IR 05000315/1992013
| ML17329A627 | |
| Person / Time | |
|---|---|
| Site: | Cook  |
| Issue date: | 09/29/1992 |
| From: | Jeffrey Jacobson, Ward K NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML17329A626 | List: |
| References | |
| 50-315-92-13, NUDOCS 9210060186 | |
| Download: ML17329A627 (11) | |
Text
U.
S.
NUCLEAR REGULATORY COMMISSION
REGION III
Report No.:
50-315/92013 (DRS)
Docket No.:
50-315 License No.:
DPR-58 Licensee:
Indiana Michigan Power Company 1 Riverside Plaza Columbus, OH 43216, Facility Name:
Inspection At:
D.
C.
D.
C.
Cook Nuclear Plant,'nit
I Cook Site, Bridgman, MI 49127 Inspection Conducted:
July 7-9, 14,-16, 21-23, 29-30, August 4-6, 11-13, 18,-27, September 1-3, and 16-17, 1992 Inspector K.
D Approved By J.-
M aco son, Chz f ials nd Proce ses Section Date
? -%~i -~il Date Ins ection Summar Ins ection conducted on Jul 7-9 14-16 21-23 29-30 Au ust 4-
11-13
27 Se tember 1-3 and 16-17 1992 Re ort No.
50-315 92013 DRS Areas Ins ected:
Routine unannoun'ced safety inspection of inservice inspection (ISI) activities including review of programs (73051),
data (73755),
procedures (73052),
observation of work activities (73753),
review of the erosion/corrosion (E/C)
program (49001),
and facility modifications (37701).
Results:
No violations or deviations.were identified.
Based on the results of the inspection, the NRC inspector noted the following:
The licensee adequately demonstrated the ability to properly implement the modifications, E/C, and ISI programs, including the eddy current examinations of the steam generator tubes.
Licensee staff and contract personnel performing nondestructive examinations (NDE) and welding were knowledgeable and competent.
9210060186 920'730 PDR ADOCK 05000461 G
Inspection Summary Management was involved in the modifications, E/C and ISI activities in an eff'ective manner.
In the E/C effort, approximately 315 components were ultrasonically examined.
This number of examinations represents a significant effort and strong commitment to the licensee's erosion/corrosion progra DETAILS P
Persons Contacted Indiana Michi an Power Com an IM
- G. Weber, Plant 'Engineering Superintendent
- C. Freer,'ISI Supervisor
- J. Fitchuk, NDE Technology Engineer E. Abshagen, General Supervisor, Design Changes E. Anderson, E/C Lead D. Timmons, Construction Modification Coordinator E. Brouwer, Project Engineer E. Teiziaff, Plant Engineering U.
S. Nuclear Re ulator Commission NRC
- J. Isom, Senior Resident Inspector
- D. Hartland, Resident Inspector
- W. Pegg, Technical'Intern Southwest Research Institute SWRI M. Teems, Level II M S Ins ection M S J.
Ryan, Level II Westin house Electric Cor oration W
W. Stock, Level -III CONAM Nuclear CONAM M. Chambers, Level III Factor Mutual En ineerin FME M. Muterspaugh, ANII
The NRC inspector also contacted and interviewed other licensee and contractor employees.
- Denotes those present during the exit interview on September 17, 199 ~
Inservice Ins ection ISI Unit 1 a ~
Pro ram Review 73051 Personnel from Dynacom Systems, Inc.
(DSI),
SWRI, IM, CONAM, and W, performed the ISI in accordance with the licensee's program and ASME Section XI, 1983 Edition, Summer 1983 Addenda.
The licensee did not make a
request for relief from the ASME Code for this outage.
The NRC inspector reviewed Audit No. 92-AR-020 and several surveillances of the ISI program activities performed by SWRI.
The audit and surveillance effort was found to be acceptable and performed by qualified personnel.
Organizational staffing for the ISI program was found to be acceptable and the services of an Authorized Nuclear Inservice Inspector (ANII) were procured from Factory Mutual Engineering.
b.
Procedure Review 73052 All applicable ISI procedures were approved by the ANII and were reviewed by the NRC inspector.
