IR 05000335/1990026

Insp Repts 50-335/90-26 & 50-389/90-26 on 901022-26.No Violations or Deviations Noted.Major Areas Inspected: Isi,Including Review of Unit 1 Plan for Outage & Associated ISI Administration Procedures

ML20062E409
Person / Time
Site:	Saint Lucie
Issue date:	10/31/1990
From:	Blake J, Kleinsorge W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
To:
Shared Package
ML17223B003	List: IR 05000335/1990026
References
50-335-90-26, 50-389-90-26, GL-90-05, GL-90-5, IEB-87-002, IEB-87-2, NUDOCS 9011200272
Download: ML20062E409 (13)

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UNITED STATES

[ A Riouq'o NUCLFAR REGULATORY COMMISslON i

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[ p REGION 11 l g- j 101 MARIETTA STREET, ;

• AT LANT A, GEORGI A 30323

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Report Nos'.: 50-335/90-26 and 50-389/90-26 Licensee: Florida Power and Light Company i 9250 West Flagler Street Miami, FL 33102 Docket Nos.: 50-335 and 50-389 License Nos.: DPR-67 and NPF-16 Facility Name: St. Lucie 1 and 2

. Inspection Cond .d: r 2-26, 1990 Inspectors:

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.W ._,4/ 4( M d i Th ~ ge P.E f Date Signed ' i Approved by: /0 //fo J. ake, Thief Date Signed P te fals and Processes Section ng neering Branch )

Division of Reactor Safety

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SUMMARY

Scope: j This routine, unannoanced inspection was conducted onsite in the areas of Inservice Inspection 'ISI) . including a review of the Unit 1 ISI plan for this outage and associated ISI administrative procedures; review of Nondestructive:

Examination (NDE) procedures; observations of Unit 2 in-progress Ultrasonic (UT), Magnetic Particle (MT), and Liquid Penetrant (PT): examinations and associated activities and, review of completed NDE examination results data, in addition the foll(wing areas were examined: Followup on Generic Letter 90-05 " Guidance for Performing Temporary Non-Code Repair of ASME Code Class 1, 2 and 3 Pioing," and Followup on NRC Bulletin 87-02 " Fastener Testing To l Determine Conformance With Applicable Material Specifications."

Results:

The Review of the licensee's Inservice Inspection (ISI) program indicates adequate management and control, of the program, is currently in place. The personnel implementing the program, and performing the examinations, were well trained and well, qualifie The inspector noted a weakoess related to weld

area of interest identification (Paragraph 2.e.(2))

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901120027;. PO 1i5 POR ADOCF 0;diOO3 ? -

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REPORT DETAILS Persons Contacted Licensee Employees

• G. Alexander, Plant Support / Juno Beach Staff (NS/JB)

• J. Barrow, Operations Superintendent

• G. Boissy, Plant Manager

• F. Carr, NS/JB Staff S. Collard, NS/JB Staff

• D. Culpepper, Engineering Supervisor

• R. Eng1meier, Site Quality Manager

• J. Geiger, Vice President Nuclear Assurance

• D. Lowens, Quality Assurance (QA)

• L. McLaughlin, Yechnical Staff

• J. Moaba, JPN/ESI

• L. Motley, JPN/ESI Staff

• D. Nowakowski, NS/JB Staff

• B. Parks, Quality Assurance

• S. Sienkiewicz, Inservice Inspection Technical Staff

• D. Stewart, Technical Staff

• West, Technical Department Supervisor Other licensee employees contacted during this inspection included craftsmen, engineers, mechanics, security force members, technicians, and administrative personne NRC Resident Inspectors

• S. Elrod, Senior Resident-Inspector

• M.: Scott, Resident Inspector

• Attended exit interview Acronyms and initialisms used throughout this report are listed in the

'last paragraph, InserviceInspection(ISI)

The inspector reviewed documents and records, and observed activities, as indicated below, to determine whether ISI was being conducted in accordance with applicable procedures, regulatory requirements, and licensee commitments. The applicable code for ISI, for Unit 1, is the American Society of Mechanical Engineers Boiler and Pressure Vessel (ASME B&PV) Code, Section XI,1983 edition with addenda through suwer 1983

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(83S83), in the second 40 month period, of the Unit 1 is operating second ten year ISI interval (P2,12). Unit I commenced commercial operations on December 21, 197 The applicable code for ISI for Unit 2 Unit is ASME B & PV code Section XI 80W8 Unit 2 commenced commercial operations on August 8, 198 Unit 2 is in the first outage of the third 40 month period, of the first ten year ISI interval (01 P3,II).

