IR 05000315/1979015
| ML17318A284 | |
| Person / Time | |
|---|---|
| Site: | Cook  |
| Issue date: | 07/27/1979 |
| From: | Danielson D, Key W, Ward K NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML17318A281 | List: |
| References | |
| 50-315-79-15, 50-316-79-12, NUDOCS 7909270188 | |
| Download: ML17318A284 (14) | |
Text
U.S.
NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT
REGION III
Report No. 50-315/79-15; 50-316/79-12 Docket No. 50-315; 50-316 License No. DPR-58; DPR-74 Licensee:
American Electric Power Service Corporation Indiana and Michigan Power Company 2 Broadway New York, NY 10004'acility Name:
Donald C.
Cook Nuclear Power Plant, Units 1 and
Inspection At:
Donald C.
Cook Site, Bridgman, Michigan Inspection Conducted:
May 30-June 8, June 12-15, June 25-July 2, 1979
)
Inspectors:
A.AW~
Approved By:
. H. Danielson, Chief Engineering Support Section
>7 7 Ins ection Summa Ins ection on Ma 30-June
June 12-15 June 25-Jul
1979 (Re ort No.
50-315 79-15'0-316/79-12)
Areas Ins ected:
Observation of feedwater nozzle pipe repair activities.
The inspection involved a total of 168 inspector-hours on site by three NRC inspectors.
Results:
Of the areas inspected, one item of noncompliance was identified in one area.
(Infraction - failure to follow procedures
- Section I, Paragraph 3.)
DETAILS Persons Contacted Indiana and Michi an Power Com an (IM)
+D. V. Shaller, Plant Manager
- B. A. Svensson, Assistant Plant Manager
- J. Stietzel, Quality Assurance Supervisor
- D. Dudding, Maintenance Supervisor
"=A. Papia, ISI Coordinator-W. D. Cornwell, Maintenance Engineer
+R. S. Keith, Outage Coordinator G. Montenegro, Quality Control Supervisor E. Moore, Quality Control Engineer American Electric Power Com an (AEP)
D. Patiance, Metallurgist B. I,ovelace, Consultant State of Michi an
+A. Kozlowski, Boiler Division Supervisor Facto Mutual En ineerin D.
C. Young, Authorized Inspector
"=Denotes those present at the exit interviews.
Functional or Pro ram Areas Ins ected Functional or program areas inspected, are discussed in Sections I and II.
-2-
Section I Prepared by W. J.
Key Reviewed by D. H. Danielson, Chief Engineering Support Section
-1.
Procedure Review The following procedures used during generator the steam nozzle/pipe repair activities were reviewed by the inspector.
S ecial Procedure Procedure No.
12MHP-SP-001, Revisions 0, 1, 2, and 3, titled "Special Procedure for Steam Generator Feedwater Inlet Nozzle Elbow Repair."
This procedure was revised as work progressed to reflect information generated from outside the plant.
Weldin Procedures 23.88e, Revision
1.7c, Revision
23.89, Revision
31-S-S, Revision 2, PQR
31-T-S, Revision
20.57b, Revision
90.1, Revision
Heat Treatment Procedure Cooper Heat Procedure No.
CH0080, Revision 3, titled "Post Weld Heat Treatment."
Nondestructive Examination Procedures Southwest Research Institute (SwRI) Procedure 800-64, Revision
(draft), titled "Manual Ultrasonic Examination of D. C.
Cook Feedwater Nozzles."
This procedure was developed on site during repair activities and is documented in Deviation and Nonconformance report No.79-071.
Procedure No. 12, QHP-5050 NDE 002, Revision 3, titled "Magnetic Particle Examination for Nuclear, Non-Nuclear and Structural Materials, Using Prods, Coils, and Yoke Method."
No items of noncompliance or deviations were identifie Elbow Removal Following radiographic examinations and removal of boat samples for metallurgical examination the elbow of steam generator No. 2-1 was cut loose from the nozzle to determine if the pipe had been s'tressed during construction.
The elbows were removed by cutting at the nozzle weld and the reducer welds.
r After removal, the inside diameter of both elbows and nozzles were visually examined for pitting.
No pitting was evident.
On Unit 2 generators, liquid penetrant (PT) examination of the nozzles revealed linear indications.
These indications were removed by gr'inding and some exceded a depth of.050".
After clearing of these PT indications, weld preparations were machined on the nozzles, After removal of Unit 1 elbows, the inside surface of the vessel nozzles showed indications of pitting and erossion.
