IR 05000353/1987012

Insp Rept 50-353/87-12 on 870908-18.Violation Noted.Major Areas Inspected:Independent Visual & NDE of Selected safety-related Piping Sys & Piping Support Structures, Independent Measurements & Qa/Qc Documentation

ML20236R425
Person / Time
Site:	Limerick
Issue date:	11/16/1987
From:	Harris R, Kerch H, Strosnider J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I)
To:
Shared Package
ML20236R331	List: IR 05000353/1987012 ML20236R329 ML20236R374
References
50-353-87-12, NUDOCS 8711230271
Download: ML20236R425 (19)

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l U..S. NUCLEAR REGULATORY COMMISSION

REGION I

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i Report No.

50-353/87-12

l Docket No.

50-353 i

i License No.

CPPR-107

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Licensee:

Philadelphia Electric Company 2301 Market Street

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Philadelphia, PA 19101 Facility Name:

Limerick-Generating Station, Unit 2 l

Inspection At:

Limerick, Pennsylvania Inspection Conducted:

September 8-18, 1987 ii Inspectors: bb b

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j H. W. Kerch, Senior Reactor Engineer date

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/R.~ ~ Harris, 'NDE Technician

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Approved by:

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. R. Strosnider, Chief, Materials and date Processes Section, EB, DRS Inspection Summary:

Inspection on September 8 through September 18, 1987

(Report No. 50-353/87-12)

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Areas Inspected: A routine inspection was conducted at Limerick Unit 2, consisting of independent visual and nondestructive. examination of selected safety related piping systems and associated piping support structures; fabri-cated to ASME Code class 1, 2 and 3.

In addition-to independent measurements, QA/QC documentation and personnel qualification records were reviewed.

i Results:

One violation was identified related to a rejectable radiographic

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indication in a Code Class 1 system weld (DLA 212-2 FW4).

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DETAILS 1.0 Persons Contacted Philadelphia Electric Company (PECo)

• G. Lauderback, Quality Assurance

• R. E. Crofton, Quality Assurance D. A. Marascio, Quality Assurance

• D. L. Schmidt, NDE Level III

• R. H. Zong, NDE Level III

• J. J. Kerecman, Construction Engineer

• R. E. Roe, Preservice Inspection

• R. J. Phelps, Sr., Quality Assurance J. J. Clarey, Superintendent l

• J. J. Fedick, Superintendent, Engineering l

D. DiPaola, Quality Assurance l

J. Corocan, Manager, QA-LGS II Bechtel Power Corporation

• S. J. Loofbourrow, Quality Control Er.gineer l

• R. Kerhin, Quality Control Preservice

• J. H. Khandhar, Quality Control Engineer

• G. C. Bell, Project Quality Assurance

• K. G. Stout, Project Quality Control l

• J. T. Hawkins, Preservice Inspection

• C. Headrick, Deputy Project Engineer

• W. Ross,. Welding Engineer

• N. Wyrych, Preservice Quality Control G. C. Kelly, Quality Assurance

• K. L. Quinter, Project Quality Control R. Poman, Coordinator R. Palaniswamy, Project Engineer A. Quaou, Project Engineer G. McIntyre, Site Construction Engineer Hartford Steam Boiler (HSB)

A. Brooks (ANII), Authorized Nuclear Inspector General Electric (GE)

E. Tschantre, Project Manager

• D. Edgel, NDE Level III S. Meeker, Assistant Project Manager l

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U.S. Nuclear Regulatory Commission J. Kaucher, Resident Inspector H. Kerch, Lead Reactor Engineer R. Gramm, Senior Resident Inspector R. H. Harris, NDE Technician J. Swoboda, IAEA

• Denotes those present at the exit meeting.

2.0 Purpose of Inspection The purpose of this inspection was to evaluate the licensee's welding quality control program and its implementation as demonstrated by the examination and evaluation of selected safety-related piping systems and structures.

The inspection included a review of procedures, quality control records, the PSI program, and quality assurance activities.

