IR 05000331/1983004
| ML20204G124 | |
| Person / Time | |
|---|---|
| Site: | Duane Arnold  |
| Issue date: | 04/18/1983 |
| From: | Danielson D, Key W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML20204G115 | List: |
| References | |
| 50-331-83-04, 50-331-83-4, IEB-78-12, IEB-82-03, IEB-82-3, NUDOCS 8305020360 | |
| Download: ML20204G124 (10) | |
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U.S. NUCLEAR REGULATORY COMMISSION
REGION III
Report No. 50-331/83-04(DE)
Docket No. 50-331 License No. DPR-49 Licensee:
Iowa Electric Light and Power Company Security Building, P.O. Box 357 Cedar Rapids, Iowa 52406 facility Name: Duane Arnold Energy Center Inspection At: Duane Arnold Energy Center Site, Palo, Iowa Inspection Ccnducted: February 16-19 and March 16-18, 1983 WW Inspector:
W. J. Key
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hNYA b%
g,ljg Approved By:
D. H. Danielson, Chief Materials and Processes Section Date t
Inspection Summary
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i Inspection on February 16-19 and March 16-18 1983 (Report No. 50-331/83-04(DE))
Areas Inspected: Review of inservice inspection program and procedures, observation of inspection activities, and review of inspection documenta-tion; followup on recirculation system and attached piping as required by IE Bulletin No. 82-03.
The inspection involved a total of 51 inspector-hours by one NRC inspector.
Results: No items of noncompliance or deviations were identified.
8305020360 830418 PDR ADOCK 05000331 o
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DETAILS Persons Contacted Iowa Electric Light and Power Company (IE)
- L. Root, Vice President, Nuclear
- D. Mineck, Plant Manager K. Harrington, Staff Engineer
- Denotes those present at either the entrance or exit meeting.
Licensee Action on Previous Inspection Findings (CLOSED) Open Item (331/78-10-01): The Lambert MacGill and Thomas (LMT)
Quality Assurance Manual was unclear on commitments to the 18 criteria of 10 CFR 50, Appendix B.
The inspector reviewed the LMT QA manual and has determined that it is responsive to those portions of the 18 Criteria of 10 CFR 50, Appendix B, applicable to the corporation.
(CLOSED) Open Item (331/78-10-02): The LMT QA Program is unclear as to disposition of final NDE examination results.
The LMT QA Manual Procedure No. QA-4, Revision 6,Section V, states,
" Examination documentation generated in the field shall be handled according to rules contained in the Process Procedure governing generation of the material. Where no specific Process Procedure is applicable, the following rules shall apply:
A.
Field Storage facilities shall provide a safe storage area, and access to files shall be limited to the LMT Field Supervisor and his designated representatives.
B.
Original documentation shall become the property and responsibility of the client upon his sign-off.
Process Procedure No. UT-11, Revision 3,Section XV, states:
A.
Examination documentation shall become the property of the client upon his sign-off. Additional reports, which may include examination documentation as reference material, shall be generated from copies.
B.
Field storage facilities shall provide a safe storage area and access to files shall be limited to the LMT Field Supervisor and his designated representatives. The inspector has no further questions.
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(CLOSED) Noncompliance (331/78-33-01):
It was impossible to determine, from documentation if welders had qualified on a shop mock-up as required by ASME Code and DCR-800-B for restricted access welding.
During repair of the recirculation nozzles confusion did exist between the various welding engineers as to what was required by GE Specification DCR-800-B, for welder qualification on the mock-up.
Documentation of welder qualifications was not being maintained as required.
Following an NRC Enforcement Meeting welder qualifications were doucmented on a computer file showing which welders were qualified and to what velding procedures. The inspector has no further questions.
(CLOSED) Noncompliance (331/78-33-02): Tools used in repair welding were not properly controlled, carbon steel tools were being used on stainless steel and Inconel welds. NRC inspectors did not observe carbon steel tools being used on welds, however, they were observed in the vicinity of welds. The licensee developed a procedure for control of tools being used on stainless steel and Inconel. All tools checked out of the tool room for use on stainless steel or Inconel were color coded. The inspector has not further questions.
(CLOSED) Noncompliance (331/78-33-03):
Portable weld rod ovens were being issued to welders that had not been calibrated, and were not in the calibration program.
All portable weld rod ovens were calibrated before being placed in the calibration program and all rod room attendents were given instructions for issuing rod and portable ovens.
Instructions were posted in issue room.
The inspector has no further questions.
(CLOSED) Noncompliance (331/78-33-04):
Partially consumed weld rod stubs littered the work area and were generally uncontrolled. All welders were instructed and issued stub buckets. When a welder withdrew weld rod all stubs or unused rod had to be returned to the issue room. The inspector has no further questions.
