IR 05000259/1992040
| ML18036B096 | |
| Person / Time | |
|---|---|
| Site: | Browns Ferry  |
| Issue date: | 12/07/1992 |
| From: | Blake J, Coley J, Kleinsorge W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML18036B095 | List: |
| References | |
| 50-259-92-40, 50-260-92-40, 50-296-92-40, NUDOCS 9212170007 | |
| Download: ML18036B096 (18) | |
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UNITEDSTATES NUCLEAR REGULATORY COMMISSION
REGION II
101 MARIETTASTREET, N.W.
ATLANTA,GEORGIA 30323 Report Nos.:
50-259/92-40, 50-260/92/40, and 50-296/92-40 Licensee:
Tennessee Valley Authority 3B Lookout Place 1101 Market Street Chattanooga, TN 37402-2801 Docket Nos.:
50-259, 50-260 and 50-296 Facility Name:
Browns Ferry 1, 2, and
Inspection Conducted:,
November 16-20, 1992 License Nos.:
DPR-33, DPR-52, and DPR-68 Inspectors:
M.
Kleinso Reactor Inspector E.
Date Signed
. Coley J Reactor Inspector Date Signed Approved by:
J. J.
lake, Chief t
ials and Processes Section n ineering Branch Division of Reactor Safety (~./~-
Date Signe SUMMARY Scope:
This special, announced inspection was conducted at the General Electric Company
{GE) Service Center and the Frank N. Hake Associates President Island facility in Memphis, Tennessee.
The purpose of the inspection was to observe TVA and GE conduct
"performance. demonstration" activities for the automated ultrasonic inspection, personnel, procedures, and equipment that is scheduled to be used to examine the Reactor Pressure Vessel (RPV) shell welds of the three Browns Ferry units.
These examinations will be performed in accordance with NRC's new rule for augmented examination of RPV shell welds,
[10 CFR 50.55a(g){6)(ii)(A)] which became effective on September 8,
1992.
9212170007 92l209 OnoaaaS9
Results:
The activities examined by the inspectors were generally well planned, implemented, and documented by TVA, and GE.
Preliminary review of detection data obtained during practice examinations revealed that the TVA and GE procedures, equipment, and personnel should be capable of achieving the high level of confidence in UT examinations that Appendix VIII of the ASME Code mandates for the nuclear industry.
TVA's proactive commitment to quality for the integrity of the reactor vessel I.D. examinations was demonstrated by the on going performance demonstration activities observed in Memphis.
Identification and resolution of technical issues are being handled in an effective manne ~
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REPORT DETAILS Persons Contacted Licensee Employees
- F. Leonard, Level III Examiner
- D. Massey, Regulatory Engineer T. Stockman, Level III Examiner General Electric Company (GE)
- 0. Bragg Jr.,
GERIS 2000 Project Manager
- C. Minor, Level III Examiner
- R. Seals, BNF Reactor Pressure Vessel (RPV) Project Manager
- M. Sodemann, guality Assurance (gA)
Electric Power Research Institute (EPRI)
- E. Kietzman, Manager, Heavy Section Laboratory
- H. Sagstetter, Level II Examiner Frank W. Hake Associates R. Applebaum, Manager Support Services
"Attended the exit interview Inservice Inspection (ISI)
a.
Background Browns Ferry Units 1 and 3 are in an extended shut down status, in the third, 40-month period, of the first, ten-year interval.
Unit 2 is operating in the third, 40-month period, of the first, ten-year interval (P3, Il) which is scheduled to end February 23, 1993.
Unit 1 received its Operating License December 20, 1973, and declared commercial operations on August 1, 1974.
Unit 2 received its Operating License on August 2, 1974, and declared commercial operations on March 1, 1975.
Unit 3 received its Operating License on August 18, 1976, and declared commercial operations on March 1, 1977.
(While the ten-year inspection interval would normally end on the tenth anniversary of the date of commercial operations, these three units are still considered to be in their first, ten-year ISI inspection interval because the ASHE code allows for the extension of inspection intervals to compensate for extended outages.)
The applicable code for ISI, for Units 1 and 3 is the ASME BKPV Code,Section XI, 1974 Edition with Addenda through the Summer 1975 (74S75) for everything except technique.
The applicable code for technique is the ASME BKPV Code Section XI, 1986 Edition and no Addenda.
