IR 05000321/1989029
| ML19332C039 | |
| Person / Time | |
|---|---|
| Site: | Hatch  |
| Issue date: | 11/08/1989 |
| From: | Blake J, Robert Carrion, Newsome R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML19332C038 | List: |
| References | |
| 50-321-89-29, 50-366-89-29, IEB-79-14, NUDOCS 8911220236 | |
| Download: ML19332C039 (15) | |
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UNITED STATES -
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- o, NUCLEAR REGULATORY COMMISslON
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REGION ll
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-g 101 MARtETTA STREET,N.W.~
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t ATLANTA, GEORGI A 30323
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~ Report Nos.: :50-321/89-29 and 50-366/89-29 Licensee: Georgia Power Company
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P.O. Box 4545 Atlanta, Ga 30302:
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Docket Nos.: 50-321-and~50-366-License Nos.: DPR-57.and NPF-5
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- facility Name
- Hatch 1 and 2 s
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Inspection Conducted: October 23 thru 27.1989 Inspectors:
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.R.W.Newsome(
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P arrion Date Signed I
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. Blake, Chief Date signed-
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rials and Processes Section-l gineering Branch-L.
- 4Hvision of Reactor Safety I
l SUMMARY
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Scope:
This routine, announced inspection was-conducted in the areas of:
review of welding documentation records and procedures and NDE records associated with the-(RWCU)g and examination of~ replaced piping in the Unit-2' Reactor Water Clean
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L weldin
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' system following the discovery of a crack in a circumferential weld; reviews of Inservice -Inspection (ISI)-documentation including review of the
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Unit 2 ISI inspection plan for this outage, reviews of nondestructive examination (NDE) procedures, reviews of NDE - personnel qualifications, reviews of NDE equipment calibration and material certification documentation, and a review of completed NDE examination data.
In addition, NRC previously opened items were addressed.
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8911220236 891114 PDR ADOCK 05000321
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-Results:
i In the areas _ inspected, violations or deviations were not identified.
This'.-inspection indicated that RWCU welding activities. were adequately
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controlled and that ISI nondestructive. examinations were conducted in an
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adequate manner as required.
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i REPORT DETAILS r
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Persons Contacted
' Licensee Employees
- J. Betsill Superintendent. Operations Support
- A.- Brown, Jr., Senior Plant Engineer S. Brunson, Senior Plant Engineer
- E. Burkett, Supervisor, Project Engineering
- P. Fornel, Manager, Maintenance.
~*G.-Goode, Manager Engineering Support
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S. Koski, Senior ~ Plant Engineer'
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- T _ Moore, Assistant General Manager, Plant Support c*P. Norris,' Senior Plant Engineer
- J. Payne, Senior-Plant Engineer
-*M. Sims,. Nuclear Specialist I
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'*L. Sumner, Assistant General Manager, Plant Operations
- S.'Tipps, Manager, Nuclear Safety and Compliance s
Other licensee employees contacted during this inspection included craftsmen, engineers,c security force members,- technicians, and
. administrative. personnel..
Other Organizations
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R. Healey, Southern Company Services (SCS), Level III
'D. Swann, SCS Engineer, ISI' Coordinator
e NRC Resident Inspector p
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- R'. Musser, Resident Inspector
- Attended exit interview
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- Acronyms and Initialisms used throughout this report are listed in the last
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paragraph.
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2.
RWCU Piping Replacement Activities, Unit 2
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a.
Background (1) Following the preparation of RWCU system Class 3, pipe to 90
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degree elbow weld, 2G31-3-RWCUM-4-D-11 for ultrasonic examination. in accordance with the requirements of NUREG 0313, a visual examination revealed a suspicious area on the weld.
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Subsequent liquid penetrant examination of, the. area revealed a 3/8" long axial linear indication.
Attempts to remove the
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indication by grinding were mace, however, during these grinding
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activities the crack like indication. developed into two circumferential indications, each approximately 1/2" long, with
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an axial indication joining the two circumferential indications
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forming an "H" shape. The pipe and elbow are 304-stainless steel
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The pipe -is 4" diameter schedule 80 with a wall thickness at this location of.337".
The grinding operations continued until approximately 1/8" pipe wall remained at the-
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i indication location.
At this time, the-decision was made to remove this section of pipe from the system and have the
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indication evaluated to determine the mechanism and causes of the cracking and to develop information that would be helpful in taking corrective actions.