The

inspection activities included various independent nondestructive exami-I nations (NDE), observation of work in progress and QA/QC records review.

l 2.1 Independent Measurements / Nondestructive Examination During the period of September 8 through September 18, 1987, an onsite inspection including independent NDE was conducted at Limerick j

Nuclear Power Plant Unit 2.

A random selection of quaihy documen-

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tation packages for safety-related pipe weldments and associated J

piping supports was made by a regional NRC inspector.

In addition to j

the above, other selections of safety-related piping were made from the plant Preservice Inspection Program to be independently verified

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by the NRC.

Based on the licensee's QA/QC records, all items selected were previously inspected and accepted by the licensea.

2.2 Nondestructive Examinations Nondestructive examinations were performed in accordance with NRC procedures using isometrics and drawings supplied by the licensee.

The intent of these examinations is to reperform the inspections

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conducted by the licensee to confirm weld acceptability in accordance with applicable code requirements.

The following examinations were performed by two regional inspectors and two contracted NDE personne.

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Magnetic Particle Twelve (12) safety-related pipe weldments and adjacent base material (

inch on either side of the weld) were examined by the dry magnetic particle method per NRC procedure NDE-6, Revision 0, and the licensee's procedure.

Samples included in this examination were ASME Class 1 and 2 carbon steel weldments, selected from the Residual Heat Remove.1 (RHR), Core Spray (CS), and Containment Atmospheric Control (CTMT) Systems.

Results:

No violations were identified.

Liquid Penetrant Eleven (11) safety related pipe weldments and adjacent base material (

inch on either side of the weld) were examined by the visible dye method per NRC procedure NDE-9, Revision 0.

Samples included in this selection were ASME Code Class 1 and 2 carbon and stainless steel weldments, selected from the Residual Heat Removal (RHR), Core Spray (CS), Feedwater (FW), Reactor Coolant (RC) and Reactor Water Cleanup (RWCU) Systems.

Results:

No violations were identified.

Thickness Measurements Twenty-two (22) safety-related pipe weldments and adjacent base material (h inch on either side of the weld) were examined using a NOVA-D 100 digital thickness gauge per NRC procedure NDE-11, Revision 0.

Minimum wall thickness was determined by use of an ASTM standard pipe size and nominal thickness chart.

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Results: No violations were identified.

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Ferrite Measurements

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Five (5) safety-related pipe weldments were examined for delta ferrite content using a type II ferrite indicator (Severn Gauge).

This test-is intended to verify that the welding filler metal composition had sufficient as-deposited delta ferrite content to eliminate hot cracking.

Included in this examination were ASME Class 1 and 2 stainless weldments selected from the Residual Heat Removal (RHR), Reactor Core Isolation Cooling (RCIC), Reactor Water Cleanup (RWCU), Core Spray Cooling (CSC)

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and Feedwater (FW) Systems.

Results: No violations were identifie m

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Ultrasonic Examination Four (4) safety-related pipe weldments were ultrasonically examined

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using a Sonic Mark 1 ultrasonic flaw detector per NRC procedure NDE-1, Revision 0, in conjunction with Bechtel procedure UT-AUSTENITIC, Revision 9, UT-FERRITIC, Revision 8, and associated Licensee' ultrasonic data reports.

Instrument calibration (linearity verification) was performed using NRC procedure NDE-2, Revision 0, the distance amplitude correction

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(DAC) was constructed using the licensee's calibration blocks, i

LIM-26.928-CS, LIM-16-1.219-CS and LIM-12.688-SS31 for this examina-tion.

Instrument settings and transducer characteristics were matched as nearly as possible to -those indicated by the licensee's ultrasonic data reports, t

Results:

No violations'were identified.

It should be noted that the

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licensee identified weldments EBB-203, FW-10 and EBB-204, FW10, as having rejectable ultrasonic indications due to lack'of fusion (NCR No. 11382). The subject welds were radiographer by the licensee i

to provide engineering with additional information to evaluate and

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disposition those indications identified. The welds were dispositioned as acceptabla by the licensee based on the radiographic examination and the licensee's level III NDE supervisor evaluation.

