IR 05000316/1979022
| ML17318A642 | |
| Person / Time | |
|---|---|
| Site: | Cook  |
| Issue date: | 01/30/1980 |
| From: | Danielson D, Ward K NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML17318A641 | List: |
| References | |
| 50-316-79-22, NUDOCS 8003200525 | |
| Download: ML17318A642 (13) | |
Text
U.S.
NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT
REGION III
Report No. 50-316/79-22 Docket No. 50-316 License No. DPR-74 Licensee:
American Electric Power Service Corporation Indiana 8 Michigan Power Company 2 Broadway New York, NY 10004 Facility Name:
Donald C.
Cook Nuclear Power Plant, Unit 2 Inspection At:
Donald C.
Cook Site, Bridgman, Michigan Southwest Research Institute, San Antonio, Texas Inspection Conducted:
October 31, November 1, 6, 13, 29, December 5, 6, 10, 1979, and January 7-8, 1980 Approved by:
D. H. Danielson, Chief Engineering Support Section
3a gd Ins ection Summar Ins ections on October
November
6
29 December
6
1979 and Januar 7-8 1980 (Re ort No. 50-316/79-22 Areas Ins ected:
gA/gC program, implementary procedures, observation of work activities, and review and evaluation nondestructive examinations (NDE)
data and reports of inservice inspection (ISI); IE Bulletin 79-13 and IE Bulletin 79-17 activities.
This inspection involved a total of 32 in-spection hours on site and 5 hours5.787037e-5 days <br />0.00139 hours <br />8.267196e-6 weeks <br />1.9025e-6 months <br /> at Southwest Research Institute by one NRC inspector.
Results:
No items of nomcompliance or deviations were identifie DETAIIS Persons Contacted Indiana and Michi an Power Com an (IBM)
-D. Shaller, Plant Manager-E. Townley, Asst. Plant Manager-A. Papai, ISI Supervisor
="J. Stietzel, QA Supervisor
="T. Beilman, Sr.
QA Auditor B. Svensson, Asst. Plant Manager J.
Gore, Construction Manager E. Morse, QC Supervisor L. Smetana, QA Auditor Power S stems Inc.
(PSI)
J.
Pedone, Project Superintendent M. Shore, Superintendent Factor Mutual En ineerin D. Young, Authorized Inspector (AI)
Su erior Industrial X-Ra Co.
(SIX)
R. Rickman, Radiographer Southwest Research Institute (SWRI)
=-W.
'L I ~
t1 I'ID
<%4% J
+r F.
Flach, Director, Dept. of Engr. Services Albrecht, Manager of Quality Assurance Rosow, Nuclear Field Services Godwin, Tech. Liaison Group Supervisor Gonzalez, Research Engineer -
QA Mengden, Inspection Engineer The inspectors also contacted and interviewed other licensee and contrac-tor employees.
-Denotes those present at the final exit interview at the site December 10, 1979 and ~ denotes those present at SWRI January 8,
1980.
Functional or Pro ram Areas Ins ected l.
General References:
a.
Letter dated July 20, 1979, AEP:NRC:00234 to Mr. J.
G. Keppler from Mr. J.
E. Dolan (response to Item No.
5 and No. 6).
b.
Letter date June 15, 1979, AEP:NRC:00221 to Mr. E. Jordan from Mr. R.
S. Hunter (information of meeting 6/11/79).
c.
Ietter dated August 3, 1975, AEP:NRC:000221A to Mr. J.
G. Keppler from Mr. J.
E. Dolan (progress report on IE Bulletin 79-13, Unit No. 2).
d.
Ietter dated September 5,
1979, AEP:NRC:00221B to Mr. J.
G. Keppler from Mr. J.
E. Dolan (second progress report on IE Bulletin 79-13, Unit No. 2).
e.
Letter dated October 12, 1979, AEP:NRC:]0221C to Mr. J.
G. Keppler from Mr. J.
E. Dolan (third progress report on IE Bulletin 79-13, Unit No. 2).
f.