The applicable
code for ISI, for Unit 2 is the ASME B&PV Code,Section XI, 1986 Edition without Addenda.
For the planned RPV inspections, ASME B&PV Code Secti,on XI, 1989 Edition with Addenda through 1991, whi.ch implements the Appendix VIII
"Performance Demonstration For Ultrasonic Examination Systems", will be used for guidance only.
TVA and GE's performance demonstration for qualification of automatic ultrasonic examination. personnel, procedures, and equipment for inspection from the I.D. of the vessel, are being conducted in the spirit of Appendix VIII.
a.
ISI Program Review, Units 1, 2, and 3 (73051)
The licensee has contracted General Electric Company (GE) to conduct automated ultrasonic (UT) examinations of the Reactor Pressure Vessels (RPVs) using the GERIS, and GERIS 2000 Data Acquisition Systems, under the umbrella of the GE Quality Assurance (QA) Program.
GE Engineering and their San Jose California based services, including the qualification program is covered by the GE BWR QA program as described GE Topical Report NEDO-11209.
On and off site ISI services is covered by GE Nuclear Projects Quality Assurance Manual, QAM-001.
The inspectors reviewed the following ISI program documents to determine whether the plan had been approved by the licensee and to assure that procedures and plans had been established for the applicable activities, procedures were also reviewed for technical content.
Procedures Reviewed ID Revision Title GE-ADM-1008 (RO)
. Qualification Plan For Operations and Data Analysts on GERIS 2000 Data Acquisition System GE-ADM-1009 (RO)
Qualification Plan for GERIS 2000 Equip-ment, Procedures, and Personnel at Brown's Ferry Units 1, 2, and
GE-ADM-2011 (RO Draft)
Procedure For The Characterizing Of the GERIS 2000 Ultrasonic Electronic System.
TVA-EPRI (R1)
Performance Demonstration Qualification Protocol Applicable To RPV Assembly Welds At Brown's Ferry Nuclear Plants Units 1, 2, and
GE (11/5/92) 'ite Specific Security Plan For The Administration of The Tennessee Valley
GE-NEDO 1209-04A (R8)
Authority Beltline Qualification Program To General Electric Personnel GE Nuclear Energy Quality Assurance Program Description GE-FQP-13 GE-FPQ-03 (1)
(R2)
Procedure For Testing Of Vision Acuity Procedure for Qualification And Certification Of Nondestructive Examination Personnel b.
Review of NDE Procedures, Units 1, 2, and 3 (73052)
The inspectors reviewed the procedures listed below to determine whether these procedures were consistent with regulatory requirements and licensee commitments.
The procedures were also reviewed for technical content.
Procedures Reviewed ID Revision Title GE-UT-700 (R1)
Procedure For The Examination of Reactor Pressure Vessel Welds With GERIS 2000 GE-UT-701 (R1)
Procedure for GERIS 2000 Flaw Sizing The inspectors compared the above, inspection procedures to the requirements of Sections V and XI (including Appendix VIII,) of the ASME Code, and NRC Regulatory Guide 1. 150.
Relative to ASME Section V, the inspectors made the followin'g observation concerning compliance with ASME Section V, Article 4:
Paragraph T-432. 1 states that, calibration shall include the complete ultrasonic examination system.
The original calibration must be performed on the basic calibration blocks.
Checks shall be made to verify the sweep range calibration and distant amplitude correction.
Checks shall include the entire examination system.
Paragraph T-432.1.1 requires a calibration check upon change in the complete ultrasonic examination system.
Paragraph T-432. 1.2 requires that, a calibration check on at least two of the basic reflectors in the basic calibration block shall be made at the finish of each examination, every 12-hours during the examination, and when examination personnel are change.i
Paragraph T-432. 1.3 states that, any simulator checks that are used must be correlated with the original calibration on the basic calibration block during the original calibration.
The simulator checks may use different types of calibration blocks or electronic simulation.
However, the simulator check shall be made-on the entire examination system.
In lieu of the above, GE's procedure GE-UT-700 would allow calibration verifications to be performed using statistical analysis of the material's ultrasonic noise level, on designated reference patches of the reactor vessel.
GE's calibration checks would be performed as follows:
A calibration verification would be performed at the beginning and end, and at approximately 12-hour intervals during the examination.
