IR 05000280/1985018
| ML18142A551 | |
| Person / Time | |
|---|---|
| Site: | Surry  |
| Issue date: | 05/30/1985 |
| From: | Blake J, Newsome R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML18142A550 | List: |
| References | |
| 50-280-85-18, 50-281-85-18, NUDOCS 8507110195 | |
| Download: ML18142A551 (13) | |
Text
UNITED STATES NUCLEAR REGULATORY COMMISSION
REGION II
101 MARIETTA STREET, N.W.
ATLANTA, GEORGIA 30323 Report Nos.:
50-280/85-18 and 50-281/85-18 Licensee:
Virginia Electric and Power Company Richmond, VA 23261 Docket Nos.:
50-280 and 50-281 Facility Name:
Surry 1 and 2 Inspection Conducted:
May 13-17, 1985 Approved Chief Safety SUMMARY License Nos.:
This routine, unannounced inspection entailed 36 inspector-hours on site in the areas of cracking in steam generator girth welds (Unit 2), licensee action on previous enforcement matters (Units 1 and 2), inservice inspection (!SI)
(Unit 2), and inspector followup items (!FI) (Units 1 and 2).
Results:
No violations or deviations were identified.
------
8507110195 050604
- DR ADOCK 05000280 PDR
- --- -"-,,
- REPORT DETAILS Persons Contacted Licensee Employees
- R. F. Saunders, Station Manager
- H. L. Miller, Assistant Station Manager
- E. S. Grecheck, Superintendent Technical Services
- J.M. McAvoy, Systems Engineer H. L. Travis, Supervisor NOE Services R. Blount, Supervisor, Performance Engineering
- E. Holloway, NOE Coordinator D. Rogers, NOE Coordinator D. Spooner, NOE Level III A. McNeil, Engineer (STA)
Other licensee employees contacted included engineers, technicians, mechanics, security force members, and office personne Other Organizations J. Bell, !SI Coordinator, Westinghouse Electric Corporation M. Diehl, Inspector, The Hartford Steam Boiler and Insurance Company R. Coder, Inspector, The Hartford Steam Boiler and Insurance Company NRC Resident Inspectors
- D. J. Burke, Senior Resident
- M. J. Davis, Resident
- Attended exit interview Exit Interview The inspection scope and findings were summarized on May 16, 1985, with those persons indicated in paragraph 1 abov The inspector described the areas inspected and discussed in detail the inspection finding No dissenting comments were received from the license The licensee did not identify as proprietary any of the materials provided to or reviewed by the inspector during this inspectio Licensee Action on Previous Enforcement Matters (Open) Unresolved Item 280, 281/85-15-02:
Adequacy of Transducer for Examination of Cast Stainless Steel Piping. This item concerns the type of ultrasonic transducer being used by the licensee's contractor, Westinghouse Electric Corporation, to ultrasonically examine Surry's cast stainless steel (CSS) piping weld The transducer referred to has been found lacking in examination of some CSS piping, as documented in NRC Inspection Report
- 395/81-22, and that more recently developed transducers appear to provide better examinations in those areas where adequate transducer contact can be maintaine The NRC inspector gave a brief demonstration of the capability of one of the NRC Region II dual element, focused longitudinal beam, ultrasonic transducers used for CSS examination verification, by calibrating on Surry 1s main coolant pipe ultrasonic calibration standar Following this demonstration, the licensee's nondestructive examination (NOE)
Level III agreed to evaluate dual element transducers for possible application at the Surry sit Pending the licensee's evaluation of the dual element transducer, this item will remain ope.
Unresolved Items Unresolved items were not identified during this inspectio.
Independent Inspection Effort (92706B)
Maintenance Progress The inspector conducted a general inspection of Unit 2 containment, turbine buildings, auxiliary buildings, and the protected area to observe maintenance progress and activities such as welding, material handling and control, housekeeping and storag Within the areas examined, no violations or deviations were identifie.
Cracking in Steam Generator Girth Welds (92701B) (Unit 2)
NOTE:
This subject is being addressed and covered as a continuation of the NRC inspection conducted April 22-26, 1985, and documented in NRC Inspection Report 280,281/85-1 To obtain additional information, references, and details of previous events, the aforementioned NRC report should be consulte Introduction The licensee identified cracks in the inside surface of the upper shell to transition cone welds of their Unit 2 steam generators (SGs).
