IR 05000259/1993034
| ML18037A519 | |
| Person / Time | |
|---|---|
| Site: | Browns Ferry  |
| Issue date: | 10/06/1993 |
| From: | Blake J, Kleinsorge W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML18037A518 | List: |
| References | |
| 50-259-93-34, 50-260-93-34, 50-296-93-34, NUDOCS 9310260256 | |
| Download: ML18037A519 (13) | |
Text
UNITED STATES NUCLEAR REGULATORY COMMISSION
REGION II
101 MARIETTASTREET, N.W., SUITE 2900 ATLANTA,GEORGIA 30323.0199 Report Nos.:
50-259/93-34, 50-260/93-34, and 50-296/93-34 Licensee:
Tennessee Valley Authority 6N 38A 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
Inspection Cond t ep mber 20-24, 1993 Inspector. il a
P.
leinsorge Date Signed t
Approved by:
Jero
~ J.
B a e, iaaf Mat ials and Pr cess Section En neering Br ch Di ision of Reactor Safety Date Signed SUMMARY Scope:
This routine, announced inspection was conducted in the areas of Inservice Inspection (ISI).
Results:
During this inspection, General Electric's examination tool was troubled by electrical and mechanical problems, which precluded the acquisition of data.
GE allocated appropriate resources toward the resolution of the problems.
Identification and resolution of technical issues are being handled in an effective manner.
In the areas inspected, violations or deviations were not identified.
'y131026025b
'yI31015 PDR ADOCK 05000259
I
REPORT DETAILS Persons Contacted Licensee Employees
- M. Bajestani, Technical Support Manager
- F. Froscel 1 o, Inservi ce Inspection (ISI)
- J. Johnson, guality Assurance (gA) Manager
- F. Leonard, Inspection Services Organization (ISO)
- J. Haddox, Manager, Nuclear Engineering D. Massey, Regulatory Engineer
- J. Rupert, Engineering and Modifications Manager
- J. Sabados, Chemistry Manager
- P. Salas, Licensing Manager
- R. Wells, Compliance Licensing Manager
- J. Whitaker, ISI Level III Examiner Other licensee employees contacted during this inspection included craftsmen, engineers, technicians, and administrative personnel.
Other Organizations General Electric Nuclear Services C. Minor, Level III Examiner
- G. Nelson, Project Manager, GE Nuclear Services R. Seals, BFN Reactor Pressure Vessel (RPV) Project Manager NRC Resident Inspectors
- C. Patterson, Senior Resident Inspector
- G. Schnebli, Resident Inspector
- R. Husser, Resident Inspector
- Attended exit Interview Inser vice Inspection
. (IS I)
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 commer-cial 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 ASHE B&PV Code,Section XI, 1974 Edition with Addenda through the Summer 1975 (74S75) for everything except technique.
-The applicable code for technique is the ASHE B&PV Code Section XI, 1986 Edition and no Addenda.
The applicable code for ISI, for Unit 2 is the ASHE B&PV Code,Section XI, 1986 Edition without Addenda.
For the planned Reactor Pressure Vessel (RPV) inspections, ASHE B&PV Code Section XI, 1989 Edition with Addenda through 1991, which implements the Appendix VIII "Performance Demonstration For Ultrasonic Examination Systems", will be used for guidance only.
TVA and General Electric's (GE)'s performance demonstration for qualification of automatic ultrason-ic examination personnel, procedures, and equipment for inspection from the I.D. of the vessel, are being conducted in the spirit of Appendix VIII.
ISI Program Review, Unit 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 O.D.,
and GERIS 2000 Data Acquisition Systems, under the umbrella of the GE Quality Assurance (QA) Pro-gram.
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 are covered by GE Nuclear Projects Quality Assurance Manual, QAH-001.
The inspector 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 TVA GERIS 2000 Scan Plan-Unit 3 ISI Beltline Examination Plan
L3
Review of NDE Procedures, Units 1, 2, and 3 (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 GE-UT-700 (R2)
GE-ADM-1002 (R2)
GE-UT-701 (R2)
GE-ADM-1001 (R2)
Procedure For The Examination of Reactor Pressure Vessel Welds With GERIS 2000 Procedure for GERIS 2000 Flaw Sizing Procedure for Performing Linearity Checks on Ultrasonic Instruments Procedure For The Review Process and Analy-sis of Recorded Indications GE-ADM-1006 (R2)
GE-ADM-2011 (RO)
Procedure For Compliance With USNRC Regula-tory Guide 1.150 Procedure For The Characterizing Of the GERIS 2000 Ultrasonic Electronic System.
