IR 05000324/1987004

Insp Repts 50-324/87-04 & 50-325/87-04 on 870223-27. Violation Noted:Failure to Follow Welding Procedure Spec Parameters

ML20205N034
Person / Time
Site:	Brunswick
Issue date:	03/13/1987
From:	Blake J, Coley J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
To:
Shared Package
ML20205N001	List: ML20205M998 ML20205N011 ML20205N034
References
50-324-87-04, 50-324-87-4, 50-325-87-04, 50-325-87-4, NUDOCS 8704020565
Download: ML20205N034 (10)

Text

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UNITED STATES

[>R Cterf,b NUCLEAR REGULATORY COMMISSION

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Report Nos.: 50-325/87-04 and 50-324/87-04 Licensee: Carolina Power and Light Company P. O. Box 1551 Raleigh, NC 27602 Docket Nos.: 50-325 and 50-324 License Nas.: DPR-71 and DPR-62 Facility Name: Brunswick 1 and 2 Inspection Conducted: February 23-27, 1987 Inspector: d, t lu __ 3 -12-87 . rey Date Sig ed ( //

Approved by: )w nJj o 7 37 J. J B1 kti, Chief Date Signed Mat i s and Processes Section Di si n of Reactor Safety SUMMARY Scope: This routine, unannounced inspection was conducted in the areas of inservice inspection (Generic Letter 84-11), and welding activities for the existing weld overlay repair Results: One violation was identified - Failure to Follow Welding Procedure Specification Parameters paragraph .

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B704020565 870318 PDR ADOCK 05000324 G PDR J .

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REPORT DETAILS Persons Contacted

, Licensee Employees C. R. Dietz, General Manager

• J. W. Chase, Assistant to General Manager

• J. A. Smith, Director, Administrative Support

• M. B. Kesmodel, Supervisor, Document Control

• E. R. Eckstein, Manager, Technical Support

• J. Titrington, Supervisor, Engineering

• L. Wheatley, Project Engineer Inservice Inspection

• W. J. Dorman, Supervisor, Quality Assurance

• K. E. Enzor, Director, Regulatory Compliance

• R. M. Poulk, Senior Specialist, Regulatory Compliance

• G. J. Oliver, Manager, Site Planning and Control

• T. H. Wyllie, Manager, Engineering and Construction

• W. Murray, Corporate Licensing Other licensee employees contacted included engineers, technicians, operators, mechanics, security force members, and office personne NRC Resident Inspector

• B. Ruland, Senior Resident Inspector

• Attended exit interview Exit Interview The inspection scope and findings were summarized on_ February 27, 1987, with those persons indicated in paragraph 1 above. The inspector described the areas inspected and discussed in detail the inspection findings. No dissenting ' comments were received from the licensee. The following new item was identified during this inspectio (0 pen) Violation 325/87-04-01, Failure to Follow Welding Procedure Specification Parameters, paragraph The licensee did not identify as proprietary any of the materials provided

, to or reviewed by the inspector during this inspectio . Licensee Action on Previous Enforcement Matters This subject was not addressed in the inspectio _

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P Unresolved Items Unresolved items were not identified during the inspectio . Independent Inspection Effort Construction Progress The inspector conducted a general inspection of the Unit 1 Reactor-Building and Rod Shack B to observe construction progress and construction activities such as welding, material handling and control, housekeeping and storag Within the areas examined, no violations or deviation were identifie . Inservice Inspection (ISI)

