ML20204H311

Insp Rept 50-412/86-13 on 860609-20.Violation Noted:Liquid Penetrant Exam Revealed Unacceptable Linear Indications on Base Matl

ML20204H311
Person / Time
Site:	Beaver Valley
Issue date:	07/30/1986
From:	Harris R, Kerch H, Wiggins J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I)
To:
Shared Package
ML20204H285	List: ML20204H281 ML20204H288 ML20204H311
References
50-412-86-13, NUDOCS 8608080076
Download: ML20204H311 (13)

See also: IR 05000412/1986013

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U.S. NUCLEAR REGULATORY COMMISSION

REGION I

Report No. 50-412/86-13

Docket No. 50-412

License No. CPPR-105 Category A

Licensee: Duquesene Light Company

Robinson Plaza Building No.2

Suite No.210 Pa. Route 60

Facility Name: Beaver Valley Power Station, Unit 2.

Inspection At: Shippingport, PA

Inspection Conducted: June 9-20, 1986

Inspectors: b4 700 4

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Inspection Summary: Inspection on June 9-20, 1986 (Inspection Report No.

50-412/86-13)

Areas Inspected: A routine, announced NRC independent measurements inspection was

conducted at the utility construction site using the NRC Mobile Nondestructive

Examination (NDE) Laboratory. Selected structural supports, fuel racks and pre-

service inspection weldments were inspected, by a team of two regional based

inspectors assisted by two contracted NDE personnel.

Results: One violation was observed concerning an unacceptable indication in

base material (86-13-01) and one violation was identified concerning liquid

penetrant indications in weldments. (86-13-02)

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DETAILS

1.0 Persons Contacted

Duquesne Light Company

J. M. Jaworski, Senior Engineer, Mechanical and Welding

D. K. Rohm, Assistant Director Quality Control

R. M. Reba, Principal Engineer

L. M. Rabenau, Compliance Engineer

W. H. Sikorski, Director In-Service Inspection

J. B. Andrews, In-Service Inspection Program Coordinator

T. Heimel, Non-Destructive Examination Specialist

R. Coupland, Director Quality Control

J. R. Houghton, Duquesne Light Company Engineering Department

M. Zaki, Duquesne Light Company Engineering Department

C. R. Davis, Director Quality Assurance

H. T. Schob1, Start-up

D. W. Dreams, Assistant Director, Quality Assurance

L. P. Williams, Director Start-up

A. F. Mosso, Quality Assurance Non-Destructive Examination

Stone and Webster Engineering Co. (SWEC)

G. Orr, Senior Training Supervisor

D. P. Lessard, Assistant Superintendent

K. Kirkman, Assistant Superintendent Construction

J. R. Hurley, Contract Manager

R. C. Wittschen, Licensing Engineer

J. J. Purcell, Assistant Project Manager

H. W. Durkin, Supervisor of Engineering

Nuclear Energy Service (NES)

M. Shallis, Site Supervisor

T. J. Koch, Project Manager

G. Griffith, Director Plant Operations

C. D. Cowfer, Director of In-Service Inspection

Nuclear Regulatory Commission

L. J. Prividy, Resident Inspector

All of the above were present at the June 20, 1986 Exit Meeting.

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2.0 Purpose of the Inspection

2.1 An onsite independent verification inspection was conducted during

June 9 through 20, 1986, using the NRC Mobile Nondestructive Exam-

ination NDE Laboratory. This inspection was performed by NRC Region

I personnel in conjunction with NRC contractor NDE personnel.

The purpose of this inspection was to perform an independent exam-

ination of selected piping weldments that were previously inspected

and accepted under the licensee's Preservice Inspection Program.

Also examined were structural steel weldments, piping supports and

cable tray support weldments to ascertain the adequacy of construc-

tion fabrication and of the welding quality control program to assure

safety and reliability during plant operation. QC/QA records were

reviewed to ascertain compliance to governing codes, standards and

regulations.

3.0 Independent Measurements

The purpose of this independent examination of weldments was to verify the

adequacy of the licensee's welding Quality Control Program applicable to

ASME Class 1, 2 and 3 components. This was accomplished by duplicating

those examinations required of the licensee by regulations and codes, and

evaluating the results. In addition to those examinations, several other

confirmatory examinations designed to verify conformance with material

specifications were performed and compared to quality assurance records.

The NRC inspectors performed the examinations on randomly selected weld-

ments that had been previously inspected and accepted by the licensee, as

indicated by vendor shop and on-site QA/QC records.

3.1 New Fuel Racks

This inspection included the visual and liquid penetrant examination

of forty fuel rack assemblies. Examinations were performed using NRC

procedure NDE-9 Revision 0 and the licensee's detailed drawings,

procedures, standards and specifications.