The licensee's nondestructive examination personnel, augmented by contract personnel from EBASCO, are magnetic particle (MT), visual (VT) , andperforming theexamination ultrasonic (UT) liquid penetrant (PT),

Steam generator tubing eddy current (EC) examination data collection is accomplished by Assea Brown Boveri Combustion Engineering (ABBCE)

contracted personnel, with contracted ABBCE, Zetec and NDE Tech personnel and FP&L personnel performing the data analysi All the above activities are being accomplished under the umbrella of the FP&L Quality ,

Assurance (QA) Program, ISI Program Review, Units 1 and 2 (73051)

The inspector reviewed the following documents relating to the ISI program to determine whether the plan had been approved by the licensee and to assure _ that procedures and plans had been established (written, reviewed, approved and issued) t) control and accomplish the following applicable activities: orginizational structure including qualifications, training, responsiailities, and duties of personnel responsible for ISI; audits ircluding procedures, frequency, and qualification of personnel; general M11ty Assurance requirements including examination *eports, deviatMns from previously established program, matarial certificctions, and identification of components to be covered; work and inspection procedures; control of processes including suitably controlled work conditions, special methods, tnd use of qualified personnel; corrective action; document control; control of examination equipment; quality records including documentation of indications ' and- NDE findings, review of documentation,

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provisions to assure legibility and retrievability, and corrective >

action; scope of the inspection including description of areas to be examined, examination category, method of inspection, extent of examinations, and justification for any excer cion; definition of inspection interval and extent of axamination; qualification of NDE personnel; and, controls of genera tion, approval, custody, storage and maintenance of NDE records, JNS-PSL-200 (RS) Inservice Inspection Plan First Ten Year

! Plan (Unit 2)

ESI-PSL-200-4 (R1) First Interval / Third Period Inservice ExaminationPlan(Unit 2)

JNS-MCI QI 2.14 (RS) Nuclear Energy Manual for ASME Section XI Inservice Inspection of Nuclear Power Plants l

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JNS-! * QI (RI) Control of Nondestructive Examination (NDE)

, Activities ADM-CIS- (R1) Procedure For Qualification of Nondestructive 4 Examination Procedure Calibration Blocks / Standards CAL-3 (RI) Calibration Verification of Temperature Measuring Devices i Review of NDE Procedures, Units 1 and 2 (73052)

-(1) The inspector reviewed the procedures listed below to ,

determine whether these procedures were consistent with regulatory requirements and licensee commitment 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 the licensee and contractor personnel' if contractor personnel are involved in the ISI effor ,

NDE-1,3 (R3) Eddy Current Examination of Non Ferromagnetic Tubing with Multi-Frequency Techniques MIZ-18 NDE- (P,2 & FCA) Magnetic Particle Examination NDE- (R2) Liquid Penetrant' Examination Solvent Removable ,

Viable Dye Technique NDE- (R3)- Visual Examination VT 1 for l Welds / Bolting / Bushing s/ Washer '

! NDE-4;2 -(RI) Visual Examination VT 2 Conducted During System Pressure Test  ;

NDE- :(R2) Visual Examination'VT-3/VT-4 l

NDE- (R2 & FCA) Ultrasonic Examination of Main Coolant Main Piping Welds ,

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Ultrasonic Eemination of Reactor Pressure ;

+: NDE- (R2 & FCA)

Vessel Stuas and Reactor Coolant Pump Studs NDE-5.12 (R2 & FCA)_ Ultrasonic Examination of Reactor Pressure Vessel Flange to Vessel Weld and Stud Hole Threads

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NDE-5.18 (R2) Ultrasonic Thickness Measurement

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The inspector reviewed the UT procedures to ascertain whether they had been reviewed and approved in accordance with the licensee's established QA procedures. The procedures were also reviewed for technical adequacy and conformance with ASME, Section V, Article 5 and other licensee commitments /re-quirements 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 discontinuities; method for demonstrating penetration; limits for evaluating and recording indications; recording significant indications; and, acceptance limit (3) Liquid Penetrant Examination (PT)

