IR 05000269/1982019
| ML20058B784 | |
| Person / Time | |
|---|---|
| Site: | Oconee  |
| Issue date: | 06/29/1982 |
| From: | Coley J, Economos N, Economus N, York J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML20058B772 | List: |
| References | |
| 50-269-82-19, 50-270-82-19, 50-287-82-19, NUDOCS 8207260146 | |
| Download: ML20058B784 (11) | |
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Report Nos. 50-269/82-19, 50-270/82-19 and 50-287/82-19 Licensee: Duke Power Company 422 South Church Street Charlotte, NC 28242 Facility Name: Oconee Docket Nos. 50-269, 50-270 and 50-287 License Nos. DPR-38, DPR-47 and DPR-55 Inspection at ne site near Seneca, South Carolina
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N. Ectino?hes, Actins 5 t on Chief Da M Signed Engineering Inspection Branch Division of Engineering and Technical Programs SUMMARY Inspection on May 25-28, 1982 Area s -Inspected This rnutine, unannounced inspection involved 56 inspector-hours on site in the areas of-Unit 3 ten year inservice inspection of steam generators; review of Unit 3 ten year inservice inspection (ISI) program and ISI procedures; thermal shield broken bolts; and modification of auxiliary feedwater system, Unit 3.
Results No violations or deviations were identified.
8207260146 820701 PDR ADOCK 05000269 G
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REPORT DETAILS 1.
Persons Contacted Licensee Employees
- J. E. Smith, Station Manager
- N. Pope, Supervisor, Operations
- T. C. Mathews, Technical Specialist
- J. J. McCool, QA Supervisor
- J. M. Crowe, QA, NDE/ Welding Other licensee employees contacted included technicians and office personnel.
Other Organizations Babcock and Wilcox, Nuclear Power Generation Division (NPGD)
- H. W. Stoppelmann, ISI Coordinator R. Matney, Level II Examiner Institute of Nuclear Power Operations (INP0)
N. Paleologos NRC Resident Inspector
- W. Orders
- Attended exit interview 2.
Exit Interview The inspection scope and findings were summarized on May 28, 1982, with those persons indicated in paragraph 1 above.
The inspection findings listed below were discussed in detail. No dissenting comments were received from the licensee.
(0 pen) Unresolved Item 287/82-19-01:
" Calibration Performed on ID Notch Reflector not Representative of Component Inspected" paragraph 8.b(1).
(0 pen) Unresolved Item 287/82-19-02:
" Improper Inspection Techniques" -
paragraph 8.b(2)(d).
(0 pen) Inspector Followup Item 287/82-19-03:
" Inspection of Painted Surfaces" paragraph 8.b(3).
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(0 pen) Inspector Followup Item 287/82-19-04:
"UT Examiner's P ra c'.i ca l Qualification Examination Requested" paragraph 8.a.
3.
Licensee Action on Previous Inspection Findings Not inspected.
4.
Unresolved Items Unresolved items are matters about which more information is required to determine whether they are acceptable or may involve violations or devia-tions. New unresolved items identified during this inspection are discussed in paragraphs 8.b(1) and 8.b(2).
5.
Independent Inspection Effort a.
Core Barrel Assembly Thermal Shield Broken Bolts (LER 269/81-11)
On July 15, 1981, the licensee found (using a remote video camera)
several bolt sections in the bottom of the reactor vessel. As a result of the subsequent investigation, the lower thermal shield bolts were replaced in Units 1 and 2 at Oconee.
The bolts will be replaced in Unit 3 during the current outage.
The original lower thermal shield bolts were made from A 286 material (SA 453, Grade 660 heat treated to condition A).
Instead of replacing the A 286 bolts with another bolt, the licensee replaced the bolts with studs and compression nuts that were made from Inconel X-750 material.
The inspector reviewed the following documents for the replacement Inconel X-750 studs and compression nuts:
(1) Hamill Manufacturing Company (stud and compression nut vendor)
Process Outline 4726-000-001, Revision 2, dated 9/23/81
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i (2) Materials Test Reports (3) Metallographic Examination Reports (4) Dye Penetrant Inspection Reports (5) Dimensional Examination Reports (6) Hardness Examination Reports The documentation for the following heats of materials were reviewed:
heat numbers, RO 73-2, 84110, 38294-3, 38343-3, 38343-4, 38343-5 and 38343-6. This LER (269/01-11) was not closed at this time because the nuclear station modification (NSM) packages have not been completed.
