IR 05000280/1994004
| ML18153A900 | |
| Person / Time | |
|---|---|
| Site: | Surry  |
| Issue date: | 03/10/1994 |
| From: | Blake J, Coley J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML18153A899 | List: |
| References | |
| 50-280-94-04, 50-280-94-4, 50-281-94-04, 50-281-94-4, NUDOCS 9403290032 | |
| Download: ML18153A900 (11) | |
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UNITED STATES NUCLEAR REGULATORY COMMISSION
REGION II
101 MARIETTA STREET, N.W., SUITE 2900 ATLANTA, GEORGIA 30323-0199 Report Nos. : 50-280/94-04 and 50-281/94-04 Licensee: Virginia Electric and Power Company Glen Allen, VA 23060 Docket Nos.:
50-280 and 50-281 License Nos.:
DPR-32 and DPR-37 Facility Name:
Surry 1 and 2 Inspection Conducted:
February 7-11, 1994 and February 22-25, 1994 Section SUMMARY Scope:
..3-io-9't Date Signed Date Signed This routine, announced inspection was conducted in the areas of inservice inspection (ISI) - Observation of Westinghouse's work activities associated with the second ten-year interval inspection of the Unit I reactor vessel, review of ultrasonic data and evaluations of recorded indications (Unit I reactor vessel), observation of manual ultrasonic examinations activities, and observation of liquid penetrant examinations activitie In addition radiographic film for welds in piping modifications were reviewe Results:
In the areas inspected, violations or deviations were not identified. Reactor vessel examination activities and evaluation of the ultrasonic data was effectively performed by Westinghouse. Other ISI activities observed or reviewed by the inspector were performed satisfactorily by examiners from Virginia Corporation of Richmond and the license One weakness was observed in that, a radiographer had indicated on the "Radiographic Inspection Reports" 9403290032 940318 PDR ADOCK 05000280
that the radiographic sensitivity for the radiographs reviewed by the inspector was 4T in lieu of the required 2T {see paragraph 3 for details).
One strength was also noted in that the licensee had assigned a health Physics inspector with each NDE team when the examinations were performed in high radiation area This arrangement worked very effectively in reducing personnel dose and improved job coordinatio========-=---~~
- REPORT DETAILS Persons Contacted Licensee Employees
- W. Benthall, Supervisor, Licensing
- D. Grady, Supervisor, Nondestructive Examination (NDE)
- M. Kansler, Station Manager
- J. Kilmer, Licensing
- D. Miller, Radiation Protection
- J. Price, Assistant Station Manager
- E. Smith Jr., Manager, Quality Assurance (QA)
- T. Sowers, Engineer
- D. Woodyard Jr., Senior Inspector, NDE Other licensee employees contacted during this inspection included engineers, technicians, and administrative personne Other Organization R. Keck, Project Manager, Westinghouse Nuclear Applications Technical Division (Reactor Vessel Inspection Activities)
NRC Resident Inspectors
- S. Tingen, Resident Inspector M. Branch, Senior Resident Inspector
- Attended Exit Interview Acronyms and initial isms used throughout this report a.re l i sted in the last paragrap.
