IR 05000266/1979014
| ML19305B871 | |
| Person / Time | |
|---|---|
| Site: | Point Beach  |
| Issue date: | 02/04/1980 |
| From: | Danielson D, Ward K NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML19305B861 | List: |
| References | |
| 50-266-79-14, 50-301-79-16, NUDOCS 8003200506 | |
| Download: ML19305B871 (16) | |
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U.S. NUCLEAR REGULATORY COMMISSION
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OFFICE OF INSPECTION AND ENFORCEMENT
REGION III
Report Nos. 50-266/79-14; 50-301/79-16 Docket Nos. 50-266; 50-301 License Nos. DPR-24; DPR-27 Licensee: Wisconsin Electric Power Company 231 W. Michigan Milwaukee, WI 53201
Facility Name: Point Beach Nuclear Power Plant, Units 1 and 2 Inspection-At: Point Beach Site, Two Creeks, WI Southwest Research Institute, San Antonio, Texas Inspection Conducted: October 11, November 14-15, December 17-19, 1979 and January 7-8, 1980 kk fY
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Inspector:
K. D. Ward d///[C
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/ 't
.-[@d% <.'t /tw Approved By:
D. H. Danielson, Chief J
d Engineering Support Section 2 Inspection Summary Inspection on October 11, November 14-15, December 17-19, 1979 and January 7-8, 1980 (Report No. 50-266/79-14; 50-301/79-16)
Areas Inspected: QA/QC program, implementing procedures, observation of work activities, and review and evaluation of nondestructive examination (NDE) data and reports of inservice inspection (ISI); IE Bulletin 79-13 and IE Bulletin 79-17 activities; and steam generator repair. This inspection involved a total of 25 on site inspection hours and five hours at Southwest Research Institute by one NRC inspector.
Results: No items of noncompliance or deviations were identified.
800s200 SD6
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DETAILS
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Persons Contacted Wisconsin Electric Power Company (WEPCo)
- G. Reed, Manager Nuclear Operations Division J. Greenwood, Assistant to Manager E. Gross, Project Engineer, Nuclear Projects Of fice R. Hassis, Nuclear Plant Engineer F. Zeman, Office Supervisor Southwest Research Institute (SWRI)
- W. Flach, Director, Department of Engineering Services
- L. Albrecht, Manager of Quality Assurance
- D. Rosow, Manager, Nuclear Field Services
- J. Godwin, Technical Laison Group Supervisor
- M, Gonzalez, Research Engineer, QA The inspectors also contacted and interviewed other licensee and contractor employees.
- Denotes those present at the final exit interview at the site on December 19, 1979.
- Denotes those present at the exit interview at SWRI on January 8,1980.
Functional or Program Areas Inspected 1.
General Reference a.
Report No. 50-301/79-12 (NRC report on activities at site on Unit 2, IE Bulletin 79-13)
b.
Lett =r, dated July 6,1979 to Mr. J. G. Keppler from Mr. L. Burstein (24 haur notification concerning feedwater system piping examinations on Unit 2, IE Bulletin 79-13)
c.
Letter, dated July 12, 1979 to Mr. J. G. Keppler from Mr. L. Burstein (Response to IE Bulletin 79-13 for Units 1 and 2)
d.
Letter, dated August-28, 1979 to Mr. J. G. Keppler from C. W. Fay.
(Final response to IE Bulletin 79-13 on Unit 2)
e.
Letter, dated November 19, 1979 to Mr. J. G. Keppler from C. W. Fay.
(Final response to IE Bulletin 79-13 on Unit 1)
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f.
Letter, dated August 27, 1979 to Mr. J. G. Keppler from C. W. Fay.
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(Response to IE Bulletin 79-17 Units 1 and 2)
g.
Reference letter to Mr. J. G. Keppler from Mr. H. Greenwood, dated December 13, 1979. (Licensee Event Report No. 79-021/01T-0 24 hour2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> written notification, Unit 1 "B" steam generator primary to secondary leakage.)