The inspector reviewed the PT procedure to ascertain whether it had been reviewed and approved in accordance with the licensee's established QA procedures. The procedure was also reviewed for technical adequacy and conformance with ASME, Section V, Article 6, and other licensee commitments / require-ments in the following areas: specified method; penetrant material identification; penetrant materials analyzed for sulfur; penetrant materials analyzed for total halogens; surface temperature; acceptable pre-examination surface conditioning; method used for pre-examination surface cleaning; surface drying time prior to penetrant application; method of penetrant application; penetrant dwell time; method used for excess penetrant removal; surface drying prior to developer application, if applicable; type of developer; e.< amination technique; evaluation techniques; and, procedure requalificatio (4) Magnetic Particle Examination (MT)

The inspector reviewed the MT 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 Code Section V. Article 7, and other licensee commitments / requirements in the following areas: examination methods;. contrast of dry 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

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spacing;_ current or lifting power (yoke); and, acceptance criteria.

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(5) Visual Examination (VT)

The inspector reviewed the VT procedures to determine 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: method - direct visual, remote visual or translucent visual; application -

hydrostatic testing, 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 performing examination, when applicable; data to be tabulated, if any; acceptance criteria is specified and consistent with the applicable code section or controlling specification; and, report form completio '

(6) Eddy Current Examination (EC)

The inspector reviewed the EC procedures for technical content relative to: multichannel examinaticn unit, multichannel examination indication equipment is specified, examination sensitivity, method of examination, method of calibration and calibration sequence, and acceptance criteri All procedures reviewed appeared to contain the necessary elements for conducting the specific examinatio c. Observation of Work and Work Activities, Unit 2(73753) '

The inspector observed work activities, reviewed certification records _of NDE equipment and materials, and reviewed N",E personnel qualifications for personnel that had been utilized during the required ISI examinations during this outage. The observations and reviews conductr. Lj the inspector are documented belo (1) UltrasonicExamination(UT)

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The inspector observed calibration activities and the

! in-process UT examinations as indicated belo These observations were compared with the applicable procedures and the ASME B&PV Code in the following areas: availability of and compliance with approved NDE procedures; use of knowledgeable NDE personnel; use of NDE personnel qualified to the proper level; type of apparatus used; calibration requirements; search units; beam angles; DAC curves;

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reference level for monitoring discontinuities; method of j demonstrating penetration; extent of weld / component !

examination coverage; limits of evaluating and recording i indications; recording significant indications; and, acceptance limit Examinations Observed The inspector observed in process UT examinations on the Main l Steam (MS) system. The inspector reviewed documentation for [

UT examinations on the Reactor Pressure Vessel (RPV), Steam )

Generators (SGs) and the Safety Injection (SI) system ;

The inspector reviewed selected calibration and certification !

, documentation for the UT instruments, calibration blocks, and ,

couplant, and spectrum analysis data for the ultrasonic transducers used in the examinations listed abov (2) LiquidPenetrantExamination(PT)

The inspector observed the in process PT examinations as ,

indicated below. The observations were compared with the

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applicable procedure and the ASME B&PV Code in the following ;

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areas: specified method, penetrant materials identified; penetrant materials analyzed for halogens and sulfur; acceptable pre-examination surface; surface temperature; ;

surface drying time prior to penetrant application; method of penetrant application; penetrant dwell. time; method used for excess penetrant removal; surface drying prior to developing, if applicaole; type of developer; examination technique; L evaluation technique; and, reporting of examination result !

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i- Examinations Observed

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L The inspector observed in process PT examinations on the Reactor Coolant (RC) system. The-inspector. reviewed records

.of PT examinations on the SI and Shut Down Cooling (SDC)

system The inspector re-evaluated the . examinations observed in process following the 'T examiner's evaluation of the area of interest but prior to the developer being removed from the surfaces. This re-evaluation was conducted in order to determine if the evaluations performed 'by the PT examiners were in accordance with the applicable procedure acceptance criteria and to determine if the examination results were being reported as required. The re-evaluations conducted by the NRC inspector indicated that the proper evaluation was made by the PT examiners and that the examination results were being reported as require _ . - - - - . _ - - . _ . J--- i i is ii - .i i i i .i s .==ii

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The inspector's review of the liquid penetract materials certification records, for the examinations indicated above,

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that the sulfur and halogen content of the material was within acceptable content limit (3) Magnetic Particle Examination The inspector observed the in-process MT examinations as indicated below. The observations were compared with the h applicable. procedures and the Code in the following areas:

- examination methods; contrast of dry powder particle color with background; surface temperature; suspension medium for wet particles, if applicable; viewing conditions; examination

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overlap and directions; pole or prod spacing; current or lifting power (yoke); and acceptance criteri Examinations Observed The inspector observed in process MT examinations on the RC system. The inspector reviewed records of MT examinations on

the RPV, SGs, and the RC and MS systems.