I.etter dated June 21, 1979, AEP:NRC:00215 to Mr. H. R. Denton from Mr. J.
E. Dolan information requested by Mr. V. Stello Jr.
on as-built piping drawings of feedwater line to SG sparger within containment, provide results of any stress or fatigue analyses, etc.).
g.
Letter dated June 7,
1979, AEP:NRC:00216 to Mr. J.
G. Keppler from Mr. J.
E. Dolan (investigation into the cause of the cracks).
h.
Letter dated November 26, 1979, AEP:NRC:000305 to Mr. J.
G. Keppler from Mr. J.
E. Dolan (additional information with regard to the analysis, inspection and modification of the main feedwater system).
Letter dated November 30, 1979, AEP:NRC:00306 to Mr. J.
G. Keppler from Mr. J.
E. Dolan (response to Revision 1 of Bulletin No. 79-17).
j.
Report No. 50-316/79-16 (NRC report of meeting conducted at AEPSC office, New York, NY dated July 31, 1979).
The NRC forwarded IE Bulletin 79-13 titled "Cracking in Feedwater System Piping" and IE Bulletin 79-17 titled "Pipe Cracks in Stagnant Borated Water SystemsSystems" for specific action to be taken.
IE Bulletin 79-13 is a follow up as a result of the meeting conducted at AEPSC office, New York, NY on July 31, 1979.
When the plant was shut down for its normal refueling outage, all eight welds were re-radiographed and met the requirements of the ASME Section III, 1974 Edition, Summer 1975 Addenda, IE Bulletin 79-13 and Report No. 50-316/79-16.
These radiographs had a better technique than the previous ones therefore, because of the fine techniques two more welds were interpreted as being unacceptable.
1, 2, and 3 elbow to reducers were repaired and SG 4 elbow to nozzle was replace The AI was contacted as the third party for the ISI, IE Bulletin 79-13 and 79-17.
SIX and SWRI performed the NDE for the ISI and Bulletin 79-13 and 79-17.
Power Systems performed the cutting and the welding.
The next scheduled outage for Unit 1 is approximately April 1980 and Unit 2 approximately June 1981.
Westinghouse Electric Corporation, Nuclear Service Division, performed the eddy current examination on the tubes of the steam generators, N2 and //3.
Approximately 700 tubes on each generator were eddy current examined.
2.
Procedures/Manuals The following procedures and manuals were reviewed:
a.
IBM, Unit 2, Weld Repair of Steam Generator Feedwater Inlet Elbows, 92MHP-SP-RFC-1716, Rev.
b.
Plan for 79-17 prepared for American Electric Power Service Corp.
(AEPSC) by SWRI UT PT data review.
c ~
SWRI, Nondestructive Examination Plan for Selected Welds in Portions of Systems containing Stagnant Borated Water, Volume 1, Final Plan, September 1979.
d.
SWRI, Recording Data from Direct Visual, Liquid Penetrant, and Magnetic Particle Examination of Welds 1X-FE-105-0, September 1978.
e.
SWRI, Manual Ultrasonic Examination of Vessel to Nozzle Inner Radius Sections 600-11, Revision 28, March 1979.
SWRI, 1979 Inservice Examination Plan, October 1979, Prepared for AEPSC by SWRI.
g.
SWRI, Measuring and Recording Search Unit Location and Signal Amplitude Data during Ultrasonic Examinations of Pressure Vessel Welds 1X-FE-109-1, February 1978.
h.
SWRI, "Black Light" Intensity Measurement's 1X-FE-110-0, January 1978.
SWRI, Fluorescent Magnetic Particle Examination 300-2, Revision 25, March 1979.
'SWRI, Dry Power Magnetic Particle Examination 300-1, Revision 17, September 1979.
SWRI, Manual Ultrasonic Examination of Pressure Vessel Welds 600-15, Revision 39, March 1979.