All evidence of cracking, as confirmed by Magnetic Particle testing (MT),
has been removed by grinding operations on the affected welds in SGs, A, B, and The inspector examined the licensee's actions in addressing this matter through a review of the data recorded and through discussions with cognizant personne The examination was conducted to evaluate the adequacy of the licensee's actions with regard to regulatory requirements and to obtain technical information that could be useful in evaluating the generic implication of the crackin A description of the inspector 1s examination and findings following crack removal operations in the Unit 2 SGs is provided belo *
3 Examination and Findings (1) Licensee Removal of Cracking Discussions with involved licensee personnel disclosed that they and their contractor, Westinghouse, had performed MT inspections and crack removal grinding operations in accordance with Surry Power Station Procedure, MMP-C-G-177, 11Steam Generator Weld Repair by Grinding
(2) Technical Findings A summary of technical findings based on the inspector's review of related data, discussions with knowledgeable personnel, and direct observation of portions of the ground out areas, is as follows:
(a) Steam Generator C - The majority of these cracks were removed by grinding to a depth of l/16 11 to l/8
- Maximum depth of cracking removal was 3/8 11 in confined localized area (b)
Steam Generator B - The majority of these cracks were removed by grinding to a depth of l/16 11 to l/8
- Maximum depth of cracking removal was 3/16 11 in confined localized area (c) Steam Generator A - The majority of these cracks were removed by grinding to a depth of 3/8
~
Grinding operations, in some localized areas, was to a maximum depth of.850
- However, documentation of the MT examinations performed on these areas confirmed that all cracking had been removed at a maximum depth of 9/16
- The inspector and a 1 i censee engineer entered SG A to visually examine the final surface of the ground area Some of the excavations appeared to have been ground in a manner which would allow high stress concentrations and some areas did not appear to meet the contour requirements of the controlling procedur The inspector expressed his concern regarding these matters to the accompanying enginee The licensee requested that a Westinghouse engineer be sent to the site to direct the blending of the ground areas with the surface to minimize stress concentration factors and to enhance the Ultrasonic Test (UT) baseline examinatio The blending operations had been completed by the end of this inspection perio The 1 i censee determined that the grinding operations, as established in the controlling procedure, had been exceeded in that maximum excavation depth was not to exceed 3/4 11 and that contour requirements were not adhered to in some area.
The licensee will write nonconformance reports (NCR) on each individual area which exceeds procedure requirement Westinghouse will conduct finite element analysis of the final condition of the steam generator shell after all corrective work has been complete (d)
Steam Generators B and C have localized sub-surface indications which appear to be related to the original fabrication of these weld Westinghouse will conduct fracture mechanics evaluations of these sub-surface flaw Region II has transferred responsibility for review of the finite element and fracture mechanics analysis to the Office of Nuclear Reactor Regulatio Ultrasonic baseline examinations were still in progress at the conclusion of this inspectio Within the areas examined, no violations or deviations were identifie Inservice Inspection (ISI) - Review of Program (73051) (Unit 2)
The inspector reviewed the licensee's !SI program for the current outage in the areas indicated belo The applicable codes are the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel (B&PV) Code,Section XI, 1980 Edition with addenda through Winter 1980, and the 1974 edition with addenda through Summer 1975. Westinghouse Electric Corporation (WEC) has the responsibility as the !SI contracto However, nondestructive examination (NOE) activities were being performed by Virginia Power Company (VPC), Virginia Corporation of Richmond (VCR), Bestco, and WEC personne The inspector reviewed the following documents relating to the !SI program to determine whether the pl ans had been approved by the license (1)
VEPCO Nuclear Operations Inservice Inspection Manual Section 3 (RO)
Organization 4 (RO)
Responsibility 5 ( RO)
Programs 6 (RO)
Visual Training Program 7 ( RO)
Procedure:
7-ISI-001, 11Changes to ISI Plans, Listings, and NRC Submittals
- 8 (RO)
9 (RO)
Procedure:
7-ISI-002, 11 Revisions to IS! Plans, Listings, and NRC Submittals
Procedure:
7-ISI-003, 11 Preparation, Submittal and Implementation of Relief Procedures
Procedure:
8-ISI-001, 11 Preparation, Issue, and Control of Inservice Inspection Plans
Procedure:
8-ISI-002, 11Control of !SI Related Drawings
Procedure:
8-ISI-010, 11Development of ISi Plans
Procedure:
