IR 05000155/1979004
| ML19289E948 | |
| Person / Time | |
|---|---|
| Site: | Big Rock Point File:Consumers Energy icon.png |
| Issue date: | 04/05/1979 |
| From: | Danielson D, Ridgway K, Ward K NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| References | |
| 50-155-79-04, 50-155-79-4, NUDOCS 7905290569 | |
| Download: ML19289E948 (10) | |
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U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT
REGION III
Report No. 50-155/79-04 Docket No. 50-155 License No. DPR-6 Licensee: Consumers Power Company 212 West Michigan Ave.
Jackson, MI 59201 Facility Name: Big Rock Point Nuclear Plant Inspection At:
Big Rock Site, Charlevoix, Michigan General Electric Office and Service Shop, Chicago, Illinois Inspection Conducted: February 13-14 and March 13, 26-27, 1979 W7/7Y
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Inspectors:
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Approved By:
D. H. Danielson, Chief
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Engineering Support Section 2 Inspection Summary Inspection on February 13-14 and March 13, 26-27, 1979 (Report No.
50-155/79-04)
Areas Inspected: Inservice inspection (ISI) QA/QC program, implementing procedures, work activities, and NDE data and reports; 1977 ISI data review and evaluation; Core Spray sparger and steam baffle replacement QA/QC program, implementing procedures, work activities and record review; licensee event report corrective actions. The inspection involved a total of 32 inspector-hours onsite by three NRC inspectors.
Results: No items of noncompliance or deviations were identified.
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DETAILS Persons Contacted Consumers Power Company (CPCo)
- T. Bordine, QA Superintendent
- C. Peterson, QA Engineer
- J. Rang, Operation and Maintenance Superintendent
- D. De Moor, Technical Engineer
- R. Schrader, Technical Superintendent
- E. Martinez, Technical Supervisor, NDT Services
- W.
Beckius, Supervising Administrator
- G. Gilbody, QA Engineer
- P. Devere QA Engineer
- M.
Bielinski, ISI Coordinator
- L. Pauly, QA Engineer
- J. Jandouizt, ISI/OSD
- S. Martin, ISI/OSD R. Kropp, General Engineer /OSD J. Popa, Maintenance Engineer D. Trefry, Team Leader (ISI)
- W. Kozik, Manager, QA
- D. Saven, Service Manager Southwest Research Institute (SWRI)
- W. Walker, Inspection Engineer The inspector also contacted and interviewed other licensee and contractor employees.
- Denotes those present at the exit interview.
Functional or Program Areas Inspected 1.
General Information CPCo and SWRI each developed the following inservice inspection programs to perform their part of the inservice inspection in accordance with ASME Section XI,1971 Edition with Winter 1972 Addenda.
CPCo, 1979, Big Rock Point Inservice Examination Program Plan, NDT-PP-1 Rev. O, January 29, 1979.
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SWRI, Project Plan Applicable for ISI No. 6 Project Plan No. 78-CPC-BRP-1/ PAL-1-1-0, Rev. 1, July, 1978.
The next outage will be approximately Spring or Summer 1980.
2.
Review of Programs
The inspector established through review and discussion with the licensee representatives that the program requirements for inservice inspection was in accordance with ASME Section XI, 1971 Edition with Winter 1972 Addenda.
No items of noncompliance or deviations were identified.
3.
Review of Procedures The following CPCo and SWRI procedures applicable to this activity were reviewed:
CPCo a.
Quality Control Procedure Manual Volume I of II, Copy No. 8.
b.
Control of Measuring and Test Equipment NDT-G-04, Rev. O, December 29, 1976.
c.
Indoctrination and Training, NDT-A-05, Rev. 1, September 29, 1978.
d.
Personnel Qualification and Certification NCT-A-07, Rev. 1, September 29, 1978, 1975 Edition.
e.
Color Contract-Solvent Removable Liquid Penetrant Examinations, NDT-PT-03, Rev. 2, January 3, 1979.
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Direct Visual Examination, NDT-VT-03, Rev. 2, January 3, 1979.
g.
Ultrasonic Examination of Welds, NDT-UT-03, Rev. 2, Janaury 3, 1979.
SWRI h.
Special Process Control, NQAP 11-1, Rev. 1, March 11, 1977, (1975 Edition).
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Liquid Penetrant Examination Color Contrast Method, SWRI-NDT-200-1, Rev. 43, July, 1978.