The NRC forwarded IE Balletin 79-13 titled, " Cracking in Feedwater System Piping" and IE Bulletin 79-17 titled, " Pipe Cracks in Stagnant Borated Water Systems," for specific action to be taken.
Being the plant was shutdown for its normal refueling outage, Phillips Getschow Company (PGCO) cut out and replaced the Unit 1 main feed piping between the steam generators (SG) and the feedline check valves.
The replacement was one weld beyond the first piping support.
October 12, 1979, Westinghouse performed a visual inspection of both steam generators through the secondary side hard holes. The purpose of the inspection was to look for any miscellaneous debris that might be wedged between the tubes. No debris was found.
The ANI vas contracted as the third party for the ISI, SG repair, IE Bulletins 79-13 and 79-17.
SWRI, Superior Industrial X-Ray Company (SIX) PGCO, and Westinghouse performed the NDE for the ISI, SG repair, and IE Bulletin 79-13 and 79-17.
The next scheduled outage is, Unit 1, approximately September, 1980 and Unit 2 approximately May, 1980.
2.
Procedurcs/ Manuals The following procedures and manuals were reviewed.
a.
Unit I refueling 7, Inservice Inspection Plan 11.10.2.1, UIR7, September 1979, was prepared for Wisconsin Electric Power Company by SWRI.
b.
SWh! Weld Joint Identification Marking on Nuclear Power Plant Piping IX-FE-103-1, February, 1977.
c.
SWRI, Measuring and Recording Search Unit Location and Maximum Signal Ampl.8tude Data During Ultrasonic Weld Examinations IX-FE-104-1, August, 1976.
d.
SWRI, Onsite NDT Records Control X-FE-101-0, March, 1976.
e.
SWRI, Nondestructive Testing Personnel Qualification, Training, Examination, and Certification 1X-AG-1-1, August, 1974.
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f.
SWRI, Qualification and Certification of Quality Assurance
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Auditors, NQAP 15-2, Revision 1, March, 1977, b.
SWRI, Special Process Control (1975 Edition SNT-TC-1A) NQAP 11-1, Revision 1, March, 1977.
i.
SWRI, Certification of Visual Examination Personnel, NDT-100-2, Revision 3, October, 1975.
j.
SWRI, Liquid Penetrant Examination Color Contrast Method, 200-1, Revision 47, July, 1979.
k.
SWRI, Manual Ultrasonic Examination Of Pressure Piping Welds, 600-3, Revision 53, July, 1979.
1.
SWRI, Manual Ultrasonic Examination of Nuclear Reactor Pressure Vessel Flange Ligaments, 600-5, Revision 27, March, 1979.
m.
SWRI, Manual Ultrasonic Examination of Reactor Coolant Pump Flywheels, 600-6, Revision 20, February, 1979.
n.
SWRI, Special Procedure for Manual Ultrasonic Examinations of Austenitic Components With High Acoustic Properties, 800-17, Revision 19, March, 1979.
o.
SWRI, Manual Ultrasonic Examination of Thin Wall Piping Welds, 800-36, Revision 24, July, 1979.
p.
SWRI, Visual Examination of Nuclear Reactor Components by Direct or Remote Viewing, 900-1, Revision 46, July, 1979.
q.
SWRI, Visual Examination of Support Members and Structures for Piping, Valves, and Pumps by Direct or Remote Viewing, 900-4, Revision 19, August, 1979.
r.
SWRI, Visual Examination of Stainless Steel Piping by Direct or Remote Viewing, 900-6, Revision 0, September, 1979.
s.
Liquid Penetrant, P.T.1, Revision 2, April 3, 1978.
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SIX, Magnetic Particle Inspection Procedure MT-1, Revision 2, April, 14, 1978.
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SIX, Radiographic R.T.I., Revision 2, April 1, 1978.
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PGCO, Feedwater Pipe Repair / Replacement Procedure PB-8, Revision 1, September 27, 1979.
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PGC0 Liquid Penetrant Examination QAP-1, Revision 1, May 24, 1976-4-
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PGC0 Personnel Qualification and Certification in Non-Destructive Tetsing WD-NDT-1, Revision 1, February 27, 1978.
y.
