IR 05000250/1992027
| ML17349A499 | |
| Person / Time | |
|---|---|
| Site: | Turkey Point  |
| Issue date: | 11/12/1992 |
| From: | Blake J, Kleinsorge W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML17349A498 | List: |
| References | |
| 50-250-92-27, GL-89-08, GL-89-8, NUDOCS 9211250039 | |
| Download: ML17349A499 (19) | |
Text
glaR REGII P0 e:-
t/ ++*d +
UNITED STATES NUCLEAR REGULATORY COMMISSION
REGION II
101 MARIETTASTREET, N.W.
ATLANTA,GEORGIA 30323 Report Nos.".
50-250/92-27 and 50-251/92-27 Licensee:
Florida Power and Light Company 9250 West Flagler Street Miami, FL 33102 Docket Nos e I 50-250 and 50-251 License Nos.:
DPR-31 and DPR-41 Facility Name:
Turkey Point 3 and
Inspection Conduct e
r 2-6, 1992 Inspector:
W.
.
sorge P
ac I spect Date Signed k
- J.
lak, Chief Haterials and Process Section'ngineering Branch Division of Reactor Safety SUMMARY ou'.
9'5~
Date Signed Scope:
This routine, announced inspection was conducted in the areas of Inservice Inspection (ISI), and followup on NRC Generic Letter (GL) 89-08:
'"Ero-sion/Corrosion-Induced Pipe Wall Thinning" Results:
In each of the areas examined the inspector discovered that nondestructive test (NDE) examiners have conducted conservative examinations in accordance with the appropriate test procedures.
NDE procedures were also noted to be very detailed, well organized and technically effective in implementing the applicable code requirements.
,Supervisors, engineers, and NDE examiners
~ contacted during this inspection were very knowledgeable in their areas of responsibility.
The licensee has established an apparently effective program to maintain high energy carbon steel piping systems within acceptable wall thickness limits.
9211250039 921118 PDR ADOCK 05000250
Persons Contacted Licensee Employees
- T. Abbatiello, Site guality Manager
- G. Alexander, Supervisor Inspections ESI
- H.
Bl,ew, ISI Coordinator
- J. Knorr, Regulatory Compliance Supervisor
- L. Motley, Supervisor Code Programs ESI
- L. Pearce, Plant General Manager
- T. Plunkett, Vice President
- R. Turner, ISI Specialist
- E.
Weinkam, Licensing Manager Other licensee employees contacted during this inspection included engineers, mechanics, technicians and administrative personnel.
NRC Resident Inspectors
- R. Butcher, Senior Resident Inspector (SRI)
G. Schnebli, Resident Inspector (RI)
L. Trocine, Resident Inspector (RI)
HE Janus, Intern
- Attended exit interview Acronyms and initialisms used throughout this report are listed in the last paragraph.
Inservice Inspection ( ISI)
The inspector reviewed documents and records, and observed activities, as indicated below, to determine whether ISI was being conducted in accor-dance with applicable procedures, regulatory requirements, and licensee commitments.
The applicable code for ISI, for Units 3 and 4 is the ASME B&PV Code,Section XI, 1980 Edition with Addenda through Winter 1981 (80W81).
Unit 3 is in refueling outage (RFO)
13, the second outage of the third 40 month period of the second ten year interval (02,P3, I2)
ending February 21, 1994.
Unit 4 is operating in the third 40 month period, of the second ten year interval (P3, I2) ending April 14, 1994.
Unit 3 received its Operating License July 19, 1972, and commenced commercial operations on December 14, 1972.
Unit 4 received its Operat-ing License on April 10, 1973, and commenced commercial operations on September 7,
1973.
The licensee's nondestructive examination personnel, augmented by contract personnel from EBASCO, are performing the liquid penetrant (PT), magnetic particle (HT), visual (VT), and ultrasonic (UT)
examinations.