However, the actual work has been completed and signed off.
Within the areas inspected no violations or deviations were identified.
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b.
Modification of Auxiliary Feedwater System (Unit 3)
Distortion of the inside headers on the steam generator auxiliary feedwater system was discovered during an early 1982 outage at the Davis-Besse Unit 1 Nuclear Plant.
The supplier of steam generators-,
Babcock and Wilcox, determined that this problem was generic for the steam generators with the internal headers in the auxiliary feedwater system. Oconee Units 1 and 2 have external headers in the Auxiliary Feedwater System and will not have to be modified. Oconee Unit 3 has the internal header and will be modified during the current outage.
The licensee will flange and seal a portion of the old feedwater line nearest the steam generator and the remaining part of < the feedwater line will be used to supply the new external header. Six holes will be drilled into the steam generator shell to accommodate the six riser pipes that supply water from the header to thefvessel. After the holes are drilled and before attaching the riser pipes, the' openings will be
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used to stabilize the internal header box by adding -fillet welds and.
braces. No post weld heat treatment will be necessary. Some hydro-static testing will be performed after the repair.
The licensee reported that as of June 14, 1982 four of the six 5 inch diameter holes and associated bolt-holes had been drilled on Steam Generator A and that six of the 1/2. inch diameter pilot holes had been drilled on Steam Generator B.
Within the areas inspected, no violations or deviations yvere identified.
6.
Inservice Inspection - Review of Program (Unit 3)
The inspectors reviewed the licensee's inservice' in pection (ISI) program for the first ten year inspection interval to ascettain whether tne program t
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was complete and in conformance with regulatory reauirements and licensee l
commitments. The applicable code for this inspection was the 1974 edition
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including S75 addenda of Section XI of the ASME Boiler and Pressure Vessel Code.
For the current outage, Babcock and, Wiledx (B&W) Nuclear Power
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Generation Division, was the inspection agency.
The inspectors reviewed the B&W program listed below to determine if it had been approved by the licensee. The following Duke f ower Company and B&W, L
ISI program related documents we reviewed to ascertain whether they were
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(1) "0conee Unit 3, Inservice Inspection Examination' Listing, Revision 0, dated 3/18/82."
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"Ad i i tmnsrative=ProcebureforControlof B&W Procedure ISI-1, Inservice J.mpection Procedures"
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B&W Pro:edure ISI-2,
" Administrative Procedure for Records Management" B&W Procedure ISI-20,
" Personnel Qualification -
Magnetic Particle Examination" B&W Procedure ISI-21,
" Personnel Qualification - Ultrasonic Examination" B&W Procedure ISI-22,
" Personnel Qualification -
Liquid Penetrant Examination" B&W Procedure ISI-23,
" Personnel Qualification - Radiographic Examination" B&W Procedure ISI-24,
" Personnel Qualification - Eddy Current Examination" B&W Procedure ISI-25,
" Personnel Qualification -
Visual Examination"
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B&W Procedure ISI-50,
" Technical Procedure Describing Surface Requirements of Welds, Adjacent Base Metal, and Components for Nondestructive Examination" B&W Procedure ISI-61,
" Administrative Procedure for Control of Manuals and Reports" B&W Procedure ISI-62,
" Administrative Procedure for Control of Documents"
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B&W Procedure ISI-63,
" Administrative Procedure for Approval of B&W Manuals and Reports for Baseline and Inservice Inspection Programs" B&W Procedure ISI-64,
" Administrative Procedure for Handling Nonreportable Nondestructive Examination
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Data" B&W Procedure ISI-65,
" Administrative Procedure for Use of the Data Base System" B&W Procedure ISI-67,
" Administrative Procedure for Preparation of Non-NDE Data for the Data Base System" l
B&W Procedure ISI-69,
" Administrative Procedure for Reporting l
of Nondestructive Examination Indica-tions and Data to the Customer"
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B&W Procedure ISI-76,
" Administrative Procedure for the Design, Fabrication, and Certification of Cali-bration Standards" B&W Procedure ISI-77,
" Administrative Procedure for Procure-ment"
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B&W Procedure.ISI-78,
" Administrative Procedure for Tagging and Correction of Nonconforming Items" B&W Procedure ISI-104,
" Ultrasonic Examination of Ligaments Between Threaded Holes and of Studs and
Bolts 1-Inch and Larger in Diameter" B&W Procedure ISI-105,
" Ultrasonic Examination of Reactor Vessel Closure Nuts" i
B&W Procedure ISI-114
" Ultrasonic Examination of Calibration Blocks Prior to Drilling of Calibration Hole"
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B&W Procedure ISI-Ilf,
" Ultrasonic Examination of Reactor Coolant Pump Motor Flywheel" B&W Procedure 151-120,
" Ultrasonic Examination of Piping ind Vessel Welds Joining Similar -and Dis-similar Materials"
B&W Procedure 151-130,
" Ultrasonic Examination of Vessel Welds and Nozzle Inside Radius Sections"-
" Remote Ultrasonic Examination Using the ARIS Device" l
