IR 05000335/1993010
| ML17228A162 | |
| Person / Time | |
|---|---|
| Site: | Saint Lucie  |
| Issue date: | 05/18/1993 |
| From: | Blake J, Economos N NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML17228A161 | List: |
| References | |
| 50-335-93-10, 50-389-93-10, NUDOCS 9305250046 | |
| Download: ML17228A162 (13) | |
Text
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UNITED STATES NUCLEAR REGULATORY COMMISSION
REGION II
101 MARIETTASTREET, N.W.
ATLANTA,GEORGIA 30323 Report Nos.:
50-335/93-10 and 50-389/93-10 Licensee:
Florida Power and Light Company 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
Inspection Condu d:
Inspector:
N.
Econom 19-23, 1993 ate gned Approved by:
J. J.
Blake, Chief t
ials and Processes Section n ineering Branch Division of Reactor Safety te Signed Scope:
SUMMARY This. routine, announced inspection was conducted in the areas of Inservice Inspection (ISI) activities, including eddy current (ET) examination of steam generator (S/G) tubes.
Other on going activities inspected included modification of the pressurizer (Pzr) safety relief valve discharge line.
Revisions of certain erosion corrosion and nondestructive examination (NDE)
procedures were reviewed.
Results:
The work observation effort and the review of engineering documents and ISI procedures indicates that adequate management controls are in place.
Personnel implementing the subject modification and ISI program were adequately trained and qualified to perform their assigned tasks.
The licensee has addressed by revision(s) to, and through the issuance of applicable procedures, certain deviations from the EPRI CHECMATE recommendations.
Violations or deviations were not identified.
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REPORT DETAILS Persons Contacted Licensee Employees
- G. Boissy, Plant General Manager
- C. Burton, Operations Manager G. Boyers, Steam Generator Program Coordinator
- J. Dyer, gC Supervisor
- R. Englmeier, Site guality Manager
- J. Geiger, Vice President Nuclear Assurance N. Hallebeck, Welding Engineer
- J. Holt, Licensing Engineer
- A. Motley, Supervisor of Codes and Programs, Equipment Support Inspections (ESI)
. *J. Scarola, Engineering Hanger C. Ward, Pressurizer Discharge Pipe Modification, Project Hanger Other licensee employees contacted during this inspection included engineers, mechanics, security force members, technicians, and-administrative personnel.
NRC Resident Inspectors
- S. Elrod, Senior Resident Inspector H. Scott, Resident Inspector
- Attended exit interview Acronyms and initialisms used throughout this report are listed in the last paragraph.
Inservice Inspection (ISI) Background 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 Unit 1 ISI, -is the American Society of Mechanical Engineers Boiler and Pressure Vessel (ASHE BKPV) Code,Section XI, 1983 Edition with Addenda through Summer 1983 (83S83).
Unit 1 is in the second outage of the second 40 month period of the second ten year ISI interval.
Ebasco, under contract with the licensee, is conducting ISI examinations during this outage.
Eddy Current (ET) examination of steam generator tubes was being conducted by Assea Brown Boveri, Combustion Engineering (ABB-CE).
The ISI activities were being conducted under requirements of the licensee's gA Progra Review of Nondestructive Examination (NDE) Procedures, Unit
(IP 73052)
The following procedures have been reviewed for technical adequacy, and consistency with applicable code and regulatory requirements, during previous inspections (e.g.,
Inspection Report 92-09).
During the present inspection, the inspector reviewed the procedures for information and to ascertain whether the latest revisions had made substantive changes to the procedures.
Procedure NDE-1.3 Rev.
(R5)
Title Eddy Current Examination of Non Ferromagnetic Tubing with Hulti-Frequency Techniques HIZ-18 NDE-2.2 (R4)
NDE-3.3 (R5)
NDE-3.4 (R3)
NDE-4.1 (R5)
NDE-4.2 (R3)
NDE-4.3 (R4)
NDE-5.1 (RG)
Hagnetic Particle Examination Liquid Penetrant Examination Solvent Removable Visible Dye Technique Liquid Penetrant Examination Visible 5 Florescent Water Washable Technique Visual Examination VT-1 for Welds/Bolting/Bushings/Washers Visual Examination VT-2 Conducted During System Pressure Test Visual Examination VT-3/VT-4 Ultrasonic Examination of Pressure Vessel Welds Except Reactor Vessel NDE-5.2 (R5)
Ultrasonic Examination of Ferritic Piping Welds NDE-5.3 NDE-5.4 NDE-5.7 (R4)
(R9)
(R3)
Ultrasonic Examination of Primary Coolant Piping Welds (PSL-1 5 2)
Ultrasonic Examination of Austenitic Piping Welds Ultrasonic Examination of Reactor Pressure Vessel Studs and Reactor Coolant Pump Studs NDE-5.11 (R4)
I Ultrasonic Examination of Dissimilar Hetal Welds
Procedure
. Rev.
