IR 05000315/1981010
| ML17319A931 | |
| Person / Time | |
|---|---|
| Site: | Cook  |
| Issue date: | 05/27/1981 |
| From: | Danielson D, Key W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML17319A930 | List: |
| References | |
| 50-315-81-10, 50-316-81-07, 50-316-81-7, IEIN-81-04, IEIN-81-4, NUDOCS 8106120313 | |
| Download: ML17319A931 (19) | |
Text
U.S.
NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT
REGION III
Report Nos.
50-315/81-10; 50-316/81-07 Docket Nos.
50-315; 50-316 Licenses No.
American Electric Power Service Corporation Indiana and Michigan Power Company 2 Broadway
'ew York, NY 10004 Facility Name:
Donald C.
Cook Nuclear Plant, Units 1 and
Inspection At:
D. C. Cook Site, Bridgman, MI Inspection Conducted:
March 16-17, 25-27, April 6-8, 22, and May 4-5, 1981 Inspector:
W. J. Key Approved By:
D. H. Danie son, Chief Materials and Processes Section Ins ection Summa Ins ection on March 16-17 25-27 A ril 6-8
and Ma 4-5 1981 (Re ort Nos. 50-315/81-10 50-316/81-07)
Areas Ins ected:
Review of feedwater line elbow replacement activities; review of radiographic examination performed in accordance with IE Information Notice 81-04; review of inservice inspection (ISI) program, procedures, work activities and records; licensee actions on IE Bulletins.
The inspection involved a total of 82 inspector-hours onsite by one NRC inspector.
Results:
No items of noncompliance or deviations were identified.
'3.06 12 0
DETAIIS Persons Contacted Indiana and Michi an Electric Co an (IBM)
+D. L. Shaller, Plant Manager
+J. Stitzel, gA Manager
+H. Bolinger, ISI Coordinator
- E. Morse, QC Supervisor D. Dudding, Maintenance Superintendent F. Pisarsky, Maintenance Engineer American Electric Power Service Co oration (AEP)
D. Patience, Staff Metalurgist J. Jensen, Staff Engineer Power S stems J.
Pedone, Site Manager M. Shore, QC Supervisor
+Denotes those present at the entrance and exit interviews.
Iicensee Action on IE Bulletins IE Bulletin 79-03A, Weld Defects in SA-312 Type 304 Stainless Steel Piping.
Item 1, required the licensee to determine whether this material was used or planned for use in safety-related systems of their facility, subject to design stresses greater than 85 percent of the code allowable stresses.
In a letter to Region III dated April 4, 1979, the licensee stated that no seam welded pipe was used or planned for use in D. C.
Cook safety-related systems.
The inspector reviewed the licensee's records and considers appropriate corrective actions were taken.
This IE Bulletin is considered closed.
IE Bulletin 80-08, Containment Liner Penetration Welds.
Item 1, required the licensee to determine whether their facility contained flued head designs as illustrated in Figure NE-1120-1, Winter 1975 Addenda=-
to the 1974 and later editions of the ASME BGPV Code, and to determine the type of weld joint, type of nondestructive examinations performed and the results.
In a letter dated July 9, 1980, to the Region III office, the licensee stated that flued head designs as illlustrated in Figure NE-1120-1, were installed in the D.
C.
Cook Nuclear Power Plant.
That
all butt~welds referred to in IE Bulletin 80-08 were inspected during construction by radiographic examination, without the use of backing bars.
The inspector"confirmed that no backing bars were present by re" viewing records and radiographs of these welds.
This IE Bulletin is considered closed.
IE Bulletin 79-13, Cracking in Feedwater System Piping.
On May 20, 1979, the licensee discovered leakage adjacent to the elbow to nozzle welds on two 16 inch steam generator feedwater lines, further radio-graphic examinations revealed cracking in all eight feedwater lines.
The elbows on all eight feedwater lines were replaced, and documented in IE Reports No. 50-315/79-10 8 50-316/79-07.
During the 1980 refueling outage for unit No. 1, the elbows were removed and replaced with new elbows with thermal sleeves designed by Westinghouse Electric Corporation.
See IE Report No. 50"315/80-10.
During this refueling outage for unit No. 2, the elbows on three steam generator feedwater lines were replaced with the thermal sleeves designed by Westinghouse.
The inspector witnessed the removal of the installed elbows, the installation, welding-and radiographic examinations performed on the replacement elbows.
This IE Bulletin is considered closed.
IE Bulletin No. 81-01, Surveillance of Mechanical Snubbers.
The licensee responded to the Region III office in a letter dated
~
March 12, 1981, that a review of safety-related snubbers installed at the D.
C.
