requirements, and Safety Analysis Report commitments. To accomplish this objective, the CAT inspectors visually inspected a number of items (tanks, pressure vessels, and heat exchangers) and evaluated the vendors NUREG-1194 2-5
that'provided these items at each plant. In addition, they examined a sample of the radiographic films for welds, seam welds, and spot welds and a sample of the radiographs of the bodies of valves, pumps, and some castings. The sample from each inspected plant and the results are given in Table 2.13. Inspection Findings Figure 2.12 summarizes the reported welding and NDE deficiencies for vendor-fabricated tanks, heat exchangers, pumps, valves, etc. Undersized welds were found in 9 of the 11 plants inspected. Undersized welds were found in the nozzle-to-shell welds of the pressure vessels and in the structural welds of the_ item supports. The NRC has issued Information. Notice 85-33, which discusses undersized weld reinforcement in ASME Code nozzle-to-shell joints. The CAT found that some plants had not taken any steps to inspect tanks and heat exchangers before the NRC CAT inspection. Poor quality radiographic films including high-or' low-density films and yel-low films were found in six plants. Poor radiographic techniques were identi-fied for three plants. Such poor techniques included the absence of station markers, missing identification markers, poor film development, or the masking of some parts of interest on the weld to be inspected. In two plants films were misfiled or impossible to locate. Defects identified in films that were not reported on the reader's sheet were found in five plants. Such defects included linear indications, cracks, and slag. 1 Figure 2.13 shows that at 8 (of 11) plants two or more reportable weld defi-ciencies were identified. Two plants had one type of reportable deficiency, and one plant had no reportable deficiencies. NUREG-1194 2-6
1 1 i. I I I I I I I I I I V///////////////////////////////////////////////////jf///////////////////////////////////4 j UNDERSIZE l UNDERCUT Ifff//////////J l 1 '///////////////////////////) V POOR PROFILE I U INSUf flCIENT z WRAPAROUND ~ E I g WEAVING 7/////////////j l 8 '" "' *!$ VZgr#MA tE ARC STRIKE f////// CRACKING F/////M E////I E////d COOL NG F 1 I /////////MN((////// R D 0C APF I I I I I I I O 1 2 3 4 5 6 7 8 9 10 NUMBER OF PLANTS 'PWHT POST. WELD HEAT TREATMENT Figure 2.1 Types of weld and NDE deficiencies in piping and pipe supports or restraints l I i l 0 OR $1$ / / // i o 5 -u pj/p![ THREE e I W 3 ffffYffffffff/ h i 1 m
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1 2 3 4 5 6 NUMBER OF PLANTS Figure 2.2 Number of weld deficiencies in piping and pipe supports or restraints NUREG-1194 2-7
(([//[ ((,(((((( I[ UNDERSIZE nz (((((( UNDERCUT O O (((((( CRATER u_ O '(((((((((((( OTHER TYPE fllllllfllllllffffflllllllllll}f) V NO DEFECT O 1 2 3 4 5 6 NUMBER OF PLANTS Figure 2.3 Types of weld deficiencies in electrical installations and supports $c 6 ORNOE O 9 W/fflllf?/// o 5 m WMff//Mffff////fM//A i ie"o o 0 1 2 3 4 5 6 NUMBER OF PLANTS Figure 2,4 Number of weld deficiencies in electrical installation and supports NUREG-1194 2-8
UNDERStZE 5. b I(((( g UNDERCUT r 8 V((f[ffffff(( f[ OTHER TYPE V//////////////////////////fff//////M//////////////A ~o oerecr ) 0 1 2 3 4 5 6 NUMBER OF PLANTS Figure.2.5 Types of weld deficiencies in instrumentation tubing and supports (((((((((((((((([ [ [ UNDERSIZE /(([ [ V g UNDERCUT 5 9 (((((( CRATER 1 m / // TH o Vl/lllllllllllllllllllllllllllllllll}flllllllllllllllll) / NO DEFECT, 0 1 2 3 4 5 6 NUMBER OF PLANTS Figure 2.6 Types of weld deficiencies in heating, ventilation, and air conditioning systems NUREG-1194 2-9 i
S ' OR MOR . o ) o. E V/////f///M////A oue O l 6 m f f ll,,) j ZERO l 0 1 2 3 4 5 6 NUMBER OF PLANTS Figure 2.7 Number.of' weld deficiencies in heating, ventilation, and air conditioning systems (( UNDERSIZE n F LLE 'EL o NNI"eNCNE ~ /////////////////////////////////b c 'lNACCURATE t RADIOGRAPHS A 0 1 2 3 4 5 6 1. l NUMBER OF PLANTS Figure 2.8 Types of weld and NDE deficiencies in structural steel NUREG-1194 2-10