The NRC inspector re-examined the subject indications and verified that the welds were acceptable based on the radiographic examinations.

Visual Examination Thirty-four (34) safety-related pipe weldments and adjacent base material were examined for cracks, gouges, linear indications, reinforcement and surface condition that may interfere with the performance of preservice inspection.

Visual examinations were performed using NRC procedure NDE-10, Revision 0, in conjunction with site documents.

Samples in this examination include ASME Code Class 1, 2 and 3 carbon and stainless j

steel, selected from the Residual Heat Removal (RHR), Core Spray (CS),

j Reactor Water Cleanup (RWCU), Feedwater (FW), Containment Atmosphere i

Control (CTMT) and Rector Core Isolation Cooling (RCIC) Systems.

- I Results:

No violations were identified.

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Radiographic Examination:

Thirty-four (34) safety related pipe weldments were radiographer using an Iridium 192 source. The technique

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and procedure used were in accordance with NRC procedure, NDE-5,

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revision 0 and licensee supplied radiographic data reports.

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Included in this examination were ASME Class 1, 2 and 3 weldments selected from the Residual Heat Removal (RHR), Core Spray Cooling (CSC), Reactor Core Isolation Cooling (RCIC), Reactor Water Cleanup

(RWCU), Containment Atmospheric Control (CMTC) and Reactor Coolant i

(RC) Systems.

Results: One radiograph was rejected by the NRC Inspector during radio-graphic examination and review (DLA -212-2 FW4).

See Paragraph 4.0, j

Radiographic Review Results, for details.

Hanger / Support Examination l

Twenty-one (21) safety-related pipe supports were visually examined I

per NRC procedure NDE-10, Revision 0, Appendix B, in-conjunction with l

site construction drawings. Attributes looked for were evidente of cracking, L corrosion, wear, misalignment, welding, floose or brokan connections, missing or bent parts and improper installation.

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I Results:

No violations were identified, j

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3.0 Review of Procedures l

The following procedures were reviewed to verify their technical adequacy

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and conformance to regulatory and code requirements.

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BECHTEL CONSTRUCTION INC.

Title QC MANUAL FOR LGS OPERATIONS SECTION II QUALIFICATION CERTIFICATION i

AND TRAINING MANUAL ULTRASONIC UT-AUSTENITIC, Revision 9 EXAMINATION PROCEDURE FOR AUSTENITIC AND DISSIMILAR METAL PIPING WELDS

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MANUAL ULTRASONIC EXAMINATION UT-FERRITIC, Revision 8 0F FERRITIC STEEL WELDS

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GENERAL ELECTRIC COMPANY PROCEDURE FOR ULTRASONIC EXAMINATION OF AUSTENITIC STEEL SUPPLEMENT 1, Revision 1

PROCEDURE FOR ULTRASONIC l

EXAMINATION OF WELD OVERLAID l

AUSTENITIC PIPING l

GE NUCLEAR PLANT SERVICES PQF-04, Revision 1 DEPARTMENT FIELD QUALITY q

i PROCEDURE PROCEDURE FOR CERTIFICATION OF ASME SECTION XI VISUAL EXAMINATION PERSONNEL 4.L Radiographs Reviewed

A sampling of the licensee's ra-graphs was reviewed.

The inspector reviewed

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radiographs for sixty-two vend'>r / elds and twenty-seven site field welds to verify compliance with ASME III code requirements, accuracy of radiographic l

film interpretation and adequacy of the licensee's radiographic program.

Additionally, thirty-four welds were re-radiographer by the NRC during this I

inspection and the resulting films were compared to licensee file films to

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independently verify that correct radiographic file film was on hand

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l (see Attachment No. 3 for details).

j Results:

NRC radiographic film for weld DLA-212-2 FW4 disclosed an elongated indication 3/8" in length that exceeded ASME Code Section III criteria.

A review of site code approved radiographic film revealed the same indication in radiographic film area 20.

This indication had not been recorded or

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dispositioned by the licensee although the weld did have final licensee QA/QC acceptance.

The inspector identified this as an apparent violation of 10 CFR 50.55a (50-353/87-12-01) which requires compliance with ASME Code i

Section III criteria.