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Dry Power Magnetic Particle Examination SWRI-NDT-300-1, Rev. 15, July 1978.
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Manual Ultrasonic Examination of Pressure Piping Welds, SWRI -NDT-600-3, Rev. 47, July,1978.
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Manual Ultrasonic Examination of Hexagonal Nuts SWRI-NDT-600-37, Rev. 1, July, 1978.
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Manual Ultrasonic Examination of Thin Wall Piping Welds, SWRI-NDR-800-36, Rev. 17, July, 1978.
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Visual Examination of Nuclear Reactor Components by Direct or Remote Viewing SWRI-NDT-900-1, Rev. 43, July, 1978.
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Visual Examination of Support Members and Structures for Piping, Valves and Pumps by Direct or Remote Viewing SWRI-NDT-900-4, Rev. 18, August, 1978.
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Florescent Magnetic Particic Examination SWRI-NDT-300-2, Rev. 24, December, 1978.
No items of noncompliance or deviations were identified.
4.
Observation of Work and Work Activities a.
The inspector observed work and had discussions with SWRI and CPCo personnel. These observations included calibrations, performance of examinations and documentation.
b.
On February 14, 1979, ultrasonic and liquid penetrant examinations were observed being performed on the ECS System welds. Weld 6"-ECS-102-2 was found to have a linear indication by ultrasonics and an unacceptable linear indication by liquid penetrant exam-ination. On March 26, 1979, the inspector reviewed the welding and NDE procedures, also the reports and found that the weld had been repaired and was acceptable.
c.
There were ultrasonic examinations performed on the ECS System, liquid penetrant examinations performed on the RDS and ECS Systems and visual examinations performed on the CRD and ECS Systems.
No items of noncompliance or deviations were identified in the areas observed.
5.
Review of Data Reports The inspector examined and determined that the data reports demonstrated that the Big Rock Point Technical requirements were
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met.
The required information was available for ultrasonic, liquid penetrant and visual examinations. The inspector also reviewed QA Audit Reports No.s FE-32 and FE-40.
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No items of noncompliance or deviations were identified in the documents reviewed.
6.
Material and Equipment Certification
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The inspector examined and verified the adequacy of calibration and certification documents related to the following items:
a.
Magnaflux Materials -
Penetrant Batch No. 7C064 - CPCo 7H151 - SWRI Developer Batch No. 7C003 - CPCo
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7LO68 - SWRI Cleaner Batch No. 7C086 - CPCo 7K043 - SWRI b.
Magnetic Particles -
8A Red Batch No. TH005 - SWRI 14AM Magnaglo Batch No. 7K088 - SWRI c.
Ultrasonic Couplant -
Ultragel II Batch No. 10784 - CPCo Glycerine Batch No. 1B-12137-2 - SWRI d.
Ultrasonic instruments, calibration blocks, transducers and magnetic particle Parker Probe instument.
No items of noncompliance or deviations were identified in the douements reviewed.
7.
NDE Personnel Certifications The inspector reviewed the following SWRI and CPCo NDE personnel certifications in accordance with SNT-TC-1A, 1975 Edition:
Name Level Methods Company E. Martinez III RT-UT-PT-UT CPCo R. Edwards II ET-UT CPCo
R. Kahle II RT CPCo
M. Denne I
RT-UT-ET CPCo T. Gabrielson I
RT-UT-ET CPCo M. Johnson I
RT-UT-ET CPCo A. Clay I(Itd)
VT-UT-MT-PT SWRI-5-9m--
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No items of noncompliance or deviations were identified in the above certifications reviewed.
8.
Steam Baffle and Core Spray Sparger Replacement a.
After the steam baffle and core spray sparger arrived at the site from GE, CPCo QA personnel found the following discrepancies. The discrepancies were reviewed and corrected
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prior to installation.
(1) Sparger connector pipe welds did not appear to be full penetration type as required by GE Specifications.
(2) Discrepancy noted on sparger replacement surveillance report which was not corrected prior to shipment from
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vendor.
(3) The sparger connector pipe weld joints had been ground on the inside diameter and ground out several places in the pipe wall.
(4) Discrepancy noted on sparger replacement Surveillance Report No. 78-03 had not been resolved prior leaving vendor.
(5) Two sets of sparger connection pipes were received without serial numbers.