During the current Brunswick 1, Reload 5, Outage, Carolina Power and Light (CP&L) has divided the scope of the ISI work among the following vendors and CP&L organizations: (1) General Electric (GE) will perform code and augmental ultrasonic examinations, (2) CP&L's Corporate Quality Assurance Department (Materials and Quality Section) will perform the surfac examinations, (3) Site Quality Control (QC) will perform the visual examinations and, (4) CP&L will perform the existing overlay repairs using Power Cutting Inc. welding operators that :have been qualified to _ CP&L's welding procedure The inspector examined documents, activities, and records of each of the above vendor /CP&L organizations to determine whether ISI was being conducted in accordance with applicable procedure, regulatory requirements and licensee commitments. The applicable code for 2nd intervals examina-tions is the American Society of Mechanical Engineers Boiler 'and Pressure Vessel (ASME B&PV) Code Section XI,1980 edition winter 1981. However, since CP&L started the 2nd interval early in order to have both Units utilizing the same code edition, 1st interval examinations completed during this outage will be performed in accordance with ASME B&PV Code,Section XI, 1977 edition with addenda through summer 1978, Review of Procedures (73052) Units 1&2 i The inspector reviewed the procedure indicated below to determine -

whether the procedures were consistent with regulatory requirements and licensee commitments. The procedures were also reviewed in the area of procedure approval, requirements for. qualification of non-destructive examination (NDE) personnel, and compilation of required records; and if applicable, division of responsibility between the licensee and contractor personnel. Welding procedures used to perform l the existing weld overlay repairs on the recirculation system will be I discussed in detail on paragraph 7 of this report. The following ISI l examination procedures were reviewed: l l

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. 3 Organization Procedure ID/ Title GE UT-51, Revision 2, Procedure for Automated Ultrasonic Examination of Dissimilar Metal Weld GE UT-30, Revision 15, Procedure for Ultrasonic Examination of Austenitic Welds for IGSC GE UT-43, Revision 9, _ Procedure for Ultrasonic Examination of Pipe Welds Using Automated Equipmen CP&L Corporate NDE NDEP-10, Training, Qualification and Certi-fication of Nondestructive Examination Personnel, Revision CP&L Cc porate NDE NDEP-20, Training, Qualification and Certification of Visual Examination Personnel for Inservice Inspection, Revision CP&L Corporate NDE NDEP-201, Liquid Penetrant Examination (Visible Dye, Solvent Removable)

Revision 1 CP&L Corpartate NDE NDEP-301, Magnetic Particle Examination (Dry Powder, Prods or Yoke) Revision 6.-

CP&L Corporate NDE NDEP-1000, Additional Examination Criteria for PSI /ISI Surface Examinations, Revision CP&L Corporate NDE NDEP-1010, Recording Data- from Direct Visual, Liquid Penetrant and Magnetic Particle Examinations, Revision CP&L Corporate NDE NDEP-1011, Weld Joint Identification Marking on Nuclear Power Plant Piping, Revision ~

Site QC NDEP-611, Revision 4, VT-1 Visual Examina-tion of Nuclear Power Plant Component Site QC NDEP-612, Revision 4, VT-2, Visual Examina-tion of Nuclear Power Plant Plan Component Site QC NDEP-613, Revision 5, VT-3, Visual Examina-tion of Nuclear Power Plant Component .

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Site QC NDEP-614, Revision 6, VT-4, Visual Examina-tion of Nuclear Power Plant Component Site QC Periodic Test: PT-91.0.52, VT-3/VT-4 Examination of Component Support (1) The inspector reviewed procedures UT-51, UT-30 and UT-43 to ascertain whether they had been reviewed and approved in accordance with the licensee's established QA procedures. The procedures were reviewed for technical adequacy-and conformance with ASME,Section V, Article 5 and other licensee commit-ments/ requirements in the below listed areas: type of apparatus used; extent of coverage of weldments; calibration '

requirements; search units; beam angles; DAC curves; reference level for monitoring discontinuities; method for demonstration penetration; limits for evaluating and recording indications; recording significant indications and; acceptance limit (2) The inspector reviewed procedure NDEP-201 to ascertain whether it had been reviewed and approved in accordance with the licensee's established QA procedures. The procedure was reviewed for technical adequacy and conformance with ASME,Section V, Article 6 and other licensee commitments / requirements in the below listed areas: specified method; penetrant material identification; penetrant materials analyzed 'for sulfur; penetrant materials analyzed for total . halogens; acceptable pre-examination surface; drying time; method of penetrant application; surface temperature; solvent removal; surface drying prior to developing; type of developer; examination technique; evaluation technique; and procedure requalificatio (3) The inspector reviewed procedure NDEP-301 to ascertain whether it had been reviewed and approved in accordance with the