(CLOSED) Unresolved Item (331/78-33-05): Weld rod stub inadvertently trapped in the recirculation system at inlet nozzle B. The weld rod was ground out and the weld repaired by rewelding then radiographic 1y examined.
(CLOSED) Unresolved Item (331/78-33-06): The licensee is to provide analytical data to show that weld quality has not been compromised by the use of uncontrolled carbon steel tools and inadequate tool control procedure.
The licensee developed an adequate tool control procedure and instructions to welders and QC engineers and all weld documentation was reviewed by NRC Region III staff. The licensee further had consultants evaluate all radiographs and ultrasonic examination reports of all recirulation system repair welds. The inspector has no further questions.
(CLOSED) Unresolved Item (331/78-33-07):
Lead wool dust from lead wool used between the lead brick shielding was in contact with alloy steel piping.
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The licensee submitted documentation from GE and other consultants showing that 10% nitric acid can completely remove lead contamination from stainless steel and Alloy 600 substrates in less than one hour at room temperature, and that the small amounts of lead corrosion products involved should be dissolved and removed by the reactor cleanup system during system flushing prior to unit start up.
The inspector has no further questions.
(CLOSED) Unresolved Item (331/78-33-05): Weld documentation is being
" Voided" and not maintained as part of the weld joint history record.
NRC Region III staff halted all repair welding until a 100% review of weld documentation could be performed by the licensee and procedures developed and implemented and QC inspectors retrained in there use.
Following their review the Region III staff reviewed the licensees corrective actions and permitted resumption of repair welding.
Licensee Actions on IE Bulletins (CLOSED) IE Bulletin No. 82-03 (331/82-03-BB; 331/82-03-1B):
IE Bulletin No. 8Z-03, Revision 1, addressing " Stress Corrosion Cracking in Large Diameter Stainless Steel Recirculation System Piping at BWR Plants" required licensees of operating BWR plants to examine welds in the recirctlation system piping and to demonstrate the effectiveness of the detection capability of their UT methodology and personnel prior to resuming power operations following a scheduled or extended outage.
During this refueling outage the licensee developed an examination program in accordance with Bulletin requirements along with their scheduled ISI program.
The examination agency performing ultrasonic examination at DAEC had peformed examinations at the Monticello Nuclear Power Plant, and had demonstrated their qualifications to the NRC staff at Battelle Laboratory. Columbus, Ohio. The inspector examined and compared the DAEC ultrasonic procedure with the procedure used at Monticello and determined that it was satisfactory for these examinations, and waved requalification of the procedure and personnel at Battelle for the DAEC.
(CLOSED) IE Bulletin 78-12 (331/78-12-BB; 331/78-12-1B): This bulletin addressed a typical weld material in reactor pressure vessel welds.
In a memorandum dated July 10, 1980 from G. W. Reinmuth, Assistant Director, Division of Reactor Construction Inspection, IE to G. Fiore111, Chief, RC & ES Branch, Region III this bulletin was closed based on a review of information submitted by Chicago Bridge and Iron Company stating that all weld material used in subject vessel met the applicable acceptance criteria.
Functional or Program Areas Examined 1.
Inservice Inspection Program (ISI)
The inspector reviewed the ISI Program for this refueling outage.
Items and components from the system listed below were included for ISI. The requirements of ASME Code,Section XI, Table IWB 2600 IWC and IWD for Class 1, 2, and 3 systems are applicable.
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Recirculation System
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RHR Head Spray
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Haad Vent
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Vessel Instrumentation
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No items of noncompliance or deviations were identified.
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2.
Inservice Examination Procedures
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The inspector reviewed the following ISI Procedures for changes and addenda.
UT-2, Revision 6, " Ultrasonic Examination of Ferritic Butt Welds
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and adjacent Base Metal in The 2.5" and Greater Thickness Range."
UT-3, Revision 4, " Ultrasonic Examination of Reactor Vessel Nozzle
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Forging Inner Radii."
UT-4, Revision 4, " Nuclear ISI and PSI Axial Longitudinal Wave
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Examination of Bolts, Nuts and Forged Parts."
UT-25, Revision 0, " Ultrasonic Examination of Nuclear Coolant System
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Piping, Fittings, and Forgings for The DAEC."
No items of nonccmpliance or deviations were identified.
3.
Personnel Certification / Qualifications The inspector reviewed the qualification / certification records for the following LMT examination personnel for conformance to NRC and ASME Code
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requirements:
MT UT PT VT R. G. Auer II II II I
R. D. Burlingame II II F. E. Dohmen II II D. J. Edgel II II K. L. Hall Trainee P. N. Nash II E. L. Thomas III III III III No items of noncompliance or deviations were identified.
4.