dc .b OR MO - O' 9 ua (( ZERO i O 1 2 3 4 5 6 7 NUMBER OF PLANTS Figure 2.9 Number of weld deficiencies in structural steel Wu 6-O .TWO @ ' OR MORE /A O + O F a [ ONE o 5 m ZERO j i 0 1 2 3 4 5 6 NUMBER OF PLANTS Figure 2.10 Number of weld deficiencies in refueling cavity NUREG-1194 2-11
f-r- G .g i N w OR MO J Q. o 5-m 2 M 1 Ir 0 1 2 3 4 5 6 7 NUMBER OF PLANTS Figure 2.11 Number of weld deficiencies in containment liner and containment penetrations 1 l l / 4 i i D ED FE T sc RADIOGRA F y o [ RADIOGR PH TECHNIQUES f 0 1 2 3 4 5 6 7 8 9 NUMBER OF PLANTS F1 ure 2.12 Types of weld and NDE deficiencies in vendor-fabricated 0 tanks and heat exchangers NUREG-1194 2-12 L__________________
Oc 3, OR MOR O 9 Y/////////////////////E "E / O 6 m (( D ZERO 4 0 1 2 3 4 5 6 7 8 NUMBER OF PLANTS Figure 2.13 Number of weld deficiencies in vendor-fabricated tanks and heat exchangers i l l i 1 l .i NUREG-1194 2-13 l l ._-.---__ ____ __ _ _ u
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y s y s e y s fb e a t a t z a t i as ws w r d tl w r w r n i n o n o i n n o e e ni2d a a p k r ea a p a p me p e me p sd g me p s e d vdl i aei r u b r u nee r r u a w d e s d e s ot r o d e s m rf E nw t nw ire s nw s s si s i a n s k aaui a n o a n' t ow ) i n ) i ap - d ) i t r wwqm a e es es ces es c rm e l k s. at m mt rs l k s .d l k s.i zn ddl zn ddd l r zn ddf s l esew enti e za l eien i za l eu za l ot eio ot eiiof w ot eit ro f h n wf c n wf n n wf rei htt r att yp ir w .s 6. i 6. i 7 d ddt aeodt d ddt na t af e d ddt s. i roh eneenmd eneenerl er eneenmic sg i o z ii z e l i. ziizel e ziizenel i(fidit i (fidi wef p i(fidiff gnod s i sif a s i sil yi e s isif oineiar rst r c rst r s t r rst r tidd ee s ed neeeo ed neeemen edneeeans - atd g dl ed rml dl ed rml meE dl ed rmeeswrsa n nedneol ned neoiodD ned neordi o ne i U wiU wS a U wiU wSfSiN U wiU wS aI mL1iR dn r i 1 2 3 4 5 1 2 3 4 56 F 1 2 3 dn ,as g ) s ,n d esi e vpt u l ms 4 5 5 n s aua 0 0 4 i h Vpc 3 1 2 t p n a o r C g ) ( o s i d t d sl o 3 a d e p 1 R l w t s e ) o 2 wr 1 p 0 e 5 ss 8)7 s 5) d d 12 e mh 4,3 l 651,l 1, 2 4 1 1,1 1 at 9 l e b eo 829 e a S( 8( + w 3( + w 1( T n n n d o o o i se i i mt s t s t s t rec ml c ml c ml c ot e eae eae eae di p t up t up t up n s iss i ss i ss ern i n i n i n Voi 6vi 9 vi 8vi tce 3 jo t r i P n U 2 s t a e x d in e r U T e V t n h n o t o a r u l l y o a P B S P Lg S' o zc 7,q)Tg
m g 4 3: CONCLUSIONS Inl general,~the CAT. inspect' ors.found that the reviewed welding and NDE activi-ties at'all plants, including-the four plants not covered in this report, were . conducted in accordance with applicable codes and specifications. However, a F -number of deficiencies in the welding area and a few discrepancies in radiogra-S .phic packages were identified. In all. cases, the applicant has' evaluated these problems-and has taken corrective actions or dealt'with the identified defi-E ciencies to ensure.. minimally significant safety consequences.. In Figure 3.1, n'+ -.the_ number of plants that were found'to have welding or NDE deficiencies for a c l~ given reactor system or component is shown. ~ On th'e basis of-the inspection findings described in'this report, the staff concludes ~the,following: (1) ~ ' Of the various t' ypes of welding deficiencies, undersized welds were the most common problem identified in the piping and pipe support or restraint area; this area.should continue to be emphasized in future inspections. (2) In the NDE area,, inadequate radiography 'was the most. common problem. (3) Minor weld deficiencies in the following areas were identified at a'few-plants: ' electrical'insta11ations instrumentation tubes and supports heating, ventilation, and air conditioning systems modification and installation of reactor internals (4) Piping and pipe supports or restraints showed the most weld deficiencies and radiographic discrepancies. However, it should be noted that the sample size was larger in this area.than in the other areas. -(5) Several welding and NDE deficiencies were identified in tanks and heat exchangers and structural steel. These were followed by the electrical installations and electrical supports, instrumentation tubes and supports, and heating, ventilation, and air conditioning systems. -(6) Few or.no weld defects and NDE discrepancies were identified in areas such as the modification and installation of reactor internals, fabrication of the refueling cavity and spent fuel pool liner, and the fire protection ' system. (7) Continued emphasis should be placed on the inspection of piping, pipe supports or restraints., and tanks and heat exchangers because more significant weld deficiencies and radiographic discrepancies were observed in tnese areas. I NUREG-1194 3-1 I
