IR 05000285/1987023

Insp Rept 50-285/87-23 on 870727-31.No Violations or Deviations Noted.Major Areas Inspected:Inservice Insp in Accordance W/Section XI of ASME Boiler & Pressure Vessel Code

ML20237F800
Person / Time
Site:	Fort Calhoun
Issue date:	08/26/1987
From:	Hunnicutt D, Tapia J, Westerman T NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
To:
Shared Package
ML20237F796	List: IR 05000285/1987023 ML20237F793
References
50-285-87-23, NUDOCS 8709010425
Download: ML20237F800 (9)

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APPENDIX ,

U.S. NUCLEAR REGULATORY COMMISSION

REGION IV

NRC Inspection Report: 50-285/87-23 License: DPR-40 Docket: 50-285

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Licensee: Omaha Public Power District (OPPD)

1623 Harney Street Omaha, Nebraska 68102 l Facility Name: Fort Calhoun Station, Unit 1 (FCS)

Inspection At: FCS, Blair, Nebraska Inspection Conducted: July 27-31, 1987 Inspectors: oh N// w w m e d (' h/24'/3 7 .

D. M. Hunnicutt, Chief, Operations Section Date

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Reactor Safety Branch j 4n1 8 [A6 [B}

J. }< Tapia', Rebcton Inspector, Operations Dat'e

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ShcVion, Reactor %fety Branch Approved: #I CiC ft/[i* f/Z f /f'7 p T. F. Westerman, Chief, Reactor Safety Branch Odte Inspection Summary Inspection Conducted July 27-31, 1987 (Report 50-285/87-23)

Areas Inspected: Routine, unannounced inspection of inservice inspection in i

accordance with Section XI of the ASME B&PV Cod Results: Within the area inspected, no violations or deviations were identifie '

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DETAILS Persons Contacted OPPD

• W. G, Gates, Plant Manager

• C. Bloyd, Senior Nuclear Production Engineer J. Ressler, Senior Test Engineer

• A. Richard, Quality Assurance (QA) Manager

• K. Stultz, Acting Manager, Technical Services

• D. Munderloh, Senior Engineering, Licensing

• T. J. McIvor, Plant Technical Supervisor

• R. Kellogg, Supervisor, Mechanical Technical Services

• R. Mueller, Supervisor, Maintenance Engineering

• Present at the exit intervie . Inservice Inspection (ISI)

An inspection was conducted to determine whether inservice testing of Class 1, 2, and 3 pressure retaining components was being conducted in compliance with the technical requirements described in 10 CFR Part 50.55a(g) and Section XI of the American Society of Mechanical Engineer's (ASME) Boiler and Pressure Vessel (B&PV) Code and with the QA requirements of Appendix B to 10 CFR Part 5 The OPPD " Inservice Inspection Program Plan for the 1983-1993 Interval" i defines the ISI program for the second 10 year inspection period. This i document was reviewed by the NRC inspectors to verify compliance with the specified testing and QA requirements. The review provided verification that the following attributes were correctly addressed: ISI program is in conformance with relevant ASME Code Section XI edition and addend Program incorporates the results of previous inserviu and preservice inspection Additional examinations are performed as required by ASME Section XI, Subsection IWF-243 Listings of partial or limited examinations are tabulate Relevant indications or conditions exceeding the allowable limits specified are evaluated in accordance with the provisions set forth in ASME Section XI, Subsection IWA-300 < .

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3 The services of an Authorized Nuclear Inservice Inspector (ANII) are procured and the ISI plan is reviewed by the ANII in accordance with Subsection IWA-2120 of the ASME Cod QA program is in place and includes methods for records retention, corrective action, and audits or surveillance of contractor ISI activitie The FCS ISI program is under contract to Ebasc The overall description of the quality program in effect for ISI activities is contained in Ebasco Inservice Inspection Quality Assurance Manual. The manual describes the organizational structure of the ISI group of the QA department and references detailed procedures that constitute the total QA program that was established to maintain quality throughout all phases of ISI activitie Implementation of the second 10-year inspection period program was assessed by reviewing the procedures utilized and test records produced during three refueling outage During March and April 1984, the first ISI of the second interval was performed to provide compliance with the ASME B&PV Code Section X ,

Visual, liquid penetrant, magnetic particle and ultrasonic examination !

methods were employed in this inspectio The following procedures, utilized to perform the ISI, were reviewed by the NRC inspectors:

No. FC-UT-1, Revision 1, " Ultrasonic Examination of Class 1 & 2 Piping Welds Joining Similar & Dissimilar Materials" No. FC-UT-2, Revision 0, " Ultrasonic Manual Examination of Class 1