(6)
Sparger clamp bolts received did not match bolts shown on drawing.
(7) The sparger nozzle target that was to be used to align the core spray nozzles did not agree with the coordinates listed on the drawing.
(8) The cable assemblies for lifting the baffle and sparger did not agree with the drawing dimensions.
(9) Visual inspection of mitered joints disclosed lack of weld penetration and oxidation on the inside deameter of all sparger nozzle pipe studs.
(10) Sparger nozzles 16 and 17 were not aimed at the correct XY target coordinates.
(11) Radiographs of the sparger inlet "T" welds showed
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incomplete penetration for all three welds and visual examination revealed incomplete penetration on two of the velds.
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(12) Visual inspection of the sparger assembly on ten of the nozzles where seal welding was performed showed r
areas of sugar (burnout).
(13) Radiographsoffthebasetospargerringveldsshowed
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that these welda did not have full penetration.
(14) Improper 'use of documented welding processes were used on the sparger/ baffle assembly.
(15) The sparger and baffle would not sit level.
(16) Baffle in tank would not sit level.
b.
The repair program required that the replacement core spray sparger be designed in accordance with ASA B31.1-1955 Edition and that the replacement steam baffle be designed in accordance with guidance from ASME Section XI, 1974 Edition with Summer 1976 Addenda, Paragraph IWA 7000.
The replacement steam baffle and core sparger assembly appears c.
to satisfy the requirements of the specification and the repair program.
d.
The old sparger is known to have had two' damaged clbows and an expected less than optimum core coverage.
The replacement was undertaken to correct this situation.
e.
The inspectors examined the welding of the steam baffle and core spray sparger and reviewed the following documents.
(1) General Nuclear Quality Assurance Manual, No. 7, Rev. O, November 13, 1975.(18 Criterion).
(2) General Welding Procedure for Nuclear Services Projects, GWP-2000, Rev. 9 January 30, 1979.
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(3) General Weld Repair Procedure, CWP-1001, Rev. 7, January 10, 1978.
(4) Welding Performance Qualificttion, GWP-1003, Rev. 5,
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November 1, 1978.
(5) Removal of Spray Nozzles from Big Rock Point Core Spray Sparger, BRP-CSS-001, Rev. O, hrch 3, 1979.,
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(6) Welding of Nozzle Bosses to Big Rock Point Core Spray Sparger, BRP-CSS-002, Rev. O, March 3, 1979.
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(7) Repair Incomplete Penetration of Sparger to Tee Welds, TSP-04, Rev. O, March 5, 1979.
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(8) Arc Welding of Austemitic Stainless Sterl, P50YP102, Rev. 5, January 24, 1978.
(9) Reactor Internal Components Specification 22A5515, Rev. 2, January 12, 1978.
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(10) Product Specification for Stainless Ste 1 Bore Wire,
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PS-5000, Rev. 8, May 23, 1978.
(11) Steam Baffle Tack Weld Repair, TWR-2, Rev. O, March 7, 1979.
(12) Core Spray Sparger Nozzle Installation, NIP-1, Rev. O, March 10, 1979.
i (13) Assembly of Inlet Pipe to Connector and Thermal Sleeve, IPC-1, Rev. O, March 11, 1979.
(14) Sparger to Baf fle Assembly, SFU-2, Rev. O, March 10, 1979.
(15) Steam Baffle Support Pad and Bolt Radius Installation, SPR-1, Rev. O, March 9, 1979.
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(16) Pre Shutdown Activities Ring Sparger Replacement, FC-464-01, Rev. O, Febr uary 3, 1979.
(17) Sparger/Baf fle Removal Procedure, FC-464-02 (Removal of sparger inlet piping. Drilling of baffle holddown bolts. Removal of sparger and baffle).
,(18) GE Specification, Steam Baffle and Core Spray Sparger,
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22A5589, Rev. 2, April 25,1978.
(19) GE Big Rock Point Core Spray Sparger and Steam Baffle Design Report, NEDC-21974, Class I, November, 1978, also Appendix II, Rev. 1, Appendix III, NUS3234, September, 1978 and Appendix IV, NUS3234A, October, 1978.
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The inspectors also reviewed several travelers, welding wire material certifications, welding procedure qualifications and the following welder qualification of GE personnel:
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J. Kayyal T. Kean Z. Kayyal J. Williams N. Zayas g.
