IR 05000333/1978018

IE Inspec Rept 50-333/78-18 on 780918-22 & 1003-06 & 1011-13 During Which No Items on Noncompliance Were Noted.Major Areas Inspected Incl:Insvc Inspec Activities & Activities Assoc W/Removal of Feedwater Spargers

ML20062G351
Person / Time
Site:	FitzPatrick
Issue date:	11/08/1978
From:	Ebneter S, Mcbrearty R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I)
To:
Shared Package
ML20062G349	List: IR 05000333/1978018 ML20062G345
References
50-333-78-18, NUDOCS 7812270457
Download: ML20062G351 (10)

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U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT Region I Report N Docket No. ,_,50-333 License N DPR-59 Priority -

Category C Licensee: Power Authority of the State of New York 10 Columbus Circle New York, New York 10019 Facility Name: James A. FitzPatrick Nuclear Power Plant Insp;ction at: Scriba and New York, New York

. ,pection conducted: September 18-22, October 3-6 and

.J)ctober 11-13 1978 Inspectors: , /4' b ///4/7V date signed R. A. McBrearty, Reactor Inspector date signed

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Approved by: .J 4 - /' a M/~.-

S. D. Ebneter, Acting Chief. Engineering cate signed Support Section No.1, RC&ES Branch 1...soection Summary: .

Inspection on September 18-22, October 3-6 and October 11-13, 1978 (Report No. 50-333/78-18)

Areas Inspected: Routine, announced inspection by a regional based inspector of inservice inspection activities and activities associated with removal of feedwater spargers and feedwater nozzle cladding removal. The inspection involved 63 inspector-hours onsite by one NRC regional based inspector in-cluding 3 inspector-hours at the home office of the licensee'.i ISI contracto Results: No items of noncompliance or deviations were identifie Region I Form 12 (Rev. April 77)

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'ETAILS D Persons Contacted Power Authority of the State of_New York

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• J. Baker, Maintenance Superintendent J. Carroll, QA Engineer

• V. Childs, Assistant to Resident Manager

• M. C. Cosgrove, Site QA Engineer W. Fernandez, ISI Coordinator

• • D. Frangu, Corporate NDE Level III

• R. J. Pasternak, Superintendent of Power

• • A. Sorrentino, Nuclear Performance Engineer EBASCO

• • S. Markowitz, QA Supervisor, NDE

• • B. Mazo, Chief QA Engineer D. Nuzzo,.ISI Site Supervisor

• • W. Sawicky, ISI Supervisor General Electric Company G. Bragan, Project Manager J. Fitzgerald, Site Manager J. Kong, I&SE Floor Engineer J. Taylor, Site QA Supervisor

• Denotes those present at exit interview on 10/12/7 ** Denotes those present at exit interview at EBASCO home office on 10/13/7 . Inservice Inspection (ISI) Activities ISI Program Review l The inspector reviewed the JA FitzPatrick ISI program with l respect to the requirements of the ASME Boiler and Pressure i Vessel Code,Section XI,1970 edition and the plant Technical Specification. EBASCO Services, Inc. was contracted by the licensee to perform the required examinations.

i The review included the following:

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' - Inservice Inspection Program for James A. Fi',zPatrick Nuclear Power Plant.

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The EBASCO QA Manual - Inservice Inspection, Revision 0, dated October 12, 197 Letter dated October 6,1978 from B. R. Mazo to D. Nuzz The items to be examined during the current refueling outage were listed and categorized in accordance with the ASME B&PV Code,Section XI, Table IS-26 The inspector found that the applicable requirements of the 1970 ASME Section XI and the plant Technical Specifications were me No items of noncompliance were identifie ISI Procedure Review The inspector reviewed the following NDE procedures which were developed by EBASCO for use during the on-going refueling outage:

- Procedure No. JAF-UT-1, Revision 1, dated September 22, 1978 entitled "UT Examination of Reactor Pressure Vessel Welds, RPV Head Weld, Nozzle to Vessel Welds".

- Procedure No. JAF-UT-2, Revision 2, dated September 22, 1978 entitled "UT Examination of Dissimilar Metal Welds, Pipe Welds and Integrally Welded External Support Attach-ments".

- Procedure No. JAF-UT-3, Revision 1, dated September 22, 1978 entitled "UT Examination of Pressure Retaining Bolt-ing 2 Inches and Larger in Diameter".

- Procedure No. JAF-PT-1, Revision 1, dated September 22,

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1978 entitled " Color Contrast - Solvent Removable Liquid

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Penetrant Examination".

- Procedure No. ISI-VT-76-1, Revision 1, dated September 22, 1978 entitled " Visual Examination of Welds".

- Procedure No. ISI-VT-76-2, Revision 1, dated September

, 22, 1978 entitled " Visual Examination of Support Members".

