IR 05000266/1984001

IE Insp Rept 50-266/84-01 on 840222-24.Violation Noted: Failure to Establish Adequate Hydrostatic Test Program

ML20087P687
Person / Time
Site:	Point Beach
Issue date:	03/06/1984
From:	Kleinsorge W, Blake J NRC Office of Inspection & Enforcement (IE Region II)
To:
Shared Package
ML20087P684	List: IR 05000266/1984001
References
NRC-2020-000157 50-266-84-01, 50-266-84-1, NUDOCS 8404090277
Download: ML20087P687 (9)

Text

. .-

.

UNITED STATES

1. g ateoq'o,,

.

NUCLEAR REGULATCRY COMMISSION

[ o REGION il 5 $ 101 MARlETTA STREET I 8 ATLANTA, GEORGI A 30303 t

g.....,/

Report No.: 50-266/84-01 Licensee: . Wisconsin Electric Power Company

,

231 West Michigan Milwaukee, WI 53201 Docket No.: 50-266 License No.:' DPR-24 Facility Name: . Point Beach Inspection at B h site near Two Rivers, Wisconsin Inspect r: 34 M W. P dins g Date Signed Appro d by: 3!d 8 J. .jfRake, Chief Date Signed Ma rdals and Mechanical Section En ineering Program Branch Division of Engineering and Operational Programs SUMMARY Inspection _ on February 22-24, 1984 Areas Inspected This routine, announced inspection involved 24 inspector-hours on site in the areas of. modification progress, preservice inspection (PSI)/ inservice inspection (ISI), steam generator replacement project (SGRP), IE Information Notice, and licensee action on previous enforcement matter Results Of the five areas inspected, no violations or deviations were identified in four areas; one apparent . violation was found in one area (Violation " Failure to

~

Establish Adequate Hydrostatic Test Program" - paragraph 6a(1)(e)). No devia-tions were found.

!

O

'%4kN G

p

- -

, ,

r-- ,- - .

..

.

- REPORT DETAILS

- Persons Contacted Licensee Employees i

• R. E. Link, Superintendent, Engineering, Quality and Regulatory Services

• T. Pohl, Superintendent, I&C

• J. Schwitzen, ISI, Engineer

• S. Pullins, Nuclear Plant Engineer Other licensee employees contacted included mechanics and office personne !

"

NRC Resident Inspectors

• R. L. Hague, Senior Resident Inspector

• B. E. Fitzpatrick, Resident Inspector

• Attended exit interview Exit Interview The inspection scope and findings were summarized on February 24, 1984, with Lthose personsLindicated in paragraph 1 above. The inspector described the areas inspected and discussed in detail the inspection findings listed below. No dissenting cmnments were received from the license (0 pen) Violation '50-266/84-01-01: " Failure _to Establish Adequate

' Hydrostatic Test- Program" -~ paragraph 6a(1)(e).

(0 pen)InspectorFollowupItem 266/84-01-02: " Calibration Block Protection"

-1 paragraph 6.b(2)(b).

_ (0 pen) inspector Followup Item 266/84-01-03: "UT Inspection of Guide Tube

- Support Pins" - paragraph ~ Licensee Action on Previous Enforcement Matters .

(Closed) Unresolved Item 266/83-20-02: " Unavailable Documents from WP 2912

A&B" The Licensee made the missing documents available to' the ' inspecto The inspector has no further questions. -This matter is considered close . Unresolved' Items JUnresolved items were not_ identified during this inspectio >

$ U

.-

... .

,; .- -

.