8-ISI-110, 11 Development of Weld/Component Inspection Plans
Procedure:
9-ISI-001, 11 Preparation, Issue and Control of Corporate Inservice Inspection Administration Procedures
Procedure:
9-ISI-002, 11 Inservi ce Inspection Procedure Authorized Inspector Interface
10 (RO)
Procedure:
10-ISI-001, 11 Identification, Correction and Documentation of Corrective Actions
(2)
Book No. 1, Sections 1 through 7.1 with change authorization S2ISI85-01 11 Inservice Inspection Plan Surry Power Station Unit 2, Refueling Outage 1985, Interval 2:
Period 1
,
ASME Section XI, 1980 Edition, Winter 1980 Addenda, Class 1 and 2 Items, and Snubbers, Hangers, and Supports
(3)
Books 1 and 2, Section 1 through 7.1, with Book 2 change authorizations S2SGT85-0l, 02, 03, 04 11 Inservice Inspection Plan Surry Power Station Unit 2, Refueling Outage 1985, Interval 1:
Period 3
,
ASME Section XI 1974 Edition, Summer 1975 Addenda, Class 1 and 2 Items, and System Pressure Tests (4)
Administrative Procedures (Units 1 and 2)
ADM-84 11 Control of Measuring and Test Equipment
ADM-8 rganization and Responsibilities
ADM-8 ASME Code Interpretations
The above documents were reviewed to assure that procedures and plans had been es tab 1 i shed (written, reviewed, approved and issued) to control and accomplish the following applicable activities:
organizational structure including qualifications, training, responsibilities, and duties of personnel responsible for IS!; audits including procedures, frequency, and qualification of personnel; general Quality Assurance (QA) requirements including examination report, deviations from previously established program, material certifications and identification of components to be covered; work and inspection procedures; control of processes including suitably controlled work conditions, special methods, and use of qualified personnel; corrective action; document control; control of examination equipment; quality records including documentation of indications and NOE findings, review of documentation, provisions to assure legibility and retrievability, and corrective action; scope of the inspection including description of areas to be examined, examination category, method of inspection, extent of examinations, and justification for any exception; definition of inspection interval and extent of examination; qualification of NOE personnel; and controls of generation, approval, custody, storage and maintenance of NOE record ~ Within the areas inspected, no violations or deviations were identifie.
NOE Inservice Inspection - Unit 2 The inspector reviewed IS! procedures, observed !SI work, and reviewed data as described below to verify compliance with licensee commitments and NRC requirements, including the requirements of the applicable cod The codes, applicable to the material and work addressed by the inspector, are ASME Section XI (74S75) and ASME Section XI (80W80). Review of Procedures (73052)
(1)
The following !SI procedures were reviewed for proper approval and for personnel qualification requirements:
Applicable Code Title Procedure N (74S75)
Manual Ultrasonic Examination of Full ISI-205, Rev. 2, Penetration Circumferential Welds Amendment 3 (74S75)
Liquid Penetrant Examination Procedure ISI-11, Rev. 9, Amendment 3 (74S75)
Visual Examination Procedure ISI-8, Rev. 7 (74S75)
Preservice and Inservice Inspection OPS-NSD-101, Documentation Rev. 5, Amendment 3
(74S75)
Preservice and Inservice Examination Manual Ultrasonic Equipment Qualification (74S75)
Ultrasonic Examination of Stud Bolts and Nuts (74S75)
Manual Ultrasonic Examination of Circumferential and Longitudinal Butt Welds in Ferritic Vessels of 2 1/2 11 Thick and Greater (74S75)
( 80~180)
(80W80)
(80W80)
(80W80)
(80W80)
(80W80)
Magnetic Particle Examinations Visual Examination Qualification of Ultrasonic Manual Equipment Liquid Penetrant Examination Manual Ultrasonic Examination of Welds in Vessels Magnetic Particle Examinations Manual Ultrasonic Examination of Welds NSD-ISI-10, Rev. 4, Amendment 1 ISI-15, Rev. 6 Amendment 2 ISI-47, Rev. 2 Amendment 6 ISI-70, Rev. 1 ISI-8, Rev. 9 NSD-ISI-10, Rev. 6 ISI-11, Rev. 10 ISI-47, Rev. 4 ISI-70, Rev. 2 ISI-206, Rev. 1 (2)
Procedures ISI-205, ISI-15, ISI-47 Rev. 2 and Rev. 4, and ISI-206 were reviewed for procedure technical 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 monitoring dis-continuities, method of demonstrating penetration, levels of evaluation and recording indications, and acceptance standards (3)
Procedure ISI-11, Rev. 9 and Rev. 10 was reviewed in the area of procedure technical content relative to:
method consistent with ASME code, specification of brand names of penetrant materials, specification of 1 imits of sulfur and total halogens for materials, pre-examination surface preparation, minimum drying time following surface cleaning, penetrant application and penetration time, temperature requirements, solvent removal, method of surface drying, type of developer and method of application, examination technique, technique for evaluation, acceptance standards, and requalification requirements.
