IR 05000286/1993016

Insp Rept 50-286/93-16 on 930802-06 & 0920-24.No Violations Noted.Major Areas Inspected:Isi Program,Procedures,Scope of ISI Work for Outage,Current Insp Plan & Testing Procedures

ML20059J992
Person / Time
Site:	Indian Point, Three Mile Island
Issue date:	10/19/1993
From:	Kaplan H, Ray A NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I)
To:
Shared Package
ML20059J980	List: IR 05000286/1993016 IR 05000289/1993016
References
50-289-93-16, NUDOCS 9311150146
Download: ML20059J992 (9)

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U. S. NUCLEAR ' REGULATORY COADdSSION  :['

REGION I

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REPORT / DOCKET NOS. 50-289/93-16  :

LICENSE N DPR-50 .;

LICENSEE: GPU Nuclear Corporation ,

FACILITY NAME: Three Mile Island Unit I  !

INSPECTION AT: Middletown, Pennsylvania _;

INSPECTION DATES: August 2-6 and September 20-24,1993 ,

i INSPECTORS: //, /d 9 7'

II. Kaplan, $r. Reactor Engineer Date'

Materials Section, EB, DRS-t

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A. N. Ray, Reactor Engineer Date

Materials Section, EB, DRS APPROVED BY: .

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/ 2 M. Modes, Chief, Materials Section / Dite ' 3 Engineering Branch, DRS

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9311150146 DR 931104'

ADDCM 05000289 i PDR ,

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Areas Insoccted: This inspection reviewed the inservice inspection program, the procedures and the scope of IST. work for this outage, the eddy current inspection plan, the testing procedures of steam generators tubes and the erosion / corrosion progiam. The inspector witnessed the nondestructive examinations related to the inservice inspection, the eddy

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current examinations'of steam generator tubes and the ultrasonic thickness measurements fo the erosion / corrosion progra Results: The ISI program and nondestructive examinations in this outage were found to be well organized and implemented properly. A weakness yas found in the program due to the lack of a formal surveillance program for ISI activities. However, the ISI program complied with the ASME Code Section XI and the regulatory requirements. The eddy current inspection program for steam generator tubes was found to be capable of determining the integrity of stem generator tubes. The eddy currect examinations were performed in -

compliance with the ASME Code Section XI"and the plant technical specification. Based on the observations, interviews with personnel and review of sample data, it was determined that -

the licensee has a well organized data collection and evaluation system to monitor effectively .

the erosion / corrosion program as committed to in their response to NRC's Generic Letter 89-0 .. .

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DETAILS

' INSERVICE INSPECTION (ISI) PROGRAM (IP 73753)

" Scope

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The purpose of this inspection was to review the licensee's ISI program and the appropriate-nondestructive examinations (NDE) procedures for ISI to ascertain that the procedures covered all required aspects of ISI program and the program was complete and in conformance with the regula+ory requirement l Findings  :

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I GPU Nuclear Corporation's (GPUN) second ten year interval ISI program plan, R.evision 0, ;

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and relief requests for Three Mile Island Unit 1 (TMI-1), were submitted by the letter, dated -

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April 19,1991, to .NRC for review and approval. By letter of October 8,1992, NRC approved the licensee's ISI plan with the relief request except the relief request number 10, .,

14 and 15 which were denied because ofinsufficient technical justificatio ]

The current refuelling outage (10R) was the first period of second ten year inspection interval. The applicable Code for the inspection in this interval was ASME Code Section X1,1986 edition with no addenda.

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The inspector reviewed the inspection plan for this outage (10R). The plan indicated that [

four hundred and seventeen (417) components were scheduled for examinations in this -

outage. The examinations of eighty three (83) components were completed and no component was rejecte ,

i The licensee contracted with a qualified vendor to perform nondestructive testing activities during this outage. The inspector reviewed the licensee's Procedure No. 6100-ADM- , f 7209.49, Rev.1, "NDE Contractor Review, Training and Proficiency Demonstration." This !

procedure detailed the reviewing process of the contractor's personnel qualification and t certification and included a proficiency test for the contractor's personnel performing hTE in ,

f this outage. The inspector reviewed the qualification and certifications of NDE personnel _

and determined that they met the requirement of SNT-TC-1 A. The inspector reviewed the following NDE procedures: ,

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• Magnetic Particle Examination (MT) Procedure, 6100-QAP-7209.01, Re e Penetrant Examination (PT) Procedure, 6100-QAP-7209.02, Rev. O j

• Manual Ultrasonic Examination (UT) procedure of full penetration ferritic vessel welds greater than two inches in thickness, 6100-QAP-7209.22, Re !

• Manual Ultrasonic Examination (UT) of similar metal piping welds, 6100-QAP-7209.08, Re !