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The inspector conducted MT verification examinations, of the examinations observed in process, using the yoke equipment, on portions of. those areas of interest previously observed

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being examined. The examinations were conducted in order to evaluate the technical adequacy of the examination procedure

__ being used by the licensee to perform examinations and to assess the validity of the information being reported by the MT examiner The information reported by the ~ MT examiners compared favorably with the verification examinations.

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- The inspector review < d documentation indicating that the 10 pound lift -test had been performed on magnetic particle alternating current (AC) yokes observed abov The

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certification records for the lift test plates that were used to conduct the tests, were reviewed to confirm the weight of

' the test plate A review of the material certification records for the particles used in the examinations above met the applicable specifications requirement (4) Visual Examination (VT)

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The inspector observed the below indicated in-process VT examination These observations were made to: determine whether the applicable drawing, instructions or travelers

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clearly specify the procedure to be used and thas a copy of g the procedure is available in the area where the work is L being performed; identify for record review the personnel performing the examination and ascertain whether they are qualified to perform the assigned task; determine whether the required tools and examination aids (as specified in the m examination procedure) are available at th work location; determine whether the specific areas, locations and extent of examination are clearly defined; determine whether the test

[ attributes are as specified in the applicable test procedure; ascertain whether the defects are evaluated in accordance r with the procedure rege4rements, correct acceptance criteria is used, and the inspection results are reported in a I

prescribed manne Exa'ninations Observed

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The inspector observed in process VT examinations on suppotts in the Component Cooling Water (CCW) systen,. The inspector

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reviewed records of VT examinations on the RPV, and Pressurizer, in addition the RC, SI, SDC, Feedwater, and

[ Pressurizer Auxiliary Spray system The inspector conducted independent examinatons, on the in process examinations, indicated above, previously observed being examined. These examinations were conducted in order to evaluate the adequacy of the examination procedure being used by the licensee's contractor and to assess the validity of the information being reported by the examiner These re-examinations generally agreed with the results reported by the visual examiner (5) SteamGeneratorTubingEddyCurrentExamination(EC)

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The inspector observed the EC octivities indicated belo The observations were comptred with t..e applicable procedures

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and the ASME Code in the following are0s: method for maximum sensitivity is applied; method of examination has been o recorded; examination equipment has be3n calibrated in accordance with the applicable perform 0nce reference; amplitude and phase angle have been cali3 rated with the proper calibration reference and is recTlibrated at predetermined frequency; required coverage of steam generator

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tubes occurs during the examination; acceptace criteria-is specified or referenced and is consistent wit'i the procedure or the ASME Code; and, results are consistent with the

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accept 6nce criteria, m

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I Activities Observed f I

The inspector examined records of the EC examinations of the !

SG tubing, as the window of opportunity had past for  ;

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observation of in process examination activitie Certification records for EC calibration standards were ,

reviewed for material type, correct fabrication, and !

artificial flaw location and siz (6) Personnel Qualification  ;

l The inspector reviewed personnel qualification documentation i for the examiners indicated belo These personnel ;

qualifications were reviered in the following areas:

employer's .:ame; person certified; activity qualified to :

perform; current period of certification; signature of employer's designated representative; basis used for certification; and. . annual visual. acuity, color vision examination, and periodic recertificatio ,

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Examiner Records Examined i

Method Number VY 3

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d. Data Review and Evaluation Unit 1(73755)

Records of completed ISI nondestructive examinations indicated below were selected and reviewed to ascertain ,

whether: the method (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 deviatici.e were recorded as required; personnel, instruments, calibrotion blocks, and NDE materials (penetrants, couplants) were designate The inspector reviewed the completed ISI report for the -

second outage, first period, second interval (02.P1,12), for L Unit 1.

E All of the examination reports reviewed appeared to contain '

the required examination information including disposition of indications, if an A random sample of current examination results were compared l with historical examination results. No major discrepancies were noted during the comparison.