- Procedure No. ISI-VT-76-5, Revision 1, dated September 22, 1978 entitled " Visual Examination of Bolting Compo-nents".

The above were considered with respect to the requirements of the 1970 ASME Code,Section XI and the facility Technical Spec-ification. In addition, Procedures UT-1, UT-2, UT-3 and PT-1 were reviewed for technical adequacy. This included, but was not limited to, the parameters described below for the ultra-sonic and liquid penetrant method:

(1) Ultrasonic Examination (a) The type of apparatus including frequency range is specifie (b) The extent of coverage, beam angles and transducer size are specifie (c) The reference level for monitoring discontinuities is defined and scanning gair, setting is consistent with 9 the applicable ASME Cod (d) Acceptance limits are consistent with ASME,Section X ,

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(2) Liquid Penetrant Examination (a) The penetrant, penetrant remover and developer are

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(b) Examination surface preparation is specifie (c) Penetrant materials used for the examination of nickel based alloys and austenitic stainless steel are required to be analyzed for sulfur content and total halogens and the specified limits are con-sistent with the applicable ASME Code.

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(d) The specified examination surface temperature range is consistent with the penetrant manufacturer's recom-mendations and is within the range of 600F to 1250 (e) The method of penetrant application and penetration time is consistent with the penetrant manufacturer's reconnendation.

i No items of noncompliance were identifie Observation of NDE in Progress The inspector observed the ultrasonic examination of tne follow-ing welds:

- Weld #12-34-375,12 Inch Pipe to Pipe Weld in the Feed- ,

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water Syste Weld #12-34-377,12 Inch Pipe to Elbow Weld in the Feed-water Syste Weld #24-29-514, 24 Inch Pipe to Elbow Weld in the Main Steam Syste The examinations were done using the longitudinal and shear mode of sound transmission. The shear wave examination was done by fitting a plastic wedge to the transducer in order so produce a 450 entry angle in steel. Each examination was done using a test frequency of 2.25 MHz.

1 The inspector observed the liquid penetrant examination of the following weld in the Reactor Water Cleanup System:

- Weld #6-12-141B, Pipe to Valve Wel The examination of the above weld was done by an NDE Level II i individual using materials certified to contain permissible

quantities of sulfur and halogen .

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The examination revealed unacceptable indications which were properly recorded and reported to the licensee. DCAR #010/78 was written and the required corrective action was taken while the inspector was onsite. Re-examination of the area follow-ing surface preparation revealed no indication The inspector found that the examinations were done in accord-ance with approved procedures using materials and equipment which were properly certified and calibrate No items of noncompliance were identifie d. NDE Personnel Qualifications The inspector reviewed records and interviewed personnel with respect to qualification of the personnel performing the exam-inations listed in Paragraph 2.c. This was done at the J. FitzPatrick site and at the EBASCO Services Inc., office at 19 Reactor St., New York, N.Y. to ascertain the adequacy of the EBASCO NDE training program and compliance with the re-quirements of SNT-TC-1A, the governing documen The review at the EBASCO New York office included the following:

- EBASCO Services, Inc. Ultrasonic Examination Training Manual, dated January,197 Fundamentals of Nondestructive Testing Prepared by General Dynamics for ASM QA Training Program - Subsidiary Chronological Log for January 25-28, 1977, January 31, 1977 and February 2,197 Attendance Records for the above dates.

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The training manual included the material covers " ' (iassroom lectures and was supplemented by the fundamentals of nondest uc-l tive testing series of audio and visual aids covering the various I aspects of nondestructive testin , . , - _ . _ _ _ _ _ _ _ ,

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The inspector was informed that a similar training manual is

available for each of the NDE methods, and that each manual

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is supplemented by the appropriate series of visual / audio aid l The inspector found that the EBASCO NDE training program met

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the applicable requirements of SNT-TC-1A and that the EBASCO ,

NDE personnel were properly qualified and certifie No itecas of noncompliance were identified.

l Feedwater Sparger Removal and Reactor Vessel Feedwater Nozzle

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During the current refueling outage, the licensee is performing the ,

following operations inside the Reactor Pressure Vessel:

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- Replace feedwater spargers.

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Examine and check dimensions of feedwater nozzle Examine feedwater nozzle cladding for defects.

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- Remove cladding from feedwater nozzles by machining.

In addition, the feedwater nozzles inner radii will be ultrasonically examined from the outside vessel wall after clad removal.

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The progress on the above projects at the time of this inspection is as fallows:

- Feedwater spargers removed from the reactor vesse Feedwater nozzle cladding examination was complete (

- Cladding removal operation partially completed on nozzle at 450 azimuth locatio D The inspector reviewed the following items associated with the sparger replacement and clad removal program:

- Procedure No. FCR 1.0, Revision 0, dated September 13, 1978 entitled " Installation of Shield Plugs, Fence Post Shielding,

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Vessel Wall Shielding and Vessel Shielding".

