IR 05000250/1988033
| ML17345A567 | |
| Person / Time | |
|---|---|
| Site: | Turkey Point  |
| Issue date: | 11/22/1988 |
| From: | Blake J, Newsome R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML17345A566 | List: |
| References | |
| 50-250-88-33, 50-251-88-33, NUDOCS 8812080193 | |
| Download: ML17345A567 (26) | |
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~O UNITED STATES NUCLEAR REGULATORY COMMISSION
REGION II
101 MARIETTAST., N.W.
ATLANTA,GEORGIA 30323 Report Nos.:
50-250/88-33 and 50-251/88-33 Licensee:
Florida Power and Light Company 9250 West Flagler Street Miami, FL 33102 Docket Nos.:
50-250 and 50-251 License Nos.:
DPR-31 and DPR-41 Facility Name:
Turkey Point 3 and
Inspection Conducted:
October 31 - November 4, 1988 Inspector:
R Approved by:
J. J.
a e, Chief ater als and Processes Section Engi eering Branch Division of Reactor Safety Data Signed (/-zz-e&
Date Signed SUMMARY Scope:
This routine, unannounced inspection was conducted onsite in the area
- of Inservice Inspection (ISI) including a review of the ISI Plan for this outage for Unit 4, review of NDE procedures including Eddy Current and Visual examination procedures, review of personnel qualifications, review of material and equipment certification records, observation of in-process ultrasonic examinations and in-process Eddy Current data collection and data evaluation activities, and a sample of completed examination records were 'reviewed.
Results:
In the areas inspected, violations or deviations were not identified.
All areas inspected appeared to be adequately controlled and managed.
Licensee ISI personnel were very receptive to any NRC suggestions.
The training and qualification of NDE personnel conducting ultrasonic examinations is superior to this type program normally encountered at other nuclear facilities.
This is evidenced by the licensee's requirement that al,l ultrasonic examiners take and pass a practical examination for pipe weld examination prior to being allowed to conduct examinations on pipe welds at the facility.
8812080193 881129 PDR ADOCN, 05000250 G
PNU
REPORT DETAILS Persons Contacted Licensee Employees
- E. Anderson, ISI Engineer
- J. Arias, Jr., Regulation and Compliance Supervisor
- R. Atkisson, Juno Beach Staff
- W. Bladow, gA Superintendent
- M. Blew, ISI Coordinator G. Boyer, Plant Support/Juno Beach Staff
- F. Carr, NDE Supervisor/Juno Beach Staff
- J. Cross, Plant Manager
- R. Earl, gC Supervisor
- K. Gross, Compliance Engineer
- S. Hale, Engineering Manager
- J. Kappe, Maintenance Superintendent
- E. Lyons, Compliance Engineer
- R. Mende, Operations Supervisor
- L. Pearle Operations Superintendent
- F. Southworth, Technical Supervisor Other licensee employees contacted during this inspection included engineers, mechanics, security force members, technicians, and admini-strative personnel.
NRC Resident Inspectors
"R. Butcher, Senior Resident Inspector
- T. McElhinney,, Resident Inspector
- Attended exit interview Acronyms and initialisms used throughout this report are listed in the last paragraph.
Inservice Inspection (ISI)
The inspector examined
'documents, activities, and records, as indicated below, to determine whether ISI was being conducted in accordance with applicable procedures, regulatory requirements, and licensee commitments.
The applicable code for ISI is the American Society of Mechanical Engineers Boiler and Pressure Vessel (ASME BSPV)
Code,Section XI 1980 edition with addenda through winter 1981.
Nondestructive examinations (NDE)
are being conducted by EBASCO with visual examinations being conducted by Southwest Research Institute (SwRI).
The Eddy Current examinations of the Unit 4 Steam Generator Tubing utilizes DEC-TECH, Zetec, NDE-Technology, and Westinghouse (W) personnel for the manual eddy current data acquisition and manual eddy current data evaluation activi-ties.