W, Multifrequer.cy Eddy Current Inspection of Steam Generator Tubing - Preservice and Inservice MRS 2.4.2 GEN-23, Revision 0, September 17, 1979 and Revision 1, November 7, 1979.
z.
Repair Plugging by Gas Tungsten Arc Welding (GTAW) NPF-80, Revision 5, October 9, 1979.
aa.
W, Installation and Removal of Temporary Nozzle Covers HRS 2.2.2 GEN-2, Revision 3.
bb.
W, Steam Generator Tube Sheet Cleaning Full Recirculation System, MRS-2.2.2 GEN-9, Revision 1, June 7, 1979.
cc.
W, Installation Procedure, Mechanical Plugs in 7/8" 0.D. X.050" wall, Inconel Tubes TS-SG-79-046, Revision 0, August 13, 1979.
dd.
W, Steam Generator Tube Removal MRS 2.3.2 GEN-3, Revision 3, October 8, 1979.
ee.
W, Steam Generator Tubesheet Evaluation MRS 2.4.2 GEN-24, Revision 0, September 27, 1979.
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W, Repair Plugging by Autogenous Gas Tungsten Arc Welding GTAV NDT-80, Revicion 1, August 24, 1977.
gg.
W, Explosive Plug Repair Using Manual Gas Tungsten Arc Welding NPT-27, Revision 1, August 1, 1972.
hh.. W, Tube / Hole Plugging Using Manual Gas Tungsten Arc Welding NPT-23, Revision 5, February 23, 1976.
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W, Weld Repair of Steam Generator Tubes / Plugs MRS 2.3.2 GEN-6, Revision 1, January 8, h979.
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W, Explosive Plugging of a Tubesheet Hole From Which The Tube Has Been Removed, NPT-33, Revision 6, October 23, 1975.
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W, Explosive Tube Plugging, NPT-33, Revision 1, February 12, 1973.
11.
W, Explosive Plugging of Steam Generator Tubes, MRS 2.3.2 GEN-9, Revision 2, July 1, 1978.
mm.
W, Dye Penetrant Examination 84350JA, Revision 9, March 23, 1977.
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W, Installation and Removal of Eddy Current Positioning Devices MRS 2.4.2 GEN-19, Revision 0, July 15, 1977.
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W, Steam Generator Tubing Inspection for Tube W'all Degradation -
Tight Radius V-Bends MRS 2.4.2 GEN-18, Revision 0, September 9, 1977.
pp.
W, Examination of Steam Generator Tubes / Explosive Plugs Repaired by Welding per MRS 2.3.2 GEN-6, QAIP-1-VT, Revision 1, January 22, 1979.
qq.
W, Post-Activity Sign-Off for Area Cleanliness MRS 2.2.2 GEN-6, Revision 2, July 31, 1979.
No items of noncompliance or deviations were identified.
3.
Personnel Certifications The inspector reviewed the following personnel certifications.
T. Collins I
II I
I R. Spinks II II II II L. Villa II I
II I
II J. Salam I LIMITED I LTD I LTD E. Boyd II
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M. Ehnstorm I
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L. Mc Farland II II II II S. Wenk III III III III E. Reuscher III III III III W. Clayton III III III R. Memeyer II II II II R. Forman II W Schick III-6-
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P. Watson-III III III D. Fournell-II II II II W'estinghouse Electric Corporation
NAME RT UT ET PT MT VT W. Woolfolk II S. Armbrister II II II II R. Ingraham-III R. Vollmer II
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M. Stefanko I
E. Nagy II R. Bedard II II II A. Terrell II II II II
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W. Bolt I
R. Hazen II J. Estel II
G. Ferenchak II ZETEC NAME ET
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E. McKee II PGC0 NAME RT UT ET PT MT VT R.'Kline II R..Marcom III III III III
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SIX NAME RT UT R. Huerter II II R. Preston II II Welders Certifications for Steam Generators
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NAME NAME F. Garofalo R. Harrell
V. Burke B. Musial E. Nagy J. Kosky B. Volmer E. Brauer J. Samios L. Retel J. Hall R. Brauer G. Orphanos D. Schmeisser R. Vollmer M. Radka M. Torcaso R. Vertz C. Pfarr W. Woolfolk
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L. Retel D. Tommarello No items of noncompliance or deviations were identified.