Steam Generator (S/G) tubing eddy current (ET) examination data acquisition and analysis is being accomplished by the licensee's nondestructive examination personnel, augmented by contract personnel from Assea Brown Boveri Combustion Engineering (ABBCE), Zetec, Master-Lee (H-L), and Allen Nuclear Associates Inc.
(ANA). All the above activities
are being accomplished under the.umbrella of the FP8L Quality Assurance (QA) Program.
a
~
ISI Program Review, Units 3 and 4 (73051)
The inspector reviewed the following 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 estab-lished for the a'pplicable activities, procedures were also reviewed for technical content.
Procedures Reviewed ID Revision Title CAL-3 (R1)
JPN QI 9.2 (Rl)
ADH-CIS-9.1 (R1)
Nondestructive Examination (NDE) Activities Procedure For The Qualification of Nondestruc-tive Examination Procedure Calibration Blocks/Standards Calibration Verification of Temperature Heasur-ing Devices b.
Review of NDE Procedures, Units 3 and 4 (73052)
The inspector reviewed the procedures listed below to determine whether these procedures were consistent with regulatory require-ments and licensee commitments.
The procedures were-also reviewed for technical content.
Procedures Reviewed ID Revision Title ABB-QAP 2.4 (RI)
Certification Program For Nondestructive Examination Personnel H-L-QAP-2.2 (R4)
Qualification and Certification of NDE Personnel ANA-A-08 (R6)
Z-QA 101 A-1 (R10)
Certification of NDE Personnel Personnel Qualification and Certification Procedure FP&L NDE 1.3 (R4w/FCA)
Eddy Current Examinations of Non-'Ferromag-netic Tubing with Hulti-Frequency Tech-niques HIZ-18
FP&L ID Procedures Reviewed Cont.
Revision Title (8/92)
ECT Data Analysis Guideline and Performance Demonstration FP&L NDE 2.2'R4)
{R4)
Magnetic Particle Examination Liquid Penetrant Examination Solvent Remov-able Viable Dye Technique Visual Examination VT-1 for Welds/Bolting/Bushings/Washers Visual Examination VT-2 Conducted During System Pressure Tests Visual Examination VT-3/VT-4 Ultrasonic -Examination of Pressure Vessel Welds Except Reactor Vessel, Ultrasonic Examination of Austenitic Piping Welds Ultrasonic Examination of Nozzle Inner Radius Areas Ultrasonic Examination of Reactor Coolant Pump Flywheels Procedures were well written and appropriate for their intended application.
Observation of Work and Work Activities, Unit 3 (73753)
Because the window of opportunity to observe active examination activities had past, the inspector reviewed records of work activi-ties, reviewed certification records of NDE equipment and materials, and reviewed NDE personnel qualifications for personnel who had been utilized in the ISI examinations during this outage.
The reviews conducted by the inspector are documented below.
PT Examination Records Reviewed Safety Injection Pipe Welds 2"-SI-1301-25 2"-SI-1302-26 3"-SI-100-1A 10"-SI-2303-2 10"-SI-2303-3 10"-SI-2303-4 2"-SI-1302-28 10"-SI-2303-1 10"-SI-2303-5
PT Examination Records Reviewed Chemical and Volume Control System Pi.pe Welds I
2"-CH-1302-29 2"-CH-1302-34 2"-CH-1302-35 3"-CH-1302-2 3" -CH-1302-28 3" -CH-1303-9 3"-CH-1303-10 2" -CH-1302-28 3"-CH-1301-42 3" -CH-1301-43
,Reactor Coolant System Pipe Welds 4"-RC-1304-23 4"-RC-1304-1A 2"-RC-1310-1 2"-RC-1310-2 Residual Heat Exchanger Intregal Attachment 3-RHE-SPA-1 Relative to the PT examinations, the inspector reviewed certifica-tion documeritation for the following PT materials (penetrant cleaner and developer),
and thermometers.
'enetrant Naterials Penetrant:
89D02K, 87L071 Cleaner/Remover:
92EIOK Developer:
91B02P, 88L084 Thermometers S/N:
92-033)92-030, 92-034,92-012, 92-003 The inspector reviewed qualification, certification and visual acuity documentation for the following PT examiners.