The licensee is utilizing an automated eddy current data evaluation system to perform a secondary evaluation of all tube examination dat a.
ISI Program Review, Unit 4 (73051)
The inspector reviewed'the below listed documents relating to the ISI program to determine whether the plan had been approved by the licensee and to assure that procedures and plans had been established (written, reviewed, approved and issued)
to control and accomplish the following applicable activities:
organizational structure including qualifications, training, responsibilities, and duties of personnel responsible for ISI; audits including
'procedures, frequency, and qualification of personnel; general Quality Assurance (QA),
requirements including examination report, deviations from previously established program, material certifications and identi-fication of components to be covered; work and inspection procedures; control of processes including suitably controlled work conditions, special methods, and use of qualified personnel; corrective action; document control; control of examination equipment; quality records including documentation of indications and NDE findings, review of documentation, provisions to assure legibility and retrievability, and corrective action; scope of the inspection including description of areas to be examined, examination category, method of inspection, extent of examinations, and justification for any exception; definition of inspection interval and extent of examination; qualification of NDE personnel; and controls of generation, approval, custody, storage and maintenance of NDE records.
Turkey Point Nuclear Plant Unit 4 Inservice Inspection Period Schedule Second Period, Second Interval Dated October 15, 1988, Revi'sion
b.
JNS-MCI.QI 2.14 (R3)
(Sections I thru 18)
(1)
The inspector reviewed the procedures 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, requirements for qualification of NDE personnel, and compilation of required records; and if applicable, division of responsibility between the licensee and contractor personnel if contractor personnel are involved in the ISI effort.
Nuclear Energy Manual for ASME Section XI Inservice Inspection of Nuclear Power Plant Components I.
Review of NDE Procedures, Units 3 and 4 (73052)
NDE 1.3 FCN-A (Rl)
Eddy Current Examination of Non Ferromagnetic Tubing with Multi-Frequency Techniques MIZ-18 Cal
(RI)
Cal ibrati on of Magnetic Parti c1 e Equipment
NDE 2.2 (R2)
NDE 3.3 (R1)
NDE 5.I (R5)
NDE 5.5 (R2)
NDE 5.2 (R4)
NDE 5.3 (R2)
NDE 5.4 (R7)
NDE 5.6 (R2)
Magnetic Particle Examination Liquid Penetrant Examination Solvent Removable Visible Dye Technique Ultrasonic Examination of Pressure Vessel Welds, Except Reactor Vessels Ul trasoni c Examinati on of Primary Coolant Piping Welds (PTP 354)
Ultrasoni c Examinati on of Ferri tic Piping Welds Ultrasonic Examination of Clad Carbon Steel Piping Ultrasonic Examination of Austenitic Piping Welds Ultrasonic Examination of Integrally Welded Attachments to Piping Turkey Point Unit 3 5 4 Steam Generator ECT Data Analysis Handbook NDE 4. 1 (R2)
Visual Examination VT-1 Welds/Bolting/
(with FC-24)
Bushing/Washers NDE 4.3 (R1)
Visual Examination VT-3/VT-4 (2)
The inspector reviewed the Ultrasonic (UT)
procedures to ascertain whether they had been reviewed and approved in accordance with the 1'icensee's established gA procedures.
The procedures were also reviewed for technical adequacy and conformance with ASME,Section V, Article 5 and other license commitments/requirements in the following areas:
type of apparatus used; extent of coverage of weldment; calibration requirements; search units; beam angles; DAC curves; reference level for monitoring discontinuities; method for demonstrating penetration; limits for evaluating and recording indications; recording significant indications; and, acceptance limits.
(3)
The inspector reviewed the Eddy Current (EC)
procedures for technical content relative to:
multichannel examination unit, multichannel examination indication equipment is specified, examination sensitivity, material permeability, method of examination, method of calibration and calibration sequence, and acceptance criteri (4)
(5)
(6)
The inspector reviewed the Liquid Penetrant (PT) procedure to ascertain whether it had been reviewed and approved in accor-dance with the licensee's established gA procedures.
