IR 05000324/1990048

Insp Repts 50-324/90-48 & 50-325/90-48 on 901203-14. Violations Noted.Major Areas Inspected:Primary Reactor Coolant Recirculation,Rhr,Core Spray,Reactor Water Cleanup, Moisture Separator Reheater & HPCI

ML20217B357
Person / Time
Site:	Brunswick
Issue date:	01/09/1991
From:	Gray E, Harris R, Mcbrearty R, Modes M, Peterson P NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I)
To:
Shared Package
ML20217B251	List: IR 05000324/1990048 ML20217B244 ML20217B320
References
50-324-90-48, 50-325-90-48, NUDOCS 9103120070
Download: ML20217B357 (9)

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U.S. NUCLEAR REGULATORY COMMISSION REGION 1 DOCKET N Q325 REPORT N /90-48 LICENSE N DPR-71

LICENSEE: CAROLINA POWER AND LIGHT P. O. Box 15 i

Raleigh. North Carolina 27602 i

FACILITY NAME: BRUNSWICK STEAM ELECTRIC PLANT INSPECTION AT: Southport. North Carolina l

INSPECTION CONDUCTED: December 3.1990 to December 14. 1990 INSPECTORS: b' 1 /%t 8//$ / !?/9/ I M. C. Modes, Pdefeci Manager NDE, date Materials and Processes Section, EB, DRS GA d Sk6% ~% sh/9) '

R. A. McBrearty, Reactor 11rfgineer, dite Materials and Processes Section, EB, DRS TA&G 7WW R. H. Harris, NDE Technicidtl, Materials ileht

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Processes Section, EB, DRS

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[e P. M. Peterson, NDE TechnicipMaterials / date Processes Section, EB, DRS D.~ C. Wiggins; TET, Inc.; Mobile, Alabama W. M. Engus; TET, Inc.; Mobile Alabama Approved by: /

ads E. H. Gray, Chief, Mst'erials and

/!7/9/date Processes Section, EB, DRS, Region I 9103120070 PDR 910226 0 ADOCK 05000324 PDR

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Inspection Summary and Conclusions: A routine announced inspection was conducted at Brunswick Steam Generating Plant, Unit 1 on Dec. 3, through Dec 14,1990 using the NRC's Mobile Nondestructive Exan,ination (NDE) Laboratory. (Report No. 50-325/90-48)

Areas inspected: Selected r.reas of the primary reactor coolant recirculation (RCRS), residual heat removal (RHR), core spray (CS), reactor water clean-up (RWC), moisture separator reheater (MSR), high pressure demineralir.er (HD), high pressure coolant injection (HPCI)

and condensate booster pump (CBP) vent line piping were independently examined by NDE methods. The licensee's procedures used for nondestructive evaluation and the licensee's evaluation results, including radiographs and ultrasonic test reports, were reviewe Results: Three violations were identified, all relating to the lack of proper documentation of essential nondestructive evaluation elements and result .

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DETAILS

.l .0 Persons Contacted:

Carolina Power and Light (CP&L)

• T. Harris Regulatory Compliance

• B. Altman Regulatory Compliance

• P. Musser Manager Maintenance Staff J. Simon Operations Manager

• J. Holder Outage Management

• J. Harness Plant General Manager

• R. Johnson Project Manager

• L. Wheatly Inservice Inspection T. Brown Onsite Nuclear Safety A. Cheatham Engineering R. Helme Technical Support C. Robertson Shift Manager W. Foss Regulatory Compliance

• E. Betz ' NDE Level III

• J. Langdon NDE Foreman

• M. Vernon

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Manager NDE Services

• A. Richards Quality Assurance Manager

• R. Toler Regulatory Compliance K. Phillips Engineer

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U.S. Nuclear Regulatory Commission R. Prevatte Senior Resident RII R. Newsome Reactor Inspector RII J. Blake Section Chief Ril

• Denotes those attending the exit meeting on December 14, 1990

The inspector also contacted other administrative and technical personnel during the inspectio .0 Independent Measurements - NRC Nondestructive Examination and Ouality Records Review of Safety Related Systems Concurrent with a recirculation piping ceplacement, during the periods Dec. 3 through Dec.14,1990 an onsite independent insyction was conducted at Brunswick Steam Electric Plant (BSEP) utilizing the NRC Mobile NDE Laboratory. The inspection was conducted by NRC Nondestructive Examination Team inspectors and NRC contracted NDE personnel. The objectives of this inspection were to assess the adequacy of the licensee's preservice inspection program (PSI), and welding quality control program.