Results: During this inspection it was noted that weld symbols shown

on SWEC drawings 12241-RV-20A indicated that welds were to be ground

flush. The inspect]r found that the majority of these welds were in

the as-welded condition. Subsequently, the licensee issued a Non-

conformance and Disposition Report (N&D 33538) which was disposit-

ioned use as is. The technical justification was that the intent of

requiring that the welds be ground was to provide a smooth surface

for liquid penetrant testing. The inspector noted that the as welded

surfaces met the 250 rms requirement specified in the drawing and

were acceptable in the as-welded condition.

No violations were identified.

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3.2 Spent Fuel Racks (SFR)

This inspection included examination of three (3) 8x8 fuel storage rack

arrays and consisted of visual and liquid penetrant examinations.

These items were previously inspected and accepted by the licensee,

as indicated by vendor shop and onsite QA/QC records. The inspectors

examined 75% of all welds denoted as critical in accordance with NES

drawing 80E7653. Attributes examined during the visual inspection,

were weld size, length, location and overall workmanship. Liquid

penetrant inspection was performed to determine if any indications

existed which were unacceptable or detrimental to the service of the

component.

The inspection of the spent fuel racks wac performed using NRC proce-

dures NDE-14, Revision 0, NDE-9, Revision 1 and Addendas BV-2-9-1 and

BV2-14 in conjunction with licensee detail drawings and site procedures,

standards and specifications.

Results: During liquid penetrant examination of a sample of critical

welds denoted on detail drawing NES 80E7653, linear indications were

found in two fillet welds on fuel bundle #16. As a result of the NRC

finding, DLC/SQC NDE laboratory reexamined those welds with identi-

fied linear indications. The results of the reexamination, substan-

tiated the indications found by the NRC. The indication were

dispositioned on Noncomformance and Disposition Report No. 32471

(DLC-SQC). Supplemental NDE and liquid penetrant records confirmed

that unsatisfactory indications such as star cracks and linear

indications were present.

Based on the above, the inspector considered the existence of SFR

weld indications a violation of 10 CFR 50 Appendix B requirements

(412/86-13-02).

3.3 Cable Tray Supports and Conduit Supports

A random sample of cable tray supports located inside the Service

building and the Main Steam Building were inspected. This inspection

was performed using NRC procedure NDE-18, Rev. O in conjunction with

site procedures and specifications. The attributes examined during

this inspection were dimensional checks and checks for support lo-

cation, support welding, and loose or broken support members. Also,

<

the size and location of the Hilti conrete anchor bolts were compared

to drawing requirements.

See Attachment 2 for specific items inspected.

Results: No violations were identified.

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3.4 Pipe Supports

A sample of pipe supports located inside the primary containment and

auxiliary building were examined. Attributes examined during this

inspection, were dimensional checks and checks for support location,

support welding and loose or broken support members. Measurements

were compared with detailed isometrics / drawings indicating support

location and orientation, support types and field weld requirements.

Results: During this inspection the inspector identified that draw-

ing BZ-1078-331-0A did not conform to the actual pipe support install-

ation. A further investigation revealed that E&DCR #2PA-M-1189 had

been issued to modify the support. Reinspection with the correct

information was performed by the inspector and no further questions

developed.

See Attachment #3 for specific items inspected.

Results: No violations were identified.

3.5 Steam Generator Support

A visual and dimensional inspection of Steam Generator lower support

assemblies A, B and C, located in the reactor containment building,

was performed. The visual examination consisted of weld inspections

,

and surface material examinations. Dimensions were taken and com-

pared to as-built dimensions shown on Steam Generator lower support

drawings.

Results: A base metal linear defect was detected by visual inspec-

tion of the lower horizontal beam member on the steam generator C

lower support assembly. The indication was open to the surface and

approximately 6" long. The inspector determined that this item had

been previously inspected and accepted by the licensee with this

defect not being identified.

The licensee issued Noncenformance and Disposition Report No. 32812.

The final indication size was 18 inches in length and 3/16 in depth.

The failure to identify and disposition this indication is a viola-

tion of 10 CFR 50.55a requirements (412/86-13-01).

3.6 Pressurizer Support

The inspectors conducted an ultrasonic examination of 16 full pene-

tration weldments on the Pressurizer component support. The ob-

jectives of this inspection were to verify weld integrity and to

assess the adequacy of previous ultrasonic examinations performed by

the fabricator. The examination was performed using NRC procedure

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NDE-1, Revision 0, Addenda BV2-1-1, in conjuction with site proce-

dures, specifications and as-built drawings. Weldments were randomly

selected by a region- based NRC Nondestructive Examination (NDE)

Specialist, based on weld accessibility.

Results: No violations were identified.

3.7 Windsor Probe

The compressive strength of concrete poured around the reactor contain-

ment was examined using the Windsor Probe test kit. Three probe results

were averaged and a compressive strength was determined using standard

conversion tables.

Results: No violations were identified. The examination indicated that

the concrete compressive strength exceeded the 6000 psi required by

the governing site specification.

3.8 Ultrasonic Examination (UT)

Ten pipe weldments were ultrasonically examined to verify the adequacy

of the licensee's PSI program. The ultrasonic parameters used during

this inspection were matched as closely as possible to those used during

the original examination performed by the licensee's UT personnel. The

instrument used was calibrated using NRC procedure NDE-2, Revision 0,

and licensee's calibration blocks.