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The procedums were found to conform to ASME Code Section XI. The inspector noted that -

the Magnetic Particle Procedure, 6100-QAP-7209.01, did not contain the calibration ,

procedure of the equipment (Yoke). The licensee resolved this finding by revising the procedure. The revised Procedure 6100-QAP-7209.01, Rev.1, included the procedure for calibration of MT equipment. The inspector also verified that the magnetic particle

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equipment used in the last and current outage was calibrated in accordance with the Code requirement The following inspections and examinations were witnessed by the inspector:  ;

• Visual inspection of Intake Support IPE - 007

• Ultrasonic Examination (UT) of Steam generator (SG) Tube Sheet to Shell Welds for

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SG B, weld No. SG 0023

• Magnetic Particle Examination (MT) of Reduce.r te Pipe Weld No. FW 0027, Main ;

Feedwater System for SG A The inspector verified the results of visual inspection and evaluation of Intake Support IPE - t

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007 which had been performed and recorded previously in the Report No. 6874-1, dated 7-20-9 The UT examination of the weld SG 0023 included the use of 0,45 and 60 degree angle ;

beam transducers. The examination was conducted 360 degree around the circumference of (

the vessel. Except for a few minor indications found by 0 degree probe, no rejectable i indications were found in this area. No rejectable indications were found when the area was examined by 45 and 60 degree angle beam probes. The outer suo.ce of the subject weld had been inspected by MT in accordance with an augmented inspection plan with no  :

rejectable indications reporte l The MT cxamination of the outer surface of the reducer-to-pipe weld No. FW-0027 was '

performed per Procedure No. 6100-QAP-7209.01; with no rejectable indication reporte ?

The licensee had a computer controlled data tracking system to maintain ISI status of all components. The inspectors witnessed the input and retrieval process of ISI data from the last outage (9R).

The inspector reviewed the licensee's Quality Assurance (QA) program. The licensee's QA program development and audit department performed audits of NDE services at a frequency of every two years. The inspector noted that there was an absence of a formal program to conduct QA monitoring (surveillances) of ongoing ISI activities to assure that the contractors'

personnel were performing their. works as required. Although some of the inspections were witnessed by the licensee's ISI personnel as reported by the licensee, the licensee did not document these activities. The licensee will review this issue and consider implementing a ,

formal surveillance program for ISI as well as E/C activities. This is an unresolved item ,

(289/URI 96-16-01). .

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, Conclusion .

GPUN's ISI program and nondestructive examinations in this outage was found to be well organized and implemented properly. A weakness was found in the program due to a lack of formal QA monitoring (surveillance) program for ISI activities. However, the licensee's ISI ,

program coraplies with the ASME Code Section XI and regulatory requirement i EDDY CURRENT EXAMINATION OF STEAM GENERATOR TUBES .l

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(IP 73753)

4 Scope

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The purpose of this inspection was to review and evaluate the licensce's eddy current testing (ECT) program, its implementation for examining nondestructive steam generator tubes and

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to determine whether the testing was performed during this outage to comply the requirement

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of the ASME Code Section XI and the plant technical specificatio .2 Findings The TMI-I reactor coolant system includes two once through steam generators (OTSGS)

identified as A and B. Each OTSG contains 15,531 Inconnel 600 tubes, fifty six feet long and nominal outside diameter of 0.625" with a nominal wall thickness of 0.034".

The licensee planned to inspect 470 tubes both in OTSG "A" and "B" per the plant technical specification. The licensee also planned to inspect 323 tubes in the lane / wedge region of OTSG "A" and 333 tubes in the lane / wedge region of OTSG "B".

The inspector observed that the general examination of tubing material was performed from the inside of the tubes using the bobbin coil probe. Following the bobbin coil examination, the tubes with indications evaluated at 40% or larger of wall thickness were examined using an 8xl absolute (ABS) probe or motorized rotating pancake probe (MRPC). The tubes with indications evaluated at 40% or larger of wall thickness were removed from service by pluggin The inspector also noted that' the licensee contracted with an outside vendor to perform the eddy current testing of the SG tubes. The eddy current test data were collected per the licensee's Procedures 6100-SPC-7230.06, Rev. I and 1300-4B, Rev. 7 in a data acquisition center where the technicians monitored the ECT probe position on each tube. The probe position was controlled by a remotely operated manipulator. During the retraction of the probe, the eddy current test data in the form of strip charts and Lissajous displays were -

transmitted to the analysis station. The collected data were analyzed by a primary analyst and a secondary analyst in the data analysis station per the licensee's Procedure 6100-QAP-7209.63, Rev 0. The lead analyst performed the final review of the results of primary and secondary analysi J

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The. inspector reviewed the above procedures for data collection and analysis and found that the procedures were in compliance with the requirements of ASME Code Section XI and technical specification. The inspector noted that the qualifications of testing personnel were reviewed and approved by the licensee's NDE specialis The inspector witnessed the data acquisition of the following tubes in the data acquisition center:

OTSG A ROW TUBE 74 18 74 19 74 20 74 21 74 26 74 27 74 28 The inspector followed r.p the data transmission and analysis of these data at the analysis center. The data acquisition and analysis were performed per licensee's approved procedures by the qualified ECT personne At the time of this inspection on September 24,1993, the inspection of tubes in SG was in progress. The inspection and tube plugging status is summarized in Table I:

TABLE I INSPECTION STATUS FOR THIS OUTAGE (10 R)

OTSG "A" OTSG "B" Examinations Scheduled Completed Scheduled Completed Total Exam Total No. of Tubes tested 1559 199 1081 256 TUBE PLUGGING STATUS OTSG "A" OTSG "B" No. plugged in 10R " 0 0 Total No. plugged 1268 372

• Number as on September 24,1993

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l .3 Conclusion l

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The eddy current inspection program for steam generator tubes at TMI-1 was found to be well organized and capable of determining the integrity of steam generator tubes. The inspection was performed in compliance with the ASME Code Section XI and plant technical specification.

l ( EROSION / CORROSION (E/C) MONITORING PROGRAM (IP 49001) Scope l

The inspection objective was to review the licensee's E/C program to ascertain that the

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program was accomplished in accordance with requirements of NRC's Generic letter 89-08 i l and licensee's commitment '

1 Findings The licensee's E/C program was initiated in 1985 (5R). The program, as specified in GPU f Specification number 1101-12-110, includes the following systems: Turbine Drains, Main Steam (including turbine related piping), Sta.am Dump and Bypass, Extraction steam l (including MSR Drains), Auxiliary Steam, Main Steam to RV post supports, Condensate, l Feedwater and Feedwater Heater Drains. The sample selection for the program is based on engineering judgement, industry experiences and CHECMATE computer Code The inspector verified that the program was managed by knowledgeable engineering j personnel who were trained in the CHECMATE program with plant engineering having ;

overall responsibility for plant performance and evaluating inspection reports as require l l

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A review of documentation representing three components 413-1001-07,431-1004-50 and 421-1000-02 indicated that a CHECMATE analysis had been performed utilizing the required input data such as component diameter, thermodynamic state, flow rate, R/P for elbow and material compositio The inspector witnessed the UT thickness measurements performed on the following )

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• Component No. 431-1004-48, Heater Drain (HD) 8" diameter pipe

• Component No. 411-1000-21, Elbow attached to 36" diameter pipe - Main Steam System i

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8 The ultrasonic thickness measurement on the_HD pipe was a retest as requested by the ,

inspector. The measurement corresponded closely to the original data recorded on the report 96271-1, dated 7-19-93. The value ranges from 0.268" - 0.347" as compared to the design minimum of 0.250". The records showed that the data were submitted for engineering evaluation (93-002) because of the 0.268" value that occurred in two isolated locations. The engineering disposition based on calculated wear rate recommended reinspection in the nex _

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outage (llR). The inspector also noted that a lamination found in the component during - l testing for wall thickness was evaluated and documented on the test repor ,

The ultrasonic thickness measurement data for elbows in the main steam line were found to vary between 0.492" and 0.676" as compared to nominal 0.500" and design minimum a 0.331".

The licensee reported that during the last refuelling outage (9R),122 inspec, ; were completed. Nine (9) components required repairs or replacements. None of these were of a 1 critical nature, and in five (5) cases replacement will be made with stainless steel in the

current outage. The weld repairs which involved two (2) nonsafety-related components were overlayed with weld metal. In the current outage ninety three (93) inspections were i scheduled and seventy (70) inspections were completed to date. Eighteen (18) out of these seventy components required further engineering evaluation.

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! Conclusion a

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Based on observations, interviews with personnel and review of sample data, it was determined that the licensee has an well organized data collection and evaluation system to monitor effectively the erosion / corrosion program as committed to in their response to ;

NRC's Generic Ixtter 89-0 .0 ENTRANCE AND EXIT MEETINGS  :

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The members oflicensee's management, engineering and technical staff were informed of the scope and the purpose of the inspection at the entrance meetings on August 2,1993. The findings of the inspection were presented to and discussed with the members of the licensee's management and staff at the conclusion of the inspection on Septembcr 24,1993. The licensee concurred with the findings of the inspection and agreed to consider implementing a surveillance program to monitor the ISI and E/C activities. A list of attendees of the exit meeting is attached to this report in t ttachment j

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- ATTACIIMENT 1

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EXIT MEETING ATTENDANCE l

Three Mile Island Unit 1 R. Barley Manager - Steam Generator J. Curry Manager - QA J. Jandovitz Manager - NDE / ISI R. Knight Licensing Engineer E. McElwain EDP R. Rogan Licensing Director L. Stauffer NDE/ISI Specialist M. Torborg -ISI Prog. Engineer M. Zeise NDE/ISI (E/C)

V. Zeppos Mechanical Engineer, Parsippany Pennsylvania State R. Janati Nuclear Engineer U.S. Nuclear Regulatory Commission (USNRC)

M. Evans Senior Resident Inspector

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