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. Observations (1) As the result of EC examination of the steam generator tubes during the most recent outages, a total of 219 tubes were plugged on both units, as indicated below:

SG 1A SG 1B SG 2A SG 2B Previously Plugged Tubes 603 456 221 162 TubesPlugged02,P1,12(U1) 126 54 Tubes Plugged 01,P3.11 (U2) 21 18 lotal Tubes Plugged 729 510 242 180

(2) The inspector noted, while observing surface examinations on

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the Reactor Coolant system loop piping, that the welds observed wers not well marked, causing the conscientious examiners to examine a significantly larger area than required by the code in order to assure complete coverage of the required area of interest. This lack of adequate markings extended the examiner's stay time in a radiation are _

(3) The following items are of relatively minor significance, but are indicative of lack of attention to detai Relative to the review of procedures, the inspector noted that NDE 5.iB, Rev.2, " Ultrasonic Thickness Measurement", paragraph 5.3, contains graphical representations of instrument controls with no identifying text. Due to the small size and complexity of graphical representations and the limitations of the reproduction process used to publish the procedure, the controls are not clearly identifiabl Relative to the review of records the inspector noted several examples where document entries were

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changed by over writing rather than an initialed and dated single line strike ou Other examples were noted where corrections were initialed but not date A number of pipe support drawings ' were noted with incorrect weld symbols (Example: Bergan-Paterson f

Pipesupport Corp. Drawing N. S!H-224, Rev.1-30-1973).

In the areas inspected, no violations or deviations were identifie _ i

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! Followup on NRC Bulletin 87 02, " Fastener Testing To Detennine Conformance With Applicable Material Specifications" NRC Bulletin 87 02 requested licensees to test safety-related (SR) and  ;

nonsafety-related(NSR) fasteners. Supplements 1 and 2 to the Bulletin requested licensees to provide a list of suppliers and/or manufacturers i from whom the fasteners may have been purchssed. TI 2500/27 required an NRC ins,2ctor to evaluate the adequacy of certain licenstes' root cause analysis and the implementation of corrective actions in response to NRC Bulletin 07-0 The inspector assessed the areas identified in Tl 2500/27 applicable to the St. Lucie plant, and determined that all three samples identified -

therein were NSR and had not been used in SR applications. This

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determination is based on interviews with licensee personnel, the i licensees material control system and that control system's implementation as observed during the recent Maintenance Team inspection conducted in the fall of 1989, at the St. Lucie sit Followup on Generic Letter 90-05, " Guidance for Performing Temporary Hon-Code Repair of ASME Code Class 1, 2 and 3 Piping." <

The inspector discussed the implementation of Generic letter 90 05 with the licensee who indicated that they had amended procedure 01 .

10-PR/PSL-8, Revision 1 " Control of Repairs and Replacements," to address the guidance of the Generic Letter. The licensee further indicated that their Engineering DeLaertment did not permit temporary non code repairs, not withstanding they were well aware of the require-ments of 10 CFR 50.55a(g)(6)(1).

^ Exit Interview The inspection scope and results were sunmarized on Octcber 26, 1990, with those persons indicated in paragraph 1. The inspector described the areas inspected. Although reviewed during this inspection, proprietary information is not contained in this repor Dissenting connents were not received from the license .

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. Acronyms and initialisms ABBCE - Asr.ea Brown Boveri Combustion Engineering AC - Alternating Current ASME - American Society of Mechanical Engineers B&PV - Boiler and Pressure Vessel B&W - Babcock and Wilcox CFR - Code of Federal Regulations DAC - Distance Amplitude Curve DPR - Demonstration Power Reactor EC - Eddy Current FP&L - Florida Power & Light ID - Identification ISI - Inservice Inspection MS - Main Steam MT - Magnetic Particle NDE - Nondestructive Examination N Number NPF - Nuclear Power f acility NRC - Nuclear Regulatory Commission NSR - NonSafety-Related OD - Outside Diameter Professional Engineer PT - Liquid Penetrant QA - Quality Assurance R - Revision RC - Reactor Coolant RPV - Reactor Pressure Vessel RT - Radiographic Test SDC - Shut Down Cooling SG - Steam Generator S1 - Safety injection SR - Safety-Related UT - Ultrasonic VT - Visual

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