PT Examiners RJV PT-II PK PT-II NV PT-II CL PT-II NT Examination Records Reviewed KLH PT-II 3-097-A1 IA 3-098-A1 IA 3-109-A1 IA 3-110-A1 IA 3-111-A1 IA 78101B-H-320-02 IA 78101B-H-320-04 IA Nain Steam Intregal Attachment Hain Steam Intregal Attachment Nain Steam Intregal Attachment Hain Steam Intregal Attachment Nain Steam Intregal Attachment
'team Generator Blowdown Intregal Attachment Steam Generator Blowdown Intregal Attachment
HT Examination Records Reviewed Cont.
78101B-H-320-09 IA 78101B-H-322-09 IA 78101B-H-322-05 IA 78101B-H-322-03 IA 78101B-H-322-02 IA 78101B-H-321-03 IA 78101B-H-321-01 IA Steam Generator Blowdown Intregal Attachment Steam Generator Blowdown Intregal Attachment Steam Generator Blowdown Intregal Attachment Steam Generator Blowdown Intregal Attachment Steam Generator Blowdown Intregal Attachment Steam Generator Blowdown Intregal Attachment Steam Generator Blowdown. Intregal Attachment Relative 'to the HT examinations, the. inspector reviewed certifica-tion documentation for the following HT Yokes, dry powder, and ten Lbs. test weights.
Yokes Hagfoil EL10 S/N 30 DA-400 S/N 1147 Dry Powder Hagnaflux 8A Red (Certification documentation was not available)
Ten Lbs. Test Weights MCI-HT-3 The inspector reviewed qualification, certification and visual acuity documentation for the following HT examiners.
HT Examiners CHR HT-II HV HT-II VT Examination Records Reviewed 3-RPC-FLB 1-24 3-SGC-I (1-16)
3-SGC-0 (1-16)
80117-H-34D-06 3-SR-347 SR-138 PS-160 Reactor Coolant Pump Studs Steam Generator Bolts Inlet Steam Generator Bolts Outlet Auxiliary Feed Pump Suction Sliding Stanchion Component Cooling Pipe Support Component Cooling Box Restraint Component Cooling Pipe Support
VT Examination Records Reviewed Cont.
3-118-A1 3-ARC-103 3-ARC-104 3-119-A1 3-CCH-10
'3-123-A1 280A-2 80117-H-320-20 3-97-A1 3-109-A1 3-110-A1 RGX 3E200 3-89-A1 Component Cooling Anchor Component Cooling Pipe Support Component Cooling Pipe Support Component Cooling Anchor-Component Cooling Box Restraint Component Cooling Anchor Component Sliding Stanchion Auxiliary Feed Dual Rigid Strut Hain Steam Penetration Anchor Hain Feedwater Penetration Anchor Hain Feedwater Penetration Anchor Regen Heat Exchanger Residual Heat Removal Penetration Anchor Relative to the VT examinations the inspector reviewed qualifica-tion, certification and visual acuity documentation for the follow-ing HT. examiners..
HV VT1-II VT Examiners CL VT3-II CHR VT3-II UT Examination Records Reviewed DN VT3-II I 3-SGB-CL Steam -Generator Transition To Upper Shell Weld 3-LDHX-2 Excess Letdown Heat Exchanger 3"-CH-1301-42 3"X. 189" Chemical and Volume Control Weld 3"-CH-1301-43 3"X.189",
Chemical and Volume Control Weld 3-SGC-I-IRS Steam Generator
"C" Inlet Nozzle 3-SGC-0-IR Steam Generator
"C" Outlet Nozzle 3-RPC-C-FLYWHEEL Reactor Coolant Pump Flywheel Relative to the UT examinations the inspector 'reviewed certification documentation for the following UT calibration blocks, UT instru-ments, thermometers, and complement.