The surfaces were cleaned and PT examined which revealed many linear indications.
UT examination of these nozzles was performed to determine the depth prior to grinding.
Some of the indications exceeded
.200" in depth after mapping the excavations were repair welded in accordance with the repair procedure.
Replacement elbows were supplied by Pullman Products and by B. F.
Shaw.
After receipt inspection, the elbows were shipped to the Kelm Manufacturing Company where the inside diameter was machined to match that of the nozzle.
The outside diameter was bulit up with weld metal and machined in accordance with a sketch supplied by the licensee.
Weld preparations were machined on both elbows ends at the shop.
No items of noncompliance or deviations were identified.
Fit-u and Weldin Fit-up and welding of Unit No.
2 was performed by IM and Central Machine Shop personnel of Appalachian Power Company of West Virginia.
Fit-up of the elbow to steam generator 2-1 nozzle was completed on June 5, 1979, in accordance with procedure and observed by the inspector prior to start of welding.
The nozzle and elbow was preheated to 300 F prior to welding in accordance with procedure.
The weld joint of the elbow to nozzle is a butt weld with the root and two passes deposited using the GTAW method, and the SMAW method used to deposit filler passes, The weld joint of the elbow to reducer utilized a backing ring.
Several cycles of repairs were made to the welds on Unit 2 but were not identified either on the radiograph or on the radiographic repor Due to the problems encountered with the weld on Unit 2, the licensee contracted Unit 1 work to Power Systems Incorporated.
During his review of repair activities, the inspector identified instances where procedure requirements for control of welding materials and entry of foreign materials were not being implemented.
This failure to follow procedures is an item of noncompliance identified in Appendix A.
(315/79-15-01; 316/79-12-01)
Except as noted, no items of noncompliance or deviations were identified.
Radio ra hic Examination and Review Radiographic examination was performed by Superior Industrial X-Ray (SIX) in accordance with approved procedure RT-1, Revision 2.
The licensee's Level II inspector, the State of Michigan's Boiler Division Supervisor, and the Factory Mutual Engineering Authorized Inspector reviewed the final radiographs taken after stress relief and interpreted the welds to be acceptable.
The RIII inspector reviewed in process radiographs taken after stress relief.
The RIII inspector's interpretation of the Unit 2 radiographs, after licensee acceptance, did not agree with the interpretation of the licensee and his agents.
Two independent RIII inspectors went to the site and evaluated the radiographs.
The results of their evaluation is documented in Section II of this report.
A meeting between RIII and licensee personnel will be held during the month of July to resolve the differences in interpretation and any required corrective actions.
This is an unresolved item.
(316/79-12-02)
The following is the inspector's evaluation of the Unit 2 steam generator 2-1, 2-2, 2-3, 2-4 final radiographs.
Steam Generator 2-1 ISO 2FW77 Weld No.
OWlF, Elbow to Reducer (Backing Ring)
0-12
- no comment 12-24 - no comment 24-36 - no comment 36-0
- no comment Weld No.
OW2F, Elbow to Nozzle (Butt)
0-12
- no comment 12-24 - remove attachment weld and PT 24-36 - no comment 36-0
- no comment
Steam Generator 2-2 ISO 2FW74 Meld No.
OWlF, Elbow to Reducer (Backing Ring)
0-14
- no comment 14-29 - nonpenetration burn through (22, 27"28)
29-42 - questionable 42-0
- questionable Meld No.
OW2F, Elbow to Nozzle (Butt)
0-14
- no comment 14-29 - no comment 29-42 - no comment 42-0
- no comment Steam Generator 2-3 ISO 2FW75 Weld No.
OW1F, Rejected, Elbow to Reducer (Backing Ring)
0-12
- no comment 12-24 - nonpenetration, 16-17 24-36 - nonpenetration, 31-34 36-0
- no comment Weld No.
OW2F, Elbow to Nozzle (Butt)
0-12
- no comment 12-24 - no comment 24-36 - no comment 36-0
- no comment Steam Generator 2-4 ISO 2FW76 Weld No.
OWlF, Elbow to Reducer (Backing Ring),
0-13
- no comment 13-26 - no comment 26-40 - no comment.
40-0
- no comment Weld No.