2 Independent -Inspection Effort

,

Modification Progress

The Linspector conducted a general inspection of Unit 1 containment and the Units'1 and 2 turbine decks .to observed modification progress and activities such as weldfag material handling and control, housekeeping and storag Within the areas examined no violations or deviations were identifie .- Preservice Inspection (PSI)/ Inservice Inspection (ISI) (Unit 1)

'

The inspector: examined-documents, activities and records as indicated below to determine 'whether: PSI and ISI was being conducted in' accordance with appplicable procedures regulatory requirements and licensee commitment The applicable code for PSI /ISI is ASME B&PV ' Code Section XI,1977 edition

'with addenda.through Summer 197 . 'Preservice Inspection (PSI)

(1) Observation of Work and Work Activities (730538)

, The inspector reviewed. applicable records of the activities described below as the window of opportunity for direct observa-tion had passe (a) Examiner Qualification The inspector reviewed the qualification documentation for the below listed examiners - in the following- areas:

employer's name; person certified; activity qualified to

. perform; effective period of certification; signature of employer's designated representative'; basis used for certification; and annual visual- acuity; color vision-examinatio '

-

Examiner Method - Level EHE UT-II LDS UT-I-MA0 MT-I-T, PT-I-T,

. UT-I-T-

_- BAR MT-II

, . CAM MT-I-T GE UT-II CMB MT-II-RAG UT-II, PT-II JWD UT-II

. -

iv -

.

.s .

-

, . ,

L l

3 (b) Ultrasonic Examination Records for the ultrasonic examination of the below listed weld joints were. examined for compliance with the (Code and the appli_ cable procedure in the following areas; availability of and compliance with approved NDE procedures; use of

. knowledgeable NDE personnel; use of NDE personnel qualified .

.in the' proper level; recording of inspection results; type of apparatus used; extent of coverage of weldment; calibration requirements; search units; beam angles; DAC caurves; reference 'leve1 ~ for monitoring discontinuities; method of demonstration of penetration; limits for evaluating and recording indications; recording significant indications; and acceptance limit Weld Joint No RC-34-MRCL-AI-3 RC-36-MRCL-BII-1

' Steam Generator A SG-A-4 Steam Generator B SC-B-4 MS-30-MS-1001-2A MS-31-MS-1002-2 FW-16-FW-1001-25 FW-16-FW-1002-17 (c) Liquid Pentrant Examination Records for the liquid penetrant examination of the below listed . weld joints were examination for comp'liance with the code and the applicable procedure in the following areas: availability of and compliance with approved NDE procedure; use of knowledgeable NDE personnel; use of NDE-personnel. qualified in the. proper - level; recording of

-

' inspection results; specified method; penetrant materials identified;.. penetrant materials analyzed for- sulfur; penetrant materials . analyzed for halogens; acceptable pre-examination surface; -drying time; method of. penetrant application; surface . temperature; solvent - removal; dry surface. prior to developing; type of developing; examination-technique; and evaluation technique.

-

Weld Joint No RC-34-MRCL-AI-3 RC-34-MRCL-BII-1 f

'

k

, - / , .e,', 4s,.- ..y ,, . 's, c.. ..-,,seM,,,m

- .-,-..s.y...'- ,mm,. . . , , -- ., n y e-wm< .m.,. y y.-, , f

.. .

.. -

(d) Magnetic Particle Examination Records for the magnetic particle examination of the below listed welds were examined for compliance with the code and the applicable procedure in the following areas: avail-ability of and compliance with approved NDE procedures; use of knowledgeable NDE personnel; use of NDE personnel qualified in the proper level; recording of inspection results; examination method; contrast of dry powder particle color with background and surface temperature; suspension medium and surface temperature for wet particles; viewing conditions; examination overlap and directions; pole or prod spacing; current or lifting power (yoke); and acceptance criteri Weld Joint No MS-30-MS-1001-2A MS-31-MS-1002-2 FW-16-FW-1001-25 FW-16-FW-1002-17 (e) System Pressure Test Records of the below listed pressure tests were reviewed and compared with 'the applicable procedures and the code in the following areas: test conditions of pressure and tempera-ture; test condition holding time; rate of temperature and pressure increase; pressure and/or temperature measuring instrumentation, source of detected leakage located; evaluated and corrective measures taken; and gauges calibra-tion prior to tes Pressure Tests Primary System Steam Generator A Steam Generator B With regard to the above inspection the inspector noted the following: .