The procedure was also reviewed for technical adequacy and conformance with ASME,Section V, Article 6, and other licensee commitments/requirements in the following areas:
specified method; penetrant material identification; penetrant materials analyzed for sulfur; penetrant materials analyzed for tota1 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 techniques; and, procedure requalification.
The inspector reviewed the Magnetic Particle (MT) procedures to ascertain whether they had been reviewed and approved in accordance with the licensee's established gA procedures.
The procedures were reviewed for technical adequacy and for conformance with ASME Section V, Article 7, and other licensee commitments/requirements in the following areas:
examination'ethods; contrast of dry powder particle color with background; surface temperature; suspension medium and surface temperature for wet particles; viewing conditions; examination overlap and directions; pole or prod spacing; current or lifting power (yoke); and, acceptance criteria.
The inspector reviewed the Visual (VT) examination procedures to determine whether they contained sufficient instructions to assure that the following parameters were specified and controlled within the limits permitted by the app'licable 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 implemented used for surface preparation, if any; whether direct or remote viewing is used; 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.
Observation of Work and Work Activities, Unit 4 (73753)
The inspector observed in-process examination activities and reviewed certification records of equipment, materials, and NDE personnel which had been and will be utilized during the required ISI examinations during this outage.
The observations and reviews conducted by the inspector are documented belo (1)
The inspector observed calibration activities and the inprocess ultrasonic examinations being conducted on the 'welds indicated below.
The observations were compared with the applicable procedures and the Code in the following areas:
availability of and compliance with approved Nondestructive Examination (NDE)
procedure; use of knowledgeable NDE personnel; use of NDE personnel qualified to the proper level; type of apparatus'sed; extent of coverage of weldment; calibration requirements; search units; beam angles; DAC curves; reference level for monitoring discontinuities; method of demonstrating penetration; limits of evaluating and recording indications; recording significant indications; and, acceptance limits.
Drawin No.
Weld ID 004-A10 004-A32 004-856 004-856 004-856 004-855 004-852 004-853 12"-RC-1401-4 10"SI-1402-1 14"-FWB-2402-11 14"-FWB-2402-8 14"-FWB-2402-2 14"-FWA-2401-1 6"-DBA-2404-FW-45 6"-DBD-2405-FW-428 The inspector conducted an ultrasonic verification examination, using EBASCO equipment, on portions of the below listed welds.
The examinations were performed in order to evaluate the technical adequacy of the ultrasonic examination procedure being used by the licensee's contractor to perform ultrasonic examinations and to assess the validity of the information being reported by" the ultrasonic examiners.
Drawin No.
Weld ID 004-853 004-856 004-A32 6"-DBD-2405-FW-428 14"-FWB-2402-11 10"-SI-1402-1 The verification ultrasonic examinations conducted by the inspector indicated that the procedure being used to conduct the examinations is adequate and that the information being reported by the ultrasonic examiners compared favorably with the verification examinations.
The following listed ultrasonic equipment and materials certification records were reviewed:
Ultrasonic Instruments Manufacturer/Model Soni c MK-1 K/B US K-7B K/B USK-7S K/B USL-48 Serial No.
06446E 31451-907 31459-525 213051 The inspector reviewed spectrum analysis data for ultrasonic transducers with Serial Numbers C14455, E24449, F03233, G16577, M07404, 40328, and 57A3053.
Ultrasonic Couplant Batch Numbers 8661, 8764, and 8330.
Ultrasonic Calibration Blocks UT-26, UT-29 UT-37, UT-41, UT-53 (2)
The inspector reviewed the below listed liquid penetrant materials certification records to ascertain if the sulfur and halogen content of the material was within acceptable content lilllits.