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licensee's established QA procedure The procedure was reviewed for technical adequacy and for conformance with ASME Section V, Article 7, and other licensee commitments /

requirements in the below listed areas: examination method; contrast of dry powder particle color with background; viewing conditions; examination overlap and directions; pole or prod

spacing; current or lifting power (yoke) and; acceptance l criteri (4) The inspector reviewed visual examination procedures N0EP.611, NDEP.612, NDEP.613, NDEP,614 and PT-91.0.52 to determine whether they contained sufficient instructions to assure that the following parameters were specified and controlled within the

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. 5 limiti permitted by the applicable code, standard, or any additional specification requirement: method - direct visual, remote visual or translucent visual; application - hydrostatic testing, fabrication procedure, visual examination of welds, leak testing, etc.; how visual examination is to be performed, type of surface condition available; method or tool for surface preparation, if any; whether direct or remote viewing is used; special illumination, instruments, or equipment to be used, if any; sequence of performing examination, when applicable; data to be tabulated, if any acceptance criteria is specified and consistent with the applicable code section or controlling specification; and report form completion. Examiner Qualifications (73052 & 73753)

(1) CP&L Corporate NDE The inspector reviewed the qualification documentation for the below listed NDE examiners in the following areas: employer's name; person certified; activity qualified to perform; effective period of certification; signature of employer's designated representative, basis used for certification; and annual visual acuity, color vision examination and periodic recertifica-tio Method Level Examiners MT PT VT RT VT III III III J. II II II J. II II II L. II II II A. II II II D. II II II II E. II II II N. II II I II G. II II II II II (2) General Electric The inspector verified GE's ultrasonic examiner qualifications for the inspector of intergranular stress corrosion cracking (IGSCC) in accordance with EPRI/BWROG/NRC training and qualifica-tion agreemen This was done by comparing GE's personnel status log against EPRI's monthly qualification status summar The following individuals were certified as follows:

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. 6 Method Level-EPRI EPRI EPRI Data Data Name VT IGSCC Sizer O' Lay Col Analysis R. Anderson II - - -

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R. Bendele II x .

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R. Bonniwell II x - - -- -

B. Bouck II x - -

x x J. L. Briggs III - - -

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T. L. Brinkman III x x x- x T. R. Brinkman III x x x x x J. P. Carson II x ,

E. Catron II x B. M. Dummer III x x x x x M. Evich II x V. Gruno II x T. Kimball II x x x x B. Lester II x x x x W. Money II x x R. Parr II x R. A. Seals III x x x x )

S. Whiddon II x x x T. R. White II x x x x Observation of Work Activities - Unit 1 (73753)

Generic Letter 84-11 initiated a reinspection program for piping susceptible to IGSC In accordance with the above guidance CP&L plans to perform the following inspection during the present Unit i

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refueling outage:

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. 7 (1) unrepaired austenitic stainless steel welds (2) IE Notice 84-41 inconel butter welds (3) existing weld overlay repairs The inspector observed the following in process examinations on the inconel butter welds:

Weld No. IB32-12-BR-K6 Weld No. 1832-12-BR-J6 In addition to the above, the inspector reviewed video tape of the examinations performed on the following welds:

Weld No. 28" B32A-1 inconel butter examination Weld No. 28 B32A-3 IGSCC examination The above welds were examined with the GE SMART UT system using examiners qualified in accordance with the EPRI/BWR06/NRC Training and Qualification Agreemen Within the areas examined, no violation or deviation was identified.