Prior to the start of examinations, a series of 2 reference scans of the vessel wall would be performed, for both the upper and lower search unit packages, to establish a statistical reference.
The reference scan would contain a minimum of 3000 trigger points per channel.
The data collected would be processed to obtain the RF C-scan.
The mean and standard deviation values for the RF C-scan data will be determined and recorded for each scan and channel.
The reference patch would be rescanned, using the same parameters as the reference, scans, at approximately 12-hour intervals during the examination.
The data collected in these scans would be compared to the values obtained in the original reference scans.
Channels which fail to pass verification would be checked for scanning failures.
,
The proposed, alternative calibration verification check methodology had been reviewed by the Code Authorized Nuclear Inservice Inspector (ANII)
to the'equirements of ASIDE Section XI, Paragraph IWA-2240.
(This paragraph would allow alternative examination methods, or newly developed techniques to be substituted for the Code required methods provided the Inspector is satisfied that the results have been demonstrated to be equivalent, or superior, to those of the specified=method.)
At the time of this inspection the ANII had not concurred with the alternative calibration verification method.
TVA indicated that several avenues of approval for the verification method were being considered, including continued communications with the ANII, a request for relief from.the Code calibration check requirements, a Code Inquiry, and/or a Code Case.
TVA and GE are seeking relief from the code requirements in order to avoid removing the scanning fixtures from the reactor vessel every
hours.
Relative to ASIDE Section XI, Appendix VIII, the following deviations were being taken by TVA & GE:
(Note ASIDE B8,PV Code Section XI 1991, Appendix VIII is being used for guidance only).
ASME Section XI, Appendix VII is not used for personnel certification as required by Appendix VIII.
The ultrasonic instrument pulser has not been characterized at this time because GE needs a function generator of greater capacity than presently available to perform this characterization.
However GE stated that, the pulser would be characterized after the qualification effort.
Appendix VIII, Supplement 4, requires that flaw sizes be uniformly distributed in through-wall depths and four categories of ranges are given.
The specimens used by TVA did not have flaws in one of the required categories.
Appendix VIII, Supplement 4,
and Supplement 6 state that for grading purposes, when a flaw is reported within I/2-inch of its true location (X and Y) it shall be considered detected.
TVA has expanded this criteria to plus or minus one-inch.
Per Appendix VIII, an examination candidate who examines the test specimens that TVA has would have to detect all the flaws correctly.
TVA, however, is allowing candidates to pass if'they detected
percent of the flaws.
The error band TVA will use for thru wall sizing of reported flaws will utilize NRC Regulatory Guide 1. 150 requirements in lieu of the more stringent requirements of Appendix VIII. Regulatory Guide 1. 150 deals with determining the maximum error band using the slope of a linear regression line.
Within the areas examined, no violations or deviations were identified.
C.
Observation of Work and Work Activities Units 1, 2, and 3; (73753)
The inspectors observed work activities, reviewed certification records of NDE equipment and materials, and reviewed NDE personnel qualification documentation.
The observations and reviews conducted by the inspectors are documented below.
The performance demonstration philosophy requires that NDE personnel and equipment demonstrate qualification on "blind" test samples.
The inspectors observed implementation of the security plan established for preservation of the "blind" test specimens during the inspection of a portion of the system setup and calibration activities related to the qualification examination for GERIS 2000 operators and lead operators.
The inspectors reviewed certification documentation for the following UT calibration block, UT calibration instruments, and search unit UT Calibration Block S/N: BF-18 Relative to the calibration block the inspectors made the following observations:
The program drawing'f the calibration block does not indicate the five added, inner, near-surface reflectors.
The licensee indicated that they would revise the drawing prior to the start of vessel examination.
The material test report for the base material of calibration block BF-18 was only partially legible.
The licensee indicated that they would provide the inspectors a legible-copy of the material test report prior to the start of vessel examination.
The I.D. surface of the calibration block is flat and smooth.
At the time of this inspection the licensee was unable to provide the inspectors with information concerning the welding method used to deposit the I.D. cladding on the'alibration test block.
In addition the licensee was unable to provide specific information relating to the surface finish of the I.D. of the RPVs.
Section XI Paragraph IWA-2232 (a)(5) of the ASNE Code requires that, calibration blocks shall be clad using the same method used to clad the component to be examined.