& 2 Vessel Welds Excluding Reactor Pressure Welds" No. FC-VT-3, Revision 0, " Manual Ultrasonic Examination of Nozzle Liner Radius" No. FC-UT-4, Revision 0, " Ultrasonic Manual Examination of Reactor Pressure Vessel Welds" No. FC-MT-1, Revision 0, " Magnetic Particle Examination of Welds &

Bolting"

• No. FC-PT-1, Revision 0, " Liquid Penetrant Examination" No. FC-VT-1, Revision 0, " Visual Examination of Fit-Ups, Welds, Bolting, and Component Internals" No. FC-VT-3, Revision 0, " Visual Examination for Mechanical and Structural Condition of Components and Their Supports"

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In November 1985, the second ISI of the second interval was performe The following procedures, utilized to perform this ISI, were reviewed by the NRC inspectors:

No. FC-PT-1, Revision 0, " Liquid Penetrant Examination" No. FC-MT-1, Revision 0, " Magnetic Particle Examination of Welds &

Bolting" No. FC-VT-1, Revision 0, " Visual Examination of Fit-Ups, Welds, Bolting, and Component Internals" No. FC-VT-3, Revision 0, " Visual Examination for Mechanical and Structural Condition of Components and Their Supports" No. FC-UT-1, Revision 2, " Ultrasonic Examination of Class 1 & 2 Piping Welds Joining Similar & Dissimilar Materials" No. FC-UT-2, Revi. ion 1, " Manual Ultrasonic Examination of' Class 1

& 2 Vessel Welds Lxcluding Reactor Pressure Vessel Welds" No. FC-UT-3, Revision 1, " Manual Ultrasonic Examination of Nozzle Inner Radius" No. FC-UT-4, Revision 0, " Ultrasonic Manual Examination of Reactor Pressure Vessel Welds" No. FC-UT-5, Revision 0, " Manual ' Ultrasonic Examination of Flange Ligament Areas of Reactor Vessel" No. FC-UT-6, Revision 1, " Ultrasonic Examination of Reactor Pressure Vessel Studs" No. FC-UT-7, Revision 0, " Ultrasonic Examination of Class 1 & 2 Vessel Welds Less Than or Equal to 2 Inches" No. FC-UT-8, Revision 0, " Ultrasonic Examination of Bolts and Studs Exceeding 2 Inches" No. FC-UT-0 Revision 0, " Ultrasonic Manual Examination of RPV Flange-to-Shell Weld"

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During the March through May 1987 refueling outage, the third ISI of the second interval was performed. The following procedures, utilized to perform this ISI, were reviewed by the NRC inspectors: Procedure No. FC-PT-1, " Liquid Penetrant Examination," Revision 1, dated November 26, 1986, defined the requirements.for. color contrast solvent removable LP of nuclear reactor system components, in j accordance with ASME B&PV Code,Section XI, 1980 including Winter Addenda for 1980.

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b. Procedure No. FC-MT-1, " Magnetic Particle Examination of Welds and Bolting," Revision 1, dated February 22, 1984, defined.the minimum i procedural requirements to be used in performing surface examinations of components by the MP method in accordance with ASME B&PV Code,Section V, Article c. Procedure No. FC-VT-1, " Visual Examination: VT-1," Revision 1, dated December 16, 1986, described the requirements for visual examination as stipulated by ASME B&PV Code,Section XI. The principal objective of the procedure was to detect and locate abnormal conditions of

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l l parts, components, and surface '

l d. Procedure No. FC-VT-3, " Visual Examination: VT-3 and VT-4 l (Limited)," Revision 1, dated December 17, 1986, described the requirements for visual examination VT-3 and VT-4 (Limited) as 1 stipulated by ASME B&PV Code,Section XI. The principal objective was to determine the general mechanical and' structural conditions of pump casings, valve body internals, components and their supports, including verification of setting i e. Procedure No. FC-UT-CP-2, " Procedure for Inspection System Performance Checks," Revision 0, dated November 27, 1986, described the methods used to perform screen height linearity, amplitude 1 control linearity, and beam spread characteristics ASME B&PV Code, 'j Sections V and XI, including Winter 1980 Addenda are a part of this procedure.

l f. Procedure No. FC-UT-1, " Ultrasonic Examination of Class 1 & 2 Piping Welds Joining Similar & Dissimilar Materials," Revision 3, dated November 20, 1986, described the manual ultrasonic testing (UT) of full penetration similar and dissimilar metal Class 1 and 2 piping welds ranging in thickness from 0.2 to 6 inches in accordance with the requirements of ASME B&PV Code,Section XI.

l g. Procedure No. FC-UT-2, " Ultrasonic Examination of Class 1 & 2 Vessel

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Welds Greater Than 2 Inches," Revision 2, dated December 2, 1986, I described the manual UT of full penetration Class 1 and 2 vessel welds in ferritic material greater than 2 inches in thickness, excluding reactor vessel welds in accordance with ASME B&PV Code, l