"MAXITEST" gauges were used to perform the secondary hydrostatic tests of the A and B steam generator WMTP 11.27 revision 0, " Hydrostatic Test Unit 1 Steam Ge.nerators" has been identified as the applicable procedure for the named hydrostatic tes The above is contrary to paragraph 3.1 of WMTP-11.27 which requires "Heise" gauges be use .

....

-

.

The MAXITEST gauges used were a 2000 PSI gauges. WMTP 11.27 specifies the test pressure as 1388 PSI, therefore the gauges used did not meet the 1.5 to 4 times the maximum test pressure requirement as specified by the ASME B&PV Code Section XI, paragraph IWA-526 The inspector determined that there was no documented record of the pressure or pressures at which the "MAXITEST" gauges were calibrated nor who performed the calibratio The above failure of the licensee to follow the hydrostatic procedure, the failure of the hydrostatic test to meet the applicable code requirements and the failure to adequately document test gauge calibrations indicated that the licensee does not have adequate control of the Hydostatic Test Program. Failure to establish an adequate test program to demonstrate systems and components will perform satisfactorily in service is in violation of 10 CFR 50, Appendix B, Criteria XI. This violation will be identified as 266/84-01-01: " Failure to Establish Adequate Hydrostatic Test Program."

(2) Review of Quality Records (73055B)

(a) The inspector reviewed selected records for the welds listed below, ' to t determine whether those documents contain or provide reference to the following documents: examination

~

results and data sheets; examination equipment data; calibra-tion data sheets; examination evaluation data; records on extent of examination; records on deviation from program and procedures including justification for deviation (if applicable); records on disposition of findings; re-examina-tion data after repair work (if applicable); and identifica-tion of NDE material 'such as penetrant, penetrant cleaner, couplant, films, tapes, et Weld Joint No RC-34-MRCL-AI-3 RC-36-MRCL-BII-1 Steam Generator A SG-A-4 Steam Generator B SC-B-4 MS-30-MS-1001-2A MS-31-MS-1002-2 FW-16-FW-1001-25

,

FW-16-FW-1002-17

(b) The inspector reviewed selected records for the below listed welds, to determine whether the following requirements had been met: the examination unit calibration data sheets show no major deviations between initial and final calibrations; a

. .

-

.

collected examination data and any recordable indications are properly recorded to permit accurate evaluation and documentation; evaluation of examination data performed by a Level II or Level III examiner; evaluation of examination data complies with the procedure; evaluation of indications (if applicable) comply with the criteria of the NDE procedure and ASME Section XI; and incomplete examinations and results were repeated to permit full evaluation (if applicable).

Weld Joint No RC-34-MRCL-AI-3 RC-36-MRCL-BII-1 Steam Generator A SG-A-4 Steam Generator B SC-B-4 MS-30-MS-1001-2A MS-31-MS-1002-2 FW-16-FW-1001-25 FW-16-FW-1002-17 b. Inservice Inspection (ISI)

(1) ReviewofProcedures(73052B)

(a) The following procedures were reviewed in the areas of procedure approval and qualification of NDE personnel:

(1) SwRI NDT-700-5 Rev. 10, " Mechanized Ultrasonic Examina--

tion of Vessel Components, Vessel Welds and Piping Welds" (2) SwRI NDT-700-6 Rev. 16, " Mechanized Ultrasonic Examina-tion Ferritic Vessels 21-inches or greater in thickness" (b) In addition to the above review, procedures SwRI NDT-700-5 and SwRI-NDT-6 were reviewed in the areas of compilation of required records and procedure technical content relative to: type of apparatus, extent of coverage including beam angles and scanning . techniques, calibration discontinuities, method of demonstration penetration, levels for evaluation and recording indications, and acceptance standard (2) 0bservation of Work and Work Activities (73753B)

(a). Personnel qualification is discussed in paragraph 6a(1)(a)