Inservice Inspection - Unit 1 (73753) (73755)
Surry Unit 1 is presently in the last outage of the third period for the second ten-year inspection interva In addition the licensee was performing some first period, third ten-year interval examinations this outage since the effective dates for the third ten-year interval was November 14, 1993, through November 14, 200 The applicable code for the second interval ISI examinations which included the reactor vessel examinations was the American Society of Mechanical Engineers (ASME)
Boiler and Pressure Vessel (B&PV) Code, Sections V and XI, 1980 Edition through Winter 1980 addend The third interval examinations were performed to the 1989 Edition of*
Sections V & XI of the ASME Cod The reactor vessel outlet nozzle to vessel welds, nozzle to inside radius sections and the outlet to pipe welds were performed using the 1989 Edition of the ASME Code since they had been examined previously in the first period of the second interva *
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The licensee had contracted Westinghouse's Nuclear Applications Technical Division to perform reactor vessel examinations and the "B" steam generator eddy current examinations. Westinghouse used their Dyna-Pulser ultrasonic system to perform the ten-year interval examinations of the reactor vessel and their UDRPS data acquisition and imaging system to process the data. Other ISI activities were performed by the licensee and Virginia Corporation of Richmon Review of Westinghouse ISI Reactor Vessel Examination Program Activities (73753)
The inspector reviewed the Westinghouse program for the examination of the reactor vessel. The review verified the following: (1) proper transducer size, angle, sound mode, and arrangement on the scanning fixture to insure coverage for each weld configuration, (2) approved procedures were available and specified the NDE equipment used, (3) personnel qualification and certification records indicated that the examination personnel were properly certified for the automated ultrasonic method and knowledgeable of the examination process, and (4) equipment certification records indicated that the system would function within its design parameter (a)
Review of vessel scan plans for weld coverage The inspector's review of ISI scan plans for transducer coverage revealed that the licensee only intended to utilize two 45 degree shear-wave transducers for the examination of the outlet nozzle to safe-end welds even though the scanning fixture had two additional 45 degree refracted longitudinal wave transducers mounte Refracted longitudinal wave transducers are generally used on dissimilar metal welds because of their ability to penetrate difficult material The ultrasonic examination of the nozzle to safe-end weld is performed on the entire thickness of the weld since the licensee has requested relief from the*code surface examination requirements on the outside nozzle and safe-end weld surface due to high radiation dose rates. The inspector held discussions with the licensee and Westinghouse concerning their selection of transducers for the examination of this wel In reply the licensee stated that the me\\als involved in the outlet nozzles did not include inconel or centrifically cast stainless steel and demonstrations on a mockup block of the same materials revealed that the shear wave transducer adequately detected a five percent notch in each of the materials of the mocku The licensee stated that shear and longitudinal wave transducers were used on the inlet nozzles because one of the materials was centrifically cast stainless steel. The licensee also stated that the only reason they did not use the refracted longitudinal wave transducers was in order save computer disk spac The inspector expressed concern
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that it is not unusual to encounter different acoustical properties from nozzle to nozzle when examining 309 weld butter, 308 weld metal, and 316 forged safe-end material Subsequent to the initial discussions the licensee informed the inspector that they had decided to use both the shear wave and the refracted longitudinal wave transducers on the outlet nozzles and to compare the data taken to insure that the best method would be used to evaluate the wel The inspector's review of completed ultrasonic data for both transducers did not reveal any indications in the outlet nozzle The examinations performed with the refracted longitudinal wave transducers were more sensitive. One adverse effect noted in using the refracted longitudinal wave transducers was when the surface was uneven, a redirected signal was observed. This phenomena required skilled examiners to interpret the examination result The inspector's review of the Westinghouse reactor vessel program did not reveal any other weld coverage, or transducer selection, concern (b}
Review of examination procedures The inspector reviewed the Virginia Power examination procedures listed below to determine whether the procedures were approved, technically sound, and specified the NDE equipment used by Westinghouse.to conduct the vessel examination Procedure N a-VPA-ISl-54, Re O-VPA-ISI-55, Re O-VPA-ISl-254, Re Procedure Title Manual Ultrasonic Examination for the Reactor Vessel Upper Shell to Flange Weld Manual Ultrasonic Examination of the Reactor Vessel Threads in Flange Remote Inservice Examination of the Reactor Pressure Vessel The procedures had been approved by the licensee and Westinghouse, met minimum Code requirements, and delineated the equipment used to conduct the Unit I reactor vessel examinations.
