ML20072T350
| ML20072T350 | |
| Person / Time | |
|---|---|
| Site: | Seabrook, 05000000 |
| Issue date: | 06/03/1982 |
| From: | Mcgarrigan D UNITED ENGINEERS & CONSTRUCTORS, INC. |
| To: | Parisano J UNITED ENGINEERS & CONSTRUCTORS, INC. |
| Shared Package | |
| ML20071K200 | List: |
| References | |
| FOIA-82-524 NRC-2117, NUDOCS 8304080049 | |
| Download: ML20072T350 (21) | |
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. r MEMORANDUM ek 3 l J JR 3112 ge .-
- e. ulited engineers . . -
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, No. 9763506 .
OFFICE: Phi 3adelphia N P.O. 248-51 .
- r. R211 ability & Qualit c .ssurance D TE: ril 16 1982
' ci Q , May 28, 1982 N# 91 l.
J. J. Parisano*- 06U6 COPfE5: A.M. Ebner - 06U0 D.H. Rhoads - 06U0 J.B. Silverwood/ - 14U6 R.H. Leonard
- D. E. McCarrigan* - 14U6 *C, Kelly - 06U6
- R. C. Lasnefsky - 14U6 -
. .. J.N. Babcock - 14U4 --
J.P. Cannon - 14U3 D.J. Reinert - 14U3 Mb Subjecc: Public. Service Company of New Hampshire 4
Seabrook Station - Units 1 and 2 Penetration / Plate Welds Pullman Ringins NCR 2117 -
l As per our meeting of April 15, 1982 I have summarized the background information, technical justification and proposed resolutions for the questions l en the containment penetration / plate welds. These questions and the subject
- MCR required extensive code review and resulted in the following:
- 1) Code Roundary Between ASME Sect _fon_IIT Division __1__and_Divisi_on 2. _
The Code boundary is d= fined by the UE&C Drawing 9763-7-805578. ..
The weld between the penetration sleeve and piste perfor:ns a containment function providine for. the process pipina to penetrate containment. At tne option or tne Division 2 designer, this weld was originally designed to be welded to Class 2 Timion I~ rules. However, this Division 1
,work is part of containment not part of the piping system. Pullman-Higgins must complete a separate N-5 Code Data Report for this weld which will be included in the Construction Report for the Containment.
- 2) Subs _ection NE Or Subsection NC Tor Penetration / Plate and Plata/ Pipe Wel_ds,.
The penetration / plate weld joint configuration provides a full penetration corner weld. The plate / pipe weld is e partial penetration weld. Both joint designs were selected to provide the structural integrity required for these joints as well as being ASME Code approved joint configurations.
These joints can be made under the requirements of either subsection as -
allowed by Division 2. The present design calls for Class 2 welds to l Subsection NC. Thf s Subsection requires raplography of the joint. Attempts to get meaningful radiography have failed. Subsection NC does not a]3ow the substitution of ultrasonics or magnetic particle method.s for the Penetration / plate velds. The design will be changed to call out the weld as Class MC, Subsection NE. Pullman-Higgins does have an MC Certification and Subsection NE does allow the use of alternate .NDE methods.
8304000049 830304 *Att. ended the Meeting PDR FOIA KINDER 82-524 PDR.
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' 3) Nondestructive Examinardon of the Plate Material and Finished Welds.
Subsection NC requires MagnetJe Particle Examina& don prior to welding:
of weld edge preps in materf al joints 2" thick and over. The change to subsection '?E will require Magnetic Particle Examination of plate material greater than h". This channe vill affect all the mechanical penetration plates because they are 3/4".1", and 2", thick. However.
the material is SA 516 GR60 supplied with U2trasonse examination.
Ultrasonic examination is n' sed by the material supplier to detect lamellar defects. The Code's reason for specifying magnetic particle examination of the veld joint preTwas to detect lamellar type defects.
The NCR should be dispositioned " Accept-as-is" based on the substitution of ultrasonic for magnetic particle examination. In addition, Sub-section NE requires thae-the final welds and all exposed cut edges be Magnetic Particle examined. This will be done. 'The NDE required
, for acceptance of the penetration /pInte. weld is Ultrasorries, Magnetic l Particle, or Liquid Penetrant. The Magnetic Particle examination will l cover both material and weld requirements.
- 4) Impact Testing of Place Material. .
