IR 05000259/1986039
| ML20207J381 | |
| Person / Time | |
|---|---|
| Site: | Browns Ferry  |
| Issue date: | 12/09/1986 |
| From: | Blake J, Coley J, Newsome R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML20207J366 | List: |
| References | |
| 50-259-86-39, 50-260-86-39, 50-296-86-39, NUDOCS 8701080426 | |
| Download: ML20207J381 (7) | |
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SmIffo UNITED STATES
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NUCLEAR REGULATORY COMM;SSION
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REGION li g
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ATLANTA, GEORGI A 30323
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Report Nos.:
50-259/86-39, 50-260/86-39, and 50-296/86-39 Licensee: Tennessee Valley Authority 6N38 A Lookout Place'
1101 Market Street Chattanooga, TN 37402-2801 Docket Nos.:
50-259, 50-260 and 50-296 License Nos.: DPR-33, DPR-52, and DPR-68 Facility Name: Browns Ferry 1, 2, and 3~
Inspection Conducted:
November 18-25, 1986 Inspectors: \\ M.
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.W w me Approved by.
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J. J.
lake, Chief Datre Slgned t
als and Processes Section iv sion of Reactor Safety
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SUMMARY Scope:
This routine, announced inspection was conducted in the areas of inservice inspection of Unit 2 and preparations for reactor vessel N-2 nozzle safe-end replacement.
Results: No violations or deviations were identified.
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0701090426 061222 PDR ADOCK 05000259
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REPORT DETAILS 1.
Persons Contacted Licensee Employees
- E. A. Grimm, Assistant to the Plant Manager
- B. Thomison, Supervisor, Technical Services
- R. R. Davis, Site Licensing, Browns Ferry Nuclear Facility (BFNF)
- M. E. Gothard, Supervisor, Nondestructive Examination (NDE) Engineering Section R. Bentley, NDE Engineer Other licensee employees contacted included construction craftsmen, engineers, technicians, operators, and office personnel.
NRC Resident Inspectors
- G. L. Paulk, Senior Resident Inspector
- C. A. Patterson, Resident Inspector
- Attended exit interview on November 21, 1986
- Attended exit interview on November 25, 1986 2.
Exit Interview The inspection scope and findings were summarized on November 21 and November 25, 1986, with those persons indicated in paragraph 1 above. The inspectors described the areas inspected and discussed in detail the inspection findings.
No dissenting comments were received from the licensee. The following new item was identified during this inspection.
(0 pen) Inspector Followup Item 260/86-39-01, Enhancement of Ultrasonic Examination Procedure Needed NOTE:
While on site during the inspection, the NRC inspectors requested a demonstration of ultrasonic examination procedure N-UT-24 which will be used to determine the remaining thickness of weld butter on the reactor vessel N-2 nozzles when the recirculation system safe-end forgings are removed.
The ultrasonic procedure demon-stration conducted by the inservice inspection examiners at the site was not successful in achieving the examination objectives.
On November 20, 1986, the licensee requested that TVA's Technical Engineering Branch be allowed to come to the NRC Regional Office-on November 25, 1986, and demonstrate that the ultrasonic examination procedure could be used effectively if the examiners employed specific equipment and received special training.
The details and results of the November 25, 1986, technical meeting are discussed in detail in paragraph 5.b.(3) of this repor _
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2 The licensee did not identify as proprietary any of the materials provided
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to or reviewed by the inspectors during this inspection.
3.
Licensee Action on Previous Enforcement Matters This subject was not addressed in the inspection, 4.
Unresolved Items s
Unresolved items were not identified during the inspection.
5.
Inservice Inspection (ISI)
The inspectors 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 American Society of Mechanictl Engineers
Boiler and Pressure Vessel (ASME B&PV) Code,Section XI,1977 edition with addenda through summer 1978.
a.
Review of Procedures (73052) Units 1, 2, and 3 The inspectors 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.
Procedure ID Title
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N-MT-1 R5 Magnetic Particle Examination of Nuclear
Power Plant Components j
N-MT-2 R2 Magnetic Particle Examination of Nuclear Power Plant Components
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N-PT-1 R6 Liquid Penetrant Examination Using the Color Contrast Solvent Removable Method
BF-UT-17 R5 Ultrasonic Examination of Nuclear Power j
with PCR #86-05 Plant Piping i
N-VT-1 R8 Preservice and In-Service Visual Examination Procedure
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N-UT-24 R2 Ultrasonic Measurement of Wall Thickness
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(1) The inspectors reviewed procedures BF-UT-17 and N-UT-24 to ascertain whether they had been reviewed and approved in accor-dance with the licensee's established QA procedures.
The procedures were reviewed for technical adequacy and conformance with ASME,Section V, Article 5 and other licensee commitments /
requirements in the below listed areas:
type of apparatus used; extent of coverage of weldments; 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; accephnce limits.
(2) The inspectors reviewed procedure N-PT-1 to ascertain whether it had been reviewed and approved in accordance with the licensee's established QA procedures.
The procedure was reviewed for technical adequacy and conformance with ASME,Section V, Article 6 and other licensee commitments / requirements in the below listed areas:
specified method; penetrant material identification; penetrant materials analyzed for sulfur; penetrant materials analyzed for total halogens; acceptable pre-examination surface; drying time; method of penetrant application; surface temperature; solvent removal; surface drying prior t) developing; type of developer; examination tecanique; ev.M uation technique; and procedure requalification.
(3) The inspectors reviewed procedures N-MT-1 and N-MT-2 to ascertain whether they had been reviewed and approved in accordance with the licensee's established QA procedures.
The procedures were reviewed for technical adequacy and for conformance with ASME Section V, Article 7, and other licensee commitments / requirements in the below listed areas:
examination method; 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 lif ting power (yoke) and; acceptance criteria.