The licensee took the following corrective actions prior to completion of the inspection:

l NCR 12,467 documented the defect and required corrective action'.

l Weld DLA-212-2 FW4 was repaired.

(The defect was ground out and

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weld repaired.)

Weld OLA-212-2 FW4 was reexamined after repair and now meets

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ASME Section III.

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The Radiographic film interpreter that had originally accepted weld

DLA-212-2 FW4 was provided additional instructions.

The licensee performed Fracture Mechanics Analysis on weld DLA-212-2

FW4. The analysis using ASME Code Section XI techniques, concluded that if this indication had gone undetected, it would not have caused a safety hazard.

Licensee's audits reviewed radiographs of over 100 welds that were read l

by the individual that reviewed the radiographs for weld DLA-212-2 FW4 and radiographs of over 60 welds from other active reviewers.

No unacceptable indications were missed.

Based on the corrective actions already taken by the licensee, documented above and the radiographic film reviews during this inspection, the inspector considers this violation closed.

5.0 Ultrasonic Data Review:

A sampling of the licensee's preservice inspection data was reviewed.

f Preservice inspection documentation packages for twenty-five (25) welds were reviewed to verify compliance with ASME Section XI code requirements for accuracy of the documentation and interpretation of ultrasonic data.

l The inspector also reviewed the NDE qualification of five (5) contract preservice personnel.

Results:

No violations were identified.

6.0 Ultrasonic Demonstration i

i Background:

Piping ID counterbores were previously machined too deep and overlay welding was required to meet design minimum wall.

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l The licensee's contractor (GE) performed an ultrasonic tett demonstration

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that was witnessed by the NRC. The purpose of this dee.onstration was to demonstrate that UT could effectively penetrate the stainless steel weld l

overlay material and inspect the inside surface of the base material for cracking.

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i A single calibration block with the sa;ue range of thickness as the subject j

l piping was used.

The calibration block was the same type of material as the j

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piping and contained overlay welding with cracks on the ID of the base j

material that represented ICSCC.

The inspector determined that this

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calibration represented the actual configuration to be examined and had no concerns regarding tat.'nical adequacy of this examination.

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7.0 Attachments Attachment No. 1 is a tabulation of specific piping systems components

insp0cted during this inspection and the results.

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Attachment No. 2 is a tabulation of specific pipe supports inspected during this inspection.

Attachment No. 3 is a tabulation of radiographic and ultrasonic data review.

8.0 Previous NRC Inspection Findings (Closed) Violation 86-07-02 radiographic film interpreters were not visually verifying the existence of surface conditions.

Corrective actions taken by the licensee:

Training sessions were held that included the proper method for film

interpretation documentation.

An additional radiographic level III was added to the staff.

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l Quality assurance audits have been increased by the licensee.

• Bechtel Quality assurance audits have been increased.

• Based on verifying the above, interviewing the site film interpreter and review of twenty-seven (27) weld radiographs during this inspection, this item is considered closed.

(Closed) CDR 80-00-11 The licensee notified the NRC on December 30, 1980, of potentially report-able items such as missing radiographs, incorrect density, and problems with penetrometer identified by QA Audit Findings of 50 stainless steel pipe spools, fabricated by Texas Pipe Bending Company. The licensee evaluated the suspect radiographs and determined the identified problems were not reportable.

Records of the licensee's evaluation of the five audit findings relating to the radiographs were reviewed.

Based on this review and NRC inspector review of 41 radiographs of Texas Pipe Bending Company piping spools, the inspector concluded that the subject audit findings represented isolated incidents that did not require reporting. This item is considered closed.

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9.0 Summary and Conclusion In summary the following examinations of safety related pipe weldments were examined by:

Magnetic particle Twelve weldments

Liquid penetrant Eleven weldments

Thickness Twenty-nine weldments

Ferrite content Five weldments

Ultrasonic Four weldments

Visual Thirty-four weldments

Radiographic Thirty-four weldments

Hanger / supports Inspections Twenty-one weldments

Radiographic reviewed Eighty-nine weldments

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Ultrasonic data reviewed Twenty-five weldments

i The quality of piping welds inspected was good.