,_ Subsection NC did not require.dapact testing of the plate. It was an option only required if specified in the Design Specification.
Engineering did not recuire impacts as directed by YAEC. Subsection NE does require '
impact tests. Dravo who supplied the materlat nas additional material and impact tests can be performed.
Pr posed Resolution Items
- 1) UE&C change the penetration / plate and plate /pige welds to " Class NC., .
Subsection NE. The penetration / plate weld is a Category C weld joint and the plate / pipe weld is a Category D weld joint.
- 2) Disposition Pullman-Higgins NCR 2117 " Accept-as-is" for all penetration Plates of Unit 1.. Attach this memo for technieml justification. Have the Authorized Inspector and YAEC concur with this disposition. Include this NCR and tha P-H N-5 Data Report in the Construction Report.
- 3) DE&C have Dravo perform Impact Test on the Plate material at the -25 P test temperature required for the containment penetration base metal.
Impact test should be done in accordance with Subsection NE requirements.
- 4) Bave Pullman-Higgins perform Magnetic Particle Examination of all mechanical penetration place welds and exposed cut edges.
- 5) Have Pullman-Higgins prepare an N-5 Code Data Report for these welds. .
The Structural Integrity Test will be the Containment Pressure Test at 1.15 times the design pressure as required by CC-6000 and specification 80-1.
- 6) UE&C have Unit 2 penetration plate veld joint preps Magnetic Particle examined by Dravo or Pullman-Higgins prior to welding. -
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- 7) Revine Drawing 9763-T-805578, Piping System Design Specification 9763.006-248-43 (Tabte 2.2-15) and Containment Design Specification to define these welds as Subsection NE, Class MC.
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APPENDIX A --
NOTICE OF VIOLATION Public Service Company of New Hampshire 3 Seabrook Unit 1 Docket No. 50-443 4 License No. CPPR-135 As a result of the inspection conducted June 21
' July 2,1982, and in accor-dance with the NRC Enforcement Policy, (10 CFR 2, Appendix C) published in Federal were Register Notice 47 FR 9987 (March 9,1982), the following violations identified:
A. a 10 CFR 50, Appendix B, Criterion Virequires that'f;,fg "gf ff, u f ,,mwm fo C o k 7/E*
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- v. I y E.r.h organization performing quality related activities covered by this
- r document control system. program, includine vendors aodat t;e_ consEu(tors, is It shall provide assuranc' The' system %all be defined in written procedures. !
instructions including changes which pregeribe activities ng quality affectie th are reviewed for adequacy and approved for release ~by authorized pdrsonn e (subsection activities 17.1.3), and distributed to the locations where are performed.I'#
quality related 3
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' . ,,To provide general instructions to assure all documents, are controlled .
The requirements shall assure that documents, including revisions, are i i
reviewed, approved and distributed to and used by personnel at the loca- '
tion where the activity is being performed. " ~h e
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This is a Severity Level IV violation (Supplement II).
Pursuant to the provisions of 10 CFR 2.201, Public Service Company of New Hampshire is hereby required to submit to this office within thirty days of
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. the date of this Notice, a written statement or explanation in reply, inclu-l ding: (1) the corrective actions which have been taken and the results s achieved; (2) corrective steps which will be taken to avoid further violations;
'g l and (3) the date when full compliance will be achieved. Where good cause is gh shown, consideration will be given to extending this response time. ..
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the le{ancepoce-The responses directed by this notice are not subject dures of the Office of Management and Budget as requ r gg;3- ,
' i--t S. Reduction Act of 1980, PL 96-511. ., g c,
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CompanyofNewHampshire 1671 Worcester Road l Framinoham, Ma==achusetts 01701 !
(617) - 872 - 8100 May 19, 1982 SBN-276 T.F. B 4.2.7 United States Nuclear Regulatory Commission .
Office of Inspection and Enforcement Region I 631 Park Avenue ~
King of Prussia, PA 19406 .