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- Procedure No. FCR 2.0, Revision 0, dated September 13, 1978 entitled "Feedwater Sparger Removal and Nozzle Inspection".

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Procedure No. FCR 12.0, Revision 0, dated August 23, 1978 entitled " Welding of the Feedwater Sparger".

- Specification No. FCR 14.0, Revision 0, dated August 28, 1978 entitled " Tool and Equipment Control".

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Procedure No. FCR 9.0, Revision 0, dated August 28,1978 entitled " Machining Procedure for Feedwater Nozzles".

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Addendum "A" to Procedure 9.0, dated October 9, 1978 entitled

"Remachining of the 450 Nozzle Deep Bore Cut".

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Minutes of Plant Operations Review Committee (PORC) Meeting No. 78-66 held on October 8,197 Procedure 18XA8401, Revision 0, dated September 13,1978 en-titled "NDE-Liquid Penetrant Examination Procedure (Color Con-trast-Solvent Removable)".

- Procedure No. TP-508-0173, Revision B, dated June 21,1977 entitled " Test Procedure for Feedwater Nozzle Inner Radius Zone 1 Ultrasonic Examination".

- Procedure No. TP-508-0174, Reivision B, dated June 21,1977 entitled " Test Procedure for Feedwater Nozzle Inner Radius Zone 2 Ultrasonic Examination".

- Specification No. E50YP14, Revision 0, dated August 17, 1976 entitled " Ultrasonic Examination of the Reactor Pressure Vessel i Nozzle Cylindrical Section".

- General Welding Procedure No. ISE-GWP-NSI, Revision 3, dated February 13, 1976.

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- General Welding Procedure No. ISE-GWP-N, Revision 2, dated l

February 14, 197 .

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- Detail Welding Procedure No. ISE-DWP-3004, Revision 4, dated March 29, 197 Welding Procedure Qualification Records for the above listed Welding Procedure Welder Performance Qualification Records for the Three Welders Supplied hy Crouse Company, Nuclear Services Division, who will weld under General Electric Company supervisio Special Process Control Sheet (SPCS) for various QC functions required by the above procedures. These included penetrant examination prior to machining 450 nozzle, verification of bore plug installation in all four nozzles and wall thickness monitoring during machining of deep bore cut on 450 nozzl The inspector performed a visual inspection of the feedwater nozzle machining operation from the refueling floor. The clad removal equipment was in place for machining the nozzle at 450 azimuth location. During this inspection, a review of the tool control log book was made. The log was found to be located at the access point to the reactor vessel. The first entry in the log was dated September 23, 1978 and the most recent entry was made at 1512 hours0.0175 days <br />0.42 hours <br />0.0025 weeks <br />5.75316e-4 months <br /> on the day of the inspectio The inspector was informed by the licensee that completion of the 450 nozzle machining was delayed due to failure of the pilot bearing to hold alignment of the deep bore cut which was being made in

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the nozzle base material. The failure resulted in eccentricity in the nozzle bor PORC Meeting 78-66 was held on October 8,1978 to discuss the prob-lems associated with the 450 nozzle deep bore machining and estab-lished that the major cause of error was movement of the pilot bear-ing during the machining of the deep bore cut. The bearing movement was attributed to ridges in the existing seating surface of the i bearing which were postulated to be root passes of the safe end to

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feedwater piping weld. Similar ridges were observed hy the licensee on the 1350 and 3150 nozzle. Inspection of the 2250 nozzle was precluded hy presence of the clad removal equipment at this tin .

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A new pilot bearing was designed to alleviate the seating problem

and additional machining verification steps were requested by the I licensee to assure the new deep bore cut is running true. The

licensee requests were incorporated in Addendum "A" to General Electric Procedure FCR 9.0.

! A determination was made that the incresea in bore diameter necessary to correct the error caused by the beari , failure would not violate the minimum wall thickness specified by General Electric Document 22A6431, Sheet 19, F62dwater Nozzle (Rapid Cycling) Design Certifi-catio Prior to the exit meeting, the inspector was informed that the new bearing was installed and appeared to function properly. Remachin-

, ing was monitored in accordance with the requirements of FCR 9.0, Addendum "A" and was progressing satisfactoril _

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The inspector found that procedural requirements were being me No items of noncompliance were identified.

! Exit Meeting

The inspector met with the licensee representatives (denoted in

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Paragraph 1) at the conclusion of the inspection on October 12, 1978 at Scriba, New York and on October 13, 1978 at New York, New l

York. The inspector summarized the results of the inspection as described in this report.

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