Section X h. Procedure No. FC-UT-3, " Manual Ultrasonic Examination of Nozzles,"

Revision 2, dated December 1, 1986, described UT of nozzle inner radii of Class 1 vessels and to nozzles exceeding 12-inch nominal pipe size in Class 2 vessels over inch in thickness. This procedure required that examination be conducted from the outside surface of the vessel and/or nozzle utilizing angle beam techniques.

l i. Procedure No. FC-UT-4, " Ultrasonic Examination of Reactor Pressure Vessel Welds," Revision 1, dated December 2, 1986, described manual contact UT of full penetration Class 1 reactor Wssel welds greater

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than 2 inches in thickness in accordance with ASME B&PV Code, i Section X Procedure No. FC-UT-5, " Manual Ultrasonic Examination of Flange !

Ligament Areas of Reactor Vessel," Revision 0, dated December 4, 1984, described the manual UT of ligament areas up to 7 inches around ;

the stud holes in the reactor pressure vessel flange in accordance '

with ASME B&PV Code,Section XI, including Winter 1980 Addend Procedure No. FC-UT-6, " Ultrasonic Examination of Reactor Pressure

, Vessel Studs," Revision 1, dated September 25, 1985, described the manual UT of Reactor Pressure Vessel Stud . Procedure No. FC-UT-7, " Ultrasonic Examination of Class 1 & 2 Vessel Welds Less Than or Equal to 2 Inches," Revision 1, dated November 24, i 1986, described the manual UT of full penetration Class 1 & 2 vessel J welds less than or equal to 2 inches in thickness in accordance with i ASME B&PV Code,Section X i Procedure No. FC-UT-8, " Ultrasonic Examination of Bolts and Studs Exceeding 2 Inches," Revision 0, dated December 7, 1984, described the UT of bolts and studs exceeding 2 inches in diameter in accordance with ASME B&PV Code,Section XI, including Winter 1980 Addenda, Procedure No. FC-UT-9, " Ultrasonic Manual Examination of RPV Flange-to-Shell," Revision 0, dated September 16, 1985,-described the manual UT of the reactor pressure vessel flange-to-shell weld, in accordance with ASME B&PV Code,Section XI,. including Winter 1980 Addenda, Procedure No. FC-UT-10. "UT Examination for Laminar and Planar Reflections, Material Thickness & Geometric Conditions," Revision 0, dated April 10, 1987, described straight beam U ~

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The review of the above listed procedures provided verification that the following attributes were correctly addressed: Requirements were specified and agreed with commitments, including specified or referenced acceptance level Qualifications of NDE personnel were specified and in accordance with the approved ISI progra Methods of recording, evaluating, and dispositioning findings were established.

, Reporting requirements were in compliance with applicable code

{ requirements and the records identified for retention included:

examination results and data sheets l

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film and tape records, as applicable examination equipment data records of consumable materials such as penetrant materials and-ultrasonic test couplants calibration data sheets Methods of examination, extent, and technique were adequately described and in conformance with the requirements and guidance of ASME Code,Section V, " Nondestructive Examination."

The NRC inspectors reviewed the available certification records for all NDE test personnel involved in the three ISIS. All Ebasco personnel performing examinations were certified in accordance with Ebasco Procedure No. NDE-1, " Qualification and Certification of Nondestructive Examination l Personnel." This procedure meets the requirements of American Society for Nondestructive Testing (ASNT) Recommended Practice No. SNT-TC-1A,

" Personnel Qualification and Certification in Nondestructive Testing."

This ASNT document requires written testimony of qualification.

l The documentation was available (statements, etc..) of verification of

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previous employment and education, however, it wasn't onsite. This is considered an unresolved item (285/8723-01) until the licensee can locate the requested documentation and make it available to the inspector for review.

l The NRC inspectors reviewed records of all examinations performed during the three ISIS. Components which were examined included the reactor pressure vessel, pressurizer, regenerative heat exchanger, main reactor coolant piping, safety injection, containment spray, feedwater, and shutdown cooling system Elements of these systems which were examined included longitudinal welds, circumferential welds, nozzle welds, safe-end welds and bolts. Included in the review of the ISI data were calibration records for UT and examination records for all NDE methods. The examination records included the following information:

type of NDE performed materials utilized in performance of examination calibration parameters for UT examinations area of component examined i date examination performed personnel performing examination results of examination All examinations which revealed relevant indications or conditions were identified and documented on the affected examination record. Relevant indications exceeding the allowable limits specified in the NDE procedures were evaluated in accordance with the provisions set forth in ASME Section XI, Subsection IWA-3000.

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The review of the ISI data provided verification that the data covered the scope of examination required by the approved ISI progra No violations or deviations were identified during this inspectio . Exit Interview The NRC inspectors met with licensee representatives denoted in paragraph I at the conclusion of the inspection and discussed the results of the inspection.

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