Attention: Richard W. Starostecki, Director Division of Resident and Project Inspection
References:
(a) Construction Permits CPPR-135 and CPPR-136, Docket Nos. 50-443 and 50-444 (b) USNRC Letter, dated April 19, 1982, " Combined Inspection Nos. 50-443/82-02 and 50/444/82-02"
Subject:
Response to Inspection Nos. 50-443/82-02; 50-444/82-02
Dear Sir:
In response to the violation, which you reported in Reference (b), PSNH offers the following:
NRC Notice of Violation: (443/82-02-02) 10 CFR 50, Appendix B, Criterion II and the Seabrook Station PSAR require that special processes, including welding and non-destructive testing, be controlled using qualified procedures in accordance with applicable codes. The applicable editions of the ASME Boiler and Pressure Vessel Code, Sections III and II, specify respectively (1) magnetic particle avamination (MT) of weld edge preparation surfaces in material two inches i
thick or more and (2) welding procedure qualification for impact required material less than 5/8 inch thick, using a test coupon representing the minimum thickness to be welded.
Contrary to the above, as of March 19, 1982, velding had 5s.en accomplished on containment piping penetrations (sleeve to end plate closure) with (1) MT not performed on the weld edge preparation of certain two-inch thick end plates and (2) a welding procedure (IT12-III-1-0B-12) not qualified to the minimum thickness listed in its '
thickness range for impact required material. ,
This is a Severity Level IV Violation (Supplement II).
.1GhD-hdk
, .. aiens Richbrd W. toroceseki ,
Paga 2
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Response
Corrective Action Taken and Results Achieved .
Due to the different provisices of ASME Codes, year and addenda, utilized as a basis for design, shop fabrication, and installation (i.e., the 1971 code for design, the 1974 code for shop fabrication, and the 1977 code for installation) inappropriate Nondestructive Examination (NDE) and impact test requirements for material and fabrication of the affected components were specified by the designer.
The design specifications and appropriate drawings are presently in the l process of being revised to properly define the required code boundary l limits and classification.
Impact tests will be performed as required by code and weld procedures ,
are in the process of being properly qualified to the required code !
provisions.
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Total corrective action is scheduled to be completed by July 15, 1982.
Notice of Violation: (443/82-02-04) 10 CFR 50, Appendix B, Criterion III and the Seabrook Station PSAR require that the appropriate quality standards be specified and the applicable design criteria be translated into drawings and procedures.
The applicable editions of the ASME, Boiler & Pressure Vessel Code,Section III, Table XVII-2452.1-1 and AUS Code D1.1, Table 2.7 specify minimum fillet weld sizes for joining members.
Contrary to the above, as of February 26, 1982, the design criteria for l fillet weld sizes specified on several UE&C Drawings (e.g.: F104038) governing pipe whip restraint installation were incorrect in detailing undersized welds with respect to either ASME,Section III or AWS requirements. Installation of certain pipe whip restraints (e.g. : l PW-203-5) to incorrect veld criteria had been completed and accepted by quality control inspection personnel.
This is a Severity Level IV Violation (Supplement II).
Response
Corrective Action Taken and Results Achieved As a result of this inspection, UE&C initiated an engineering review of all pipe whip restraint drawings and analysis. This review resulted in the following determinations:
, a) Fillet weld sizes were based on stress requirements only and AISC i
and ASME minimum weld size requirements had not been introduced.
b) Forty-two undersize fillet welds had been specified in the design drawings. Thirty-seven configurations of pipe whip restraints are involved, from a total of one hundred and twelve pipe whip l restraints.
secesc Nucicer Regulctory C mmiscica May 19, 1982 -_
eign Richar J. ractccki Pags 3 UE&C, the designer, has initiated Engineering Change Request (ECA) NO.
- 19/0289A which listed the weld:s identified above and requested that the installation contractor reinspect the one hundred and twelve pipe whip restraints to determine if the weld sizes met the minimum weld size criteria of ASME and AISC. Non-conforming welds will be identified and corrected.
The reinspection is expected to be completed by May 31, 1982.
Very truly yours, YANKEE ATOMIC ELECTRIC COMPANY W hn Vice President COMMONWEALTH OF MASSACHUSETTS)
)ss MEDLESEX COUNTT )
Then personally appeared before me, W. P. Johnson, who, being duly sworn, did state that he is a Vice President of Yankee Atomic Electric Company, that he is duly authorized to execute and file the foregoing request in the name and on the behalf of Public Service Company of New Hampshire and that the statements therein are true to the best of his knowledge and belief.
- 8% .