SWRI, Manual Ultrasonic Examination of Vessel Support Skirt Attachment Welds 600-16, Revision 21, March 1979.
SWRI, Manual Ultrasonic Examination of Pressure Retaining Studs and Bolts 2" or Greater in Diameter Containing Access Holes 600-18, Revision 26, March 1979.
SWRI, Manual Ultrasonic Examination of Pressure Retaining Round Nuts 2" or Greater in Diameter 600-19, Revision 26, March 1979.
SWRI, Weld Joint Identification Marking on Nuclear Power Plant Piping 1X-FE-103-1, February 1977.
SWRI, Measuring and Recording Search Unit I,ocation and Maximum Signal Amplitude Data During Ultrasonic Weld Examinations 1X-FE-104-1, August 1976.
SWRI, On Site NDT Records Control X-FE-101-0, March 1976.
SWRI, Nondestructive Testing Personnel Qualification, Training, Examination and Certification 1X-AG-1-1, August 1974, (1968 Edi-tion SNT-TC-(A)).
SWRI, Special Process Control NQAP, ll-l Rev.
1, March 1977 (Personnel Certification 1975 Edition SNT-TC-lA).
SWRI, Liquid Penetrant Examination Color Contrast Method 200-1, Revision 46, 2/79 and Revision 47, July 1979.
SWRI-NDT-100-2, Revision 3, October 1975, Certification of Visual Examination Personnel.
SWRI, Visual Examination of Nuclear Reactor Components by Direct or Remote Viewing NDT 900-1, Revision 46, July 1979.
SWRI, Manual Ultrasonic Examination of Pressure Piping Welds 600-3, Revision 52, March 1979.
SWRI, Manual Ultrasonic Examination of Reactor Coolant Pump Flywheels 600-6, Revision 20, February 1979.
SWRI, Special Procedure for Manual Ultrasonic Examinations of Austenitic Components with High Acoustic Attenuation Properties, 800-17, Revision 19, March 197 z.
SWRI, Manual Ultrasonic Examination of Small Diameter Piping Welds 600-39, Revision 0, October 1979.
aa.
SWRI, Manual Ultrasonic Examination of Thin Wall Piping Welds 800-36, Revision 22, March 1979 and Revision 24, July 1979.
bb.
SIX, Radiographic R.T.1, Revision 2, April 1, 1978.
cc.
SIX, Magnetic Particle M. T. 1, Revision 2, April 14, 1978.
dd.
SIX, Liquid Penetrant P.T.l, Revision 2, April 3, 1978.
ee.
SIX, Ultrasonic Inspection U.T.1, Revision 3, May 15, 1979.
ff.
W, Steam Generator Tubesheet Cleaning, Full Recirculation System MRS 2.2.2 GEN-9, Revision 1, May 18, 1979.
gg.
W, Installation and Removal of Eddy Current Positioning Devices MRS 2.4.2 GEN-19, Revision 0, July 15, 1977.
hh.
W, Installation and Removal of Temporary Nozzle Covers MRS 2.2.2 Gen-2, Revision 3, July 31, 1979.
ii.
W, Post Activity Sign-Off for Area Cleanliness MRS 2.2.2 GEN-6, Revision 2, July 31, 1979.
jj.
W, Multi-frequency Eddy Current Inspection of Steam Generator Tubing - Preservice and Inservice MRS 2.4.2 GEN-23, Revision 1, November 7, 1979.
No items of nomcompliance or deviations were identified.
3.
Personnel Certifications The inspector reviewed the following personnel certifications:
SWRI NAME J ~ Melendez C. Trout R. Bendele D. Fournell R. Reaves R. Forman UT PT MT VT-6-
SIX Name t
C. Andersen R. Valazaz R. Rickman J. Ouellette VT PT MT Westin house Electric Cor Name J. Paracat R. Ingraham R. Pollice R. McKeever T. Pfarr J. Mills S.
Beehner G. Ferenchak J. Estel D. Tommarello W. Bolt Welders Certification ET Name J.