4.
Material and Equipment Certifications The following material and equipment certifications were reviewed.
l a.
Pipe, 28 fi.16" diameter wall 0.844" Ht. #57144.
b.
Reducer, u 18" x 16" diameter Schedule 80, Ht. #N10204.
c.
Two Long Radius (LR) Elbows 90, Schedule 80, Ht. #18441 and Ht.
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.#284161
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Pipe, 3 1/2" diameter wall 0.300", Ht. #L65412.
e.
Two inch weldolets, 16" x 3" Lot #P927.
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EB Flat Insert Type 131, 1/16" x 3/16", E70S-2, Lot #2652-131.
g.
Inconel Weld Wire Ht. #NX84B.1.D.
h.
Weld Rod E7018 1/8" Ht. 4121H9561 E7018 3/32" Ht. #412H6743
'E7018 5/32" Ht. #401E6991 E7018 1/8" Ht. #432E0081
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E70S-2 3/32" and 1/8" Ht. #L40165 E70S-2 1/16" Ht. #L39265 i.
Magnaflux Materials, Liquid Penetrant Penetrant - Batch No. 78B032 Developer - Batch No. 79B082 Cleaner - Batch No. 78C056 j.
.Turco Products, Liquid Penetrant Remover - Batch #B-096 Penetrant - Batch #E-216 Developer - Batch #H-176 k.
Ultrasonic Couplant Dow Chemical Glycerine - Batch No. TB-09058-3 1.
Ultrasonic instruments, transducers, calibration blocks, and pyrometers.
m.
Eddy Current Equipment, Vector analyzer Oscilloscope, Brush recorders, FM tape recorders, M1Z-12 Display module, 5111 - Display O' Scope.
n.
Calibrations of portable weld rod ovens, therometers, and recorders.
No items of noncompliance or deviations were identified.
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5.
Spools Removal Unit #1
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The spools removal for SG "A" and "B" included replacing a 18" x 16" reducer, 16" diameter pipe approximately 56" long, 16" diameter LR
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-90' elbow, adding a 3" weldolet and a length of 3" pipe to the check valve. The welds for SG "A" are #38, 38A, 67, 37, 39, B39, A39, 63, i
63A, and 63B. The welds for SG "B" are #46, 46A, 45A, 45, 47, A47,
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B47, 68, 68A, a*J 68B. The pipe and elbows are schedule 80.
Visual (VT) ar liquid penetrant (PT) examinations were performed on the outside diameter (0D) and inside diameter (ID) of the steam generator nozzles, "A" and "B" and existing piping. The examinations revealed-pitting and'some linear indications, that were satisfactorily repaired by welding or blending.
No items of noncompliance or deviations were identified.
6.
Observation of Work And Work Activities The inspector observed the following activities:
a.
Liquid penetrant examinations performed of feedwater nozzles SG
"A" and "B".
b.
Ultrasonic and liquid penetrant examinations on Weld #1, RC-36 MRCL-BII and Weld #3 RC-34 NRCL-BI, this included the instrument
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calibration, SG "A".
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c.
Eddy current examinations on SG "A".
No items of noncompliance or deviations were identified.
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Radiography i
The inspector reviewed the following final radiographs of the replace-ment welds.
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i Weld No.
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W63B Weldolet to Pipe
"A" W63A Pipe to Check Valve
"A" I
W63 Pipe to Check Valve
"A"
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W37 Elbow to Check Valve
"A" W38 Reducer to Nozzle
"A"
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W67 Pipe to Elbow
"A"
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Weld No.