Materials Batch Number Liquid Penetrant Cleaner/Remover Developer 87L071 86K029 83F015 87M025 88E035 (3)
The inspector reviewed documentation indicating that a ten pound lift test had been performed on magnetic particle AC yokes 811 and 8950.
(4)
The inspector observed the Steam Generator tubing Eddy Current examination activities indicated below.
The observations were compared with the applicable procedures and the Code in the following areas:
method for maximum sensitivity is applied;
- method for determining material permeability; method of.
examination has been recorded; examination equipment has been calibrated in accordance with the applicable performance reference; amplitude and phase has been calibrated with the proper calibration reference and is recalibrated at predetermined frequency; required coverage of steam generator tubes occurs during the examination; acceptance criteria is specified or referenced and is consistent with the procedure or the ASME Code; and, results are consistent with acceptance criteria.
(a)
In-process tube data acquisition, including calibration confirmation and tube location verifications were observed for the following steam generator tubes:
SG-C Tube ID Row Column SG-8 Tube ID Row Column
37
35
33
15
12
3
9
3
4
53
53
53
53
65
65
77
77
78
78
4
4
7
9
11
18
20
21
73
73
74
74
74
86
86
86
87 (b)
In-process Eddy Current inspection data evaluation, including calibration confirmation, was observed for the below listed steam generator tubes.
Data analysis is accomplished by first having the data evaluated manually by qualified data analysts with this analysis designated as the Primary evaluation.
The data is then evaluated by an automated data analysis system, Computerized Data Screening (CDS), with this evaluation designated as the Secondary evaluation.
If any differences are noted between the Primary and Secondary evaluations a resolution evaluation is conducted by an independent manual examination of the conflicting evaluations.
A qualified analyst is assigned the task of resolving the differences between the Primary and Secondary evaluations and is designated as the Resolution analyst.
SG-C Row Column PRIMARY ANALYSIS SG-B Row column
60
60
28
30
68
68
PRIMARY ANALYSIS SG-C Row Column Row SG-B Column
24
26
33
29
60
60
60
60
72
40
20
32
26
68
67
78
81
81 SECONDARY ANALYSIS SG-C Rou Column Row SG-B Column
28
25
23
21
19
31
72
72
59
59
59
72
72
33
8
10
12
14
23
68
68
68
- 68
68
81
RESOLUTIONS SG-C Rom Column Row SG-B Column
24
56
68
34
13
31
74
75
75 (c)
During.the observations of the analysis activities for the above listed tubes, the inspector jointly evaluated a
sample of the data with the Primary and Resolution analysts.
No significant discrepancies were note I
(5)
(d)
Certification records for Eddy Current calibration standards with Serial Numbers Z3455 and Z1544 were reviewed for material type, correct fabrication, and artificial flaw location/size.
The inspector reviewed the qualification documentation for the below listed 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 recertification.
Method-Level
~Com an Examiner UT pT NT EC VT -
2 - 3 a
W DEC-T ZETEC ZETEC ZETEC NDE-T'DE-T NDE-T SWRI SWRI EBASCO EBASCO EBASCO EBASCO EBASCO BP DC JD GM DD TB MM JS JJ LS RB RD GI JN CD I
I I
II II II III II II III III I
I I I=
II II II II III III IIA IIA II III I IA I IA I
I I
I II II II II III III III III II -
II II d.
Inservice Inspection, Data Review and Evaluation, Unit 4 (73755)
(1)
Records of completed nondestructive examinations were selected and reviewed to ascertain whether:
the method(s),
technique and extent of the examination complied with the ISI plan and applicable NDE procedures; findings were properly recorded and evaluated by qualified personnel; programmatic deviations were recorded as required; personnel, instruments, calibration blocks and NDE material (penetrants, couplants)
were designated.
Records selected for this review are listed below.
Drawin No.
