IR 05000280/1991017
| ML18153C668 | |
| Person / Time | |
|---|---|
| Site: | Surry  |
| Issue date: | 07/08/1991 |
| From: | Economos N NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML18153C667 | List: |
| References | |
| 50-280-91-17, 50-281-91-17, NUDOCS 9107160101 | |
| Download: ML18153C668 (11) | |
Text
UNITED STATES NUCLEAR REGULATORY COMMISSION
REGION II
Report Nos.:
101 MARIETTA STREET, ATLANTA, GEORGIA 30323 50-280/91-17 and 50-281/91-17 Licensee:
Virginia Electric and Power Company Glen Allen, VA 23060 Docket Nos.:
50-280 and 50-281 Facility Name:
Surry 1 and 2 License Nos.: DPR-32 and DPR-37 Approved by:--=---=::;;~~,.....,...!:~~~::::::=-~~~~~~~~~~~ Ma er"als and Processes Section E gineering Branch Division of Reactor Safety SUMMARY Scope:
This routine, unannounced inspection was conducted in the areas of Unit 2 Inservice Inspection (ISI) activities, design changes, and modification Results:
Radiographs of welds associated with certain design changes and engineering work requests were evaluated and found satisfactor Similar ISI records and supporting quality records were reviewed and found in compliance with applicable code and regulatory requirement Retrieving quality records of certain weld filler material, purchased in the late seventies, but still in use, proved very difficul Also ISI drawings/
sketches with errors in as-built conditions, (i.e.,
piping and weld configuration) were identified to the licensee as programmatic weaknesse In the areas inspected, violations or deviations were not identified.
9107160101 910711 PDR ADOCK 05000280 G
- REPORT DETAILS Persons Contacted Licensee Employees
- W. Benthall, Supervisor Licensing
- R. C. Belyea, Licensing Engineer
- D. Erickson, Superintendent Radiation Protection
- D. Grady, Supervisor, Nondestructive Testing
- J. A. Price, Assistant Station Manager M. Ringler, Welding Engineer K. Rowland, Maintenance Engineer Check Valves
- E. R. Smith, Jr., Manager, Quality Assurance
- T. B. Sowers, Superintendent Engineering D. Spooner, Level III NDE Examiner Other licensee employees contacted during this inspection included craftsmen, engineers, technician NRC Resident Inspectors M. Branch, Senior Resident Inspector J. York, Resident Inspector
- Attended exit interview Independent inspection Effort, Design Changes and Modifications (37700/
55050)
Several design changes and engineering work requests (EWR(s)), affecting both the primary and secondary side of the plant were scheduled for this outag Of these, the inspector selected three for observation of work activities and/or a review of engineering documents, drawings, procedures and field generated records to determine their technical adequacy and compliance with applicable standards and code requirement The selected modifications and engineering work requests were as follows: DC 87-31:
New Letdown Isolation Valves DC 90-34:* Feedwater Flow Element Replacement EWR 91-003:
MI-NS Single Phase Piping Replacement EWR 91-003 was issued as the controlling engineering document for rep 1 acement of piping components determined to re qui re rep 1 a cement due to erosion-corrosion (E/C), phenomen This document addressed only non-safety related (NS), portions of secondary side piping systems that are affected by single phase flow and includes feedwater, condensate turbine and auxiliarie Design basis criteria addressed in FSAR Section 10.2 were not affected by this pipe replacemen *
The degraded pipe and associated fittings i.e., elbow,. tees, reducers, are made of low carbon steel material which is being replaced with 2\\ percent chromium, one percent molybdenum, or chrome-moly, low alloy, P-22 Grade, steel materia This material selection is based on satjsfactory performance in similar applica-tions. According to this document, industry experience, shows that chrome-moly material improves resistance to E/C, by a factor of four over carbon steels, while materials having a chromium content> 12 percent (stainless steel), are virtually immune to E/ Other factors taken into consideration in the selection of this type of replacement material included availability; ease of fabrication; and compatibility of physical and mechanical properties (i.e.,
coefficient of thermal expansion, unit weight and yield strength)
with existing components at operating condition DC 90-34 was issued as the controlling engineering document for the replacement of the complete flow element assemblies, FE-2476, -2486,
-2496, with assemblies fabricated from mate~ials resistant to erosion-corrosio Replacement of these as~~mblies was deemed necessary when an inspection of the carbon steel piping components, which encase the feedwater venturi flow elements, revealed significant wall thinning which was attributed to erosion-corrosion.