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W38A Pipe to Reducer
"A" W68 Pipe to Check Valve
"B" W68A Pipe to Weldolet
"B" W68B Weldolet to Pipe
"B" W45 Elbow.s Check Valve
"B" W45A Pipe to Elbow
"B" W46A Pipe to Reducer
"B" W46 Nozzle to Reducer
"B" No items of noncompliance or deviatious were identified.
t 8.
Data and Audit Review The following data and audits were reviewed.
a.
NDE data for the ISI,Bulletins 79-13 and 79-17 and steam generator repair and examinations.
b.
Field fabrication process data sheets.
c.
Post weld heat treatment strip charts.
d.
Calibration status
. FM recorders
. Brush recorders
. M1212 Frequency modules
. Display module Indicator O' scope
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e.
Audit of W personnel certifications and equipment by WEPC QA.
f.
Audit of PGCo NDE observation by ANI.
.g.
Audits of W, ZETEC, PGCo, and SIX NDE by WEPCO.
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No items of noncompliance or deviations were identified.
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9.
Steam Generators SG "A" October and November, 1979 3260 tubes were eddy current examined this outage.
251 tubes were previously plugged.
77 tubes were plugged this outage for the follow-ing reasons:
I leaking tube, failed hydro
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. 2 plugged by mistake
. 2 good tubes removed for metallurgical evaluation
. 3 defects under 40%
. 69 defects over 40%
SG "B" 3260 tubes were eddy current examined this outage.
251 tubes were previously plugged. 68 tubes were plugged this outage for the follow-ing reasons:
. I plugged by mistake
. 2 leaking tubes, failed hydro
. 3 defects under 40%
. 62 defects over 40%
December 15, 1979 there was a shutdown after 11 days of' operation because of a leak in Unit 1, "B" steam generator (SG), tube in row 2, column 72, No. R2C71. Also there were plugs in two tubes found to be leaking when a hydro was performed. The two tubes are located in row 12, column 55 No. R20C55 and in row 20, column 55 Ka. R12C55. The leak was the primary to the secondary, 250 to 260 gallons per day.
950 tubes in SG "A" were ET and approximately 19 were found to have 20% to 94% reduction in wall thickness.
A meeting was held at the site between NRR and RIII personnel and the licensee on the above subject.
In the discussion, there was a compar-ison between pictures of the ET performed last October,1979 and the
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present December ET of the following tubes.
It was found that approx-
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imately 6 indications were the same in the present ET as last October, except that the present ET revealed a more clear presentation and being larger because of the signal noise ration (a finer technique).
"A" Steam Generator Tube Defects Tube Defects Location 1.
R8C19 81%
8" Above tube end 2.
R10C20 42%
20" Above tube end 3.
R7C21 95%
13" Above tube end 4.
R18C21 85%
15-21" Above tube end 5.
R8C25 85%
15-20" Above tube end 6.
R9C28 92%
6" Above tube end i
7.
R20C31 92%
15-21" Above tube end 8.
R18C32 92%
12" Above tube end 9.
R19C32 60%
20" Above tube end 10.
R18C33 88%
12" Above tube end 11.
R7C34 88%
2 1/2-5" Above tube end 12.
R23C40 69%
10" above tube end 13.
R27C42 20%
12" Above tube end 14.
R24C47 20%
8" Above tube end 15.
R19C51 37%
6" Above tube end
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R12657 83%
20" Above tube end 17.
R4C59 94%
17" Above tube end i
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R6C33 84%
5" Above tube end 19.
R9C54 small 20" Above tube end indication No items of noncompliance or deviations were identified.
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10.
Southwest Research Institute
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The inspector made a trip to Southwest Research Institute in San Antonio, Texas for the purpose of reviewing nondestructive examination personnel certifications, including experience, and four NDE personnel certification procedures.
When SWRI submits a, " Statement of Certifi-cation", for an NDE individual to the licensee, it is not complete or is there enough information available to evaluate. The following items are found in reviewing the SWRI, " Statement of Cerfification of their NDE personnel.
SWRI NDE personnel are certified in accordance with the require-a.
ments of one of the following procedures.