Equipment and Materials The inspector examined the following LMT equipment and materials for certification and calibration as required by NRC and ASME Code Section XI.
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l Ultrasonic Instruments, Nortec 131D, S/N-128, 129, 273, 291, 371, 409.
Recorders: Astro-Med Dash, S/N-0A244, IA335 Guiton TR-722J, S/N-2091001, 8082501 Surface Thermometers, S/N-495, 494, 498
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Transducers Tranducers Frequency Size Serial No.
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Harisonic 5 MHZ 1/4"x1/4" W2124 Harisonic 5 MHZ
.250" W2123 Harisonic 2.25 1" x 1" V1075 Harisonic 2.25 1" x 1" V10704
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Harisonic 2.25 1/4"x1/4" V12038 Aerotech 2.25
.25" B94731 Aerotech 2.25
.5" B10617 Aerotech 5 MHZ
.5" F05134 Aerotech 1.5 MHZ
.5" H10143 si Aerotech 2.25MHZ
.25" F13105 Panametrics 2.25 1"
7585
'i Penetrant Materials Cleaner - SKC-NF/ZC-7B 82L018 Cleaner - SKC-NF/ZC-7B 82K002
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Cleaner - SKC-NF/ZC-7B 82H001 Cleaner - SKC-NF/ZC-7B 82J008 Penetrant - SKL-HF/S 82F059 Developer - SKD-NF/ZP-9B 82J022 Developer - SKD-NF/ZP-9B 82H010
Ultrasonic Calibration Blocks
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The inspector examined the calibration blocks listed below. These blocks were made from pipe segments representing piping material installed at the DAEC.
Class I-SS Size Schedule Heat No.
Material 2"
308028 A312-304 3"
M6445 A312-71-304 4"
80359 A312-304 8"
80407 304 10"
651345 304 16"
132002 A182-G.F-304 18"
A3533 304 l
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Class I-CS Size Schedule Heat No.
Material 10"
62163 A106Gr. B 12"
DXR8155 A106Gr. B 16"
49069 A106Gr. B 18"
89C753 A106Gr. 67 Class II-CS Size Schedule Heat No.
Material 10"
N8024 A 106-B 12"
N8025 A 106-B 16"
N8026 A 106-B No items of noncompliance or deviations were identified.
5.
Observation of Examination The inspector witnessed inprocess NDE examination of five recirculation system welds and instrument calibrations being performed to satisfy the requirements of ASME Code ISI program and the requirements of IE Bulletin No. 82-03, Revision 1.
6.
Recirculation System Documentation Review To satisfy the requirements of IEB, 82-03, Revision 1, the licensee performed volumetric examination of recirculation system welds as identified below.
Recirculation Pump "A" and Discharge Valve By-Pass.
Isometric Drawing No. 19.
Examination Calibrations Material /
Weld No.
Report No.
Block Size Remarks RCA-BY-18 83-080 28730 SS-22" RCA-BJ-30 83-081 28730 SS-22" RCA-BK-30 83-082 28730 SS-22" RCA-BJ-32 83-083 28730 SS-22" RCA-BJ-32 83-084 28730 SS-22" Long Seam RCA-BJ-41 83-088 28730 SS-22" RCA-BK-42 83-149 28730 SS-22" RCA-BJ-41 83-097 28730 SS-22" Long Seam 1 RCA-BJ-43 83-085 28730 SS-22" RCA-BJ-43 83-086 28730 SS-22" Long Seam 1&2 RCA-BJ-38 83-096 28730 SS-22" RBA-BJ-1 83-048 80359 SS-4" RBA-BJ-6 83-049 80359 SS-4" RBA-BJ-8 83-050 80359 SS-4" RBA-BJ-12 83-051 80359 SS-4"
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Recirculation Manifold "A" and Risers E, F, G, H, RMA, RRE, RRG, RRH, RRF, Isometric Drawing No. 20.
Examination Calibrations Material /
Weld No.
Report No.
Block Size Remarks RRG-BF-2 83-028 NX9724 CS/Inc.
N0Z/SE RRG-BF-2A 83-009 651345 Inc/CS SE/P RRG-BJ-3 83-010 651345 SS 10" RRG-BJ-4A 83-M7 651345 SS 10" RRG-BJ-4 83-018 651345 SS 10" RRH-BF-2 83-027 NX9724 CS/Inc.
N0Z/SE RRH-BF-2A 83-022 NX9724 Inc/CS SE/P RRH-BJ-3 83-023 651345 SS 10" RRH-BJ-4A 83-024 651345 SS 10" RRH-BJ-4 83-025 652345 SS 10" RMA-BJ-5 83-033A/
132002 SS 16" Long Seam 83-033 Manifold /P RMA-BJ-6 83-087 28730 SS 22" RMA-BJ-7 83-034/
132002 SS 16" Long Seam 83-034A RMA-BJ-1 83-035 132002 SS 16" RRG-BJ-5 83-019 651345 SS 10" RRH-BJ-5 83-026 651345 SS 10" Recirculation Pump "B" and Discharge Valve By-Pass, RCB-RBB.