{c)
Review of Westinghouse examiner certification records The inspector reviewed certification and qualification records for the examiners listed below to determine whether the examiners were properly qualified, certified, and knowledgeable of the NDE metho Examiner Level of Certification J. Level II Visual Examiner S. Level III Limited UT Examiner D. Level III Limited UT Examiner A. Level II Limited UT Examiner J. Level III Limited UT Examiner J. Level II Limited UT Examiner The qualification and certification records showed that the examiners were adequately qualified to perform the reactor vessel examination (d)
Review of equipment certification records The inspector reviewed certification records for the following NDE equipment:
Equipment Seri al N Dynapulser 09747 Dynapulser 10791 Dynapulser 09746 RTD Transducer 89-190 RTD Transducer 89-183 RTD Transducer 89-105 RTD Transducer 89-187 RTD Transducer 89-740 RTD Transducer 89-741 RTD Transducer 89-191 RTD Transducer 89-606 RTD Transducer 89-585 RTD Transducer 89-592 The above equipment met or exceeded ASME Code requirement Review of Reactor Vessel Automated Data and Evaluation of Indications - (73155)
The inspector reviewed the automated data for the reactor vessel and verified that the evaluation of indications was performed satisfactorily, examination limitations were identified, and required documentation was available, complete and satisfactor Examination records for the following welds were reviewed:
Weld No Weld Description Weld No. 1 Upper Shell to Flange Weld No. 2 Intermediate Shell to Upper Shell Weld No. 3 Intermediate Shell to Lower Shell Weld No. 4 Bottom Head to Lower
- shell Weld No. 5 Bottom Head Weld No. 6 Intermediate Shell Longitudinal Weld No. 7 Intermediate Shell Longitudinal Weld No. 8 Lower Shell Longitudinal Weld No. 9 Lower Shell Longitudinal Weld No. 10 Vessel Shell to Outlet Nozzle Weld No. 12 Vessel Shell to Outlet Nozzle Weld No. 14
.Vessel Shell to Outlet Nozzle Welds Nos. 11 Vessel Shell to 13 and 15 Inlet Nozzles Welds No Inlet Nozzle to 100-AZ-1, 1-17DM Safe-end 101-AZ-1, 1-17DM 102-AZ-1, 1-17DM Welds No Outlet Nozzle to 100-AZ-1, 1-0lDM Safe-end 101-AZ-1, 1-0lDM 102-AZ-1, 1-0lDM Comments Perform from Vessel ID
{2) Indications Recorded
{3) Indications Recorded
{4) Indications Recorded No Indications Recorded No Indications Recorded No Indications Recorded
{1) Indication Recorded No Indications Recorded (3) Indications Recorded
{6) Indications Recorded (1) Indication Recorded No Indications Recorded No Indications Recorded Nozzles# 11, 13, and 15 No Indications Recorded Nozzles# 10, 12, and 14 The ISi data for the Unit 1 reactor vessel was complete and within established ASME Code acceptance criteri Observation of.Manual ISi Ultrasonic Examinations (73753)
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The inspector observed examiners from Virginia Corporation of Richmond performing manual ultrasonic examinations of the welds listed belo The welds were examined and evaluated in accordance with Virginia Power's Ultrasonic Examination Procedure No. NDE-UT-201, Rev. The examinations were observed to determine whether the examination personnel were knowledgeable of procedural requirements, the examination method, operation of the test equipment, and properly evaluated the indications in accordance with the appropriate procedural acceptance criteria. The following welds were examined:
Drawing No.and Weld N WMKS-1103A3, Re Weld No. 1.02 11448-WMKS-1103A3, Re Weld No. 1.03 11448-WMLS-OlOlGl Weld No. 1-01 Pipe Configuration 8" Diameter Reactor Coolant Elbow to Pipe 8" Diameter Reactor Coolant Elbow to Pipe 16" Diameter Feedwater Nozzle to Reducer (Loop B)Bulletin 79-13 Weld The inspector's verification of the above examinations revealed that the examination procedure was being followed, examination personnel were knowledgeable of the examination method and operation of the test equipment, and examination results and evaluation of the results were properly documente Certification records for the examiners and equipment involved in the above examinations were also verified to be satisfactory by the inspecto An interesting observation was made by the inspector during the examination of the 16" diameter feedwater nozzle to reducer weld (Weld No. 1-01).
In 1980, the licensee replaced the Steam Generator tube bundle During the replacement activities the license elected to redesign the piping to improve the mix of the fluids in the auxiliary feedwater and the feedwater line. The replacement piping run has the shape of an inverted The ultrasonic examinations of the feedwater weld and the associated fittings conducted this outage and witnessed by the inspector revealed that no cracking is presently detectable in the weld or fittings. The ultrasonic examinations made this determination when scanning at an enhance sensitivity. The results of the ultrasonic examinations indicated to the inspector
that the licensee's piping modification has achieved its designed function of mixing the fluids in the auxiliary feedwater and feedwater syste Observation of Liquid Penetrant Examinations for ISi Welds (73753)
