IR 05000302/1978012
| ML19317G238 | |
| Person / Time | |
|---|---|
| Site: | Crystal River  |
| Issue date: | 06/06/1978 |
| From: | Conlon T, Economos N NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML19317G201 | List: |
| References | |
| 50-302-78-12, NUDOCS 8002280869 | |
| Download: ML19317G238 (8) | |
Text
{{#Wiki_filter:a e s ' N, 9, k' Kffug(o, UNITED STATES NUCLEAR REGULATORY COMMISSION , 1* o R EGloN il I 230 PEACHTREE STREET. N.W.sulTE 1217 _ ,[ ATLANTA, GECRGI A 30303 ....+ Report No.: 50-302/78-12 - Docket No.: 50-302 License No.: DPR-72 Category: C Licensee: Florida Power Corporation P. O. Box 14042, Mail Stop C-4 St. Petersburg, Florida 33733 Facility Name: Crystal River Unit 3 Inspection at: Crystal River Site, Crystal River, Florida Inspection Conducted: May 8-12, 1978 Inspector: N. Economos Reviewed /N M 64-7[ T. El Conlon, Chief ' Date Engineering Support Section No. 2 Reactor Construction and Engineering Support Branch Inspection Summary Inspection on May 8-12, 1978 (Report No. 50-302/78-12) Areas Inspected: ISI examination of pressure boundary welds, record and QA program review; waste gas disposal modification - welding and NDE; steam generator B repair program. The inspection involved 36 inspector-hours onsite by one NRC inspector. There were no Part 21 or 50.55(e) items included in this inspection.
Results: Of the three areas inspected no apparent items of nonenmpliance or deviations were identified.
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4,, RII Rpt. No. 50-302/78-12 I-1 . (J \\ ~ % DETAILS I Prepared by a-M4e [[ N. Economos, llurgical Engineer / Date Engineering upport Section No. 2 Reactor Cons ruction and Engineering - Support Branch Dates of Inspection: May 8-12, 1978 d 4 7T Reviewed b T. E. Conlon, Chief Date Engineering Support Section No. 2 Reactor Construction znd Engineering Support Branch 1.
Persons Contacted a.
Florida Power Corporation (FPCO)
- G. P. Beatty, Nuclear Plant Superintendent
- J. Cooper, Compliance Engineer
- S. W. Johnson, II, Inservice Inspection Engineer m
- J. Hollis, Contract Supervisor
, b.
Babcock and Wilcox Construction Company (B&W) L. Syverson, Group Leader R. Nelson, Field QA Supervisor P. D. Berstein, Level II, UT Examiner c.
Catalytic Incorporated (Catalytic) William Benoist, Project Superintendent
- Terry Austin, Project Engineer
- Denotes those present at the exit interview.
2.
Licensee Action on Previously Identified Inspection Findings _.
Previously identified inspection findings were not reviewed during this inspection.
3.
Unresolved Items Unresolved items are matters about which more infomation is required in order to ascertain whether they are acceptable items, items of noncompliance, or deviations. Unresolved items disclosed during this inspection are discussed in Paragraph Nos. 4.b. and 4.c.
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- . . . ,- - RII Rpt. No. 50-302/78-12 I-2 ' - . 4.
Independent Inspection Effort a.
Waste Gas Disposal Modification . Catalytic under contract with FPC0 is installing and welding the piping involved in the modification of the waste gas disposal (WD) system. Piping in this system is being installed in accordance with USAS B31.7 Nuclear Power Piping Code; the welding is controlled by Section IX of the ASME Code.
Design consideration and control is established by compliance procedure CP-114 " Procedure for Control of Permanent Modifi-cations...." This procedure controls changes from original design requirements through a design review equivalent to that imposed on the original.
Requirements for documentation are included.
Work authorization is issued in the form of Modification
Approval Records (MAR), this is a data package with drawings instructions and engineering approval for the impending modifi-cation.
Within this area the inspector selected drawing number CR3- -l 3612-WD-10.16 and applicable MARS 77-10-5 and 77-10-3 for review. These documents were reviewed for compliance with the CP-114 and accuracy. Pipe runs, indicated on the drawing, were inspected for location and position. Completed field welds were inspected for appearance, workmanship, are strikers, etc. Qualification of applicable weld procedures and welders were reviewed for compliance with section IX requirements.
In addition, the inspector reviewed quality records for materials used in the modification including stainless steel piping and flanges and fittings produced from Heat numbers #15970 and DiBA-J respectively.
b.
Weld Rod Control Weld consumables are issued and controlled by the licensee under procedure CP-103R4 " Weld Rod Control." Work areas and the issue station were inspected; quality records for weld consumables produced from heat numbers 422K2921, 61788, 29854, 336135 and 13594C were reviewed as was the aforementioned
procedure. Within these areas the inspector noted that the procedure contained no provisions for (a) control of used bare ) wire material (stubs) and (b) color coding bare wire ends.