" Penetrant Examination of Welds and Base l
Materials, Including Studs and Nuts" J
i B&W Procedure ISI-270,
" Wet or Dry Methods of Magnetic Particle Examination of Welds, Studs, Bolts, and Pump Motor Flywheets" (
B&W Procedure 151-300,
" Radiographic Examination of Welds and Base Materials" B&W Procedure 151-350,
" Visual Examination of Welds and Surface
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Conditions"
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B&W Procedure ISI-353,
" Visual Examination of Pipe Hangers,
Supports, and Restraints"
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6-I B&W Procedure ISI-354,
" Remote Visual Examination of Welds and Surface Conditions" B&W Procedure ISI-362,
" Identification and Layout of Welds and System Components" B&W Procedure 151-401,
" Eddy Current Examination for Defects in OTSG Tubing" These documents were reviewed to assure that procedure and plans had been established (written, reviewed, approved and issued) to control and accomplish the following activities:
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Organizational structure including qualifications, training, responsibilities, and duties of personnel responsible for ISI
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Audits including procedures, frequency, and qualification of person.nel
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General QA requirements including examination report, deviations from previously established program, material certifications and identification of components to be covered Work and inspection procedures
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Control of processes including suitably controlled work condi-tions, special methods, and use of qualified personnel
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Corrective action
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Document control
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Control of examination equipment
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Quality records including documentation of indications and NDE findings, review of documentation, provisions to assure legibility
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and retrievability, and corrective action
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Definition of inspection interval and extent of examination
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Qualification of NDE personnel
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Controls for generation, approval, custody, storage and mainte-i nance of NDE records.
i Within the areas examined, no violations or deviations were observed.
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7.
Inservice inspection - Review of Procedures (Unit 3)
The inspectors reviewed the ISI procedure indicated below to determine whether the procedures were consistent with regulatory requirements and licensee commitments. See paragraph 6 above for the applicable code.
_i a.
The following procedures were reviewed in the areas of procedure approval, requirements for qualification of NDE personnel and compila-tion of required records:
(1) B&W 151-130, Revision 16, " Ultrasonic Examination of Vessel Welds and Nozzle Inside Radius Sections"
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(2) B&W ISI-120, Revision 13, " Ultrasonic Examination of Piping and Vessel Welds Joining Similar and Dissimilar Materials" b.
In addition to the review above, Procedures ISI-130 and ISI-120 were reviewed in the areas of compilation of required records and procedure content relative to: type of apparatus, extent of coverage including beam angles and scanning techniques, calibration requirements,. search units, DAC curves, transfer requirements, reference level for moni-toring discontinuities, method of demonstrating penetration, levels for evaluation and record indications, and acceptance standards.
Within the areas examined, no violations or deviations were observed.
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8.
Inservice Inspection - Observation of Work and Work Activities (Unit 3)
The inspectors observed the ISI activities described below to determine
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whether these activities were being performed in accordance with regulatory requirements and licensee procedures.
Ultrasonic examination of vessel welds conforms to requirements of the ASME Boiler and Pressure Vessel Code,Section XI, 1974 edition through the summer of 1975 Addenda. The method of performing these examinations conforms to the requirements of ASME Boiler and Pressure Vessel Code,Section V, Article 4, 1977 edition through the summer 1978 Addenda with the exception that the more sensitive calibration of T-432.3.2 and the more conservative recording criteria of T-441.9.1 are used.
a.
Personnel qualification records for a Level I, Level II and Level III examiners were reviewed. Qualification records for B&W UT examiners at the Oconee site contain only percentile and composite grades.
SNT-TC-1A requires that a practical examination be administered and that at least one work specimen be examined so that the person considered for certification can demonstrate that he can analyze ultrasonic indications.
To verify that examiners are certified to characterize and size indications, the inspectors requested and B&W agreed to provide a copy of the practical examination for the Level II
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examiner that performed the examination listed in b. below. This item was reported as inspector followup item No. 287/82-19-04, UT Examiner's practical Qualification Examination Requested.