7. Existing Weld Overlay Repairs - Unit 1 (73753 & 55055)

There are currently 32 weld overlay repairs on Brunswick-1. These are designed repairs; however, as-built dimensions show that many meet the standard guidance as propcsed in the draft of NUREG-0313 Revision The length and surface finish of these repairs do not allow UT inspection using the EPRI qualified technique; therefore, reinspection will require lengthening and surface finishing prior to the UT examination. Ten of the repairs on Brunswick-1 were applied in 1983 and 1984 and have been in service for two fuel cycles. The remaining 22 repairs were applied during the 1985 Reload 4 outage and, as such, will have been in service for only one cycl CP&L plans to upgrade the ten repairs applied in 1983 and 1984 such that inspections can be accomplished using the EPRI qualified UT techniqu Upgrading these weld overlay repairs consists of adding length and thickness to the overlay, as required, and performing surface finishin CP&L has endorsed a NUTECH analysis which justifies continued operation of Brunswick-1 for an additional 18-month fuel cycle without upgrade or inspection of 21 of the 22 weld overlay repairs applied in 1985. As recommended by the report, the licensee will upgrade and inspect weld 12"-B32-BR-J-3. In addition, the licensee plans to upgrade and inspect as many of the remaining 21 repairs applied in 1985 as possible without impacting the outage critical pat .

. 8 The inspector reviewed the licensee's welding program, procedure, procure-ment, qualifications activities, filler material control and storage and in process welding activities to determine whether the licensee quality control systems met the applicable procedure, regulatory requirements and a licensee commitments. The applicable code for the overlay repair welding is ASME,Section IX, the mandatory edition and addenda in effect on the date of the welding procedure qualificatio New procedures, evaluation procedures and acceptance criteria for austenitic piping is ASME Code Section XI paragraph IWB-3640 and Section IX, 1983 Edition with Addenda thru Winter 1983. Review of Procedures The inspector reviewed the procedure indicated below to determine whether the procedures were consistent with regulatory requirements and licensee commitments. The procedures were also reviewed in the areas of procedure approval, and compilation of required records:

Procedure ID Title Plant Model 86-068 Existing Weld Overlay Repairs WP-502 Revision 9 Welding Procedure Control WP-503 Revision 11 Welder Qualification WP-510 Revision 4 Qualification of Welding Procedure Specification WP-511 Revision 2 Welding Equipment Control WP-501 Revision 5 Procurement of Welding Materials Base Materials & Filler Metal Compatibility The inspector reviewed purchasing and receiving records for the filler material used to repair the weld overlays (P.O. B-31925, Heat No. S8t'530, ER-308L(.035)) and verified that the filler material was

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properly identified, storage and controlled in weld shack B. Welding Procedure Specifications The inspector verified the licensee's welding specifications were in accordance with Section IX and XI of the ASME Code, supported by acceptable Procedure Qualification Reports (PQR's) that had received the required mechanical tes The following welding specifications and their applicable PQR are listed below:

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,- 9 Welding Procedure Specification / Effective Code PQR WPS-8BU7 Revision 0 - ASME (77579) 68 WPS-88U12 Revision 5 - AMSE (80W81) 33 WPS-43BU1 Revision 3 - AMSE (83584) 147 Welder Performance Qualification The inspector reviewed the qualification status for the weld operators listed below and observed in process qualification efforts for the overlay repair welding in the weld test sho Welder WPS 8BV7 88V12 43BV1 P15 / / /

P29 / / /

P20 / / /

P38 / / /

YD8 / / /

P16 / / /

Y7G / / /

P10 / / /

P18 / / /

P12 / / /

P34 / / /

P5 / / /

V1N / / / Production Welding The inspe. tor observed in process repair welding activities on weld overlays for weld numbers 28" B32-B-4 and 28" B32-A-4. During this observation, the inspector reviewed the plant modification require-ments for these welds, welding filler material control records and welding procedure parameters used by the welders to make the repair welds. The inspector noted that the welder on weld 28" -1832-A-4 was operating in the sync pulse mode and had his machine set at .05 for the oscillation amplitude. The required welding procedure WPS-88U12 for this repair required that the oscillation amplitude ' be -set between .06 and .200 when operating in the sync pulse mod Failure to follow the qualified parameters of the welding procedure is a violation of regulatory requirements and was reported to the licensee as Violation 325/87-04-01, Failure to Follow Welding Procedure Specification Parameter Within the area examined, no violations or deviations were identified, except as noted in 7.e. above.