(2) The 90 degree elbow and several inches of pipe at each end of the elbow were removed from the system.
The replacement elbow and pipe sections were replaced "in kind" with 304 stainless steel.
Weld filler material, used to fabricate the replacement welds, was 308L stainless steel.
Removal of this section of the RWCU system resulted in four new welds being -introduced -into the system, one. at each end of the 90 degree elbow to pipe spool pieces _and field welds at each end of the pipe spool pieces to the existing:RWCU system.. In addition, two 1"- diameter branch
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connection welds had to be replaced at this location due to the
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-length of pipe which had to be removed to accommodate the pipe lL cutting tool.-
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l (3) The removed section of the RWCU system was sent-to the General Electric laboratory near San Jose, California for evaluation at that facility. Preliminary results indicate that a repair to the
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weld, at-the defect location, was made during-the original l
fabrication of the weld which resulted in a lack of-fusion condition, however, further evaluation of the area in question was continuing at the conclusion of this NRC inspection. _The licensee is keeping NRR informed of all activities associated with the RWCU system.
I b.
Welding Program (55050)(73051)
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The inspectors reviewed the below listed documents relative to the licensee's welding program, in the area of replacement welding, in order to determine the adequacy of the welding program in the following areas; program approval, organizational structure, welding process controls, material control, welding procedure qualification, personnel qualification, and document control.
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42EN-EME-012-0S(R2)
Weld Process Control
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51GM-MNT-029-0S(R1)
Repair And Replacement Welding
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Control Of Welding Materials
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General Welding Requirements For
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Pressure Boundary Applications
Welding Procedure' Qualification
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Identification And Control Of Material
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And Equipment c.
RWCU Replacement Welds - Review of Weld Records (55050) (73052)
The inspectors reviewed the weld records for the RWCU replacement welds, as detailed below.- These records were reviewed to determine s
whether applicable code and procedure requirements were being met.
The applicable code for welding activities -is the ASME B&PV Code, 1980 edition with addenda thru winter 1981.
(1) Maintenance Work Order 2-89-5240 Revision 2.
(2) Weld records and weld data forms for new welds 2G31-3-3RWCUM-4-D-11'and-12, and 2G31-3RWCU-12A and 10A.
(3) Welder qualification and qualification status records, including verification of mock-up training, for the two welders used to make the replacenent welds.
i-(4) Welding Procedure. Specifications T88CA-1-Revision 0 and T880A-1 Revision 0.
(5) Procedure-Qualification Records 515, 516, and 519.
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(6) Welding material certification records, for the below listed materials, were reviewed and compared with code requirements.
The filler materials were verified as being the correct materials
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as specified by the Welding Procedure Specification and that in general the filler materials stipulated were compatible with the
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replacement base materials.
1/8" ER-308-L HT. P0443 3/32" ER-308-L HT. 57701 1/16" ER-308-L HT. S469929 4"
K-INSERT HT. 3548R All areas reviewed appeared to be adequately controlled.
Within the areas inspected, violations or deviations were not identified.
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Inservice Inspection (ISI) and Preservice Inspection (PSI)
The inspectors reviewed documents and records, as indicated below. - to
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determine whether ISI and PSI of the RWCU replacement welds were being conducted in accordance with applicable procedures, regulatory requirements, and licensee commitments..The applicable code for IS PSI is the American Soctety of Mechanical: Engineers Boiler and Pressure k;sel (ASME B&PV), Code,Section XI,1980 edition with addenda through Winter
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Southern Company Services (SCS) has the primary responsibility as
the ISI/ PSI contractor for Georgia Power Company and is performing overview
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functions for the licensee in all ISI NDE areas.
. General Electric Corporation personnel are conducting the ultrasonic (UT), liquid penetrant
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(PT), magnetic particle (MT), and visual (VT), examinations.
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ISI Program / Plan P,eview, Unit 2(73051)
The inspectors reviewed the inspection plan for this outage and the below listed Georgia Power Company (GPC) and SCS documents relative to J
the ISI program.