The inspector determined that applicable weld procedures
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b and weld material were used, appearance of weld _ surface was
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acceptable and work area was reasonably clean.
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The inspector reviered the following procedures and the GE NDE personnel certification of S.RA21, Level III in liquid examination who performed the NDE.
(1) Color Contrast Visible Dye Penetrant Fve=4n= tion, E50YP22, Rev. O, September 23, 1977.
(2) Visual Examination Procedure, NDE-VT-5001, Rev. 1, Janaury 25, 1979.
(3) Cleaning and Cleanliness Control for Field Modifications of Vessel Components, 21A2040, Rev. O, January 11, 1974.
(4) Visus 1 Inspection Procedure, FC-464-03, Brushing and TV Examination of foffle Support Lugs and Thermal Sleeve.
i.
The construction testing and installation of the steam baffle and core sparger assembly appears to satisfy the applicable procedure and code requirements.
No items of noncompliance or deviations were identified.
9.
Unacceptable Weld in 6" Inlet Line to Emergency Condenser (LER No. 79-07)
Weld 6-ECS-102-3 was found to have external under cut and insufficient weld filler on external cap of weld in accordance with Visual Procedure NDT-VT-0 3 In weld was built-up, radiographed, visually examined and four4 to de acceptable.
The inspector reviewed procedures and reports.
No items of noncompliance or deviations were identified.
10.
1977 Inservice Inspection Report Review The Inservice Inspection No. 5 was conducted during the period July 27, 1977, through September 20, 1977.
Inspections were conducted in accordance with Section 9.0 of the Big Rock Point Technical Specifications and in accordance with ASME Section XI, 1971 Edition with Winter 1972 Addenda, except the RDS, which was in accordance with ASME Section XI, 1974 Edition with no Addenda.
Areas examined during this ISI included various components of the reactor pressure vessel, portions of the nuclear steam supply system and various support piping systems. The ISI was performed using ultrasonic, radiographic, liquid penetrant and visual exam-
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inations. ISI was performed by CPCo and SWRI personnel using
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Evaluation of inspection data resulted L.,
in two weld repairs and various cosmetic grindings and stud and nut replacements. The two weld repairs were welds 2-RCS-106-1
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and 6-ECS-102-8.
The repairs were performed by CPCo personnel.
The inspector reviewed, repair data, procedures, material test reports and personnel qualifications.
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No items of noncompliance or deviations were identified.
11.
Crack-Like Indications in Reactor Clean-up System (LER No. 79-06)
Ultrasonic indications revealed crack-like indications at the junction of a 3" line and a 1" drain line stub. The section containing the defect was cut out and the line replaced by CPCo personnel in accordance with Welding Procedure GT-8-8.
Liquid penetrant examination was performed by CPCo personnel in accordance with Liquid Penetrant Procedure, NDT-PT-01.
The inspector reviewed the procedures, reports and personnel qualifications.
No items of noncompliance or deviations were identified.
12.
Unacceptable Weld in 6" Inlet Line to Emergency Condenser (LER No. 79-04)
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Weld 6-ECS-102-2 was found to have a linear indication by ultrasonics examination. Supplementary radiographic examination of the weld also detected a linear indication that was interpreted to be incom-plete penetration. The weld was repaired and re-radiographed in accordance with procedures GT-1-1 and NDT-RT-01, Rev. O.
The inspector reviewed procedures and reports.
No items of noncompliance or deviations were identified.
13. Minor Steam Leak at a Connection to the Clean-up Demineralized Water Return Line (LER No. 78-44)
The inspector performed a visual examination of the area where a minor steam leak was observed.
(A 3/4" connection to the 3" clean-up demineralized water return line.) The 3/4" line was approximately a foot long, capped and valved for use as a vent.
The 3/4" line and an adjacent section of 3" pipe have been removed for metal surgical examination. A 3" section of pipe has been installed with no attachment since the postulated fatigue failure may have been induced by vibration of the 3/4" stub attachment.
CPCo personnel performed the weldings and NDE in accordance with Welding Procedure SM-8-8 and Liquid Penetrant Procedure PT-01.
The inspector reviewed the procedures, reports, welder qualifications and material certifications.
No items of noncompliance or deviations were identified.
Exit Interview The inspector met with site representatives at the conclusion of the inspection and summarized the scope and findings of the inspection. The licensee acknowledged the information.
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