The ISI procedures were found to be acceptable and in accordance with ASME Section V,
1983 Edition, Summer 1983 Addenda.
c ~
Data Review 73755 (1)
General The examination data was found to be in accordance with the applicable ISI procedures and ASME Code requirements.
The NRC inspector reviewed documents related to nondestructive examination equipment, data, and evaluations.
(2)
Edd Current Examinations ET During this outage, 100~ of the accessible tubes were examined full length.
The examinations were conducted utilizing the Zetec MIZ-18 multifrequency digital examination equipment with associated acquisition software and remote positioning devices.
Motorized rotating pancake coil (MRPC)
examinations were performed to supplement the bobbin coil examinations.
The MRPC was used to further characterize crack orientation, manufacturing burnish marks, undefined indications, and distorted indication Most of the unacceptable indications were located at the top of the tube sheets on the hot leg side.
There were very few unacceptable indications in the support plate area.
A total of 1,840 tubes were sleeved and 512 were plugged with Inconel 690 tube plugs during this outage.
Westinghouse also removed 364 Inconel 600 alloy steam generator tube plugs from the four generators due to IGSCC concerns and replaced them with the Inconel 690 alloy plugs.
Observations of Work Activities 73753 The NRC inspector observed work activities and had discussions with personnel during the ISI activities.
These observations included the following:
SWRI personnel performing ultrasonic examinations on pipe weld No. 1-SI-3-045.
This weld was in the safety injection system.
Ultrasonic examinations were also observed on the stub barrel to shell weld'No.
STM-12-05, steam generator No.
12.
(2)
SWRI personnel performing liquid penetrant examinations on pipe weld No. 1-CTS-2-18-F.
This weld was in the containment spray system.
Liquid penetrant examinations were also observed on pipe weld No. 1-I-3-045. 'his weld was in the safety injection system.
(3)
Westinghouse personnel performing eddy current examinations on the tubes in the four steam generators and Westinghouse and CONAM personnel evaluating eddy current examination data.
(4)
Westinghouse personnel performing sleeving operations on the tubes, removal of the Inconel 600 plugs, and replacement of those plugs with Inconel 690 type in the four steam generators.
(5)
DSI personnel performing visual examinations (VT)
of the reactor vessel internals using an underwater TV camera (Mini Rover) in conjunction with video tape recorders to record. the examinations.
The following components were VT'd:
/
(a)
(b)
(c)
(d)
(e)
upper core plate support columns control rod guide tubes upper barrel to lower barrel girth weld reactor vessel
"0" ring seating-surface
I The NRC inspector reviewed the qualifications and certifications of all ins'pection personnel performing ISI to ensure conformance with SNT-TC-1A.
3 ~
No vi'olations or deviations were identified.
Erosion Corrosion E
C Activities 49001 Indiana Michigan Power Company began their E/C program in 1982.
In 1986, a formalized procedure and administrative controls were established to ensure continued long term implementation of an E/C monitoring program for piping and components (Reference NRC Inspection Report No. 50-316/92007 (DRS)).
For this refueling outage, IM selected an inspection sample of approximately 315 components, utilizing the EPRI Chec, Checmate computer program.
Of the 315 components examined, 27 were unacceptable and were replaced this outage.
The NRC inspector reviewed the E/C program, procedures, NDE certifications, data from previous inspections, and observed M&QS personnel performing ultrasonic thickness examinations of several piping components on the bleed steam and feedwater systems.
To date, several components and pipe sections have been repaired/replaced as a result of the E/C program.
The NRC inspector observed the National Installation Services
'Company (NISCo) personnel performing cutting, fitting, and welding operations, and visually examined several completed repairs "in the bleed steam, main steam drain, essential service water, and steam jet air ejector systems.
The NRC inspector also reviewed work requests, drawings, weld data sheets and other related documentation.
4 ~
Modifications 37701 The NRC inspector reviewed several plant modifications in progress during the current outage.
The designs of the following modifications were in accordance with ANSI B31.1, and the required inspections were in'ccordance with ASME Section XI.
/
a.
Main Steam Enclosure Slab and Beam Modification No.
RFC-DC-12-3100 A commitment was made to the NRC in LER 92-001-00 to restore the West main steam enclosure floor slabs and beams to their design basis, meeting seismic Class
requirements.