004-B50 004-850 004-B50 004-B55 004-B55 Weld/Item ID
'"-BDB-2402-16 6"-BDB-2402-18 6"-BDB-,2402-19 18"-FWA-2401-FW-1A 18"-FWA-2401-A-1 NDE Method MT MT MT MT MT
Drawin No.
004-842 004-842 004-856 004-810 004-825 004-82/64 004-89/071 004-826/088 004-826/088 004-88/070 004-A4/010 004-A4/010 004-816/078 004-A30/036 004-87/69 004-8 18/80 004-81/63 004-Alo/016 004-815 004-820 004-C51 004-C41 004-C50 004-C38 004-825 004-A33 004-A45 004-838/100 004-838/100 004-819 004-819 004-827 004-827 004-827/89
.004-827/89 004-V15 004-824 004-A33 004-818 004-818 004-A2 004-A5 004-Al/7 004-A6/012 004-A4/010 004-A4/100 Wel d/I tern ID 26"-MSC-2406-2 26"-MSC-2403-9LS 14"-FWB-2402-2 10"-RHR-2403-5 8"-SI-2405-1 14"-RHR-2403-10 8"-RHR-2404-1 8"-SI-2406-FW1 8"-SI-2406-11 10"-RHR-2401-13 31"-RCS-1402-6 31"-RCS-1402-5 10"-SI-2401-1A 14" -RHR-1401-5 12"-RHR-2402-27 10"-SI-2403-4 14"-RHR-2401-1LS 12"-RC-1401-4 4-SI H-48 4-SR-616 H-190-01 H-323-03 J
SR-667 4-218-A 8073-H-810-01 27-773-002 26"-MSB-2402-7 31"-MSB-2402-1A 10"-SI-2407-4 10"-SI-2407-5 8"-SI-2407-1 8"-SI-2407-2 8"-SI-2407-1 8"-SI-2407-10A 4-LDHX-1 8"-SI-2404-2 8"-RHR-1404-2 10"-SI-2403-1A 10"-SI-2403-4 29"-RCS-1404-4 29"-RCS-1405-4 31"-RCS-1401-8 27. 5"-RCS-1406-BC-18 31"-RCS-1402-5 31"-RCS-1402-6 NDE Method MT MT MT PT PT PT PT PT PT PT PT PT PT PT PT PT PT PT VT-3 VT-3/4 VT-3 VT-3 VT-3 VT-3/4 VT-3 VT-3 VT-3 UT UT UT UT UT UT UT UT UT UT UT UT UT UT UT UT UT UT UT
(2)
While reviewing the completed ultrasonic examination records for the reactor coolant system welds that require examinations from the fitting side. (elbows, valves, etc.), the NRC inspector noted that the calibration sheets indicated that the inside diameter ( I.D.) notch was not discernable on the calibration block.
The calibration block used for this examination is designated as UT-26 and is manufactured from SA351 Gr.
CFSN, Centrifugally Cast Stainless Steel material 3" in thickness, and is inherently difficult to penetrate ultrasonically due to the materials large grain structure and grain orientation.
The block is constructed so that it has a,.300" deep, square groove, I.D. notch, and
side drilled holes, 3/16" in diameter, at depths of I/O, I/2, and 3/4 material thickness.
The side drilled holes were easily detectable, according to the calibration sheets, but without the detection of the I.D. notch there is no absolute assurance that the I.O. of these welds are being examined from the fitting side of the welds.
The NRC inspector additionally noted that the ultrasonic equipment used to accomplish these examinations was not the same as what he has observed at other facilities where detection of the I.D. notch in this type material has been possible.
The NRC inspector discussed his concern with knowledgeable ISI personnel with regard to detection of the I.O. notch in the calibration block and whether ultrasonic equipment similar to that used at other facilities was available at this facility.
The ISI personnel indicated that they had modified one of their ultrasonic instruments to include a 600 volt pulser which is the same as what has been used at other facilities to inspect this type material.
The NRC inspector requested that the modified ultrasonic instrument be used on calibration block UT-26 to see if the I.D. notch could be identified with this instrument.