OW2F, Rejected, Elbow to Nozzle (Butt)
0-13
- no comment 13-26 - Backing plate nonfussion slag 22, 24-31 26-40 - Nonfussion backing plate 40-0
- no comment The following is the inspectors evaluation of the Unit 1 Steam Generator 1-1, 1-2, 1-3, 1-4 final radiographs.
- 6-
Steam Generator l-l ISO 1FW77 Weld No.
OWlF, Elbow to Reducer (Backing Ring)
Meets Code acceptance standards.
Weld No.
OW2F, Elbow to Nozzle (Butt)
Meets Code acceptance standards.
Steam Generator 1-2 ISO 1FW74 Weld No.
OWlF, Elbow to Reducer (Backing Ring)
Meets Code acceptance stnadards.
Weld No.
OW2F, Elbow to Nozzle (Butt)
Meets Code acceptance standards.
Steam Generator 1-3 ISO 1FW75 Weld No.
OW1F, Elbow to Reducer (Backing Ring)
Meets Code acceptance standards.
Weld No.
OW2F, Elbow to Nozzle (Butt)
Meets Code acceptance standards.
Steam Generator 1-4 ISO lFW76 Weld No.
OWIF, Elbow to Reducer (Backing Ring)
Meets Code acceptance standards.
Weld No.
OW2F, Elbow to Nozzle (Butt)
Meets Code acceptance standards.
No items of noncompliance or deviations were identified.
Ultrasonic Examination Ultrasonic examination (UT) of the nozzles and elbow welds was performed by Southwest Research Institute (SwRI) prior to cutting of elbows to confirm material thickness and radiographic indications in accordance with SRI procedure No. 600"3"52.
Following final radiography all nozzle welds were UT examined by SwRI in accordance with draft procedure 800-64, Revision 0, developed on site and documented on Deviation and Nonconformance Report No.
79"071, titled "Manual Ultrasonic Examination of D.
C.
Cook Unit
and 2 Steam Generator Feedwater Nozzles."
This procedure was used
to establish a new baseline for future ISI examinations.
The inspector observed the collection of some of the data, and reviewed the results as follows:
Steam generator l-l, elbow to nozzle weld, Sheet No. 13011-140015,
.12 indications above 50$ dac recorded.
Steam generator 1-2, elbow to nozzle weld, Sheet No. 130312-130313-140016, 16 indications above 50/ dac recorded.
Steam generator 1-4, elbow.to nozzle weld, Sheet No. 130307-130308-140013, 12 indications above 50$ dac recorded.
Steam generator 2-1, elbow to nozzle weld, Sheet No. 130041-140006-140007-140008-140009-140010, 20 indications above 50'/ dac recorded.
SwRI Customer Notification Form Serial 1 recorded 3 indications exceeding Subarticle B-2-160 of USAS B31.7, 1969.
Indications 8"12"13 recorded as being 5/16" long.
Sheet No. 130042-140012,
indications above 50$ dac recorded.
Steam generator 2-2, elbow to nozzle weld, Sheet No.
130303,
indications above 50$ recorded.
Steam generator 2-3, elbow to nozzle weld, Sheet No. 130024-140001, 18 indications above 50$ dac recorded.
Steam generator 2-4, elbow to nozzle weld, Sheet.
No. 130309-130310-140014, 8 indications above 50/ dac recorded.
No items of noncompliance or deviations were identified.
6.
Personnel ualifications The inspector reviewed the qualification records of the following personnel involved in the feedwater nozzle/pipe repair activities.
a ~
Indiana and Michi an Quality Assurance Quality Control Welder b.
A alachian Power Com an Co Welder Power S stems Inco orated Welder-8"
d.
Southwest Research Institute Nondestructive Examination Inspectors Qualifications were in accordance with ANSI N45.2.6, ASME Section IX and SNT-TC-lA as applicable.
No items of noncompliance or deviations were identified.
7.
E ui ment and Material Certifications The inspector confirmed the certification and calibration of the following equipment and materials use on feedwater nozzle/pipe repair activities.
Penetrant Materials Cleaner - SKC-NF-87F097 Penetrant
- 4A118 Developer SKD-NF"78E125 Ultrasonic E ui ment Instruments Sonic Mark
S/N " 774206, 774711, 780419, 740518 Transducers S/N 776
- 2.25 Mhz 234
" 2.25 Mhz 808
- 2.25 Mhz C03844 - 2.25 Mhz 582
- 2.25 Mhz Glycerine Lot No. TB-09058-3 Heat Tieatment Instrument Model-9B, S/N-68121956 Elbow Material Certifications Heat No. 284161, 184414, 5885 Weldin Material 1/8" E70S2 - ASP-904 3/32" E70S2 - ASP"912 No items of noncompliance or deviations were identifie.
