IR 05000334/1986009

Insp Rept 50-334/86-09 on 860519-0627.No Violations Noted. Major Areas Inspected:Licensee Revised Inservice Insp Program & Performance of NDT Activities,Including Eddy Current Testing of Facility Steam Generator Tubes

ML20204H527
Person / Time
Site:	Beaver Valley
Issue date:	07/30/1986
From:	Lodewyk A, Wiggins J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I)
To:
Shared Package
ML20204H509	List: IR 05000334/1986009 ML20204H506
References
50-334-86-09, 50-334-86-9, NUDOCS 8608080142
Download: ML20204H527 (8)

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U.S. NUCLEAR REGULATORY COMMISSION

REGION I

Report N /86-09 Docket N License N DPR-66 Category Licensee: Duquesne Light Company Post Office Box 4 Shippingport, Pennsylvania 15077 Facility Name: Beaver Valley Power Station, Unit 1 Inspection At: Shippingport, Pennsylvania Inspection Conducted: May 19 - June 27, 1986 Inspector: 7-30-g6 Agd: Lodewg,peactor gineer date Approved by: [~20'b5 JgT.Wiggi(g(Chief,Materialsand date Processes Section, EB, DRS -

Inspection Summary: Routine, unannounced inspection conducted May 19-June 27, 1986 (Report No. 50-334/86-09) of the licensee's Inservice Inspection (ISI)

activities during the fifth refueling outag Areas Inspected: Those areas inspected include previously identified NRC items, the licensee's revised ISI Program, and performance of nondestructive testing activities including Eddy Current Testing of the facility steam generator tubes and ultrasonic examination of the reactor vessel.

l Results: During this inspection, three previously identified NRC items were

! closed and one unresolved item was opened regarding reactor vessel closure I head documentation. No violations were identifie PDR ADOCK 0500

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DETAILS 1.0 Persons Contacted Duquesne Light Company (DLCo)

• Dennis Weakland, Supervisor ISI Services

• William Sikorski, Director of ISI Ronald A. Perry, Supervisor of NDE Services

• Brian Sepelak, Licensing United States I!uclear Regulatory Commission

• Troskoski, Senior Resident Inspector

• A. Asars, Resident Inspector

• Indicates those who attended the exit meeting on June 26, 1986.

The inspector also interviewed other site and corporate personnel during the inspectio .0 Actions Taken on Previously Identified Items (Closed) NC4 (50-334/84-02-01) Uncontrolled Ten Year Inservice Inspection (ISI) Program NRC inspection report 50-334/84-02 identified that the 10 year ISI plan in use at BVPS was not distributed in a controlled manner or documented to have been reviewed or approved by authorized personnel. In response to this finding, the licensee committed to a series of corrective actions which included completing the following: (a) establishing the review and approval process of procedures and administrative controls for the Ten-Year ISI program (b) submittal of an updated, controlled copy of the program i plan and (c) development of a unique set of controlled. drawings which ensures inclusion of all plant modifications required for inservice l

inspection. During inspection 84-26, the inspector reviewed actions taken i by the licensee pertaining to this item and found that the licensee had met its commitment to review and approve procedures for the administra-tive control of the ISI Progra During this inspection, a sampling of procedures and the ISI revision control log were reviewed to ensure ISI documents are issued and controlled in accordance with ISID Procedure l

A3.1, Revision 1, " Distribution of Controlled Documents". The licensee has written and issued the third revision to the Ten Year ISI Program Plan which does not include the controlled drawings which are used to plan, perform and control inspection activities. The ISI Program drawings are used for reference and censistency in nomenclature. The ISI control drawings (8700-ISI series), are cross-referenced with the program and will be

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maintained separately until the next revision of the program plan. The j inspector utilized the cross-reference listing of drawings throughout the