By review of engineering documents, the inspector ascertained that wa 11 thickness measurements, taken during the 1988 Fa 11 outage, showed the carrier component for flow element FE-2476 was below code minimum in certain location Wear rate predictions f~r the piping components for flow elements FE-2486 and -2496 indicated that their wall thickness would erode to below code minimum by the next refueling outage and the second upcoming refueling outage respectivel As a temporary solution to this problem, the licensee performed a we 1 d repair bui 1 d-up on the outside surf ace of the carrier pipe for flow elements FE-2476 and -248 This repair was done during the 1988 outag The venturis of the replacement flow elements are made of SA182-F304L stainless steel forgings and flanged ends made of A182-F11 chrome-moly materia Since the replacement venturis are one ~iece forgings with flanges on either end, the need for a carrier pipe has been eliminate In addition, adjoining piping and components between the isolation MOVs upstream of the flow elements and the feedwater regulating valves downstream of the flow e 1 ements were rep 1 aced with 14 11 schedule 100 A335-P22 chrome-mo ly piping. Also the carbon steel reducers on the inlet side of two out of the three feedwater regulating valves were replaced with reducers made from chrome-moly materia In summary, with this design change the 1 i censee has rep 1 aced the three fl ow e 1 ements and associated piping between the feedwater regulating valves and the isolation MOVs upstream of ~he flow-elements with erosion-corrosion resistant material The replacement components have been designated as Quality Assurance Category MQS or (Non-safety related with Special Quality/Regulatory Requirements).
The applicable * design and fabrication/installation code is ANSI 831.1-1967 Editio Because the feedwater-flow elements are not safety-related, the repair/
J
modification requirements of ASME Code Section XI are not applicable,
to the subject replacement equipmen At. the time of this inspection all work and testing on this design change was complete with pipe insulation in plac Therefore, the inspector reviewed fabrication and quality records including radiographs, materials certifications, weld records, et Results of the radiograph review is discussed elsewhere in this repor DC 87-31 was issued as the controlling engineering document for the installation of a new letdown isolation valve No. 2-CH-TV-2204A, inside containmen Reasons given for this design change included difficulty of meeting leakage criteria for containment isolation with existing isolation valves (HCV-2200A, B and C), existing valve location in high radiation area results in substantial radiation doses to craft and difficulty in determining which valve is leaking during testing or operation Under this design change, new valve 2-CH-TV-2204A which is installed inside containment in the Letdown L;ne between valves HCV-2200A, B and C, will assure the containment isolation function of the above mentioned -2200 valve According to DC 87-31, the CI-HI Pressure trip on HCV-2200A, Band C, will be retained in order to prevent the lifting of relief valve RV-2203 upon a CI-HI pressure signal. Trip valve 2-CH-TV-2204A will be redundant to the existing outside containment Letdown Line isolation valve, 2-CH-TV-2204 which was relabeled as 2-CH-TV-2204 Installation of trip valve 2-CH-TV-2204A was performed under the repair/r~placement rules of ASME Code,Section XI, 1980 Edition 11 Rules for Inservice Inspection of Nuclear Power Plant Components 11,
article IWA-7000 entitled 11 Replacements 11 *