UT Calibration Blocks UT-41, UT-44, UT Instruments S/N 136 1 71A~
136 701H ~
136 592G
~
136 300D~
Thermometers S/N:
92-032)92-033)
92-012)92-002
Couplant Ultragel II batch No.
9092 The inspector reviewed qualification, certification and visual acuity documentation for the following HT examiners.
UT Examiners CL UT-III KJK UT-II KLH UT-II RJV UT-II ET Examination Records Examined RJV UT-IT The inspector reviewed selected data acquired for all. three genera-tors.
The inspector reviewed certification documentation for the following Remote Data Aequi'sition Units (RDAUs),
and calibration standards.
RDAU Certifications Examined S/N:
009, 020, 023, 041, 056, 061, 069, and 072 Calibration Standard Certifications Examined S/N: Z-1546, Z-1544, Z-3455, AV-009-89, AV-001-91, and AV-002-91 The inspector reviewed qualification, certification and visual acuity documentation for the following ET examiners.
ET Examiners FPLL GTB ET-I IA DAL ET-I IA JCJ ET-II AP ET-I IA JER ET-II EGW ET-III EDD ET-I JMF ET-II FCH ET-I DPF ET-I IA JRR ET-III ASF ET-IIA AN ET-I IA BCP ET-IIA SAS ET-IIA RMW ET-IIA ERE ET-IIA WEI ET-IIA JZ ET-II ZK ET-III WKH ET-III TGW ET-IIA ABBCE RRP ET-I BKS ET-I JEA ET-I HGE ET-II HL ET-III EL ET-I IA DEL ET-III WDJ ET-IIA KEC ET-I CCP ET-I HJW ET-1 DB ET-I IA JAF ET-IIA ELM ET-II DEC ET-I IA RSM ET-III
COB ET-I SJP ET-, IT SWF ET-IT SJP ET-IT M-L LH ET-, IT BGS ET-I LTP ET-IIA JAT ET-IIA CJR ET-II CLG ET-IIA RSM ET-I IA ANA CAW fT-II LD ER-III
.
PJD ET-IIA DWH ET-IIA VSL ET-IIA
.
DEM ET-IIA JR ET-III WJW ET-IIA Zetec PAA ET-IIA DJC ET-IIIA RLF ET-IIIA WAG ET-IIIA DHI ET-IIIA EOM ET-IIA KJN ET-. IIIA RAN fT-IIIA TJS ET-IIA The. licensee performed a
100% bobbin'oil examination of the non-plugged tubes in all three generators.
Rotating Pancake Coil (RPC)
examinations were performed on 76 tubes with signals exceeding 40%
through wall and non-qualifiable indications (S/G "A"-36, S/G "B"-
20, and S/G "C"-21).
The RPC examination confirmed the presence of 9 signals (S/G "A"-3, S/G "B"-1, and S/G "C"-5).
A total o~ seven tubes were plugged in all three generators as indicated below.
Steam Generator Tube Plug Summary S/G II All Tubes Previously Plugged
Tubes Preventively Plugged RFO
Tubes Plugged RFO
a40%'/G IIB II
0 S/G IIC II
Total Tubes Plugged
15,
Surveillance The inspector reviewed the licensee's program for NDE surveillance.
The licensee performed a surveillance on each examiner for each method that examiner used during the outage.
The ratio of surveill-ances to total examinations is commendable.
A summary of NDE surveillances is provided below.
NDE Method HT PT UT YT-1 VT-3 No.
Exams Performed During RFO
14 24llll
No. Surveillances Performed During RFO
2
6
13 Data Review and Evaluation, Unit 4 (73755)
Records of completed ISI repair activity indicated below were reviewed.
A slow weeping leak was noted on the bottom of the 4A Residual Heat Removal (RHR)
pump discharge nozzle near the support.
The licensee PT examined the area of the leak.
The resulting indications were removed by grinding leaving a through wall groove suitable for welding.
As the indications were chased through wall, their removal was visually verified.
The 'root layer of the repair weld was deposited with the Gas Tungsten Arc Welding process and PT and VT examined.
The remainder of repair weld was deposited with the Shielded Hetal Arc process.