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t SME Code pipe weldments and pipe were independently examined by various NDE nethodsJIncluded in this examination were components, welds and areas selected from the primary reactor coolant recirculation (RCRS), residual heat removal (RHR),

core spray (CS), reactor water clean up (RWC), moisture separator reheater (MSR),

high pcessure demineralizer (HD), and condensate booster pump (CBP) vent line piping. This was accomplished by duplicating those examinations required of the licensee by regulations and codes, then evaluating the result .1 Nondestructive Examination (NDE) Visual Examination (57050)

Ten (10) safety related pipe weldments and adjacent base material (1/2 inch on either side of the weld) were visually examined in accordance with NRC procedure NDE-10, Rev.1, Appendix A, and CP&L procedu.c NDEP-611, Rev 6. Visual examination was performed of pipe systems and attached components utilizing QC documents, isometrics and as-built drawings. Examined during this inspection were ASME Class 1, Class 3 and ANSI B31.1 pipe weldments selected from the RCRS, MSR and HD systems. The examinat. ion was performed specifically to identify any cracks or linear indications, gouges, leakage, are strikes with craters, or corrosion, wt.<h may infringe upon the minimum pipe wall thickness. Mirrors, flash lights and weld gauges were used, as required, to aid in the inspection and evaluation of the weldment Results: No violations or deviations were identified in the review of this program are .3 Liquid Penetrant Examination (57060)

Three (3) safety related pipe weldments and adjacent base material (1/2 inch on either side of the weld) were examined using the visible dye, solvent removable, liquid penetrant method per NRC procedure NDE-9, Rev.0, in conjunction with the licensee's procedure and associated QC re'ords. Included in this inspection were ASME Class I stainless steel weldments selected from the RCR RESULTS: No violations or deviations were identified in the review of this program are . , .-, -

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5 Magnetic Particle Examination (57070)

Five (5) safety related pipe weldments, one support weldment including the adjacent base material (1/2 inch on either side of the weld) were examined using the direct

- contact, magnetic particle method utilizing a solid state yoke with dry powder as the inspection medium. The examination was performed in accordance to NRC procedure NDE-6,Rev.1 in conjunction with the licensee's procedure and associated QC record Included in this examination were ASME Class 3 and ANSI B31.1 pipe weldments selected front the RWCS and RCR Results: No violations or deviations were identified in the review of this program are .5 Radiograohic Examination (57000)

Eight (8) safety related pipe weldments were examined radiographically using an Iridium 192 source. Thirty (30) ASME code quality radiographs were produced in this process. The method of radiography was in conformance with the requirements of NRC procedure NDE-5, Rev.1 in conjunction with the licensee's radiographic

. procedure NDEP-101 Rev.13. The following welds were examined:

SYSTEM WELD RCRS A IBi l N2E-RPV-FWABA B 1B1: N2C-RPV-FWABA C IBi l N2 A-RPV-FWAB A D IB32FFA-12-FWRRBIOA

.RWC A 1-G31-0195 B l-G31-1094 HPCI A HIPCI-A7A B HIPCI-31 A Results: The resulting radiographs were compared to radiographs produced by the licensee to ensure that the welds identified were the same as those identified by the NRC. The radiographs compared favorably in all cases. The licensee's radiographs revealed :he same weld imperfections, flaws and anomalies as the NRC's radiograph With the exception of the RCRS:D weld above, the interpretation of the radiographs was the same. The licensee failed to record their evaluation of a weld imperfection (linear porosity) located in the RCRS:D weld; for which a violation is being issued (50-325/90-48-01).

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6 Ultrasonic Examination (57080)

Five (5) welds were ultrasonically examined using a Stavely Model 136D ultrasonic flaw detector in accordance with NRC procedure NDE-1, Rev.1 and the CP&L procedure for ASME weldments NDEP 402, Rev. 4. The Stavely Model 136D was verified for linearity in conformance with NRC procedure NDE-2, Rev 1 To obtain the greatest possible repeatability the examination was undertaken utilizing transducers and cable that matched those used by the licensee as closely as possible. The distance amplitude compensation curve was established utilizing CP&L calibration standard Results: The licensee failed to record indications independently revealed by the NRC in weld 1-G31-1095 for both the categories of flaw type and geometric reflectors. A violation is being issued for this failure (50-325/90-48-02). The licensee also did not record the use of a special transducer wedge (known commonly as a bull-nose) in the calibration and results of examination for weld IE218-39-FW6. Since the volumetric coverage chin cd,1,y the licensee, for this weld could not be obtained without this transducer wedge a violation is being issued (50-325/90-48-03).