The inspector stated, and the licensee agreed, that stub j .... .- . - . - .. - . ,. _. , -. -. - _... . - -.,,.. - _. _.,
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. - . . -% , RII Rpt. No. 50-302/78-12-I-3 . . control is needed to preclude the use of uncontrolled / discarded ' material, while color coding will assure material identification in cases where the tag (flag) falls off. The licensee agreed ' . to make the necessary procedural changes and to implement i these controls. This was identified as unresolved item number (78-12-01).
, c.
Liquid Penetrant Examination Records Liquid penetrant examination of welds is performed by Branch Radiographic Laboratories, Inc. (BRLI) under contract with the licensee. Discussions with the licensee representative disclosed
that FPCO's QA/ Engineering in St. Petersburg, Florida had ' reviewed and approved BRLI's liquid penetrant procedure, penetrant material certifications and NDE personnel qualification.
Two liquid penetrant inspection reports, on Form BRLI-5, were selected for review of test results, material certifications and personnel qualification records.
One report, dated March 28, 1978, related to socket welds FW-10A, 10B and 11 on dwg. #CR3-P-3664-WD-13 Rev. A, while the other, dated March 28, 1978, related to butt welds FW-19 to -25 on dwg. #CR3-P-3435-WD-4.8 Rev. 2-A.
The reports referenced liquid penetrant procedure ' ~ BRLI PT-73-9-62 and identified Magnaflux Spot Check materials with S/N 6J065, 6M098 and 6M015 as having been used for the tests. The work was performed by BRLI's level III NDE examiner.
In response to the inspectors request for the approved procedure and quality certifications for the aforementioned materials and NDE personnel qualification, the licensee stated these documents were available but could not be located at this time. The inspector requested and the licensee agreed to have these documents available for review on a subsequent inspection and to take appropriate measures that would assure similar documents would be available for review at the site. This was identified ,
as unresolved item number (78-12-02).
' d.
Steam Generator Repair , - Efforts to correct the damage sustained on the once through steam generator (OTSG) B from the failure of a fixed burnable poison rod assembly discussed earlier in reports RII:78-05 and i RII:78-06 had not started at the time of this inspection.
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- = . . . . ,.. RII Rpt. No. 50-302/78-12 I-4 , - Discussions with the licensee and B&W disclosed that: Approximately 2800 tube-ends on the upper tube sheet will a.
. require some machining and/or grinding to remove deforced metal (burs) in order to minimize possible formation of metal chips during operation.
Some of the tube-ends were
'l bent to the extent that an eddy-current probe could not pass through this section.
b.
Upon completion of a. above, all tubes will be tested for obstructions.
' c.
Leak testing had been completed and no leaks were identified.
d.
Current plans call for B&W to develop the necessary tooling required to remove deformed weld metal and to restore these areas to original condition. No date has been established for this repair however. On April 6, - 1978 FPC0 provided NRR with a description of the damage and the proposed corrective action. Within the areas inspected no items of noncompliance or deviations were identified.
, 5.
Inservice Inspection - Review of Program This first ISI inspection is being conducted at this time in order to take advantage of the unplanned defueling imposed by the failure of the fixed burnable poison rod, see reports RII:78-05 and RII:78-06. The ISI is being performed by B&W under contract with FPCO.
ISI requirements for Class 1, 2 and 3 components are delineated in Section 4.0.5 of Crystal River - Unit 3 technical specification (TS). The TS specifies Section XI of the ASME Code and applicable Addenda, as required by 10 CFR 50, Section 50.55a(g), to be the governing Code for ISI activities. Accordingly, this ISI is being performed in accordance with the 1974 edition through the Summer 1975 addenda of Section XI. Qur.lity assurance requirements are implemented through the B&W quality assurance manual (QAM) which contains policies that describe the methods used to achieve
compliance with NRC requirements. Approved B&W instructions and procedares are used to control NDE activities and documentation - these are contained in the B&W PSI /ISI Manuals. Activities specifi-cally addressed and controlled by the manuals include training and responsibilities of QA personnel, audit requirements, documentation, acceptance criteria, review and evaluation of test data, identifica-tion of components subject to ISI examinations, administrative , and/or NDE' procedures, process control, corrective action requirements, document control,. calibration, etc. The'ISI program provides for
.
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, .. - - . ,. RII Rpt. No. 50-302/78-12 I-5 . - ten planned inspections to be performed over the next ten years.
Components scheduled for examination are listed by category, item , number, coverage and method of examination as per table IWB-2600 of . the Code. The program requires that NDE personnel be qualified in accordance with section XI requirements and the ANSI Standard N45.2.6.