Ponton M. Alfieri D. Harris R.
McGee V. Vochaska No.
55 PS-1 PS-16 PS-4 No items of noncompliance or deviations were identified.
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4.
Materials and E ui ment Certifications The following materials and equipment certifications were reviewed:
a.
Coated Electrodes 1/8", 8018-C3, Ht. PJO-97931 5/32", 8018-C3, Ht PJO 94340 3/21
~ 7018 ) Ht L62441 b.
Sub Arc Wire - 1/8" Linde 81, Ht. 081176 c.
One 16" Elbow with thermal sleeve, 500" wall, Ht. S-6645-Xl d.
Reviewed certifications on transducers, UT instruments and cali-bration blocks e.
Ultrasonic Couplant - Dow Chemical Glycerine Batch, Lot TB-09058-3 f.
- Magnaflux Materials Penetrant Batch 78B032 Developer Batch 78B082 Cleaner Batch 78C056 g.
Magnetic Particles and Equipment Yoke, Parker Contour Probe
$/4447, and materials Batch 79D044 No items of noncompliance or deviations were identified.
5.
Observation of Work and Work Activities a.
The inspector observed the following activities and had discus-sions with the NDE personnel.
These observations included cali-brations, performance of the examinations and the documentation:
b.
Liquid Penetrant Examinations performed on weld 2S-1-17-5, Suction Line to Unit 2 containment spray eductor.
c.
Ultrasonic Examinations performed on weld RC26-1RS, Unit 2 d.
Eddy Current Examination on Steam Generator 2, 3, including calibration.
No items of noncompliance or deviations were identified.
The inspector reviewed the radiographs of the following welds in accordance with IE Bulletin 79-1 FW 76 2FW 76 2FW 77 2FW 74 2FW 75 2FW 76 2FW 76 2FW 77 2FW 77 2FW 77 2FW 77 2FW 74 2FW 74 2FW 74 2FW 74 2FW 75 2FW 75 2FW 75 2FW 75 2FW 75 2FW 75 2FW 76 2FW 77 2FW 75 OW3 OW2CO OW1R OW1R OW1R2 OW2A 09F OW2 OW2 OW9F W10$
W10F W9$
11$
01F OW2 OW2 01F 11$
09$
08$
01F 01F OW10F SG4 SG4 SG1 SG2 SG3 SG4 SG4 SG1 "B"
$ 61 "A" SG1 SG1 SG2 SG2 SG2 SG2 SG3 "A" SG3 SG3 SG3 SG3 SG1 SG4 SG1 SG3 Reducer to Pipe Nozzle to Elbow Reducer to Elbow Reducer to Elbow Reducer to Elbow Liner to Liner Pipe to Elbow Nozzle to Elbow Nozzle to Elbow Pipe to Elbow Pipe to Pipe Pipe to Elbow Pipe to Elbow Pipe to Reducer Pipe to Flange Nozzle to Elbow Nozzle to Elbow Pipe to Flange Pipe to Pipe Pipe to Elbow Pipe to Elbow Pipe to Pipe Pipe to Pipe Pipe to Pipe No items of nomcompliance or deviations were identified.
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7.
Data and Audit Review The following documents were reviewed:
a.
Audit of Superior Industrial X-Ray Corp. by IBM b.
I&M, QA inspection reports of ISI,Bulletin 79-13 and 79-17 c.
IBM, QA reports of SWRI d.
Receipt inspection reports e.
Information available for ISI,Bulletin 79-13 and 79-17 f.
Reports of Eddy Current Examinations on steam generators (SG)
g2 and g3.
No unacceptable indications were revealed.
No items of noncompliance or deviations were identified.
8.
Southwest Research Institute The inspector made a trip to Southwest Research Institute in San Antonio, Texas, for the purpose of reviewing nondestructive examina-tion personnel certifications, including experience and four NDE personnel certification procedures, When SWRI submits a "Statement of Certification", for an NDE individual to the licensee, it is not complete nor is there enough information available to evaluate.