2,7 Erostori/Carrasjon (57080)

Concem regarding erosion and corrosion in balance of plant piping systems has been heightened as a result of the December 9,1986 feedwater line rupture that occurred at Surry Unit 2. This event was the subject of NRC Information Notice 86-106 issued December 16,1986 and its supplement issued on February 13, 198 The licensee's actions with regard to the detection of erosion / corrosion in plant components were reviewed with respect to NUREG-1344, " Erosion / Corrosion induced Pipe Wall Thinning in U. S. Nuclear Power Plants", dated April 1989, Generic Letter 88 08 issued May 2,1989, and NUMARC Technical Subcommittee Working Group on Piping and Erosion / Corrosion Summary Report, dated June 11,198 Piping classes that were not considered susceptible based on known criteria of erosion / corrosion were eliminated from the licensee's inspection program. Piping which was not thus eliminated was then selected based on factors identified by industry and plant experience. Subsequent to the licensee's original selection process the EPRI "CHEC" computer program was used to verify that the proper systems were include in the licensee's progra , - _

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The program, in general, follows the guidance found in the NUMARC report although l specine details are lacking in several areas such as sample expansion, engineering {

evaluation, and required action based on inspection results including the scheduling of subsequen. inspections. Additionally, trending and calculations such as the rate of i ero-ion / corrosion are performed manually and require the review of numerous data poine obtained from previous inspections. The data are stored on microfilm and in loose leaf binders. The manual review process is time consuming, and appears to be pre > error due to the great number of dva points for each inspectio The asce was made aware of the inspector's concerns; they stated that they plan to computerize the program in 1991, although no specific date was state In addition to the program review discussed above, two areas originally inspected by the licensee were reinspected by the NRC NDE team. The results were compared and the measurements were found to be in close agreemen Results: No violations or deviations were identined in the review of this program are .0 ' Review Of Site NDE Procedures and Manual The followir.g Carolina Power and Light procedures were reviewed in the regional office during this inspection period for compliance with the licensee's FSAR commitments, technical specifications, applicable codes, and standard Procedure title __ Number / Revision

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Training, Qualification and Certification of Nondestructive Examination Personnel NDEP-10 Rev.12 Liquid Penetrant Examination (Visible Dye, Solvent Removable) NDEP-201 Rev.13 a

Magnetic Particle Examination (Dry Powder, Prods and Yoke) NDEP 301 Re Ultrasonic Examination of Pipe and

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- Tubing NDEP-422 Re Ultrasonic Examination of Welds (ASME) NDEP-402 Re Ultrasonic Examination Procedure for Piping Systems NDEP-425 Re ,

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VT-1 Visual Examination of Nuclear Power Plant Components NDEP-611 Re VT-2 Visual Examination of Nuclear Power Plant Components NDEP-612 Re VT 3 Visual Examination of Nuclear Power Plant Components NDEP-613 Rev.10 Radiographic Examination NDEP 101 Rev.13 The procedures were found to be generally in compliance with the applicable-requirement Results: No violations or deviations were identified in the review of this p.ogram nic .0 Synopsis Of 11uptc. tion Results WELD NDE PERFORMED SYSTEM IDENTIFICATION ---; - - -

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RWC 1-G31-1095 x x x x x 1-G31-1096 x x x x RCRS 1811N2E-RPV-FWABA x x x

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1811N2C-RPV-FWABA x x -x 1B11N2A-RPV-FWABA x x x 1B32FFA-12-FWRRB10A x x

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HPCI FP-60610-A7A x x FP-60085 31A x x

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CS 1E216-39-SWC x x x 1E218-39-FW6 x x x 1E216-39-FW5-1 x x x

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!- Management Meetings Licenset' management was informed of the scope and purpose of the inspection at the entrance intxview on December 4,1990. The findings of the inspection were discussed with the liccusee representatives during the course of the inspection and presented to licensee m 'nagement at the exit interview (see paragraph 1.0 for those who attended). At no time during the inspection was written material provided to the licensee by the inspector. The licensee did not indicate that proprietary information was involved within the scope of this inspectio t

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