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In process Ultrasonic (UT) examination including calibration was i
observed for the following vessel weld.
Weld Examination Contractor
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35GA-WGA-WG8-1 60 Scans B&W The inspection was compared with applicable procedures in the following
areas:
Availability of and compliance with approved NDE procedures j
Use of knowledgeable NDE personnel Use of NDE personnel qualified to the proper level
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Recording of inspection results
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Type of apparatus used Extent of coverage of weldment Calibration requirements
Search units
Beam angles l
DAC curves l
Reference level for monitoring discontinuities
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Method for demonstrating penetration
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Limits for evaluating and recording indications
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Recording significant indications Acceptance limits (1) During the calibration for 3SGA-WGA-WG8-l', the inspectors noted that although the unclad secondary portion of the steam generator
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was to be inspected the examiner calibrated on an ID notch in the portion of the calibration block which was cladded. This item was i
reported to the licensee as Unresolved Item 287/82-19-01, Cali-bration Performed on ID Notch Reflector Not Representative of j
i Component to be inspected.
I (2) During the UT inspection of Once Through Steam Generator (OTSG)
"A" weld joint 35GA-WGA-WG8-1, the inspectors observed the following UT scanning and technique problems.
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(a) The examination of weld 35GA-WGA-WG8-1 was limited for the
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entire axial length of the weld because of a welded obstruc-l tion. However, the inspectors noted that the examiner made i
no attempt to define the weld area or to calculate the l
distance from the weld to his transducer at the point of the l
limitation, in order to establish the location of the sound i
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path with respect to the weld. However, the examiner did locate the weld when weld coverage was questioned by the inspectors.
(b) During the UT examination the Level II examiner observed the UT instrument screen with his back turned to the Level I examiner scanning the weld. No attempt was made by the Level II examiner to insure that adequate weld coverage or correct transducer overlap was being maintained.
(c) During the examination of the initial 12 inches of weld 3SGA-WGA-WG8-1, the Level I examiner was observed by the inspector's not maintaining good contact with the inspection surface.
The inspectors also noted that the screen presen-tation observed by the Level II examiner did not show any base line noise. The inspectors noted that this Level II examiner never questioned why the instrument baseline display was not revealing any indication of sound penetration or if the Level I was maintain good contact. When the inspectors questioned the examiner's technique for inspecting the weld, the weld was rescanned and baseline signals were observed on the scope.
(d) The inspectors also noted during the examination that signals were exceeding the 100% ID notch reference.
The examiner however made no attempt to investigate the extent, shape, identity and location of these signals. When questioned by the inspectors the examiner stated that these signals were of no consequence since he was scanning with an additional 14 dbs.
However, the inspectors were aware that 14 dbs added to the instrument for scanning would make a 20% signal equal to the 100% reference level since 14 dbs equals a 5 to 1 scanning sensitivity.
The ASME code and B&W procedure ISI-130 require signals that exceed 20% to be investigated.
This item was not reported as a violation because the examiner had unknowingly calibrated on the wrong calibration notch and was inspecting at a far greater sensitivity than he was aware. However, this may not have been the case for the three OTSG "A" welds that the examiner had inspected prior to the Region II audit.
The above concerns were reported to the licensee who agreed to reinspect all five welds.
In addition, the licensee agreed to conduct additional training for the examiners prior to their l
l performing any additional examinations. This matter was identi-fied as Unresolved Item 287/82-19-02, Improper Inspection Techniques.
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(3) During the examination of OTSG"A", the inspectors also noted that some areas of weld outside the area specifically inspected by the examiners were painted. The inspectors asked the examiners if paint, on surfaces being examined, compromised the effectiveness of the examination. The examiner's answer was that if the paint was tightly adhered to the surface, they would inspect the weld.
In the inspector's opinion this was not an acceptable answer.
Although a tightly adhered painted surface is an acceptable surface condition for scanning, some oxide paints greatly atten-uate sound transmissions.
This matter was discussed with the licensee's representative who stated that weld selection and preparation was done by Duke.
Also the licensee stated that although it is a matter of practice not to inspect painted welds, Duke would perform attenuation tests on painted material surfaces, and evaluate the results. The inspectors stated this data would be reviewed by RII staff when it becomes available.
This matter will be tracked as Inspector Followup Item 287/82-19-03, Inspection of painted surfaces.
Within the areas examined, no violations or deviations were observed.
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