Cook plant. had been performed, and had determined that mechanical snubbers were not installed on safety-related systems at the D.
C. Cook Plant.
The inspector reviewed the licensee's records and considers appropriate corrective actions were taken.
This IE Bulletin is considered closed.
Functional or Pro ram Areas Examined l.
ISI Pro ram Review The Southwest Research Institute (SwRI) Project No. 17-5806, 1981 Examination'Plan of Selected Components of D.
C.
Cook Nuclear Plant Unit 2, was reviewed.
The following Class 1 and Class 2 components are to be examined during this refueling outage.
Class 1 Items Vessel to Flange Welds Nozzle to Shell and Shell to Nozzle Welds Nozzle Inside Radius Sections Nozzle Integral Extentions Vessel Penetrations Nozzle to Safe-End and Safe-End to Nozzle Welds Closure Studs, Nuts, and Washers Heater Connections/Instrument and Sample Penetrations Pressure Retaining Bolting Circumferential Welds
Class 2 Items Various Pipe Restraint Components No items of noncompliance or deviations were identified.
2.
ISI Examination Procedure Review I
The following Southwest Research Institute (SwRI) examination procedures were reviewed for conformance to NRC and ASME Code requirements and licensee review and approval.
IX-FE-101-1, Deviations to Nuclear Field Service Section Operating Procedures IX-FE-103-1, Weld Joint Identification Marking on Nuclear Power Plant Pip'ing IX-FE-104-2, Measuring and Recording Search Unit Location and Maximum Signal Amplitude Data During Ultrasonic Weld Examination.
IX-FE-105-0, Recording Data From Direct Visual, Liquid Penetrant, and Magnetic Particle Examination of Welds.
IX-FE-110-0, Black Light Intensity Measurements.
IX-FE-119-0, Measuring and Recording Search Unit Data During Ultrasonic Examination of Pressure Vessel Welds.
X-FE-101-1, On-Site NDE Record Control X-ill-AC-101-1, Control of Nuclear Inspection Equipment and Materials.
SwRI-NDT-200-1/51, Liquid Penetrant, Color Contrast Method.
SwRI-NDT-600-15/42, Manual Ultrasonic Examination of Pressure Vessel Welds.
SwRI-NDT-600-18/28, Manual Ultrasonic Examination of Pressure Retaining Studs and Bolts 2" or Greater in Diameter Containing Access Holes.
SwRI-NDT-700-5/6, Mechanized Ultrasonic Examination of Vessel Components, Vessel Welds, and Piping Welds.
SwRI-700-6/7, Mechanized Ultrasonic Examination of Ferritic Vessels 2.5" or Greater in Thickness.
SwRI-NDT-900-1/48, Visual Examination of Nuclear Reactor Components by Direct or. Remote Viewing.
/
-4<<
X11-PM-116-0, Calibration of Model ISI-2 Inservice Inspection Position System and Attachments (PAR) Device.
17-3389-PV-01, Positional Verification Guide for the Model ISI-2 Inservice Inspection Position System and Attachments (PAR) Device.
The following drawings used for mechanized ultrasonic examination of the reactor vessel were reviewed as part of the examination procedures.
Dwg. No. D-3378726, Vessel Flange to Upper Shell Circumferential Weld Examination from Seal Surface.
Dwg. No. D-3378717, Integral Extension
'
Examination.
Dwg. No.'-SK-3378713"A, Outlet Nozzle to Shell Examination Cook P2.
Dwg. No. C-SK-3378719-A, Outlet Buttwelded Examination Cook 82.
Dwg. No. D"3378716, Inside Radius Examination of Outlet Nozzles.
Dwg. No. D-3378955, II Inch Clad Vessel Ultrasonic Calibration Block.
Dwg. No. D-3378-066-A, Main Reactor Coolant Loops Standards.
Dwg. No. D-3378052, 3" Inch Plate Ultrasonic Calibration Block.
r Dwg. No. D-3378059, Inlet and Outlet Nozzle Inner Radius Ultrasonic Calibration Block Dwg. No. D-3378058-B, Nozzle to Shell Ultrasonic Calibration Block.
3.
Feedwater Elbow Installation Procedures The following approved procedures for feedwater elbow installation were reviewed.
IQi Procedure 2QHP-SP<<RFC-2435A, Revision 0, Installation of Feedwater Thermal Sleeve Elbows, Steam Generators No. 21, 22, 23.
33F, Shielded Metal Arc Welding, PQR-92"33 11I, Gas Tungston Arc Welding, PQR-02-11 13D, Gas Tungston Arc Welding/Shielded Metal Arc Welding, PQR-106-14 llA, Gas Tungston Arc Welding/Shielded Metal Arc Welding, PQR-101-11 11AT, Gas Tungston Arc Welding, PQR-02-11 Cooper Heat Procedure CH-0099', Unit 2 No, items of noncompliance or deviations were identified.