(4) The inspectors reviewed the visual examination procedure N-VT-1 to determine whether it contained suf ficient instructions to assure that the following parameters were specified and controlled within the limits permitted by the applicable 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 tool for surface prepara-tion, if any; whether direct or remote viewing is used; special illumination, instruments, or equipment to be used, if any; sequence of performing exutnation, when applicable; data to be
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tabulated, if any; acceptance criteria is specified and consistent with the applicable code section or controlling specification; and report form completion.
b.
Observation of Work Activities (73753) Unit 2 (1) Examiner Qualification The inspectors reviewed the qualification documentation for the below listed NDE examiners in the following areas:
employer's name; person certified; activity qualified to perform; effective period of certification; signature of employer's designated representatives; basis used for certification; and annual visual acuity, color vision examination and periodic recertification.
Method - Level-VT Examiner VI PT MT RT 1-2-3-4 II II II II II MBA
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II II II JDB II II II
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II II KRP
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II II II LBM II II II
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II II II MSC II II II
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The inspectors reviewed documentation indicating that lif t tests had been performed on yokes with serial numbers 524129 and 506775 using a ten pound steel plate, serial no. E83523, with the yoke being operated in the alternating current (AC) mode.
Certifica-tion records for the lift test plate were reviewed to confirm the plate weight.
The lift tests were performed satisfactorily.
(2) Visual Examination The inspectors observed the visual examination indicated below.
The observation was compared with the applicable procedure and the Code in the following areas:
type of examination; lighting levels; cleanliness; measurements; and results.
ID Description Drawing No.
HPASH-2-13 Spring Can Support ISI-0079-C Note:
The above item was rejected and an NOI was written due to a bent spring can center rod which prevents movement of the sprin.
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(3) Ultrasonic Examination Activities Units 1, 2, and 3 During this inspection, TVA's inservice inspection personnel were requested to demonstrate their ultrasonic inspection procedure N-UT-24. This procedure defines the inspection requirements and techniques for determining the thickness of weld butter remaining on the reactor vessel N-2 nozzles after the safe-ends are removed.
This is a critical measurement because a temperbead weld repair, in accordance with Section XI of the ASME code, would have to be performed if more than the minimum required weld butter is removed and this would result in a significant increase in radiation exposure to craft personnel.
In additiun, if the ultrasonic examination was not reliable in determining the weld butter thickness, TVA's implementing procedure (MAI-49) for the replace-ment of the safe ends did not address a reliable alternative method for obtaining the weld butter thickness.
The ultrasonic procedure demonstration performed by the ISI examiners at the site was not successful in achieving the examination objectives. On November 20, 1986, the inspectors were requested by TVA to allow the ISI Technical. Engineering Branch to come to the NRC Regional Office on November 25, 1986, and demonstrate that the procedure could be used effectively.
On November 25, 1986, representatives from TVA's Technical Engineering Branch and from the Browns Ferry site demonstrated that ultrasonic procedure N-UT-24 could be used effectively.
However, as a result of the demonstration, the inspectors con-cluded that the examination procedure should be enhanced to insure that the following items are addressed by the procedure:
(1) examiners performing an examination using this procedure should receive special training from the technical engineering branch on signal recognition; (2) transducers used to perform these examination should be described in the examination procedure; and (3) an appropriate calibration block should be provided and described in the examination procedure.
The licensee has agreed to revise the examination procedure to incorporate the inspectors concerns.
This item was reported as Inspector Followup Item 260/86-39-01, Enhancement of Ultrasonic Examination Procedure Needed.
c.
Inservice Inspection, Data Review and Evaluation (73755) Unit 2 Records of completed nondestructive examinations were selected and reviewed to ascertain whether: the method, 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, instru-ments, calibration blocks and NDE materials (penetrants, couplants)
were designated.
Records selected for this review are listed below:
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Weld I.D.
NDE Method CHM-2046-C
- N2J TSC UT-45 and 60a CHM-2069 GMS-2-3 UT MSG-0023-C H-65 MT MSG-0023-C H-65 VT MSG-0023-C H-122 VT MSG-0023-C R-53 VT MSG-0023 H-8 MT MSG-0018-C TRHR-2-231 UT MSG-0018-C TRHR-2-241 UT CHM-1095 Vessel / Fig.
UT ISI-0130-C HPCIH-2-2 VT ISI-0130-C HPCIH-2-3 VT
- Introspect/98 data
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Within the areas examined, no violation or deviation was identified.
6.
Ccde Replacement-Activities (73753) Unit 2 When performing ultrasonic examinations of the reactor vessel nozzle thermal sleeve welds in accordance with NRC Information Notice 84-89, TVA detected intergranular stress corrosion cracking in all ten N-2 nozzle safe ends on Unit 2.
As a result of this discovery, TVA decided to replace the nozzle safe-ends and pipe to a point below the elbow in the discharge riser piping.
General Electric was selected as the design and the field machining contractor.
TVA will perform all other replacement activities including welding. All fabrication, installation and inspection will be performed in accordance with TVA's Quality Assurance Program.
The applicable code for the above replacement activities is the American Society of Mechanical Engineers (ASME), Boiler and Pressure Vessel (B&PV)
Code,Section XI, 1980 edition with addenda through winter 1981 for installation and ASME Section III,1980 edition with addenda through summer 1983 for fabrication and inspection.
The inspectors reviewed TVA's tentative procedure (MAI-49) for performing the safe-end replacement activities and discussed TVA objectives with cognizant engineering personnel. The inspectors also observed TVA welders on mockup specimens in the welding test shop and reviewed welding qualifica-tion radiographs for the following welders:
S. Thompson
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T. Streit
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W. Fisher
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T. Davenport
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Within the areas examined, no violation or deviation was identified.