The inspector observed Virginia Power and Virginia Corporation of Richmond examiners performing liquid penetrant examinations of the ISi welds listed belo These examinations were performed using Virginia Power's Liquid Penetrant Examination Procedure No. NDE-PT-201, Rev. The inspector observed the liquid penetrant examinations to determine whether the examination procedure was being followed, whether examination personnel were properly certified and knowledgeable of the NDE method, whether the examinations were performed satisfactorily, and whether the examiners properly evaluated and documented the test results. The following weld examinations were observed by the inspector:
Drawing and Weld N WMKS-012762 Weld No. I-AMF 11448-WMKS-012762 Weld No. 1-AKF 11448-WMKS-012762 Weld No. 53 11448-WMKS-012762 Weld No. 1-AWF 11448-WMKS-012762 Weld No. CEF 11448-WMKS-1103A3 Weld No. 1-02 11448-WMKS-1103A3 Weld No. 1-03 Piping Configuration 8" Diameter Pipe to Valv High Head Safety Injection 8" Diameter Elbow to Elbow High Head Safety Injection 8" Diameter Elbow to Pipe High Head Safety Injection 8" Diameter Tee to Pipe High Head Safety Injection 8" Diameter Elbow to Pipe High Head Safety Injection 8" Diameter Elbow to Pipe Reactor Coolant Bypass Line 8" Diameter Elbow to Pipe Reactor Coolant Bypass Line The inspector concluded that the above liquid penetrant examinations were successfully performed in accordance with the licensee's approved procedure by qualified and knowledgeable examiners. Certification records for the 5 applicable liquid penetrant examiners and the liquid penetrant test materials were also verified by the inspecto *
8 Status of Steam Generator "B" Eddy Current Examinations The eddy current examination of "B" Steam Generator tubes had been completed prior to the reactor vessel examination, so discussions were held with Westinghouse to determine the scope of the examinations and the condition of the tubes. This outage Westinghouse had eddy current examined 100 percent (3338 tubes) of the "B" Steam Generator tube As a result of the examinations the licensee had elected to plug the 4 tubes listed belo Plugging the 4 tubes however, was a conservative decision by the licensee since the examinations revealed that all of the tubes met the Technical Specification requirements for wea The 4 tubes plugged were located in the anti-vibration region of the steam generator tube bundl The following tubes were plugged this outage:
STEAM GENERATOR TUBES PLUGGED THIS OUTAGE Row N Column N Percent Wear
17
34
22
23
43
21 Within the areas examined, no violation or deviation was identifie.
Review of Radiographic Film for Piping Modification Welds - Unit 1
{57090)
The inspector examined the radiographic film and associated records for the welds listed below to determine whether they had been processed, examined, evaluated, dispositioned, and maintained in accordance with the licensee's approved Radiographic Procedure No. NDE-RT-101, Re Acceptance criteria for the welds listed below was the American National Standard Institute 831.1 Standard, 1989 Edition. The following welds were fabricated in accordance with Design Change Plan {DCP-92-43) and worked on Job Order No. 94-09 I,**
Drawing and Weld N Configuration Size Dwg. No. E-101 Weld 4 Pipe to Elbow 3/4" Dia. X.219" Th Dwg. No. E-101 Weld 12 Pipe to Elbow l" Dia. X.250" Th Dwg. No. E -101 We l d 11 Pipe to Elbow l" Dia. X.250" Th Dwg. No. E-101 Weld 13 Pipe to Elbow l" Dia. X.250" Th Dwg. No. E-101 Weld 8 Pipe to Elbow 3/4" Dia. X.219" Th Dwg. No. E-101 Weld 9 Pipe to Tee 3/4" Dia. X. 219" Th Dwg. No. E-101 Weld 6 Pipe to Elbow 3/4" Dia. X.219" Th Dwg. No. E-101 Weld 3 Pipe to Elbow 3/4" Dia. X.219" Th Dwg. No. E-101 Weld 5 Pipe to Elbow 3/4" Dia. X.219" Th As a result of the above review one weakness was observed; a radiographer had indicated on the "Radiographic Inspection Reports" that the radiographic sensitivity for the radiographs reviewed by the inspector was 4T in lieu of the required 2 The radiographic film quality however had obtained the required 2T sensitivity and an interview with the licensee's film interpreter revealed they had been evaluated to the 2T sensitivity. The radiographer had not been aware that a recent revision to the procedure had changed the sensitivity from 4T to 2 No other film had been exposed since the procedure was revise The radiographic film reviewed met minimum Code requirement Within the areas examined, no violation or deviation was identifie.
Exit Interview The inspection scope and results were summarized on February 25, 1994, with those persons indicated in paragraph The inspector described the areas inspected and discussed in detail the inspection result Although reviewed during this inspection proprietary information is not contained in this report. Dissenting comments were not received from the license.
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DCP Di ISI NOE N No QA Re Th UDRPS -
UT II American Society of Mechanical Engineers Boiler and Pressure Vessel Design Change Plan Diameter Inservice Inspection Nondestructive Examination Number Numbers Quality Assurance Revision Thickness Ultrasonic Data Recording and Processing System Ultrasonic Testing inch