The NRC inspector and two Ultrasonic level III qualified ISI personnel calibrated the modified ultrasonic instrument on block, UT-26 using the 3 side drilled holes as reflectors but the I.D.
notch was not discernable from the general back ground signals caused by the grain structure of the calibration block.
Several attempts were made to positively'dentify the I.D. notch, i~eluding excessive gain settings and various other techniques, but none were conclusive even though a signal could be seen, on occasion, at the proper location on the CRT of the instrument.
The NRC inspector concluded that this particular calibration block, is much more difficult to penetrate ultrasonically than similar blocks at other facilities and suggested that a
new notch, placed at a different location in the block, might yield
, better ultrasonic identification of the I.D. notch if the current location of the notch is in an unusually grainy portion of this particular block.
The NRC inspector also suggested that obtaining a
new calibration. block, that still meets the require-ments of the ASNE code, might be pursued.
At this point the NRC
inspector was informed that the plant had been granted relief by NRR to allow the use of this calibration block because the block has been used since the plant was built and its continued use would tend
.to provide consistent results.
The ISI personnel indicated that they would consider the above suggestions and in addition were continuing to seek new ultrasonic technology advancements that might enhance the examination of this type material.
The NRC inspector then interviewed the qualified ultrasonic examiner that had conducted the examinations on these welds.
This interview was conducted in order to determine if it was possible to determine if the ultra-sound was penetrating to the I.D. of the item during the examinations.
The UT examiner indicated that low amplitude signals, well below recording level at the I.D. position of these welds, had been observed during the examinations and this would tend to indicate that at least some sound was penetrating to the I.D. of the fittings.
Because there is an adequate ultrasonic examination of these welds conducted from the pipes forged stainless steel base material side, and since forged material is relatively easy to examine ultrasonically, and an examination from at least one direction is assured, which is the case in many instances where an items geometric configuration will not permit examinations from both sides of a weld, and because of the ultrasonic examiners favorable observations during the actual examinations, the NRC inspector has concluded that in all probability an adequate inspection of these pipe to fitting welds has occurred even though the I.D. notch on calibration block UT-26 could not be verified during the ultrasonic equipment calibration process.
(3)
Eddy Current Examination of Steam Generator Tubing (a)
The inspector reviewed a sample of the associated records of the steam generator tubing eddy current examinations.
The reviews were compared with the applicable procedures and the code in the following areas the multichannel eddy current examination equipment has been identified; material permeability has been recoded; method of examination has been recorded; and, results are consistent with acceptance criteria.
(b)
By the conclusion of the NRC inspection all EC examina-tions had not been completed.
The final examination results will be reported to the NRC in accordance with the TECH SPEC requirements.
The status for the Unit 4 steam generators is listed below.
Examination of steam generator A had not starte Tubes to be examined Tubes Completed SG-B 3214 2830 SG-C 3219 2690 In the areas inspected, violations or deviations were not identified.
Exit Interview The inspection scope and results were suomarized on November 4, 1988, with those persons indicated in paragraph 1.
The inspector described the areas inspected and discussed in detail'he inspection results.
Proprietary information is not contained in this report.
Dissenting comnents were not received from the licensee.
Acronyms and Initialisms AC ASME B&PV CDS CRT DAC DEC-T DPR EC FCN ID I.D.
Alternating Current American Society of Mechanical Engineers Boiler and Pressure Vessel Computerized Data Screening Cathode Ray Tube Distance Amplitude Curve DEC-TECH Demonstration Power Reactor Eddy Current Field Change Notice Identification Inside diameter Inservice inspection Magnetic particle Nondestructive Examination NDE Technology Number Nuclear Regulatory Commission Nuclear Reactor Regulation Liquid penetrant Quality Assurance Revision Steam Generator Southwest Research Institute Ultrasonic Visual Westinghouse Electric Corporation