These documents were reviewed in order to determine whether. the program / plan had been approved by the licensee and to
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assure that procedures and plans had been established (written,
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i reviewed, approved and issued) to control and accomplish the following applicable-activities:
organizational structure including qualifications, training, responsibilities, and duties of personnel-responsible for ISI; audits including procedures, frequency, and qualification of personnel; general QA requirements including examination reports, deviations from previously established program, material certifications, and identification of components to. be covered; work and inspection procedures; control of processes including suitably controlled work conditions, special methods, and use of. qualified personnel; corrective action; document control; control of examination equipment; quality records including documentation of indications and NDE findings, review of documentation, provisions to assure legibility and retrievability, and corrective action; scope of the inspection including description of
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areas to be examined, examination category, method of inspection,
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extent of examinations, and justification for any exception; definition of inspection interval and extent of examination; qualification of NDE personnel; and, controls of generation, approval, custody, storage and maintenance of NDE records.
-SCS Inservice Inspection Outage Plan Edwin I. Hatch Nuclear Plant Unit 2 - 1989 Fall Refueling-GPC 40AC-ENG-001-0S (R2)
Inservice Inspection (ISI) Program-SCS ITE 09.3-50 (R1)
Outage Planning / Control / Revision-SCS ITE 09.5-51 (R1)
Final Reports Preparation, Approval, And Submittal
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-SCSITE09.6-51(R1)
Control of Contractor Services
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-SCS ITE 09.5-100(R2)
Quality Assurance Record Control-SCSITE09.50-4(R2)
Indication Notifications
-SCSITE09.50-5(RI)
On-Site Receipt. Inspection, Control.
And Storage Of N0ndestructive Examination Equipnent. Materials, and
Supplies l-SCSITE09.60-1(R3)
Plant Hatch - Responsibilities For ITE Activities The review of the ISI plan and program procedures indicated that adequate ISI controls are in place and that the ISI plan was properly approved and contained the necessary information.
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ReviewofNDEProcedures, Units 1and2(73052)
(1) The inspectors reviewed the procedures listed below to determine whether these procedures were consistent with regulatory requirements and licensee consnitments.
The procedures were also reviewed in the areas of procedure approval, requirements for qualification of NDE personnel, and compilation of required records; and, if applicable, division of responsibility between
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the licensee and contractor personnel if contractor personnel are involved in the ISI effort.
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SCS-AUX-H-302(R3)
Preservice and Inservice
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Inspection Documentation
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t SCS-AUX /H/F/V-300(RO)
Control Of Measuring And Test i
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Equipment
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SCS-UT-H-450(R2)
Qualification Of Manual Ultrasonic
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Instruments SCS-UT-H-400(RB)
Manual Ultrasonic Examination Of
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Full-Penetration Welds (Greater
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than 0.400 Inch)
SCS-UT-H-415(R3)
Ultrasonic Examination Of
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Recirculation Inlet Nozzle Thermal Sleeve Attachment (RINTSA) Welds SCS-UT-H-418(RO)
Ultrasonic Examination Of Shroud
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Head Hold Down Bolts SCS-UT-H-480(R3)
Manual Ultrasonic Examination Of
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Nozzle Inner Radius Section B
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SCS-UT-H-481(RI)
Manual Ultrasonic Examination Of
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Feedwater Nozzle Cylindrical Bore Sections SCS-MT-H-500(R3)
Dry Powder Magnetic Particle
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Examination SCS-VT-H-710(R2)
Visual Examination (VT-1)
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SCS-VT-H-730(R4)
Visual Examination (VT-3 and VT-4)
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All procedures listed above have been reviewed during previous NRC inspections.
Only current revisions were reviewed during this inspection.
(2) The inspectors reviewed the Ultresonic procedures to ascertain whether they had been reviewed crA 4 proved in accordance with the licensee's established QA y ares.
The procedures were also reviewed for technical adeqt.<y ad conformance with ASME,Section V. Article 5 and other 11wm commitments / require-ments in the following areas:
type of apparatus used; extent of coverage of weldment; calibration requirements; search units; beam angles; DAC curves; reference level for monitoring discontintities; method for demonstrating penetration; limits for evaluating and recording indications; recording significant indications; and, acceptance limits.
(3) The inspectors reviewed the Magnetic Particle procedure to ascertain whether it had been reviewed and approved in accordance with the licensee's established QA procedures. The procedure was reviewed for technical adequacy and for conformance with the ASME
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Code Section V. Article 7, and other licensee commitments / requirements
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in the following areas:
examination methods; contrast of dry
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powder particle color with background; surface temperature; suspension medium and surface temperature requirement for wet particles; viewing conditions; examination overlap and directions; pole or prod spacing; current or lifting power l
(yoke);and,acceptancecriteria.