4.
Pe'rsonnel ualifications and Certifications Records of the following NDE personnel, and welders were reviewed for conformance to ASME Code and NRC Requirements.
Indiana and Michi an Electric Com an (IBM)
Name E. A. Morse R. E. Kernosky C. A. Freer D. I. Hickcox R.
C. Roop D. M. Ruth M. W. Wiederwax RT PT IIIR II IIR IIIIIIIIIIII II II II II IIIIIIIIII IIIIIIIIIIIIII Su erior Industrial X-Ra (SIX)
Name R. T. Rickman G. P. McGrath J. L. Ouellette J. F. Steinhauser J.
E. Turner D. J. McMullin IIIIIIIIIII II II II II II II II II II II I
'
II IIIIIIIIII RT PT MT UT VT Southwest Research Institute (SwRI)
Name R.
W. Williams J. T. Smith R. A. Ries R. L. Niemeyer P.
N. Nash F.
C. Leonard D. A. Kling A. R. Jaschke P.
C. Gaines G. A. Ergish M. R. Ehnstrom PT MT UT VT I
I I
I IT I
II I
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I II II II II I
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I II II II II I
II II I
I II IT I
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Westin house Electric Co oration (W)
Name J. L. Samios R. D. Rehak E. J.
Hako (Zetec)
D. R. Francis R. P. Hazen J.
E. Mills Welder Certifications (Power S stems)
Name D. Harris B. Graham V. Vochaska R. Buckland E. Felt J. Ieto S. Motz J.
McCoer M. Davis W. Robinson Stamt No.
PS-1 PS"10 PS-4 PS-12 PS-35 PS-53 PS-91 PS-114 PS-125 PS-127 No items of noncompliance or deviations were identified.
5.
E ui ment and Materials The following eqiupment and materials for ISI examinations were examined for certifications and calibration requirements.
Ultrasonic E ui ment Data Collectin Sonic MK-1, S/N-792026, 771216, 771217, 771218.
Data Display Panel, S/N-103 Brush Recorder, Model 260, S/N-13720
,Apex 500 Tape Recorder, S/N-13403
Transducers S/N
.Size M104 11278 11869 013083H 012655 016406M H22986 938 2044 1232 1"
1/2"xl" 1/2"xl" 1/2lt 3/4 It 3/4tl 1/4lt 1/2"xl" 1/2" 1/2"xl" 2.25 2.25 1.0 2.25 2.25 2.25 2.25 1.5 2.25 1.0 Ma netic Particle Materials White Line Probe - S/N - WL-1-4 Parker Probe - S/N-1784 Thermometers, Dayton guick-Tem.
Model 5X666 S/N-930307, 940367, 741423 Black Light Intensity Meter, Model (Black-Ray)
J 221, S/N'-20924, 11655 Magnetic Particles, Magnaflux 14AM Prepared Bath, Batch No. 80H105.
Li uid Penetrant Materials Spotcheck, Cleaner, SKC-S Batch No.
81A055 Spotcheck, Penetrant, SKL-HF/S, Batch No.
79C127 Spotcheck, Developer, SKD-S, Batch No. 800094 No items of noncompliance or deviations were identified.
Observation of Activities The inspector witnessed the setting up and calibration of the mechanized ultrasonic examination device (PAR) and the collection of ultrasonic data on-the reactor vessel and nozzle welds.
The following reactor vessel studs, nuts, and washers were nondestructively examined and witnessed by the inspector.
No 5, 9, 10, 12, 22, 28, 32, 34, 40, 45, 48, and 52.
The inspector witnessed the cutting and removal of the standard
feedwater line elbows on steam generators no. 21, 22, and 23, including the weld buildup of the outside diameter of the inlet nozzles, machining of the OD and weld preparations.
The new elbows containing thermal sleeves were designed by Westinghouse.
The inspector witnessed inprogress NDE and reviewed final radiographs of completed weld During a surveillance of the reactor vessel head for tools, the licensee noted boric acid deposits around some of the CRDM's.
On further investigation it was determined that the deposits were around No.
P6 and H10.
Westinghouse Electric Corporation was contracted to perform further investigations and make repairs as needed. On May 4, 1981, a liquid penetrant (PT) examination was performed on both CRDM's to pinpoint the source of leakage, however, this examination did not reveal any indications.
The'icensee has decided to return to operation as'cheduled and examine these areas during the next refueling outage, or sooner, should indications of excess leakage appear.