Documentation Review A documentation package for repair activities on each steam generator was developed.
The inspector reviewed Unit 1 and 2 documentation.
Several questions on Unit 2 documentation were corrected by the maintenance engineer prior to the exit meeting.
No items of noncompliance or deviations were identified.
9.
Audit An audit of repair activities was performed by IBM QA department between June 12, 1979, and July',
1979.
The inspector reviewed the draft report of this audit.
No items of noncompliance or deviations were identifed.
-10-
Section II Prepared by K. D. Ward J. J. Harrison Reviewed by D. H. Danielson, Chief Engineering Support Section
Messrs.
J. J. Harrison and K. D. Ward conducted an independent examination interpreting Unit 2 radiographs June 27, 1979, and found the following discrepancies.
~
General a.
No one knew actually to what Code, year or addenda the radiography was performed to or the acceptance criteria.
b.
There was no indication on the reports or the radiographs that a repair had been made.
The licensee stated that all the welds had been repaired.
C ~
There were areas where the weld extended beyond the sides of the backing ring that could not be interpreted because of the areas being over 4.0 density.
d.
There were areas where the film density through the diagnostic area varied by more than -15 or +30 percent from the density through the penetrameter.
e.
Definition, latitude and sensitivity were poor.
Denfinition:
Sharpness of outline of the image on a radiograph.
Latitude:
The range of thickness of material that can be transferred on the radiograph within the useful reading range of film density.
Sensitivity:
A measure of the capability to detect a
discontinuity.
2.
~Secifics Steam Generator 2-1 Weld OWIF, ISO 2FW77,
Elbow to Reducer 0"12, Over 4.0 density adjacent to backing strip, does not meet
"15 +30.
<<11-
12-14, No comments 24-36, No comments 36-0, Over density in backing ring gap.
Weld OW2F, ISO 2FW77, Elbow to Nozzle 0-12, Areas over 3.8 density, does not meet -15 +30 12-24, Penetrameter on the edge of weld.
24-36, No comment 36-0, No comment Steam Generator 2-2 Meld OW1F, ISO 2FW74,
Elbow to Reducer 0-14, Over density in backing ring gap, over 4.0 density adjacent to backing strip, does not meet -15 +30.
14-29, No comment 29-42, No comment, 42-0, No comment Weld OW2F, ISO 2FM74, Nozzle to Elbow 0-14, Penetrameter in weld, area over density.
14-29, Penetrameter in weld 29-42, No comment 42-0, Does not meet -15 +30, report does not state acceptable or reject.
Steam Generator 2-3 Meld OW1F, ISO 2FW75,
Elbow to Reducer 0-12, No comment 12-24, Area 16-17, 27-28, and 29-32, lack of penetration (LP).
Requested a reradiograph because of poor radiography and a
reinterpretation before repair.
24-36, No comment 36-0, Over density adjacent to backing strip.
Weld OM2F, ISO 2FW75, Elbow to Nozzle 0-12, Does not meet -15 +30 12-24, Does not meet -15 +30 24-36, Does not meet -15 +30, linear indication 1/2" across root.
Licensee stated surface indication, but was not indicated on report, could be LP.
36-0, Does not meet -15 +30 Steam Generator 2-4 Weld OWlF, ISO 2FW76,
Elbow to Reducer 0-13, Over density in backing ring gap, does not meet -15 +30 13-26, Over density adjacent to backing strip 26-40, No comment 40-0, No comment 12 "
Weld OW2F, ISO 2FW76, Nozzle to Elbow 0-13, No comment 13-26, Backing ring used as a patch 26-40, In repairing weld the patch has an abrupt configuration, making a dark straight line in the area of interest.
This could be masking a defect.
40-0, No comment Unresolved Items Unresolved items are matters about which more information is required in order to ascertain whether they are acceptable items, items of noncompliance, or deviations.
Unresolved items disclosed during the inspection are discussed in Section I, Paragraph 4.
I Exit Interview The inspector met with licensee representatives (denoted in the Persons Contacted paragraph)
at the conclusion of each portion of the inspection, and at the final exit on July 2, 1979.
The inspector summarized the scope and findings of the inspection, and discussed the item of noncom-pliance identified in Appendix A of this report.
i