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inspection and found no discrepar.cies or omissions. Based upon the com-pletion of the licensee committments including submittal to the NRC of the revised ISI Program, this item is close (Closed) UNR (50-334/84-14-01) Visual Inspection of Class 1&2 Hanger Supports During inspection 84-14, it was noted that the program for inspection of Class 1&2 hanger supports did not require documentation to reflect if hot or cold spring can settings were inspected. Inspection of the revised ISI Program showed that currently the licensee is required to show the spring hanger set points and perform a review of the set point readings to de-termine acceptabilit Based upon the implementation of these revised requirements and upon discussions with the licensee's representatives, this item is close (Closed) UNR (50-334/85-12-01) Supplemental Inservice Inspection of Pressurizer Manway On April 26, 1985, operations personnel made an at power containment entry to identify a source of leakage as coming from the pressurizer manway cover. Subsequent inspection by licensee personnel found steam cutting of up to 0.826 inches deep on the carbon steel manway flange and 0.344 inches on the manway cover, with a width of approximately 6 inches. No damage was visible on the stainless steel sealing surface. In. mediate corrective actions taken by the licensee have been reviewed and documented in NRC inspection report 85-12. Re-examination of the repaired area was added to the BVPS Inservice Inspection Program and completed during the fifth refueling outage. Visual and magnetic particle inspections did not show further degradation of the repaired area. The inspector had no further questions at this tim .0 Inservice Inspection Program Beaver Valley Power Station Unit 1 Inservice Inspections Program is based upon the ASME B&PV Code 1974 Edition through Summer 1975 Addenda (74S75)

of Section XI as required in 10 CFR 50.55 This inspection consisted of a review of the ISI program as revised and updated (reference NCR 84-02-01) and observation of onsite ISI activities performed by Babcock and Wilcox (B&W) personnel during the fifth refueling outag .1 Program Review The ISI Program review during this inspection included comparisons to the applicable ASME Code Editions, control of procedures as dis-cussed in item 84-02-01, and completion of outage examination re-quirements per the BVPS Ten Year ISI Plan. The inspector noted that licensee efforts, apparent during this outage, showed adequate vendor and procedure control within the ISI department. Completion of the

scheduled outage activities and ISI Program requirements will be subject to further NRC review.

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3.2 Procedure Review Throughout this inspection, various procedures were reviewed, in part to facilitate observation of work activities in the fiel Some of the procedures reviewed included the following:

B&W procedure No. ISI-350, Rev. 20 " Visual Examination of Welds and Surface Condition" B&W procedure No. ISI-240, Rev. 21 " Penetrant Examination of Welds and Base Materials, Including Studs and Nuts"

B&W procedure No. ISI-119, Rev. 6 " Ultrasonic Examination of Stainless Steel and Nickel Base Alloy Weld Seams" B&W procedure No. ISI-130, Rev. 22 " Ultrasonic Examination of Vessel Welds and Nozzle Inside Radius Section"

B&W procedure No. ISI-131, Rev. 11 " Remote Ultrasonic Examina-tion Using the ARIS Devic In addition to the inspector referencing ISI procedure No. ISI-131, Rev. 11 for verification of field activities, this procedure was also reviewed for compliance with Appendix I of the 74S75 edition of the ASME cod The information addressed during this review included the following:

Weld type and configurations to be examined

surface condition and examination requirements couplant specifications

equipment (transducer and ultrasonic instrumentation)

characteristics scanning, recording and calibration criteri Based on the review of the above, the inspector determined that the equipment and techniques utilized in tSt field were in agreement with those required by facility procedures and the ASME Cod . . ___ _ _ . _