Prior to service, the new va 1 ve was tested to verify operabi 1 i ty and to demonstrate that performance parameters were within acceptable limits. The valve test included a valve exercising, valve indicator and valve leak rate tests per Surry Administrative Procedure VPAP-030 The controlling procedure for field activities was PI-U2 and the referencing drawing was No. S8731-2-2FP3 Materi a 1 was procured under purchased order BNT-172991 in accordance with the licensee 1 s specifications NUS-2095 and NUS-20 for the new valve and associated pipe respectivel Installation and testing were performed in accordance with ASME Code Section XI (80W80) !WA and !WC require-ment The new line was hydrostatically tested in accordance with applicable code and procedure PI-U2 paragraph 4.27 requirements. The inspector reviewed applicable material, fabrication, personnel qualification and nondestructive examination results (radiographs)
for compliance with applicable code requirements completeness and accurac Specific information on items reviewed are listed below:
- Document Review:
DC 87-31-2 NUS-20 NUS-2095 DC 90-34-2 EWR 91-003 Pl-U2 P2-U2 NDE-RT-101 Radiographs Weld N.15A 16A DC 87-31-2
4
7 6-1 1-3 7-9 DC 90-34
2
ERW 91-003 1, R1, R2
New Letdown Isolation Valve/Surry/Unit 2 Specification for Piping Specification for 2 11 600 lb. valve Feedwater Flow Element Replacement MI-NS Single Phase Piping Replacement Instruction to Replace Unit 2 Condensate System Header to Feedwater Pump Isolation Valves Instruction for Fabrication of Piping and Components Required Rev. 1, Radiographic Examination of Welds Drawing Size 11548-FM64 411 dia. Pipe to Ell 11548-FM64 411 dia. Pipe to Valve E-203
.154 11x2 11 tt, Pipe to Valve E-203
.154 11x2 11 tt, Pipe to tee E-200
.154 11x2 11 tt, Pipe to Valve E-200
.154 11 x2 11 tt, Pipe to Valve E-200 Pipe & Ell E-201
.154 11 x2 11 tt, Pipe to Ell E-201
.154 11x2 11 tt, Pipe to Valve E-201
. 938 11x14 11 tt, Pipe to Reducer E-200
. 938"xl4 11 tt, Pipe to Flange E-202
. 938 11x14 11 tt, Pipe to Reducer 91-003-2-M l.156x18"tt> Pipe to Ell Purchase Orders/Material, Certifications
Pipe and Components BNT-172991 Inside Containment Copes - Vulcan.
Isolation Valves
11
' 600 l *
CSY-220712
- CSY-213941
Stainless Steel Copes-Vulcan Globe Valves
11 ¢ Sch. 100.LR 90 1 A234, Gr. WP-22 forging Ht#-LSP
11¢ Sch. 40 A335 Gr. P22 Seamless Ht#-680378 CSY-299680/09 90° Ell, 14 11 Std. x A234 Gr. WP-22
.375 11 mominal Ht#-OIJ8F CSY-299678/01
11 ¢ x 1.156 11 Pipe A335 Gr. P22 Ht#-176342 Welding Consumables E-8018-82 CSY-324022 E-80S-B2 CSY-319214 ER-308 CSY-32468-1
- IP14474-l
- IP12421-3 l/8 11 di /32 11 di l/8 11 di /32 11di /32 11 di /32 11 di /32 11 di Ht#-88767 Ht#-2F011P02 Ht#-F2874 Ht#-F2874 Ht#-24054 Ht#-5108E918 Ht#-D4186T308 Retrieving quality records for this material (*) was very time consumin The licensee expended an inordinate amount of time and resources to 1 ocate these and other materi a 1 record The reason given for the difficulty with the filler metal was that the material had been purchased in the seventies and the records were sidetracked in the revamping of the storage progra In response, the inspector pointed out that measures should be taken to assure that qua 1 ity records of welding consumables and other safety-related materials are on hand and readily retrievable before their us When these records cannot be located, at the time of the installation, the material should be either be discarded or used in nonsafety-related application The inspector identified this matter to the licensee as a programmatic weakness.