L (4) The inspectors reviewed the Visual examination procedures to l-detennine whether they contained sufficient instructions to assure that the following parameters were specified and controlled.within the limits permitted by the applicable code, standard, or any other specification requirement:
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direct visual, remote visual or translucent visual; application-fabrication procedure, visual examination of welds, leak testing, etc.; how visual examination is to be performed; type of surface condition available; method or implement used for surface preparation, if any; whether direct or remote viewing is used;
sequence of perfoming examination, when applicable; data to be i
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specification; and, report form enmpletion.
All procedures reviewed appeared to contain the necessary elements for conducting the specific examination.
c.
Observation of Work and Work Activities. Unit 2(73753)(730538)
The inspectors did not observe in-progress examinations because all ISI examinations had been completed prior to this inspection.
The inspectors reviewed certification records of NDE equipment and materials, and reviewed NDE personnel qualifications for personnel that had been utilized during the required ISI examinations during this outage.
The reviews i.onducted by the inspectors are documented belcw.
(1) The following listed ultrasonic equipment and materials certification records were reviewed:
Ultrasonic Instruments Manufacturer /Model Serial No.
KK/USIP-11 21197-6574 KK/USK-7 27276-4951-2 KK/USK-7 27276-4641 KK/USK-7 27276-4676
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KK/USK-7 27276-4317-2 KK/USL-48 213669 The inspectors reviewed spectrum analysis data for the ultrasonic transducers listed below:
Serial No.
Size Frequency E08673
.5" 2.25 MHz LH6673
.5" X 1.0" 2.25 MHz
G22103
.75" 2.25 MHz l
B21531
.5" X 1.0" 2.25 MHz l
W2149 1.5" 1.0 MHz l-K06635 1.0" 2.25 MHz Ultrasonic Couplant Batch Numbers 8871, 8874, 8868, and 8982 Ultrasonic Calibration Blocks 136-H 125-H. 62-H, 61-H, 81-H,
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and 88-H (2) The inspectors review of the below listed liquid penetrant materials certification records which indicated that the sulfur
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and halogen content of the material was within acceptable content limits.
Materials Batch Nuneber Liquid Penetrant 870037, 84H027, 84LO58*
Cleaner / Remover 86E057, 88C078, 88K040*
Developer 85H029, 85K080, 88L019*
- These materials were used during the grindout of the defect detected in RWCU weld WG31-3RWCU-4-D-11.
(3) The inspectors reviewed documentation indicating that a 10 pound lift test had been performed on magnetic particle alternating current (AC) yokes 6661, 443, and 43530.
The certification record for the lift test plate that was used to conduct the tests, SCS113, was reviewed to confirm the weight of the test plate.
A review of the magnetic particle material certification record for batch numbers 87J014 and 87A035 indicated the particles met the applicable specifications requirements.
(4) The inspectors reviewed personnel qualification occumentation for 9 UT examiners, 7 PT examiners, 7 MT examiners, and 3 VT examiners.
These personnel qualifications were reviewed in the following areas:
employer's name; person certified; activity qualified to perform; current period of certification; signature of employer's designated representative; basis used for certifi-cation; and, annual visual acuity, color vision examination, and periodic recertification.
In all cases reviewed the NDE personnel appeared to be adequately qualified.
d.
Data Review and Evaluation, Unit 2(73755)(73055)
Records of completed ISI/ PSI nondestructive examinations for 51-UT,
31-PT, 40-MT, and 17-VT examinations were selected and reviewed to ascertain whether:
the methods (s), technique, and extent of the examination complied with the ISI plan and applicable NDE procedures; findings were properly recorded and evaluated by qualified personnel; programmatic deviations were recorded as required; personnel, instru-
ments, calibration blocks, and NDE materials (penetrants, couplants)
were designated.
All of the examination reports reviewed appeared to contain the required examination information including disposition of indica-tions, if any.
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i A random sample of current examination results were compared with
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historical examination results.
No major discrepancies were noted during the comparison.
In the areas inspected, violations or deviations were not identified.