Based on this inspection, l

the preservice inspection program is being im;,lemented in accordance with

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applicable regulatory and Code requirements and should provide an adequate d

baseline tc. support the inservice inspection program.

10.0 Exit Meetiqg

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l On September 18, 1987, the NDE Van personnel attended an exit meeting

with the licensee staff.

The findings of this inspection were described at this meeting.

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i No written material was provided to the licensee during this inspection.

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. - _ _ _ _ _

o

.

ATTACHMENT #2 INDEPENDENT MEASUREMENT PROGRAM VISUAL HANGER INSPECTION VT VWAC AND NRC DATE:

SEPT. B - SEPT. 18, 1987, SITE:

LIMERICK UNIT 2

"

Hanger No.

Class System Line/ Iso Accept / Reject Remarks H23

CSC GBB-212-2 l

H25

CSC GBB-212-2 H26

CSC GBB-212-2 H27

CSC GBB-212-2 i

!

H36

RHR HBB-204-2 H41

RHR HBB-204-2

H32

RHR HBB-204-2

1

H31

RHR HBB-204-2 I

l H1

WTR-STG-2 HCB-204-1

H3

WTR-STG-2 HCB-204-1 H9

WTR-STG-2 HCB-204-1 H1

RCIC HBB-203-1 H2

RCIC HBB-203-1 l

H6

RCIC HBB-203-1 H4

RCIC HBB-202-1 H5

RCIC HBB-202-1 H9

RWCU DBA-212-1-9 H11

RHR DLA-212-2 Acceptable H2

FW D LA-207-1 Acceptable H29

FW DLA-207-1 Acceptable H3

RHR DCA-418-2 Acceptable H8

RHR DCA-418-2 Acceptable I

W__-__-_________--------_---

--

--

_ - _ _ _ - _ _ - _ _ _ _ _ _ _ _ - _ --

. _ _ _ _ _.

_

c

.

ATTACHMENT #3 TABULATION OF RADIOGRAPH REVIEWED AND ULTRASDNIC DATA REVIEWED SYSTEM /LINE WELD ID ACC REJ COMMENTS Delta Southern Radiographs TRI-SG2 X

TRI-CG2 X

TRI-SG1 X

l TRI-CG1 X

TRI-SL4 X

TRI-SL3 X

TRI-SL1 X

TRI-SL2 X

TRI-SG5 X

TRI-SG4 X

TRI-SG3 X

TRI-CL1 X

'

TRI-N4-1 X

Southwest Fabrication Radiographs DBD-201-1-8 W1 X

GBB-201-3-1 W1 X

I i

GBB-201-3-1 W2 X

I GBB-201-3-1 W3 X

!

GBB-201-3-3 W1 X

j DBD-201-1-1 W4 X

DBD-201-1-1 W3 X

D80-201-1-1 W2 X

l l

t-1-

.

.

ATTACHMENT #3 TABULATION OF RADIOGRAPH REVIEWED AND VLTRASONIC DATA REVIEWED

.:

SYSTEM /LINE WELD ID A_CC REJ COMMENTS Texas Pipe Radiographs DCC-202-2-1 W1 X

DCC-202-2-1 W2 X

DCC-202-2-1 W3 X

DCC-202-2-1 W4 X

DCC-202-2-1 W5 X

DCC-202-2-1 W7 X

DCC-2C2-2-1 W8 X

DCC-202-2-1 W10 X

DCC-202-2-1 W11 X

DCC-202-2-2 WI X

DCC-202-2-2 W2 X

DCC-202-2-3 W1 X

l DCC-202-2-3 W2 X

DCC-202-2-3 W3 X

l DCC-202-2-3 W4 X

DCC-202-2-3 W5 X

DCC-202-2-3 W6 X

DCC-202-2-3 W7 X

DCC-202-2-3 W8 X

DCC-202-2-3 W9 X

i

- __ - _ _-__-________________________________ ___ _ _

_._ - _ ___-__

. _ _ _ _. _ _ _ _ _ _ _ _ _ _ _ _ - _

,-

ATTACHMENT #3 TABULATION OF RADIOGRAPH REVIEWED AND VLTRASONIC DATA REVIEWED SYSTEM /LINE WELD ID ACC REJ COMMENTS Texas Pipe Radiographs DCC-202-2-3 W10 X