Administrative controls, established through the QA manuals, contain provisions for the control of NDE records including data sheets for all ISI examinations, equipment, instrumentation, calibration sheets, quality certifications, personnel qualifications and drawings ' as applicable. Within these areas the inspector noted that the licensee had made no provision for periodic QA surveillance and documentation of ISI activities. This matter was discussed with the licensee who agreed to establish and implement QA surveillance in this area. This matter was identified as inspector followup i item number (78-12-03) and will be reviewed on a subsequent inspection.
~ There were no items of noncompliance or deviations identified.
6.
Inservice Inspection - Observation of Work and Work Activities ~ The components scheduled for examination during the outage are listed on the B&W inspection plan (outage #1) dated April 26, 1978.
They include portions of the reactor vessel, pressurizer, nozzles, ' reactor coolant pipe welds and other pressure boundary piping, flywheels, various studs nuts and, Class 2 welds in the main steam, feedwater and decay heat systems.
The Code governing these examinations is discussed in paragrpah 5 above.
' At the time of this inspection the automated UT inspection of the reactor vessel had been completed. The inspector elected to witness the manual UT examination of reactor coolant (RC) welds in the cold leg of loop B2. These were identified as follows: Fig.
Identification Size Comments , B4.5.33 Pipe to Ell 2.30"x33.5 B4.5.34 Inner Ell to 2.30"x33.5 0 -One indication Long Seam in base metal,.1" long 100% DAC.
Acceptable.
34.5.35 Outer Ell 2.30"x33.5 0*-two indications Long Seam in base metal - <DAC - nonmetallic acceptable.
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. _.. _..__ - - ___ ___________- _- . - - - ' RII Rpt. No. 50-302/78-12 I-6 . .. Each weld was scanned with a 0, 45 and 60 transduc ir.
For these velds the inspector reviewed the qualifications of the Level I and II NDE personnel involved in the examination, verified that examina- . tion personnel were familiar with procedure ISI-120 R6, that it was being followed and that the examination was being conducted as required by the ISI plan.
In addition the inspector witnessed instrument calibration, and DAC curve construction. The following were checked for compliance with procedural and code requirements: couplant, type of UT apparatus used, transducers, weld coverage, identification and evaluation of reflectors, calibration checks, and documentation. Within the areas inspected no items of noncompliance , or deviations were identified.
7.
Inservice Inspection Data Review and,, Evaluation The scope and applicable code for this ISI inspection are discussed in paragraphs 5 and 6 above. NDE examination records of welds and/or components were selected at random for a review of the recorded information to verify compliance with code and procedural requirements. These were as follows: Reactor Vessel Scan Comments . Fig. Bl.3.1 - Flange 0, 45, 60 Some mode conversion to Circular Seam indications otnerwise clear.
Fig. B4.5.18 - Pipe to 0, 45 Some Mode Conversion RV Nozzle C.L. Loop A . Fig. Bl.9.1-Ligaments O Clear Fig Bl.4.4-Inlet Nozzle 0, 70 Clear X-Y axis Fig. B.1.4.6-Inlet 0* Iudications detected during Nozzle Z-W Axis PSI could not be located.
Note - see below.
Fig. Bl.4.6A-Inlet
Clear Nozzle Z-W Axis Fig. C2.1.5-Pipe to Ell 0, 45 Indications identified during Main Stan 24V PSI located - no size changes noted.
- Fig. C2.3.1-Pipe to 45" 5% DAC indication in center Weldolet 6.6"9 of weld - could be damped.
. Fig. C2.3.4 - Pipe to 0, 45* 50% to 63% DAC indications Sweepolet 6.6"9 detected with 45. , . - - ,- ., - -, _,,, -, ,- ,.-,,,___m-,.,_----.yy -,% .w _-g, ___y.
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r - ('~'} RII Rpt. No. 50-302/78-12 I-7 ' \\s_ / . Discussions with B&W concerning the UT results of the RV inlet nozzle Z-W axis, scanned scan with the remote equipment (ARIS), disclosed that the inability to locate the base metal indication ~ noted during the PSI could probably be attributed to the use of new calibration blocks and the new scanning technique used for the ISI examination. Apparently the new technique precluded scanning the entire area of interest, whereas the new blocks were required to meet updated code requirements.
Before the close of the inspection on May 12, 1978 discussions with the B&W representative disclosed that efforts were under way to reassemble the ARIS and re-examine the area in question. The re-examination was scheduled to start on , May 14, 1978. This matter was identified as inspector followup item number (78-12-04) and will be reviewed on a subsequent inspection.
8.
Exit Interview The inspector met with the licensee representatives denoted in paragraph 1, at the conclusion of the inspection on May 12, 1978.
j , The inspector identified the areas inspected which included: observation, program and record review of ISI activities; waste gas disposal modification (welding and NDE): OTSG "B" repair program.
- The licensee acknowledged the inspection findings.
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