A. (A.V Leg'endre, CJf. Notary Public My Commission Expires August 5, 1988 1
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APPENDIX A
. NOTICE OF VIOLATION Public Service Company of New Hampshire Docket No. 50-443 Seabrook Unit 1 '
License No. CPPR-135 As a result of the inspection conducted February 16 - March 22,1982, and in accord-ance with the NRC Enforccment Policy, 47 FR 9987 (March 9,1982), the following violations were identified:
A. 10 CFR 50, Appendix B, Criterion IX and the Seabrook Station PSAR require that special processes, including welding and nondestructive testing, be controlled using qualified procedures in accordance with applicable codes.
The applicable editions of the ASME Boiler and Pressure Vessel Code, Sections III and IX, specify respectively (1) magnetic particle examination (MT) of weld edge preparation surfaces in material two inches thick or more and (2) welding procedure qualification for impact required material less than 5/8 inch thick, using a test coupon representing the minimum thickness to be welded.
Contrary to the above, as of March 19, .1982, welding had been accomplished on containment piping penetrations (sleeve to end-plate closure) with (1)
MT not perfonned on the weld edge preparation of certain two-inch thick end-plates and (2) a welding procedure (IT12-III-1-08-12) not qualified to the minimum thickness listed in its thickness range for impact required material.
This is a Severity Level IV Violation (Supplement II).
B. 10 CFR 50, Appendix B, Criterion III and the Seabrook Station PSAR require that the appropriate cuality standards be specified and the applicable design criteria be translatec, into drawings and procedures. The applicable editions of the ASME, Boiler & Pressure Vessel Code,Section III, Table XVII-2452.1-1 and AWS Code DI.1, Table 2.7 specify minimum fillet weld sizes for joining l members. ,
Contrary to the above, as of February 26, 1982, the design criteria for fillet weld sizes specified on several UE&C drawings (eg: F104038) govern-ing pipe whip restraint insta11stion were incorrect in detailing undersized welds with respect to either ASME,Section III or AWS requirements. Installa-tion of certain pipe whip restraints (eg: PW-203-5) to incorrect weld cri-l teria had been completed and accepted by quality control inspection personnel.
This is a Severity Level IV Violation (Supplement II).
Pursuant to the provisions of 10 CFR 2.201, Public Service Company of New Hampshire would be required to submit to this office within thirty days of the date of this Notice, a written statement or explanation in reply, including: (1) the corrective MMMb
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DETAILS l
..Ui.;PersonsContacted f .%. ~
J :.~; $iir Yankee Atomic Electric Comoany (YAEC)
T'9/.
F W. Bean, Lead Electrical QA Enginrier O. L. Covill, Lead Civil QA Engineer e- R.. E. Guillette, QA Engineer (Framingham) -
J.H.Herrin,SiteManager(PSNH)
G. F. Mcdonald, Jr., QA Manager (Framingham)
J. F. Nay, Jr., Lead Mechanical QA Engineeer
- 5. B. Sadosky, Lead Start-up/ Test QA Engineer l J. W. Singleton, Field QA Manager R. Tucker, Engineer (Framingham)
United Engineers and Constructors (UE&C)
R. H. Bryans, Site Engineering Manager .
T. R. Frolo, Welding Engineer J. A. Grusetskie. Engineering Manager Assistant R A. Kountz,. Welding Superintendent l D. C. Lambert, Field Superintendent of.QA D.E.McGarrigan, Pro,jectQAManager(Philadelphia) .
J. J. Murphy, Area Field Engineer Fischbach-Boulos-Manzi (FBM) l M. A. D'Orsay, QA Document Specialist.
) D. Kester, CASP Engineer Pullman-Higgins (Pullman)
R. G. Davis, Field QA Manager D. B. Hunt, QA Records Supervisor C. Scannell, Chief Field Engineer Royal Insurance J. C. Anzivino, Authorized Nuclear Inspector
4-
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. l L License Action on Previous Inspection Findings (Closed) Noncompliance (443/81-09-02): Undersized welds on Steam Generator lateral suppdrts. The inspector reviewed.the content and disposition of UE&C Nonconfomance Report (NCR) 1086, thru Revision 2, and correspondence between Westinghouse and YAEC regarding the weld deviations. The following actions were noted:
engineering analysis of each undersized weld condition with acceptability based upon loading direction, allowable design !
stress, and structural overdesign considerations.
-- evaluation of the Westinghouse QA program relative to the specific problem at Teledyne-Brown and other fabricators with corrective action emphasized at both the design and QA levels.