No items of noncompliance or deviations were identified.
7.
Documentation Review The inspector reviewed the following records of ISI examinations performed and feedwater line elbow replacements.
SwRI Instrument Calibration Records Sheet No.
190003 Instrument, Sonic MK-1, S/N1707E Procedure, 600-15, Revision 42 Transducer, S/N M104, 1239 Calibration Block RV-3 Sheet No.
190004 Instrument Same as above Transducer, S/N 1715 Sheet No. 250001 Instrument, Sonic MK-1, S/N, 01107E Tranducer, S/N 1715 Instrument I,inearit Verification Records Sheet No. 370026 Calibration Block, TV-3 Mechanized Instrument Calibration Records Sheet No. 57001 Instrument, Sonic MK-II, S/N, 771216 Calibration Block, NS-CSCL-7-DCC Transducer, S/N, M0105
- 9 "
Sheet No. 570002 Instrument,, Sonic, MK-II, S/N, 771217 Calibration Block, IR-CSCL-8-DCC Transducer, S/N, M0104 Sheet No. 570003 Instrument, Sonic MK-II, S/N, 771215 Tranducers, S/N, M0102 Sheet No. 570004 Instrument, S/N, 792026 Transducer, S/N, 0130844 Sheet No. 57008 Instrument, S/N, 792026 Transducer, S/N, 689/1919 Examination Records Sheet No. 700001-123, 700002, 700003 RPV, Outlet Nozzle, Loop
Weld No. 2-Nl-0 Sheet No. 70004, 5, 6.
RPV Outlet Nozzle, Loop 2 Weld No. 2-N2-0 Sheet No. 700011 RPV Outlet Nozzle, Loop
Weld No. 2-RPV-1-01 Sheet No. 700013 RPV Outlet Nozzle, I,oop 2 Weld No. 2-RPV-2-01 Scan Plan Examination Table Examination No.
1 RPV Nozzle to Shell, Loop 2 Weld No. 2-N2-0 Examination No. 5, RPV, Ioop
Integral Extension Weld No. 2-Nl-0-0-lE Examination No. 8, RPV, Ioop 2 Nozzle to Safe-end Weld No. 2-RPV-2-01 Examination No. 10, RPV, Loop
Safe-end to Pipe Weld No. 2-RC-17-01-10-
Examination Summa Records Sheet No. 001800 RPV to Flange Welds,
, 57
,
125 Sheet No. 002100 RPV, Nozzle to Shell Weld,
,
, From Nozzle Base Sheet No. 002900 Inside Radius, Nozzle Bore, 2 Nl-0 Sheet No. 003100 Inside Radius Nozzle Bore 2-N2-0 Sheet No. 003700 Nozzle to Safe-end, 2-RPV-1-01 and W-2-RC-17-01 Sheet No. 003700 2-RPV-2-W.Ol and 2-RC-18-01 Sheet No. 009500 Steam Generator 22-01 Weld 30" from 240" to 270" Feedwater Line radio ra hs The following final, after stress relief, radiographs of feedwater line welds were reviewed for acceptance.
Steam Generator No.
Field Weld No. 3, Line 2FW77, Pipe to Reducer and Field Weld No. 2R1, Nozzle to Elbow.
Steam Generator No.
Field Weld No. 2, Line 2FE74, Nozzle to Elbow and Field Weld No. 3, Pipe to Reducer.
Steam Generator No. 23, Field Weld No. 2Rl, Line 2FW-75, Nozzle to Elbow and Field Weld No. 3, Pipe to Reducer Steam Generator Tube Examination Following eddy current examination of steam generators 21, and 24, the following tubes were plugged.
Steam Generator No. 21 Row
1
1 Column
91
94 11-
Steam Generator No. 24 Row Columns
1
1
1
1
t
91
93
1
3
5 No items of noncompliance or deviations were identified.
8 ~
IE Information Notice No. 81-04 Crackin in Main Steam Lines This information notice recommended that licensees perform ultrasonic and/or radiographic examination of the welds and counterbore areas of the T-fittings.
On March 24, 1981, the licensee performed radio-graphic examination on the following steam line welds.
Weld No. 2, Line M592-R5, SWB, Pipe to Tee Weld No. 2, Line MS-92-R5, SWD, Pipe to Tee Weld No. 2, Line MS-96-R5, FW2, Valve to Tee This inspector reviewed these radiographs during this inspection.
No indications of cracking were identified.
Exit Interview The inspector met with licensee representatives (denoted under Persons Contacted) at the conclusion of each inspection, and the final inspection on May 5, 1981.
The inspector summarized the scope and findings of the inspections during this outage.
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