In the areas inspected, violations or deviations were not identifie *
6 Welding Inspection - Procedures and Welder Qualifications 55050 Welding procedures used to fabricate chrome-moly and stainless steel welds discussed earlier under Design and Modifications were identified on the field records and in the Welding Specification P-101 by welding technique numbers and joint details (i.e., 508/4A and 801/3A respectively). These documents and supporting procedure qua l ifi cation records were revi e*wed to ascertain whether all essential and supplementary variables were identified and consistent with ASME Code Section IX requirement Also welder performance qualification records were reviewed to ascertain whether the licensee had a workable system for maintaining a continuous record of qua l ifi cation status and whether this system/program was effectively utilize Performance qualification records of selected welders involved in the subject design change projects were reviewed to determine whether they had been and were currently qualified to weld under the respective welding procedure Welders selected for this review included:
Welder RS2394 W02847 RY3596 MC1713 KS5816 KW5435 LG2298 Technique/Joint Detail 801/3A 801/3A 508/4A 508/4A 508/4A 508/4A 508/4A Within the areas inspected violations or deviations were not identifie.
Data Review and Evaluation Inservice Inspection Records Review (73755)
Unit 2 At the time of this inspection all ISI activities had been completed and the plant had resumed operation Therefore as an alternative to work observation, records of completed nondestructive examination(s) were selected and reviewed to ascertain whether:
the method(s), technique, and extent of the examination complied with the ISI plan and applicable NOE procedures; findings were properly recorded and evaluated by qualified personnel; programmatic deviations were recorded as required; personnel, instruments, calibration blocks, and NOE material (penetrants, couplants)
were designate The applicable code for Unit 2 Inservice Inspection requirements is ASME Code Section.XI (80W80).
ISi activities during this outage were list~d under the Second Interval, second period of the Unit 2 progra Records selected for this review are listed below:
Code/Item 8-K-1 8-K-1 8-K-1 82.11 82.12 8.11 89.11 89.11 89.40 89.40 Dw MKS-125Al MKS-123Nl VIR-1-3204 VIR-1-2100
Component Pzr. Spray Line Recirc. Spray Line Safety Injection Hot Leg Pzr. Top Circu Weld 96-192 Weld/Other H-15 H-03 H-01 W#l Type Exam,
VT-3 VT-3 VT-3 UT Code relief requested because interferences precluded 100 percent examinatio Plan to remove interferences and examine by end of second Interval Letter S/N 91-18 VIR-1-2100 Pzr. Long Seam 2-RC-E-2 W#3 UT Partial examination because of Weld,Reinforcement Configuration
- best effort basis VIR-1-3100 SIG Channel Head to tube sheet W#l UT Partial examination because of numerous weld pads and insulation ring interferences, 96.5 percent of weld inspecte VIR-1-4200 VIR-1-4100 VIR-1-4104 VIR-1-4207 VIR-1-4109 Coolant Pipe W#8 31"-RC-305 Cold Leg Loop Stop W#13 Valve on RC Pump Side of Valve 27.5"-RC-303 Ell to Valve W#7 6"-RC-316-1502 3"-CH-379 W#68 2"-RC-345 W#21 UT/PT UT/PT UT/PT PT PT 0 Personnel Qualifications Qualification and certification records for the following personnel were reviewed to ascertain whether training and vi sua 1 acuity tests were current and consistent with code and regulatory requirement Name Qualification Organization L. M. Gi 11 RT II US Testing R. D. Hanvey RT II US Testing J. C. Lyscom RT II US Training D. Spooner UT, RT, PT III VEPCO
~Certifications/calibration records of UT equipment, standards, and materials were reviewed to ascertain whether they were complete, accurate and consistent with applicable industry standards and regulatory requirement These records were for the following item Equipment Soni c-136 Soni c-136 Panametrics Transducers L22855 G28612 013232 Hl4008sp C02602/CD2604 Couplant Soundclear Material Cleaner Penetrant Developer ULTRASONIC S/N 136-153 136-158 1211X 1MHz 2.25HHz 2.25HHz 2.25HHz 2.25HHz Batch-8590 LIQUID PENETRANT Type DR-60 DP-51 D-100 1. 00