. --- detemination that the deficiency did not represent a major breakdown in the QA program and that 10CFR50.55(e) reportability was not required. '
The inspector evaluated the above actions and conclusions, along with supporting eng.ineering data. A generic approach to this prcblem and reinspections by YAEC, UE&C, and Westinghouse personnel were noted. The
( inspector has no further questions on either the acceptability of field l .
conditions or the direction of future corrective action.
- 4. Containment Piping Penetrations and Isolation Valves (Unit 1)
, a. Containment On-Line Purge (COP) Valves The inspector examined the condition of the two C0P Valves (V1 and 4) installed in the supply and return lines outside Unit 1 containment.
The UE&C design specification (248-45), Posi Seal drawings and cer-tifications, and connecting Dravo piping spool piece drawings were all reviewed as was the FSAR chapter 3.8, governing design pressure and temperature criteria. The inspector verified proper valve actuator orientation and confirmed " active" valve requirements for all four containment isolation valves in this system.
. No items of noncompliance were identified.
- b. Containment Piping Penetrations
~
The ins ~pector witnessed welding and grinding on the multiple piping penetration end plate to cantainment sleeve closure, governed by Pullman isometric drawing SL-X57-01. UE&C drawings were reviewed in conjunction with Regulatory Guide 1.19 and the ASME Boiler and Pressure Vessel Code,Section III to detemine code boundaries and installation criteria. Paragraph 3.8.2.1C of the FSAR. indicates the jurisdictional boundary between ASME III, Division 1 and 2, to be the outside face of the containment concrete, while UE&C drawings (eg: F805575) illustrate the end plate connecting weld to be the code boundary. The specific delineation of this boundary affects material requirements (impact)
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and weld NDE. The irispector questioned both the specified method of NDE (UT) for the closure welds and the detemination that impact requirements need not be considered.
While it is recognized that the A/E has the authority to establish code boundaries as an engineering prerogative, the results shculd be consistent with connitments made to the applicable editions of the ASME code. Since these closure welds are open to the containment
- atmosphere and essential to containment integrity, the questions raised by the inspector and the apparent inconsistency between the FSAR and drawings remain unresolved pending further analysis by the licensee (443/82-02-01).
The inspector also reviewed the welding procedure specifications (WPS) for both the end plate to sleeve closure weld (IT12-III-1-08-12) and the piping to end plate partial penetration welds- (81-III-8/1-08-12).
Supporting procedure qualification records (PQR) were examined for qualification of the WPS to essential variables of ASME, Section. IX.
The Dravo test reports and certifications for certain end plates (X20,21,22, and 23), each two inches thick, were compared to the material and NDE requirements of the applicable subsection of ASME,Section III.
With regard to both Section III and IX requirements, the following findings were noted:
(1) Contrary to ASME III, NC-5130, no magneti: particle examination was perfomed on the weld edge preparation surfaces of three of the above four, two-inch thick end plates. All are currently installed.
(2). Contrary to ASME IX, QW-403.6, WPS IT12-III-1-08-12 lists a ~
thickness range below the minimum for which it is qualified by PQR 016A irr impact required material.
~ ~ ~ ~ - ~
TNse~1tems lndidte a licT3Tc$ftsol over welding of the end plate
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to sleeve, penetration wieds. Tfle inspector infomed the licensee Site Manager, and Corporate and Field QA Managers during an exit interview on March 19, 1982 that this failure to control a welding process represented a noncompliance with regard to 10 CFR 50, Appendix B, Criterion IX (.443/82-02 02).
Additionally the inspector examined material records for the liner sleeve material for several containment penetrations listed on UE&C drawing F101497. Ishikawajima-Hurima Heavy Industries (IHI) process records, material certifications, and noncomformance dispositions were spot-checked to confirm conformance to purchase and code requirements.
No further items of noncompliance were identified.
l S. Pipe Whip Restraint Installation (Unit 1)
The inspector examined the installed condition of pipe whip (PW) restraints PW-203-5 for a safety injection line. He checked welds, configuration, L.__ _. _ _ . . _ _ .- .. _ _ _ _ . - _ - _ __ _
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- 9. Unresolved Items i
- s Unresolved items are matters about which more information is required in order to ascertain whether they are acceptable items, items of noncompliance, or deviations. Unresolved items disclosed during the inspection are l discussed in Paragraphs 4b and 5.
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- 10. Management Meetings l
At periodic intervals during the course of this inspection, meetings were held with senior plant management to discuss the scope and findings of this inspection.
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