The problem was identified as the inability of the 621'-6" floor slab and integral supporting beam in both West main steam enclosures to
meet the design basis criteria for a steam line break.
The modifications consisted of adding steel plates to the top and bottom of the concrete beams, and connecting this reinforcement with steel rods inserted vertically through the beams.
In addition, three columns were installed between the 612'-0" floor and the underside of the 621-6" slab to provide additional reinforcement.
These modifications restored 'the slabs and beams to meet their design basis.
The NRC inspector reviewed drawings, the design change overview, job orders, and related documentation.
Also, the NRC inspector observed drilling of holes in concrete, installation of plates and columns, and visually examined the completed modification and* found
'it to be acceptable.
b.-
Pi in Su ort Modifications No. RFC-DC-12-3078 and No.
RFC-DC-12-3077 A commitment was made to the NRC in IM letter AEP:NRC:1100A to restore.and/or modify approximately
large bore Class 1 piping pipe supports to their design basis.
These supports were identified during EBASCO's large bore pipe study as not meeting IM's design basis as defined in the FSAR.
An additional 20 supports requiring modification were identified during several IM inspections.
The NRC inspector reviewed NRC reports, drawings, the design change overview, and related documentation.
Also, the NRC inspector observed the pads being installed for several pipe supports, and visually examined several of the completed modified *pipe supports and found them to be acceptable.
No violations or deviations were identified.
Ice Condenser Baskets 62703 During an IM visual examination (VT) of an ice condenser basket, the fillet welds that connect the ice basket support bar (ASME-A36 material) to the ice basket bottom ring (ASME-A622 material)
assembly were found to be separated.
After a VT of 100>
(1,944) of the basket assemblies, a total of 22 end assemblies were found to be in the above condition in Unit 1.
'After the same amount (1,944)
were VT'd in Unit 2, three end assemblies were found to be in the above conditio The ice condensers maintain a large volume of borated ice to serve as a heat sink for condensing steam released during design basis LOCA accidents.'he geometry of the ice bed is maintained using a complex lattice frame structure in combination with ice baskets that provide the required flow passage to achieve the overall heat transfer properties.
The equipment was classified as ANS Safety Class 2.
The original welds were welded with the gas metal arc process in accordance with AWS D1.1-72.
Westinghouse had LAMCo Industries, Inc., fabricate the original baskets in 1974.
This contractor is now out. of business.
Stearns Airport Equipment Co. Inc. of Ft. Worth, Texas, fabricated the new replacement baskets and were evaluated by IM QA prior to fabrication.
The new baskets were welded in accordance with AWS D1.1-90.
The ice condenser baskets are one foot in diameter and fabricated by roll forming and welding perforated sheet metal into cylinders.
Four 12'ylinders were coupled together to form a 48'olumn used to. contain borated ice.
The column is secured to the ice condenser lower support structure at the bottom assembly with two U bolts to prevent ejection during the design basis accident.
The bottom assembly also supported the borated-ice particles with a system of grid bars and wire mesh.
The 22 unacceptable ice baskets were replaced this outage and the 3 in Unit 2 will be replaced the next outage.
Beams have been secured over the 3 baskets as a safety measure.
The NRC inspector was given a tour of the chillers, ice machine area and inside the lower and upper ice condenser areas.
The inspector also observed vibrating of the ice in the ice baskets, ice basket replacement, personnel assembling ice baskets and VT's of eight failed welds in Bay 23.
-The support bar measured 1/2" x 4" x 12" and was welded inside the bottom ring fabricated from 12 gauge sheet metal.
The 1/2" bar had good weld fusion but the 12 gauge sheet metal was not fused.
Galvanizing material was on the weld and the sheet metal where the weld and metal were to be fused.
The presence of galvanizing material in this area indicates that the unfused welds were manufacturing defects and not serviced induced.
It was.very difficult to VT the welds because of their location which may have contributed to not identifying the problem earlier.
No violations or deviations were identifie Exit Interview 30703 The NRC inspector met with licensee representatives (denoted in Paragraph 1) at the conclusion of the inspection and summarized the scope and findings of the inspection noted in this report.
The NRC inspector also discussed the likely informational content of the inspection report with regard to documents or processes reviewed by the inspector during the inspection.
The licensee did not identify any such documents/processes as proprietary.