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3.3 Observation of Work Activities Observations by the NRC inspector of ISI examination activities performed at BVPS by B&W personnel included NDT of a cast stainless steel circumferential weld, eddy current testing of the facility steam generator tubes, and the remote ultrasonic examination of the reactor vessel. Licensee commitments and inspection observations for these activities are discussed in further detail belo .3.1 Examination of Cast Stainless Steel At BVPS, the Reactor vessel safe end to elbow pipe welds are centrifugally cast stainless steel material and are required to be examined volumet.rically by Section XI of the ASME Cod Amendment No. 22 of the BVPS Technical Specifications requires a supplemental surface examination to be performed in conjunction with the ASME Code required volumetric exam. This is due in part to the inherent characteristics of the material which make it difficult to examine ultrasonicall The inspector witnessed the calibration for the scheduled ultrasonic examination (N B4.5.3) of the weld to check for complete penetration of the UT sound beam, as a minimum, in the calibration block materia Additionally, the supplemental surface examination (B4.5.3.1)

was observed to have been performed in accordance with the appropriate B&W procedure ISI-240, Rev. 2 .3.2 Eddy Current Testing (ECT) of Steam Generator U-tubes BVPS Technical Specifications section 4.4.5 discusses the sur-veillance requirements for the steam generators. The steam generator tube examination requirements are as prescribed in ASME Code Section V, and as referenced in Section XI, Appendix IV, 1980 Edition through Winter 1980 Addenda (80W80). Technical t

Specification acceptance criteria define a degraded tube as one l containing imperfections greater than or equal to 20%. A defective tube is one which will not allow passage of the eddy-current inspection probe or one with indications that l exceed the plugging limit (greater than or equal to 40% through l wall).

l l The majority of U-tubes found to be degraded or to have record-l able indications during current and previous inspections, are i located in the outer periphery of each steam generator. The l nature of tube degradation is believed to be a phenomenon l referred to as " cold leg thinning". Typically, these ECT indications are located within the region of the lower tube support plates on the cold leg side. Similar indications have been identified in 29 steam generators at various sites. It is believed that cold leg thinning is a result of both chemical and mechanical (fluid flow) activity within the steam generators.

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Preliminary studies also indicate cold leg thinning degradation does not exceed 60% through-wall. Based upon BVPS site history, wall thinning has occurred at a growth rate of approximately 1%

per mont Steam generator IB was scheduled for inspection during the fifth refueling outage. The initial inspection sample size included examination of 305 steam generator U-tubes, from tube-face to tube-face. Five pluggable or defective tubes were identified in the initial sample size, requiring the licensee to expand the scope of the steam generator inspection (Technical Specification Category C-3). DLCo anticipated inspection of 100% of all three steam generators at BVPS Unit 1 due to the TS surveillance requirements and by biasing their expanded sample to the suspect tube areas. In an attempt to avoid undue radiation exposures and an extension of the licensee's outage critical path, the licensee submitted a request to NRR for relief from these TS surveillance requirements. The request limited the ECT examin-ation areas to those susceptible to ' cold leg thinning' in each of the two steam generators remaining to be examined (generators 1A and IC). The relief request was denied by NRR based upon station FSAR accident analysis assumptions. This denial and the results of the ECT resample required the licensee to inspect 100% of all three steam generators to meet TS surveillance re-quirements. Based upon the results of the ECT inspections, the licensee is also reanalyzing the 10 CFR 50 Appendix K "ECCS Evaluation Model" calculation to increase the allowable number of pluggable tubes for the steam generators from 1%.

The inspector reviewed the use of the Multi-frequency Inspection System (MIZ 18) by B&W for ECT of the reactor coolant steam generator U-tubes. This review included (a) calibration of the inspection probe (b) collection and recording of ECT data and (c) data review and characterization of indications. MIZ 18 allows for analysis of data in two modes, the differential mode and the absolute mode. Due to this analysis capability, DLCo's position is that a third party review of the ECT data, as is common throughout the industry is not required. However, the inspector noted that by specification QCSI-0004, Rev.0, DLCo provides for a final analysis of an identified indication by a Level III examiner. This ensures that indications identified by a Level II will be verifie ,

3.3.3 Reactor Vessel Inspection For the fifth refueling outage, the reactor vessel inspection was performed by B&W personnel using the Automated Reactor Inspection System (ARIS). ARIS is a remote ultrasonic examin-ation device which can be used in an automatic (programmable)