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LicenseeActiononPreviouslyOpenedItems(92701)(92702)
(Closed)
Violation 50-321, 366/89-02-02
Failure to Complete Adequate i
Corrective Actions"
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This violation consists of two issues:
(1) Failure to-implement the recommendations generated in response to Request for Engineering Assistence HT-0718, when the need to have i
unique fittings for the plant breathing air system (Service Air System) was recognized.
Maintenance Work Orders (MW0s) 1-89-2641
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and 2-89-3409, were both issued June 2, 1989, for Unit I and Unit 2, i
respectively, to replace the existing fittings with unique fittings and check valves. The replacement of the fittings in accessible areas
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of Unit 2 was completed in August, 1989 and is continuing during the current refueling outage in the inaccessible areas and will be
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completed prior to re-start.
All Unit 1 fittings in accessible areas
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be replaced before the the start of the next scheduled Unit 1 will. ling outage (March,1990) while those in inaccessible areas will
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refue be replaced prior to re-start f rom that outage. To avoid any further violations, strict followup of the referenced MW0s will be observed to
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assure that the work is completed as scheduled.
Also, Respiratory l
Protection Training material has been revised as of August 17, 1989 to incorporate the fitting modifications.
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_(2) Failure to verify the torque of the top mounting bolts of the Hydraulic Control Units (HCUs) in addition to the bottom hold-down
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bolts.
During construction, the torque value for the hold-down bolts was not specified.
The infonnation was later supplied by General Electric (GE) via letter G-GPC-6-266, dated July 22, 1986.
However, the specified values for the top mounting bolts were overlooked by
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engineering personnel and, therefore, the torque of those bolts was
not verified.
The corrective action consisted of issuing MW0s 1-89-1077 and 2-89-0724 on March 3,1989 for Units 1 and 2 respec-tively to check the torque of the top mounting bolts of the HCUs and
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restore them to the specified values.
To avoid further violaticns,
" Lessons Learned" by this incident was included in the Continuing
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Engineering Training Session (Media No. EC-IH-00762-10, dated August 10,1989), held in late August, emphasizing attention to detail.
The inspectors verified the installation of the new Breathing Air System fittings, valves, and Health Physics tags identifying the fittings as for Breathing Air in the Unit 2 accessible areas via a walkdown of the Turbine, Radwaste, and Reactor Buildings where eleven of the new fittings were
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observed. The work appeared to be satisfactorily done. Therefore, in view of the completed work, as well as comitments to current and future efforts in this area, the NRC considers this item to be closed.
(0 pen)
Deviation 50-321, 366/88-38-02
" Suppression Pool Temperature Monitoring System".
In order to provide a more technically correct average supprassion pool temperature, the licensee has undertaken a program to utilize a representative average of the eleven temperature elements, T48-N301 thru T48-N311, plus the original four temperature elements,148-N009A thru T4.5-N0090.
The licencee's AE developed a formula for manually calculating the Torus Bulk Water Temperature using the readouts available in the Main Control Room and sent this information to the licensee via letter B-GP-16915,
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dated March 17, 1989.
Furthermore, administrative controls were initiated via Unit 1 Standing Order 50-0PS-01-0589, Revision 0, entitled, " Torus Temperature Monitoring," effective for one year beginning May 1,1989.
Standing Order 50-0PS-02-0589 Revision 0, serves the sane purpose for Unit 2.
They were issued to assure that the torus water temperature remains in compliance with Technical Specifications.
The following plant procedures were revised to reflect the average of the fifteen sensors for compliance with the Technical Specifications:
Document Type Title Document No.
Rev. Approved Abnormal Operating Torus Temperature 34AB-E0P-034-25
July 31, 1989 Procedure Above 95 F Abnormal Operating Torus Temperature 34AB-E0P-034-15 1 July 31, 1989 Procedure Above 95 F Surveillance Surveillance 345V-SUV-019-25 2 July 31, 1989 Procedure Checks Surveillance Surveillance 34SV-SUV-019-1S 2 July 28, 1989 Procedure Checks The licensee has comissioned its AE to revise the Unit I and Unit 2 Plant Unique Analysis Report (PUAR) to show that the Torus Water Temperature Monitoring System consists of the N300 series temperature sensors plus those of the N009 series.
The revision is expected to be completed by December 31, 1989.
Also, the Unit I and Unit 2 Technical Specifications are expected to be revised by December 31, 1989 to incorporate the related changes.