(4)
Procedure ISI-70, Rev. 1 and Rev. 2 was reviewed in the area of procedure technical content relative to:
examination by the continuous method and adequate material surface preparation is
--- -- ----------------------------------~
specified; if dry particles are used, the particle color provides good contrast with background and component surface temperature is less than 600°F; examination is conducted with sufficient overlap to achieve 100% coverage and two separate examinations are made with field directions perpendicular to each other; if yoke method is used, pole spacing is within three-six inches and minimum lifting power is 10 pounds for alternating current and 40 pounds for direct current; acceptance criteria is specified or referenced and is consistent with the applicable ASME Code Sectio Observation of Work and Work Activities (73753B)
The inspector observed a limited amount of work activities due to the massive examination effort being directed toward the Unit 2 steam generators, see paragraph 6 above for details. The inspector reviewed certification records of equipment, materials, and NOE personnel which had been and will be utilized during the required ISI examinations during this outag The reviews conducted by the inspector are documented belo (1)
Examiner Qualification The inspector reviewed the qualification documentation for the below listed WEC, VPC, VCR, and Bestco examiners in the following areas:
employer's name; person certified; activity qualified to perform; effective period of certification; signature of employer's designated representatives; basis used for certifi-cation; and annual visual acuity, color vision examination and periodic recertificatio Examiner (WEC)
JWB JRD JDF GAM SAS TAS TRS Examiner (VPC)
KHG VLL JED UT II I
II I
II I
UT I
Method - Level PT VT MT II II II II I
II II II II I
I II II II II I
Method - Level PT VT MT II II II II II II II II
- EGH II II II II JLM I
II II II OMW II II II OLS II I III II I II I HLT III II I II I III Examiner (VCR)
Method - Level UT PT VT MT JSB II II II CAH I
JOO I
I I
MJB I
I I
GLL II I CEF II II II II Examiner (Bestco)
Method - Level UT PT VT MT MS II II GGR II II II II TLS II II II (2)
The inspector reviewed the below listed liquid penetrant materials certification records to ascertain if the sulfur and halogen content of the material was within acceptable content limit Materials Liquid Penetrant Cleaner/Remover Developer Batch Number 214E47, 81K027, 84L025 82G078, 214E47, 84H030, 840054 45F6, 230K6, 84B091, 84E003, 84H075 (3)
The inspector reviewed documentation indicating that 10 pound and 40 pound lift tests had been satisfactorily performed by magnetic particle yokes 6579 and 760 (4)
Ultrasonic (UT) Examination The inspector observed portions of the ultrasonic examinations indicated belo The observations were compared with the applicable procedures and the code in the following areas:
availability of and compliance with approved Nondestructive Examination (NOE) procedure; use of knowledgeable NOE personnel; use of NOE personne 1 qua 1 ifi ed to the proper 1 eve 1; type of apparatus used; extent of coverage of weldment; calibration requirements; search units; beam angles; OAC curves; reference level for monitoring discontinuities; method of demonstrating