In the event the cladding method is not known, the calibration shall be performed using a calibration block clad by a manual weld deposited method.
When the parent material on opposite sides of a weld are clad by different methods, the cladding on the calibration block shall be applied by the method used on the side of the weld from which the examination will be conducted.
If the examination will be conducted from both sides of the weld, the calibration block shall provide for calibration for both methods of cladding.
Section V Article 4 of the ASNE Code also requires the surface finish of the block to be representative of the surface finish of the component.
The licensee indicated that attenuation measurements will be taken for the surface differences using a transfer method or a new calibration block will be fabricated. prior to examination of the reactor vessels.
UT Calibration Instrument Le Croy squad 150 Hhz Oscilloscope S/N:
9414-1603 Search Units S/N: 92-865,92-866)
92-852,92-853)
92-854)92-855, 92-826,92-827, 92-828,92-829, 92-839,92-840, 92-841,92-852
i
3.
The inspectors reviewed qualification certification and visual acuity documentation for the following" UT examiners:
JCG UT-II, CAM UT-III, TK UT-III, and ROF UT-II In the 'areas inspected, no violations or.deviations were identified.
Discussion
- Examination Limitations The present examination requirements for the Browns Ferry reactor vessels require 100% ultrasonic testing of the reactor vessels.
Performance demonstration activities for the ID automated ultrasonic examinations of the reactor vessels are in the spirit of Appendix VIII to Section XI of the ASME Code, 1989 Edition with Addenda through 1991.
However, TVA's qualification effort in Memphis is for examinations performed from the I.D. of the reactor'vessel only.
The new rule emphasizes that in order to obtain essentially 100% coverage of the reactor vessel shell welds, both O.D.. and I.D. examinations may be required.
GE is presently performing a survey to determine how much additional coverage can be obtained from the O.D. of the reactor vessel.
On November 19, 1992, telephone conversations were held between the Region II inspectors, TVA, GE, and NRRJEMCB to discuss supplemental O.D.
reactor vessel examinations, and to solicit NRR's position on performance demonstration qualification for these examinations.
NRR was informed that since performance demonstration activities are not required by the invoked codes, TVA had neither conducted nor planned any performance demonstrations to qu'alify personnel, procedures, or equipment to be used for manual or automated ultrasonic O.D. examinations.
'I NRR response was that additional correspondence has been expected from TVA whi'ch would identity the welds',
or portions of welds, which could not be examined from the I.D., and the percentage of welds that can be examined from the O.D.
NRR stated the adequacy of the present
,
qualification activities could not be determined until this correspondence is received.
It is apparent that the licensee will most likely have to seek Code Relief for some of the weld coverage which cannot be inspected by the combination of I.D. and O.D. examinations.
It is also apparent that documentation of the capability of the O.D. inspection method capability by some means such as performance qualification activities can aid in providing a sound basis for relief.
gualification of procedures, personnel, and equipment to Appendix VIII, for all of the accessible welds 'examined, is one criteria where the reliability of examination data can be established and safety significance determined.
Violations or deviations are not applicable for addressing noncompliance to minimum Code requirements during this qualification effor Exit Interview C
The inspection scope and results were summarized on November.20, 1992,
'with those persons indicated in paragraph 1.
The inspectors described the areas inspected.
Although reviewed during this inspection, propri-etary information is not contained in this report.
Dissenting comments were not received from the licensee.
Acronyms and Initi ANII ASME BNF B&PV BWR DPR EHCB EPRI GE GERIS ID I.D.
NRC NRR
'.D.
P.E.
RPV S/N TVA UT alisms Authorized Nuclear Inservice Inspector American Society of Mechanical Engineers Browns Ferry Nuclear Facility Boiler and Pressure Vessel Boiling Water Reactor Demonstration Power Reactor Materials L Chemical Engineering Branch Electric Power Research Institute General Electric Company General Electric Remote Inspection System Identification Inside Diameter Inservice Inspection Megahertz Nondestructive Examination Number-Nuclear Regulatory Commission Nuclear Reactor Regulation
'Outside Diameter Professional Engineer Quality Assurance Quality Assurance Manual Quality Control Revision Reactor Pressure Vessel Serial Number Tennessee Valley Authority Ultrasonic a
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