The inspector 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.
As discussed in NRC inspection report Nos 50-259,260,296/92-40 and 42, paragraphs Nos. 2.b and 2.b (2) respectively, Procedure GE-UT-700 does not comply with ASME B&PV Code Section V, Paragraph Nos.T-432. 1.2 and T-432. 1.3.
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.
The proposed alternative calibration verification check methodology had been reviewed by the Code Authorized Nuclear Inservice Inspector (ANII)
with respect to the requirements of ASME Section XI, Paragraph IWA-2240.
(This paragraph would allow alternative examination methods, or newly developed techniques to be substituted for the Code re-quired methods provided the ANII is satisfied that the results have been demonstrated to be equivalent, or superior, to those of the specified method.)
On November ll, 1992 GE performed an IWA-2240 demonstration of the GERIS 2000 Invessel Inspection System Calibra-tion Verification using statistical analysis.
The ANII concurred that the GERIS 2000 statistical analysis method of calibration sensitivity as described in GE-UT-700 was demonstrated to be an
acceptable method of calibration verification providing a quantita-tive measurement of both sensitivity and sweep calibration, as allowed by ASME B&PV Code Section XI, paragraph IWA-2240, by memo-randum dated January 4,
1993.
Based on record reviews and discussions with the licensee, the inspector is in agreement with the ANII that the GERIS 2000 statis-tical analysis method of calibration sensitivity as described in GE-
-UT-700, is an acceptable method of calibration verification provid-ing a quantitative measurement of both sensitivity and sweep cali-bration.
GE has submitted the statistical analysis method of performing calibration checks for reactor vessels to ASME for approval as a
Code Case.
This Code Case inquiry is identified as ISI 93-10.
As discussed in NRC inspection report Nos 50-259,260,296/92-40 and 42, paragraphs Nos. 2.b and 2.b (2) respectively, the ultrasonic instrument pulser had not been characterized.
GE has now character-ized the ultrasonic instrument pulser, and the inspector has re-viewed records substantiating the same.
Observation of Work and Work Activities Unit 3, (73753)
The licensee scheduled the GE invessel examination to start September 15, 1993 and continue for 17 days.
During the time the inspector was on site (September 20-24, 1993),
GE's examination tool was troubled by electrical and mechanical problems, which precluded the acquisition of data.
The inspector observed the GERIS 2000 equipment setup in the RPV and the calibration block setup on the refueling deck.
The inspector observed a portion of the GE trouble shooting activities.
The inspector verified the transducer trigger pattern as well as the required examination area on several patches on weld C-1-3.
As discussed in NRC inspection report Nos 50-259,260,296/92-40 and 42, paragraphs Nos. 2.c and 2.b (4) respectively, the licensee's calibration block S/N: BF-19, was not in compliance with ASME B&PV Code section XI paragraph IWA-2232 (a)(5).
The licensee located a
calibration block from one of the Phipps Bend or Hartsville RPVs.
Because there was no documentation available for the new calibration block (identified BF-109), the licensee conducted chemical analysis, hardness testing, and microstructure analysis on BF-109 to substan-tiate compliance with ASME B&PV Code Section V Paragraph T-441. 1.2. 1 (c), verified by the inspector by record review.
The clad surface on calibration block BF-109, as verified by the inspector by direct visual examination, is as-welded with parallel weld beads approximately one inch wide, with the appearance consis-tent with an automatic multi-wire welding method.
The clad surface on the Unit 3 RPV shell plate, as verified by the inspector by
review of fabrication records and viewing of a video tape of a, remote visual examination of the RPV inside surfaces, is automatic strip welded in the as-welded condition with parallel weld beads approximately 2 3/4-inches wide.