penetration; limits of evaluating and recording indications; recording significant indications; and, acceptance limit Sketch N Weld N VIR-2-1100 2-6 VIR-2-1100 3-6 Description Steam Generator Cone to Upper Shell Weld Steam Generator Cone to Upper Shell Weld UT Seams 0° & 45° 45° & 60° NOTE:
The above listed examinations were being accomplished to establish new baseline information for these welds following defect removal operations on the inside surface of the steam generator Examinations were still in progress at the conclusion of this inspection perio The following listed ultrasonic equipment and materials certifi-cation records were reviewed:
Ultrasonic Instruments Manufacturer/Model Soni C MKl Sonic MKl Sonic MKl Sonic MKl Sonic MKl Sonic MKl Krautkramer USM2 Ultrasonic Transducers Size Frequency 1/2
X 1
2.25 MHz
.75
2.25 MHz 1/2
2.25 MHz 1/2
5.0 MHz 1/2 X 111 2.25 MHz 1/2 X 111 2.25 MHz 1/4
2.25 MHz 1/2 11 2.25 MHz 1/211 2.25 MHz 1/4
2.25 MHz 1/411 5.0 MHz
.375
5. 0 MHz
.375
5.0 MHz Serial N E 11221E 07964E 05304E 03704E 02307E 10363 Serial N E18246 P47183 El0460 C08322 49302 20186 63481 40397 20187 C16353
!84106
!84117.375
3.5 MHz 54044 1/2
3.5 MHz 57061 1/2
2.25 MHz 40731 1/2
2.25 MHz G07150 Ultrasonic IIW Block Serial No. 782180 Ultrasonic Couelant Sonotrace #40 Batch Nos. 8448, 8444, 8225 Ultrasonic Calibration Blocks VIR-1 2 3/16 11T SA351 GRC FSA VIR-6
11 Sch. 140 1.125 11T A312 TP 304SS VIR-7
11 Sch. 40
.375 11T A312 TP 304SS VIR-8
11 Sch. 20
.250 11T A312 TP 304SS VIR-12
11 Sch. 160
.906 11T A312 TP 304SS VIR-14
11 Sch. 160
. 719 11T A376 TP 304SS VIR-21
11 Sch. 160.344 11T A376 TP 304SS VIR-26 3.5 11T x 6 11W x 18.2 11 L SA533 GRA C VIR-29
.625 11T x 4 11W x 9 11L A240 TP 304SS VIR-34
11 Sch. 80
.844 11T SA106 GR.B CS Data Review and Evaluation (737558)
The below listed NDE data sheets were reviewed to ascertain whether the NDE procedure criteria was followed and whether the limitations for acceptability satisfy the applicable Technical Specification Weld N Sketch N System Examination
VIR-1-4506 Pressurizer Spray UT-45°
VIR-1-4506 Pressurizer Spray UT-0°, 45°
VIR-1-4103 By-Pass UT-45°
VIR-1-4101 RHR Take Off UT-45°
VIR-1-4306 RTD Return UT-45°
VIR-1-4306 RTD Return UT-45°
VIR-1-4306 RTD Return UT-45°
VIR-1-4506 Pressurizer Spray PT 1BC VIR-1-4101 RHR Take Off PT Flange Ligaments VIR-1-1100 Reactor Vessel UT-0° 4, 5, 6, 20, 21, 22, 36, 37, 38
r
--
r\\
- .
In addition to the above, the NOE records were reviewed to ascertain whether the following requirements were met:
the examination unit calibration data sheets show no major deviations between initial and final calibrations; 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 indicators (if applicable) comply with the criteria of the NOE procedure and ASME Section XI; and incomplete exami nati ans and results were repeated to permit full eva 1 uation (if applicable).
Within the areas inspected, no violations or deviations were identifie.
Inspector Followup Items (!FI (92701B)
(Closed) !FI 280,281/85-15-03:
"Verification of Augmented Inservice Inspections".
This item deals with Surry commitments to examine certain sensitized stainless steel welds in addition to those welds normally required by ASME Section XI requirement The inspector reviewed Inservice Inspection plans and past examination documentation which indicated the augmented !SI of the additional welds is being accomplishe The inspector has no further questions regarding this matter.