The final weld surface was PT and VT examined.
Hetallurgical evaluation of a boat sample removed from the 4A RHR pump casing indicated that the failure resulted from original casting defects.
The licensee VT examined the 3A, 3B, and 4B RHR pump casings for through wall leaks.
No leaks were identified.
The inspector reviewed the NCR N-92-0243 and construction turnover package for CWO 500990.
These packages included: the repair in-structions, the root cause analysis, the weld traveler, inspection reports, and weld material request reports.
In addition the inspec-tor reviewed the associated welding filler material receiving inspection reports, certified material test reports, welder qualifi-
-cation and qualification maintenance documentation, and PT and VT examiner'ertification and visual acuity documentation.
The inspector determined that the repair was accomplished consistent with Westinghouse Equipment Specification, E-676428,
"Auxiliary
ll Pumps" (the original fabrication specification),
and ASME B&PV Code Section XI 80W81'.
Within the'reas examined; no violations or deviations were identified.
Followup (92701)
NRC Generic Letter (GL) 89-08:
"Erosion/Corrosion-Induced Pipe Wall Thinning" This GL requested licensees to provide assurances that a long term Erosion/Corrosion (E/C) monitoring program, consisting of systematic measures to ensure that E/C does not lead to degradation of single and two phase high energy carbon steel piping systems.
The licensee has established an E/C inspection program which partially implements the CHECMATE EPRI (Electric Power Research Institute)
computer program, industry experience, and previous inspection-data as predictive tools for determining and prioritizing inspection locations.
The,licensee's CHECMATE electronic model includes the systems that have been predicted to be susceptible to E/C, and 'ranks the systems components, according to their E/C susceptibility.
The. primary basis for the selection of components for UT examination during the-next refueling outage, is the results of predictive analyses.
In addition to the.
results of predictive analyses the licensee uses:
the results of
. previous UT examinations including sample expansion points; engineering judgement, including plant specific design characteristics; and industry and operating experience.
The licensee has criteria for excluding a
system from the E/C program.
The licensee's E/C program includes the following systems:
Feedwater; Condensate; Steam Generator Blowdown; Feedwater Heater Vents and Drains; Main Steam; Turbine Crossunder; Heater Extraction Steam; Heater Drain Pump discharge; Reheater Drain Tank Drains Vents and Drains; Moisture Separator Drain Tank Drains.
Components in the.licensee's program include: control/check valves; tees and branches; expanders and reducers; flow nozzles and orifices; and elbows and reducing elbows.
The licensee's procedure for performing UT thickness examinations of
.carbon steel piping is approved by the Plant Nuclear Safety Committee (PNSC).
The'icensee's procedures define the method for the following:
performing UT measurements; grid pattern for the inspection zone; ensuring location repeatability followup UT examinations; ensuring certified UT examiners perform the'xaminations; analyzing results of UT
.measurements; and establishing acceptance criteria for evaluating UT data.
The licensee uses hoop stress calculations and system stress analysis data when available to establish minimum wall thickness (t )
requirements for both safety-related (SR)
and Balance of Pl'ant (BOP)
pipin The point to point method and the band method were each used once to calculate wear rate (wr).
The wr= (1. 125 X t. '
t g )/
(total operating time to date).
The predicted thickness (t,~)=t,,~
- -(wr x current operating cycle time)].
Component acceptability at the next outage is determined by the following method:
t, ~ > t and t,~ > t.
Remaining life (rl) calculations have not been made by the licensee.
To date, no ASME Code class I, 2, or 3 components have been identified by the E/C program which require repair. or replacement.
Welding and NDE of BOP piping replacements are being accomplished by qualified personnel and suitable procedures.
The Corporate Nuclear Engineering Department is responsible for the implementation of the E/C program.
The licensee has
.
no program to oversee and self assess the E/C program.
The licensee's E/C program as it relates to Class I, 2, and 3 components is not covered by their gA program.