The use of calibration block BF-109 associated with the invessel UT examination of the Unit 3 RPY is not consistent with ASHE B&PV Code section XI paragraph IWA-2232 (a)(5) in that the welding method employed for clad weld deposit for block and vessel are different.
TVA's, Inspection Services Organization (ISO) administered a (Spirit of Appendix VIII) performance demonstration to GE personnel before their arrival on site.
The demonstration was used to qualify procedures, equipment and personnel using specimens representative of those delineated in Appendix VIII. Calibration Block BF-18 (the only block available at the time) was used to calibrate the GERIS 2000 system and subsequently applied to the examination of the test specimens.
Calibration Block BF-18 has a machined clad surface and the block is flat which provides for optimum calibration (i.e.,
optimum search unit contact).
During the qualification, Specimen SB-2 (obtained from the EPRI NDE Center)
was included in the test matrix.
SB-2 represented the worst cladding condition as defined in Appendix VIII which was applied using manual Shielded Metal Arc Welding (SHAW) with minimal grind-ing.
The results of the qualification indicate that all flaws requiring detection were in fact recorded and properly detected during analysis.
BF-109 was substituted for BF-18 prior to the start of on-site examinations.
In order to assure that the qualification using block BF-18 was transferable to BF-109, the licensee conducted a comparison at the ISO facilities.
The comparison was performed using transducers which were considered equivalent to Appendix VIII requirements and included 45, 60 and 70-degree search unit angles.
The results indicated that BF-109 was at least 8dB more attenuative than BF-18.
Based on the performance demonstration results, the conservative cladding method and surface condition of Block BF-109, the ANII (as documented in a September 23, 1993 TVA memorandum)
determined that the results were equivalent or superior to those of the specified method, therefore the use of BF-109 associated with the invessel UT examination of the Unit 3 RPV is acceptable as allowed by ASNE B&PV Code Section XI, paragraph IWA-2240.
This inspector and the inspector of record for NRC inspection report 50-259,260,296/92-42, witnessed a portion of the TVA administered performance demonstration qualification testing of GE personnel, as discussed in NRC inspection report Nos 50-259,260,296/92-40 and 42.
Based on the testing observations, record reviews and discussions with the licensee, the inspector is in agreement with the ANII that the use of BF-109 associated with the invessel UT examination of the Unit 3 RPV is appropriat As discussed in NRC inspection report Nos 50-259,260,296/92-42, paragraph 2.b(3), indications on the outer extremity of the qualifi-cation test specimens were consistently being plotted inboard of their actual position.
GE determined that this problem was caused by the geometry of the qualification setup.
GE developed a compen-sation table to account for the offset based on the six inch pivot of that setup, thus solving the problem.
This issue does not apply to examinations on the RPV.
Within the areas examined, no deviations or violations were identified.
3.
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 I.D. automated ultrasonic examinations of the reactor vessels are in the spirit of Appendix VIII to Section XI of the ASHE Code, 1989 Edition with Addenda through 1991.
GE's current estimate of coverage of weld examinations including both I.D. automated and O.D.
UT examinations is approximately 78 percent of total weld length.
The GERIS automated I.D. examination should cover approximately 72 percent and the O.D. examination should cover an additional approximately six percent of the total weld length.
When the actual coverage is determined after the completion of the examinations, the licensee will submit a relief request for the unexamined areas.
Within the areas examined, no deviations or violations were identified.
4.
Exit Interview The inspection scope and results were summarized on September 24, 1993, 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 Cj 5.
Acronyms and Initialisms
ANII ASHE BLPV BWR DPR EPRI GE GERIS ID I.D, ISI ISO NDE No.
NRC O.D.
P.E.
QA QAM R
RPV SMAW S/N TVA UT Authorized Nuclear Inservice Inspector American Society of Mechanical Engineers Boiler and Pressure Vessel Boiling Water Reactor Demonstration Power Reactor Electric Power Research Institute General Electric Company General Electric Remote Inspection System Identification Inside Diameter Inservice Inspection Inspection Services Organization Nondestructive Examination Number Nuclear Regulatory Commission Outside Diameter Professional Engineer Quality Assurance Quality Assurance Manual Revision Reactor Pressure Vessel Shielded Metal Arc Welding Serial Number Tennessee Valley Authority Ultrasonic