The following items are found in reviewing the SWRI "Statement of Certi-fication" of their NDE personnel:
a
~
SWRI NDE personnel are certified in accordance with the require-ments of one of the following procedures:
SWRI, Nondestructive Testing Personnel Qaulification, Training, Examination and Certification (1968 Edition SNT-TC-1A) 1X-AG-1-1,'ugust 1974.
SWRI, Special Process Control (1975 Edition SNTC-1A) NQAP ll-l, Revision 1, March 1977.
SWRI, Certification of Visual Examination Personnel, NDT-100-2, Revision 3, September 1975.
SWRI, Visual Examination of Nuclear Reactor Components by Direct or Remote Viewing, NDT-900-1, Revision 47, August 1979.
Very seldom are there one of the above procedures found on site; therefore, the certifications can not be evaluated without the procedure of the requirements on how the personnel were certified.
The licensees have audit reports stating that NDE certifications and procedures have been reviewed at SWRI, 10-
but the individuals that have conducted the audits very seldom review the certifications when submitted by SWRI for a specific job on site, and do not have copies of the procedures to refer to if they were to review the certifications.
b.
The "certification limitations" (if any), stated on the certifi-cation, are always blank when there is not a limitation.
The blank area should have the word "NONE" if there is not a limit-ation.
The "Signed" area on the certification does not state if the individual is a Level III but does state his title in the company.
In reviewing the certfication at the site it is not known who administered the test or if the I,evel III Examiner was qualified because his tests are not always at the site.
d.
"Training," on the certification, states classroom and labor-atory hours combined and the examination grade.
The methods are not stated and without a procedure to refer to one can not say the hours are in accordance with the procedure.
"Educational History," on the certification, states name of high school, any additional, the major field of study, year and degree.
In some cases it would be difficult to know the city and state of the school and if the person is a graduate.
If a person is a graduate of a high school or certain type of college it could reflect the experience needed.
The procedure states the education needed.
"Employment History," on the certification states date employed, previous NDT related, company and years.
SWRI does not state amount of experience in an NDE method on the certification when employed by SWRI.
The documented experience is located at SWRI and the procedure for the amount of experience required is at SWRT also.
The inspector has reviewed certifications where part of the education is the experience, which should be stated in the procedure.
The certification should state all the NDE experience to time of certification, including company, city, state, method, month and years to and from.
g.
"Visual Acuity and Color Perception Test,"
on the certification, states date, correction if required, and verified by.
The eye test does not state if the Jaeger Jl was given, the type of color test or who gave the test.
The inspector was informed by SWRI that the following actions would be taken.
a
~
The four above procedures will be on site or can be obtained by calling Larry Albrecht at SWRI 512-648-5111.
11 "
b.
The "Statement of Certification," form QA-11-4, shall be revised and will be in the SWRI QA Manual approximately the end of March 1980.
At that time all SWRI NDE personnel experience shall be documented on the form up to their certification date.
c.
Approximately all NDE personnel shall be re-certified by written examination by the end of Summer, 1980.
No items of noncompliance or deviations were identified.
9.
Conclusions The repair of the feedwater sections, IE Bulletin 79-13, examinations and evaluations, IE Bulletin 79-17, and construction testing appeared to satisfy the applicable procedures and code requirements.
RIII will review the licensee's written response to IE Bulletin 79-17 and 79-13.
These are unresolved items IE Bulletin 79-13 (316/79-22-01)
and IE Bulletin 79-17 (316/79-22-02).
No items of noncompliance or deviations were identified.
Unresolved Items Unresolved items are matters about which more information is required in order to ascertain whether they are acceptable items, items of noncompli-ance, or deviations.
The unresolved items disclosed during the inspection are discussed in Paragraph 9.
Exit Interview The inspector met with the site and SMRI representatives at the conclusion of the inspections.
The inspector summarized the scope and findings of the inspections noted in the report.
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