Isometric Drawing No. 21 Examination Calibrations Material /
Weld No.
Report No.
Block Size Remarks RCB-BJ-6 83-077 28730 SS 20" Long Seam 1&2 RCB-BJ-7 83-078 28730 SS 20" T/P RCB-BJ-7 83-079 28730 SS 20" Long Seam RCB-BJ-24 83-073 28730 SS 20" P/E RCB-BJ-24 83-074 28730 SS 20" IA/0A RCB-BJ-25 83-075 28730 SS E/P RCB-BJ-33 83-076 28730 SS V/E RCB-BJ-33 83-099 28730 SS IA/0A RBB-BJ-1 83-052 80359 SS 4"
RBB-BJ-6 83-053 80359 SS 4"
RBB-BJ-8 83-054 80359 SS 4"
RBB-BJ-12 83-055 80359 SS 4"
Recirculation Manifold "B" and Risers A, B, C, D, RMB, RRA, RRB, RRC, RRd.
Isometric Drawing No. 22 Examination Calibrations Material /
Weld No.
Report No.
Block Size Remarks RRC-BF-2 83-029 NX9724 CS/Inc.
N0Z/SE RRC-BF-2A 83-005 651345 Inc/CS SE/P 83-005A
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Examination Calibrations Material /
Weld No.
Report No.
Block Size Remarks RRC-BJ-3 83-004 651345 SS-10" RRC-BJ-4A 83-003 651345 SS-10" RRC-BJ-4 83-002 651345 SS-10" RRD-BF-2 83-030 NX1924 N0Z/SF RRD-BF-2A 83-006 651345 Inc/SS SE/P RRD-BJ-3 83-007 651345 SS-10"-
RRD-BJ-4A 83-008 651345 SS-10" RRD-BJ-4 83-015 651345 SS-10" RMB-BJ-6 83-036 132002 SS-16" P/ Manifold RMB-BJ-7 83-098 28730 SS-22" Manifold /C RMB-BJ-8 83-037 132002 SS-16" RMB-BJ-1 83-038 132002 SS-16" C/P RRC-BJ-5 83-001-A 651345 SS-10" EL/P RRD-BJ-5 83-016 651345 SS-10" EL/P 7.
Documentation Review The inspector reviewed the documentation listed below for recirculation system piping weld examinations and inservice examinations of welds in other systems and components.
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UT Report No.83-001, Calibration Report No. PNN-001, Pipe to
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Elbow 10", S/N RRC-BJ-5, Calibration Block No. 651345 UT Report No.83-002, Calibration Report No. PNN-001, Pipe
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to Elbow 10", S/N-RRC-BJ-4, Calibration Block No.651345 UT Report No.83-005, Calibration Report No. PNN-001, Safe-end
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to Pipe 10", S/N-RRC-BF-2A, Calibration Block No. 651345 Ur Report No.83-009, Calibration Report No. PNN-002, Safe-end
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to Pipe 10", S/N-RRG-BF-2A, Calibration Block No. 651345 UT Report No.83-016, Calibration Report No. PNN-003, Elbow to Pipe
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10," S/N RRD-BJ-5, Calibration Block No. 651345 UT Report No.83-027, Calibration Report No. PNN-004, Nozzle to
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Safe-end, S/N-RRH-BF-2, Calibration Block No. 9724 UT Report No 83-033, Calibration Report No. PNN-005, Pipe to
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Crossover, S/N-RMA-BJ-5, Calibration Block No. 132002 UT Report No.83-045, Calibration Report No. RDB-001, KVH 20"
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Recirculation, S/N-RHC-BJ-1, Calibration Block No. 28730 UT Report No.83-053, Calibration Report No. PNN-008, Pipe to Tee
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By-Pass 4",
S/N-RBB-BJ-6, Calibration Block No. 80359 UT Report No.83-056, Calibration Report No. PNN-009, Sweepolet to
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Pipe 6",
S/N-MSC-BJ-19, Calibration Block No. L40321
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UT Report No.83-118, Calibration Report No. PNN-007, Nozzle to
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Shell Weld 8", CS Clad S/N-CSA-BD-1, Calibration Block No. B-0402 UT Report No 83-137, Calibration Report No. RDB-002, Reactor Vessel
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Seam, S/N-VCB-BC i, Calibration Block No. B-0402 Exit Interview The inspector met with licensee representatives (denoted in Persons Contacted, Paragrash) at the conclusion of the inspection. The scope and findings of the inspection were discussed.
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