. SWRI, Nondestructive Testing Personnel Qualification, Training, Examination, and Certification (1968 Edition SNT-TC-1A)
1X-AG-1-1, August, 1974.
. SWRI, Special Process Control (1975 Edition SNT-TC-1A) NQAP 11-1, Revision 1, March 1977.
. SWRI, Certification of Visual Examination Personnel, NDT-100-2, Revision 3, October 1975.
. SWRI, Visual Examination of Nuclear Reactor Components by Direct or Remote Viewing, NDT-900-1, Revision 47, September 1979.
Very seldom are there one of the above procedures found on site, therefore the certifications can not be evaluated without the proce-dure of the requirements on how the personnel were certified. The licensee have audit reports stating that NDE certifications and proce-dures have been reviewed at SWRI, but the individuals that have con-ducted the audits very seldom review the certifications when submitted by SWRI for a specific job on the site, and do not have copies of the procedures to refer to if they were to review the certifications.
b.
. The " certification limitations (if any)", stated on the certifi-catio is always blank when there is not a limitation. The blank area should have the word "NONE" if there is not a limitation.
c.
. The " Signed" area on the certification does not state if the individual is a Level III but does state his title in the com-pany.
In reviewing the certification at the site, it is not known who administered the test or if the Level III Examiner was qualified because his tests are not always at the site.
d.
. " Training" on the certification states classroom and laboratory hours combined and the examination grade. The methods are not
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stated and without a procedure to refer to, one can not say the
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hours are in accordance with the procedure.
. " Educational History" on the certification states name of high e.
school, any additional, the major field of study, years and degree.
In some cases it would be difficult to know the city and state of the school and if the person is a graduate.
If a person is a graduate of a high school or college, it could reflect the experience needed. The procedure states the educa-tion needed.
f.
. " Employment History" on the certification states, date employed, previous NDT related, company and years, SWRI does not state amount of experience ir. an NDE method on the certification when employed by SWRI. The documented experience is located at SWRI and the procedure for the amount of experience required is at SWRI also. The inspector has reviewed certifications where part of the education is the experience which should be stated in the procedure. The certification should state all the NDE experience to time of certification, including company, city, state, method, month, and years to and from.
" Visual Acuity and Color Perception Test", on the certification g.
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states, date, corrected if required, and verified by.
The eye test does not state if the Jaeger J1 was given, the type of color test, or who gave the test.
The NRC inspector was informed by SWRI of the following actions that will be taken.
The four above procedures will be on site or can be obtained by a.
calling Larry Albrecht at SWRI 512-684-5111.
b.
The " Statement of Certification", Form QA-11-4 shall be revised and will be in SWRI QA Manual approximately the end of March, 1980.
At that time all SWRI NDE personnel experience shall be documented on the form up to their certification date.
Approximately all NDE personnel shall be recertified by written c.
examination by the end of the summer, 1980.
No items of noncompliance or deviations were identified.
11.
Conclusions The fabrication of the feedwater sections, IE Bulletin 79-13, Units 1 and 2, examinations and evaluations, IE Bulletin 79-17, Units 1 and 2. ISI, repair of steam generator tubes and construction testing sp-peared to satisfy the applicable procedures and code requirements.
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The inspector reviewed the response and actions for IE Bulletin 79-13
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Units 1 and 2 and have no questions at this time. RIII will review the licensee's written response to IE Bulletin 79-17 Units 1 and 2.
These are unrescived items, IE Bulletin 79-17 Unit 1 (266/79-14-1)
and IE Bulletin 7. 17 Unit 2 (301-79-16-1).
No' items of noncompliance or deviations were identified.
Unresolved Items Unresolved items are matters about which more information is required in order to ascertain whether they are acceptable items, items of noncom-pliance, or deviations. The unresolved items disclosed during the in-spection are discussed in Paragraph 11.
Exit Interview The inspector informed Mr. G. Reed at the site and SWRI representatives at the conclusion of the inspection. The inspector summarized the scope and findings of the inspections noted in the report.
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