The inspector reviewed the licensee's program, interviewed licensee personnel, reviewed inspection data, calculations, and selected records to evaluate the licensee's E/C program Procedures Reviewed ID Revision Title MN-3.9 (Rl)
Evaluation of Erosion/Corrosion in Power Plant Piping NDE 5. 18 (R3)
. Ultrasonic Thickness Measurement The licensee sets a minimum wall thickness screening criteria for each component examined.
The components which exhibit wall thicknesses below the screening, criteria are evaluated to the following criteria t,, >
t, and tp p > t.
The components that fail to meet the preceding acceptance criteria are repaired or replaced.
The inspector reviewed inspection results and evaluation reports for the following components, that failed to meet the screening criteria:
3GOIBIO, 3GDSE4X, 3GDSE2X, 3IADSE, 3IAEIX3, M09F60, 43, and 50.
The inspector reviewed the following Customer Notification Reports related to E/C degraded components:
92-3-013, 92-3-002, and 92-3-006.
Relative to the components that failed to meet the screening criteria, the inspector reviewed the qualification, certification and visual acuity documentation for the following UT examiners:
CMR UT-II, RD UT-II, and RJV, UT-II.
Relative to the replacement oF the degraded components, the inspector examined the below listed welder qualification, welder qualification maintenance, welding filler material certification and receiving inspec-tion documentatio i'
'Welders TFIV TFHP TFFX
.
TFMB Melding Filler Naterial E7018 E7018 ER70S-2 ER70S-2 3/32" 0275 1/8" 0224 1/8" 0222 3/32" 0255 NDE Examiners RD UT-II RJV UT-II ACP HT-II L VT-II Observations/Findings The E/C inspection sample is selected on an outage by outage basis, based on the data from previous outages.
In the last two outages, the licensee has tested approximately 260 test locations total, of which
have been inspected more than once.
The last outage, RF12, the licensee tested 150 locations.
As a result of the E/C program during the last two outages the licensee has replaced 15 fittings.
The licensee indicated that data from examinations for outages prior to RF012 was not readily available.
The licensee does not use the T-Dat portion.of the CHECKMATE program and therefore misses out on the iterative benefits built into the program.
The calculations used in the program are not proceduralized.
The remaining life of components is not calculated.
This calculation if done.would provide an effective means to schedule reinspection of components to achieve maximized results.
Notwithstanding the above the licensee has,established an adequate program to maintain high energy carbon steel piping systems within acceptable wall thickness limits.
Within the areas examined, no violations or deviations were identified.
Exit Interview
. The inspection scope and results were summarized on November 6, 1992, with those persons indicated in paragraph 1.
The inspector described the areas inspected.
Although reviewed during this inspection, proprietary information is not contained in this report.
Dissenting comments were not received from the license '
Acronyms and ABBCE ANA ASME BOP.
. CWO DPR E/C ET EPRI FP&L GL, ID ISI H-L HT NCR NDE No.-
NPF NRC NSR P.E.
RDAU RFO RHRll RI RPC
.
S/G SR SRI tmeasurcd tmin tnominni
$
fCd VT wr Initi al i sms Assea. Brown Boveri Combustion Engineering Allen Nuclear Associates Inc.
American Society of Mechanical Engineers Balance of Plant Boiler and Pressure Vessel Construction'ork Order Demonstration Power Reactor Erosion/Corrosion Eddy Current Electric Power Research Institute Florida Power and Light NRC Generic Letter Identification Inservice Inspection Master-Lee Magnetic Particle Nonconformance Report Nondestructive Examination Number Nuclear Power Facility Nuclear Regulatory Commission Non Safety-Related Professional Engineer Plant Nuclear Safety Committee Liquid Penetrant Quality Assurance Revision Remote Data Acquisition Unit Refueling Outage Residual Heat Removal Remaining Life Resident Inspector Rotating Pancake Coil Steam Generator Safety Related Senior Resident Inspector Measured Thickness
.
Minimum Wall Thickness Nominal Thickness Predicted Thickness Ultrasonic Visual Wear Rate
I'