See Attachment 1 for specific weldments examined.

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Results: Three (3) geometric reflectors, two (2) indications veri-

fied as redirected sound path in austenitic stainless steel weldments

and one (1) planer indication were identified. These results matched

those previously identified by the licensee during its examination.

No violations were identified.

4.0 Preservice Inspection (PSI) Data Review

Selected PSI data for the RCS System were reviewed to verify that exami-

nations were done in compliance with the governing procedure and that

applicable ASME Code and Regulatory requirements were met. The review

also was undertaken to verify that the licensee had properly recorded

ultrasonic evaluations.

A review of PSI /ISI procedure A 3.6, Revision 3, paragraph 2.93, indicated

that the Supervisor of NDE Services or his designee shall review and

accept the ultrasonic examination data for the licensee. This inspection

revealed that this individual did not process the requisite ASNT NDE

certifications. The licensee reviewed and changed procedure A 3.6 to

indicate that the contractor's Level III would review and accept the

examination results. The inspector interviewed the contractor's Level III

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who had reviewed the majority of PSI data for piping and concluded that

his signature on each of the NDE data reports represented acceptance of

those reports. The inspector thus concluded that the requirements of

Section XI of the ASME code regarding acceptance of data had been met.

The inspector noted during the review of data reports, that the examin-

ation record did not clearly state whether the weld was found to be

acceptable or rejectable based on the results of the examination. The

inspector was told that a master tracking list indicated the status of the

welds. The inspector expressed a concern that completed ultrasonic exam-

ination records should stand on their own relative to a statement of the

acceptability of the weld examined. The adequacy of NDE records is

considered unresolved pending licensee review of the inspector's concern

described above (86-13-03).

Overall, the inspector found that the preservice piping inspection at

Beaver Valley 2 and its documentation had been performed professionally

and that a meaningful PSI program had resulted.

Results: No violations were identified.

5.0 Followup on Previously Identified Items

(Closed) Unresolved Item 84-02-01: Technical Justification to waive D1.1 when

using design allowables of AISC

(Closed) Unresolved Item 84-02-02: Method to establish and control ' Engineers"

authority to waive explicit rules of 01.1 not documented

(Closed) Unresolved Item 84-02-03: Engineering justification to use Para A515 in

D1.1 not documented

(Closed) Unresolved Item 84-02-04: Engineering justification to waive 10 mil

undercut rule for D1.1 FAB not documented

(Closed) Unresolved Item 84-02-05: Engineering justification to substitute SWEC

FC P601.8 figure 7 effective throat rules for Para. 61.1 of 01.1 rules

not documented

(Closed) Unresolved Item 84-02-06: Basis for qualification of welding over

galvanized steel unistruts with E6010 not documented

Background: During an earlier field inspection, an NRC inspector

observed that several items had not been properly addressed in

regard to the application of AWS D1.1 at Beaver Valley Unit 2.

During this inspection, the licensee's responses No. 2 NCD-04478 and

2 DLS-23722 and references No. 2 DLS-23064 and 2 DLS-23491 were

reviewed. Procedures No. 2 BVM-7 for Preparation of Specification,

and 2 BVM-102 for Pipe Support Welding Design Guide, were also

reviewed. The inspector verified that the appropriate corrective

action to these items had been taken.

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Based on these reviews, the inspector considers items 84-02-01 through

84-02-06 closed.

(Closed) Unresolved Item 84-15-01: Potential PSI problems due to weld

overlay of piping and lack of vendor as-built drawings and RT maps.

During NRC inspection 85-05, the inspectabililty of the overlay welds

was established. During this inspection, the inspector reviewed the

RT maps and found them to be excellent. Also reviewed, were some of

the required as built drawings (1104552 Revision 4, 1104J50 Revision

2, 1104J51 Revision 4 and 1101J46 Revision 1). The inspector also noted

that in letter ND2 ISI: 0261 the licensee has requested SWEC to obtain

the required as built drawings for the reactor pressure vessel.

Based on this and the previous NRC inspection of this subject, item

84-15-01 is closed.

(Closed) Unresolved Item 86-05-01: Incomplete Transducer Certification

Documentation

The licensee performed calculations and physical measurements to

determine that the transmit and receive crossover point and focal

depth of dual transducers serial numbers J-22462 and J-22463 were

adequate. The transducers were marked. Transducers serial numbers

F-16030 and F-20320 listed in inspection report 86-05-01 as focused

dual element were in fact found to be single element and thus did not

require additional documentation. This item is therefore closed.

6.0 Unresolved Items

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An Unresolved Item is that for which more information is necessary for

the NRC to determine whether the item is acceptable or a violation or

deviation. An unresolved item is contained in paragraph 4.

7.0 Exit Meeting

An exit interview was held on June 20, 1986 with members of the licensee's

staff. The inspector summarized the scope and findings of this inspec-

tion. No written material was provided to the licensee during the course

of the inspection.

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