DCC-202-2-3 W11 X

DCC-202-2-3 W32 X

DCC-202-2-3 W13 X

HBB-227-2 FW14 X

DBA-212-1-4 SW1 X

Compared

DBA-212-1-4 SW2 X

Compared

DBA-212-1-4B FW3 X

VRR-2RD2A-21 FWA11 X

Compared

VRR-2RD2A-16 FWA10 X

Compared

GBB-212-2-10 FW2 X

Compared

GBB-212-2-12 FW8 X

Compared GBB-213-2-6 FW8 X

Compared GBB-213-2-9 FW11 X

Compared GBB-213-2-1F FW12 X

Compared EBB-229-1-2-1F W1 X

EBB-229-1-2 W4 X

EBB-229-1-2 W5 X

EBB-229-1-4 W1 X

EBB-229-1-4 W2 X

EBB-229-1-6 W1 X

l

_ _ _ _ _ _ - _ _ _ _

_ _ _ _ _ _

_

_ _ _ _ _ _ _ _.

I

'

.

,

ATTACHMENT #3 TABULATION OF RADIOGRAPH REVIEWED AND ULTRASONIC DATA REVIEWED SYSTEM /LINE WELD ID ACC REJ COMMENTS Bechtel Radiographs GBB-205-1-3 FW4 X

Compared GBB-205-1-3A FW5 X

Compared GBB-205-1 FW8 X

Compared HBB-227-2-25 FW2 X

Compared HBB-227-2-7 FW3 X

Compared HBB-227-2-11 FW13 X

Compared DCA-418-2-2 FW6 X

Compared

DLA-210-1 FW7 X

Compared DCA-418-2-2 Sv!!

X Compared

DCA-418-2-2 SW3 X

DLA-211-1-4 FW6 X

Compared

D LA-212-2-2 FW7 X

Compared

DLA-212-2-2 FW4 X

Compared

• Film A 18-20 DLA-208-1-5 FW6 X

Compared

DLA-212-4-2 FW4 X

Compared

DLA-207-1-3 FW3 X

Compared

'*

GBC-211-1-2 FW4 X

Compared HBB-203-1-2 FW4 X

Compared

• Indicates Ultrasonic Data was also reviewed.

- - _ _ _ _ _ - _ - _ _ _ - _ _ _ - _

. _ _ _ _

r~

.

ATTACHMENT #3 TABULATION OF RADIOGRAPHS REVIEWED AND ULTRASONIC DATA REVIEWED SYSTEM /LINE WELD ID ACC REJ COMMENTS Bechtel Radiographs HBB-202-1-6 FW5 X

Compared HBB-202-1-4B FW12 X

Compared HBB-204-2-3 FW3 X

Compared HBB-204-2-1F FW5 X

Compared HBB-204-2-1G FW6 X

Compared HCB-204-1-4G FW8 X

Compared DLA-210-1-3 FW7 X

DCC-203-1-14F FW21 X

Compared HBB-227-2-2C FW14 X

Compared SYSTEM /LINE WELD ID ACC Ultrasonic Data Review COMMENTS DCA-205-3 FW2 X

Auto DCA-418-4-4 FW5 X

Manual l

DCA-205-3 FW1 X

Auto i

l Manual DBB-203-1-1A SW5 X

Manual EBB-203-1 FW10 X

Manual l

EBB-204-1 FW10 X

Manual APE 2MS-LD-11 SWA X

Manual l

APE 2MS-LD-11 SWL X

Manual

]

APE 2MS-LC-8 SWG X

Manual

!

APE 2MS-LC-8 SWK X

Manual

!

Also see radiographic review with items with asterisk pages 3 and 4.

i

____________a

_