l l l l l l l l l l l P'%'eo'M M////////////f/////////////////////////////f///////J'M Y G ! !!/!d IN JAL o ELECTRICAL e Z INSTRUMENT AllON / l 'MIEESI^e'o??r NE4 ~ l 5 d uvAc Vfff////////fr/ffffff//////) 3 l l STRucTgRA c E "s's rf//#/f/////> z PROTECTI J O CoNTAnNy ypppppppg 2 TANKS PRESSURE V/////////////////fff/////////////////////f/////////////////}{f//////$$ y VESSELS Et HEAT p EXCHANGERS l l l l l l l v> 0 1 2 3 4 5 6 7 8 9 10 11 12 NUMBER OF PLANTS Figure 3.1 Number of plants found to have welding or NDE deficiencies in a given system or component l 1 NUREG-1194 3-2
l 4 REFERENCES American National Standards Institute, 831.1, " Power Piping," 1973. American Society of Mechanical Engineers, Boiler and Pressure Vessel Code, Section III, subsection NF, " Compound Supports," 1971 Edition. American Welding Society, Structural Welding Code 0.1.1, " Structural Welding Code.1972 Through 1974," American Welding Society, Miami, Florida. U.S. Nuclear Regulatory Commission, Office of Inspection and Enforcement, IE Information Notice 85-33, " Undersized Nozzle-To-Shell Welded Joints in Tanks and Heat Exchangers Constructed Under the Rules of the ASME Boiler and Pressure Vessel Code," April 22, 1985. NUREG-1194 4-1
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sit FN3f kVCf son e DN T at N$t ) /'+f6 4 AND 5L91tfLE I LE A.E 6LaNn Construction praisal Team Inspection Results on i Welding and N estructive Examination Activities j o.n. ..,,n cuo,avio y,- l .. 1 -0.,, U f une 1987 Paul C. S. Wu, H. . Shaaban MONTM v6AM September 1987 ,.... o om, o%,Nie. noN N....No.. m,.oo.. n,,,,,,,,,, c,
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.t. j Division of Reactor spection and Safeguards ) Office of Nuclear Rea or Regulation U.S. Nuclear Regulato Commission Washington, DC 20555 h 10 FDN$0.iNG ORGANel A f sQN N Apt AND Maill4G.O E SS,,wis,m le cades Iis f 'Pt O, PEPOHT Same as 7 Technical e PERIO3 COVtRED f,estms e cenre, i. .j 4 a sueruvi r.av Nous ) e \\ o..... c, _ t This report summarizes data and dings on deficiencies and discrepancies in onst}'ctionAppraisalTeam(CAT)duringits welding and nondestructive exa on (NDE) activities identified by the U.S. na Nuclear Regulatory Commission inspection of 11 plants. Th CAT re 'ewed selected welds and NDE packages in l its inspection of the follo ng plant reas: piping and pipe supports and/or restraints; modification a,d installa on of reactor internals; electrical installations and'electri 'l supports; tostrumentation tubing and supports; heating, ventilation, an air condition 1 (HVAC) systems and supports; fabri-cation and erection of tructural steel; $brication of refueling cavity and spent fuel pool liner containment liner i d containment penetrations; and fire protection systems. he CAT inspected bott tructural welds and pressure-retaining welds and eviewed welder qualifid ion test records and welding pro-cedure documents f ' code compliance. The N actiyities that were evaluated included visual e ~mination, magnetic partici examination, liquid penetrant examination, uit osonic examination, and radio 'aphic examination of welds. hy se Docuwt NY amatvs.si. m a r usios scairt ons 35 ava,gasioit, 5 STATEMENT Constructi Appraisal Team Inspection, Welding, Non , Radiography,UltrasonicExamination, Liq (;struction Examinati id Penetrant Unlimited Testing, eactor Systems. s l \\ m., \\ t Unc1assified N a,,,,..,, CAT I spection, NDE, RT, UT, PT, Shop Welds, Field Welds. N 5 ii Nuvetao. Paces 19 PRiCf e U. S. C0".Rh4E WT PRlhT ING 041CE 1987.101-6B 2s 60220
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