(b) In process ultrasonic (UT) inspection of the below listed welds was observed and compared with the requirements of procedure SwRI NDT-700-5 and the code in the following areas: availability of and compliance with approved NDE

. -

.

procedures; use of knowledgeable NDE personnel; use of NDE personnel qualified in the proper level; recording of inspection results; type of apparatus used; extent of coverage of weldment; calibration requirements; search units; beam engles; DAC curves; reference level for monitoring discontinuities; method of demonstration of penetration; limits for evaluating and recording indications; recording significant indications; and acceptance limit Weld No RPV-2-686-A IRS RPV-2-686-C IRS RPV-2-686-C With regard to the above inspection the inspector noted that SwRI Procedure NDT-700-6, Revision 16 invoked Regulatory Guide 1.150 which in turn specifies that measures should be established to control calibration blocks to prevent deteriation so their characteristics do not change during storag The licensee has no documented program for protection of UT calibration block The licensee indicated that they would look further into the matter. The inspector stated that the above would be identified as inspector followup item 266/84-01-02: " Calibration Block Protection",

k (3) Review of Quality Records (73755B)

The inspector reviewed the NDE records for the ISI examinations of the below listed welds to determine whether the examination unit calibration data sheets show any major deviations between initial and final calibrations; collected examination data and any l recordable indications are properly recorded to permit accurate

evaluation and documentation; evaluation of examination data was performed by a Level II or Level III examiner; evaluation of examination data complies with the procedures; evaluation of indications (if applicable) complies with the criterial of the NDE procedure and ASME Section XI; and incomplete examinations and results are repeated to permit full evaluation (if applicable).

Weld No Steam Generator-A-5 Steam Generator-A-7 Within the areas examined no violations or deviations were identified except as noted in paragraph 6a(1)(e).

-

, .,. . .-

-

.

'

.a ,

. Steam Generator Replacement Project (SGRP) (Unit 1)

The Point Beach Nuclear Plant Unit 1, owned by Wisconsin Electric Power Company. (WEPCO), has replaced the lower steam generator assemblies. The work was ' accomplished by Westinghouse (W) the customer / client of Morrison-

.Knudsen (M-K). The hierarchy of project documents is: WEPCO-Point Beach Quality Program, W NSID QA Program, W NSID Steam Generator Repair Supplenent and QA Program Pfan- Supplement, W SGRP Quality Procedures, and M-K Quality Procedures.= The applicable. codes for.the 56RP are listed below:

.ASME Section-III

~

- -

-77S79

- ASME Section V 77S79 SD -- ASME Section IX 77579

-- AWS DI.1-1982

-

SNT-TC-1A-1975-

' Radiographic Examination (570908)

Review of Quality Records. .The inspector reviewed the certification documentation and calibration. records for the below listed materials and-equipmen Size Set 1

"

Penetramete' F T-35 7 45 3 45- 7

, _ J0ensity Strips MK-324 MK-325-i NBS-118204-

" '

Within the area examined no violations or deviations were identifie .- IE Informa' tion Notices

. IE Information Notices No. 82-29,' dated July 23,-1983 '" Control Rod Drive

.(CRD) Guide . Tube Support Pin _ Failures at Westinghouse PWRs" reported several failures in both domestic and foreign -reactor The inspector. reviewed

. Westinghouse -Procedure MP 2.4.1/WEP-1, Revision 1,. "UT Inspection of Guide-Tube ' Support Pins at Point Beach Unit 1," and observed a portion of the examination.- Preliminary-results from Westinghouse indicate that of:the 74

pins inspected 67 contained indications 'in -the shank-to-flange region, none

' contained. indications leaf area and no reportable indications were noted in

.the remaining seve .

- The inspector . stated that the' licensee's closed out actions for the above would .-be evaluation : by the NRC. . This' will be- identified as~ inspector Lfollowup item 266/84-01-03: "UT . Inspection of Guide Tube Support Pins".

.Within' the: area examined' no violations or deviations were note .

L __