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mode or in the manual mod This BVPS vessel inspection was the first inspection in which the ARIS device was used for a contact ultrasonic examination. Mechanical movement of the equipment permits ten degrees of freedom to allow for access to the vessel inner wall and nozzle weld contour. The ARIS head contains nine transducers, eight of which may record data simultaneously. The ARIS device typically scans at 0.8 inch increments which pro-vides an overlap of approximately 0.2 inch as the typical trans-ducer used for inspection is one inc If a rescan of an area is required for analysis, the ARIS device is programmed to scan at 0.1 inch increments to obtain better coverage of indication The inspector verified the field scanning rate of 70 inches per minute was less than the maximum acceptable rate of 2 inches per secon The Automated Data Aquisition System (ADAS) was used for analysis of the ARIS ultrasonic data. ADAS is highly sensitive to noise levels including noise from (a) changes in surface con-tour and subsequent head lift-off and (b) changes in grain size and thus weld locations. The computer enhanced data display shows the inspection area face, top and side views with color display of data DAC percentages. The display may be varied to better focus on the area of interest. The enhanced ADAS display of ultrasonic data confirmed the as-built drawing location of the reactor vessel weld During the manual ultrasonic examination of the reactor vessel closure head, examination personnel found what appeared to be six extra meridinal welds. This configuration did not agree with ISI weld location drawing DLW-1-1300. The area of interest was scanned completely to ensure completion of the Code required examination. Preliminary inquiry by the ISI department in-dicated the six extra weld areas to be remnants of welding used to attach fitup fixtures during vessel head fabrication. To establish the actual as-built candition of the vessel head, the inspector requested to review the shop fabrication traveler, NDE data and related records. This item is unresolved pending re-view of these items (86-09-01).

3.3.4 Qualification of Personnel During this inspection, the qualification records of those in-dividuals observed performing NDE onsite were reviewed to verify that applicable documentation demonstrated acceptable ASNT qualifications in the following areas:

results of eye examinations for color and accuity (where applicable)

practical examination results training hours and years of practical experience

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Personnel credentials were reviewed against the applicable portions of (a) ASNT-TC-1A,1980 Edition, (b) ANSI N45.2.6,1978, and (c) ISID procedure A4.2, Rev. O " Personnel Qualification and Certification in Nondestructive Examination".

Throughout the inspection of ISI Program activities described above, no violations were identified. Overall, the ISI activities during the fifth refueling outage were found to be in compliance with Code requirements and licensee commitment .0 Quality Assurance The inspector reviewed the BVPS Unit 1 ISI program requirements intended to meet the requirements of 10 CFR 50 Appendix B Criterion XVII " Quality Assurance Records". Criterion XVII requires inspection and test records to identify the inspector, type of observation, results, test accept-ability, and any actions taken in connection with any deficiencies noted, as a minimum. B&W nondestructive test data records readily identify the NDE examiner and results of examinations. For acceptability of exami-nation results and record of disposition, an Evaluation Report is com-pleted and logged against the test record. The actions and responsibi-lities required for recording of examination results is discussed in B&W procedures:

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ISI-69, Rev. 15 " Administrative Procedure for Reporting Nondestruc-tive Examination Indications and Data to the Customer"

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ISI-64, Rev. 19 " Administrative Procedure for Handling Nonreportable Nondestructive Examination Data" Through review of the site records and procedures, the inspector determined that the program for recording the ISI NDE test results is adequate and meets the requirements of Criterion XVI .0 Unresolved Items Unresolved items are those matters about which more information is re-quired in order to ascertain whether they are acceptable, violations or deviations. An unresolved items is discussed in paragraph 3.3.3 of this repor .0 Exit Interview The inspector met with the Personnel denoted in paragraph 1.0 at the conclusion of the inspection on June 27, 1986. The scope and findings of the inspections were discussed at that time. At no time during this inspection was written material provided to the licensee by the NRC in-spector.

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