'1>
0.50
'1>
1. OO"it>
1. OO"lfi 1.00"lf, Batch 027-C4 914-B47 06K6 41° 45° 60° QOL 45°R This review di scl os.ed that !SI/sketches with errors in as-built fie 1 d configuration (i.e., piping and weld configuration) are still in use in spite of the length of time the station has been in servic This condition causes considerable confusion when one compares weld location/
description on the inspection reports with the ori the !SI sketches. The licensee 1 s cognizant engineer indicated that the drawings in question are being replaced with isometrics depicting as-built condition In the areas inspected, violations or deviations were not identifie Eddy Current Examination of Steam Generator Tubes, Unit 2 By memorandum, seri a 1 number NSD-RNE-1010 dated March 20, 1991 Westinghouse~), submitted for review and approval the Surry Unit 2 Eddy Current Inspection Plan and Analysis Guidelines, for the recently complsted outag ~ included their proposed five year (5) outage
inspection plan which considers opening only two Steam Generators (S/Gs)
per outage and incorporates EPRI guidelines for inspecting 100 percent of all S/G tubes over a time frame.of five (5) fuel cycle Data Analysis Guidelines incorporated findings from previous inspections as well as general industry experienc For this outage, the inspection plan called for the examination of S/Gs 11A 11 and 11 C11 only. The inspection plan was as follows: Bobbin coil inspection of 35 percent of all tubes in S/G A and S/G C through their full lengt Additionally, inspect all tubes with previous indication The 35 percent sample, to include all Row 1 and 2 tubes and tubes on the periphery two rows dee * Use Rotating Pancake Coil Inspection (RPC) to resolve uninterpretable indications found during routine bobbin inspectio This plan was reviewed and approved by the licensee 1s on-site SNSOC committee on April 19, 199 By memorandum, S/N 91-259, the.licensee reported to the Commission that no S/G tubes were plugged in S/G 11A 11 as a result of this inspectio Tube (R41, C28) which had been previously plugged was replugged in response to NRC Bulletin 89-01 concerns and tube (R41, C27) which was previously plugged from the hot leg side in error was tested and returned to servic No tubes were plugged in S/G 11C 11 during this inspectio In the areas inspected, violations or deviations were not identifie.
. Check Valve Maintenance Program The licensee's check valve maintenance program is implemented through Administrative procedure MDAP-001 The procedure provides the require-'
ments and guidelines to test and inspect the performance and operability of Surry 1 s check valve The subject procedure was recently revised and approved for issue as Rev. 1 effective June 1, 1991; Rev. 0, of the subject procedure continued in effect until that tim The licensee's commitment to INP0 1s, SOER 86-3, October 15, 1986 is include The inspector reviewed the subject procedure for techni ca 1 content and adequac Areas of specific interest included, non-intrusive testing methods, trending, preventive maintenance, personnel training, documenta- *
ti on/computerized data base and inspection frequenc The program was discussed with the cognizant engineer who appeared kn owl edgeab 1 e and adequately trained for the assigned task. A copy of the summary report on check valves inspected during this refueling was presented for revie A total of sixty check valve were inspecte Of these 26 involved corrective maintenance, 16 internal bolting commitments (i.e.,
NRC BU-89-02 and 27 inservice inspection).
The inspector stated that this information and other related data to be forwarded by the licensee will be reviewed and the entire area will be revisited in depth on the next inspectio. *,
Within the areas inspected violations or deviations were not identifie.
Exit interview The inspection scope and findings were summarized on June 14, 1991, with those persons indicated in paragraph 1 abov The inspector described the areas inspected and discussed in detail the inspection result No dissenting comments were received from the license Proprietary information is not contained in this report.