This Deviation remains open pending NRC review of the final PUAR and Technical Specification incorporation '
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(Closed)
Unresolved Item 50-366/87-10-01
" Adequacy of Measures to Assure that Purchased Services Meet Requirements" This finding was the result of confusion about which edition of the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code Section III, was used in the Reactor Water Cleanup (RWCU) Flued Head Penetration Cycle Analysis and whether it had been approved by the NRC prior to being used in the analysis.
The licensee's Architect / Engineer (AE), Bechtel Power Corporation, claimed that the Sumner Addenda to the
1980 Code was used. However, that addenda had not been approved by the NRC
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at the tine.
In reviewing the calculations related to the analysis, it
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appears that the analysis had been done in accordance with the 1977 Code.
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Summer 1979 Addenda, which had been approved at the time by the NRC. The NRC has approved the originally-referenced Code and the issue is moot at i
this time.
Furthennore, no safety concerns are raised regarding the RWCU flued head. Therefore, the NRC considers this item closed.
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(0 pen)
Inspector Followup Item 50-321,366/89-02-06 " Design Verification of Containment Isclation Valves T48-F310 and T48-F311" The referenced valves are part of a larger issue concerning the dual
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function of the vacuum breaker relief lines to relieve the potential vacuum in the torus following an accident as well as to maintain contain-ment isolation.
Because the vacuum relief function is the more important
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of the two, the air-operated betterfly valves (T48-F310 and T48-F311, at Plant Hatch) have been designed to fail open upon loss of instrument air or AC power. The containment isolation function is assured by the check valve in the line, which is tested in accordance with 10CFR50, Appendix J.
On June 2,1989, Northeast Utilities submitted a response to various NRC j
questions concerning this issue at Millstone Unit 1.
The utility's position
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is that no immediate safety concern exists, based on the consideration that
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the self-actuated vacuum breaker may be thought of as a passive elenent
with no need for the butterfly valves to perfonn a containment isolation i
function. Plant Hatch is currently monitoring the developments of the
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Northeast Utility submittal, awaiting the NRC detennination bt. fore launching
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I an extensive analysis.
If a negative response is made by the NRC, the corrective action will commence. A response is expected by February, 1990 Therefora, pending review of this response. IFI 50-321, 366/89-02-06 remains open,
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(0 pen)
Inspector Followup Item 50-321/88-38-04
Piping System Modification Completion for IEB 79-14" t
This item is expected to be completed before re-start from the Unit 1
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l refueling outage, which is scheduled to begin in March, 1990. Pending NRC
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(0 pen)
Inspector Followup Item 50-321/88-38-05
" Piping System Document Completion for ICB 79-14" This item is expected to be completed about one year after re-start from
the Unit I refueling outage, or, more precisely, during the summer of 1991.
Pending NRC review of the completed documentation, this item remains open.
(0 pen)
Ins 50-321/88-38-06 " Final Summary P.eport for IEB 79-14" pector followup Item
This item is expected to be completed about six months after restart from the Unit I refueling outage, or, more precisely, during December,1990.
Pending NRC review of the report, this item remains open.
5.
Exit Interview The inspection scope and results were summarized on October 27, 1989, with those persons indicated in paragraph I.
The inspectors described the areas inspected and discussed in detail the inspection results. Although reviewed during this inspection, proprietary information is not contained in this
report. Dissenting comments were not received from the licensee.
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.
6.
- Alternating Current
'
AE
- Architect / Engineer
ASME - American Society of Mechanical Engineers B&PV - Boiler and Pressure Vessel i
DAC - Distance Amplitude Curve GE
- General Electric Corporation GPC - Georgia Power Conpany HCU - Hydraulic Control Unit IEB - Inspection and Enforcement Bulletin i
ITI - Inspector Followup Item
ISI - Inservice Inspection l
KK
- Krautkramer MT
- Magnetic particle MHz - Megahertz MWO - Maintenance Work Order NDE - Nondestructive Examination No. - Number NRC - Nuclear Regulatory Commissicn PSI - Preservice Inspection PT
- Liquid penetrant PUAR - Plant Unique Analysis Report QA
- Quality Assurance
,
R
- Revision RWCU - Reactor Water Clean Up SCS - Southern Company Services UT
- Ultrasonic
,
- Visual l
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