Title NDE-5.12 (R3)
Ultrasonic Examination of Reactor Pressure Vessel Flange to Vessel Weld and Stud Hole Threads NDE-5.13 (R4)
NDE-5. 14 (R2)
Ultrasonic Examination of Nozzle Inner Radius Areas Ultrasonic Examination of Reactor Vessel Welds NDE-5. 15 (R3)
NDE-5.16 (R4)
NDE-5.18 (R3)
NDE-5.21 (RO)
Ultrasonic Examination of Reactor Coolant Pump Flywheels Ultrasonic Technique for Evaluation of Cracking in Steam Generator Feedwater Piping.
Ultrasonic Thickness Heasurement Inplace Surface Examination Technique of Reactor Coolant Pump Flywheels Using Ultrasonics These revisions addressed items of concern identified in Report 92-02 which included wearing of photosensitive eye glasses while performing fluorescent NDE examinations; performing fluorescent penetrant examinations following color contrast penetrant examinations; etc.
Within the areas inspected violations or deviations were not identified.
Observation of Work and Work activities, Unit 1 (IP-73753)
The inspector observed work activities, reviewed certification records of NDE equipment and materials; reviewed qualifications for personnel utilized for ISI examinations observed.
The observations and reviews conducted by the inspector are documented below.
a.
Volumetric 5. Surface Examinations Wel d C-F-2/C.5.52 HS-28-FW1-LS-B d
P d
~tl UT, HT
.
NDE-5.2,-2.2 Pipe Long Seam C-F-2/C.5.52 HS-28-FW5-SW-1LSA UT, HT NDE-5.2,-2.2 Pipe Long
'eam
C-F-2/C.5.51
.. HS-28-FN5A-SR C-F-2/C.5.51 MS-28-FN5-SW1 B-A Reactor Vessel, Closure Head-To-Flange Weld Weld C-F-2/C.5.51 HS-28-FW5A-LR UT, HT UT,'HT NDE-5.2,-2.2 NDE-5. 14,-
2.2 Elbow to Pipe Stud hole
¹18 to 37 E
P d
0~i UT, HT NDE-5.2,-2.2 Elbow Long Seam UT, HT NDE-5.2,-2.2 Elbow Long Seam The inspector observed certain elements of these examinations i.e.
calibration, verification of calibration, documentation and portions of the actual ultrasonic and magnetic particle examinations (UT/HT).
The UT examination on the main steam line welds was limited to one weld due to operational difficulties experienced with the UT instrument.
Examinations were rescheduled for a later time during this outage.
Examinations of the closure head seam progressed without difficulty.
The start of this examination experienced repeated delays resulting from inadequate weld preparation/cleaning.
These examinations identified one recordable indication in the closure head-to-flange weld, which was evaluated at about 50% of the reference distance amplitude correction (DAC) curve.
The location and appearance of the indication suggested that it was a weld fabrication, non-metallic inclusion, possibly slag.
By these observations, the inspector ascertained that the examinations were performed by personnel who were adequately trained to perform their assigned tasks.
Indications were thoroughly investigated and adequately documented in accordance with procedural and code requirements.
Within the areas inspected violations or deviations were not identified.
Review and Evaluation of Data (IP-73755)
a.
Personnel qualifications The inspector reviewed personnel qualification documentation as indicated below for examiners who performed the subject examinations.
These documents were reviewed in the following areas:
employers's name; 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 Examiner Records Examined Method UT Level II III IIIII I
~Em lo er Ebasco Ebasco Ebasco Ebasco Ebasco Ebasco Number Equipment Certification Records:
Certification records for equipment used in the inspections detailed in the previous paragraphs, were reviewed to ensure compliance with applicable requirements.
E ui ment T
e E ui ment Identification MT Parker Probe Hag. Foil¹ EL0110, Yoke Power,{Magnaflux 8A Rod)
HT Calibration Weight UT - Sco es Sonic ¹136 Staley UT - Transducers Megasonic 60'" x 1" Hegasonic 60'" G Hegasonic 45'" x 1" Megasonic 45'" G Aerotech 0'" G UT - Cou lant Ultragel II Calibration block Thermometer S/N 1580, B-300 S/N 30 Batch ¹91E057 S/N HT-B008 10 lbs.,6 oz.
S/N-502G S/N-171A-876K-590G S/N-C0277-B1007-81060-004-J01202-091011 UT-3A 93-010 Results In the areas inspected, no violations or deviations were identified'.
In general, a good ISI program was in place with good implementation.
Examination procedures, meeting code requirements
were being used and inspections were being performed with adequate conservatism by qualified personnel, providing a reasonable assurance of continued weld integrity consistent with acceptance standards.
Eddy Current (ET), Examination of Steam Generator Tubes (IP73753)
Background The two S/Gs at St. Lucie Unit-1 (PSL-1) are Combustion Engineering (CE), Series 67, with 8519 tubes per SG.
The tubing material is mill annealed Inconel 600, with ~/i OD x 0.048" nominal wall thickness.
A review of previous examination results showed the majority of intergranular stress corrosion cr acking damage/degradation was located at the hot leg egg crate supports followed by the hot 'leg sludge pile region of the S/G.
Circumferential tube damage i.e., cracklike indications, has been present at the top of the hot leg tube sheet.
This degradation has been shown to be OD initiated and located within the expansion transition region of the tubes in the tube sheet.
The total number of tubes removed from service prior to this outage totaled 1013 (11.9%), in S/G"A" and 675 (7.9%) in S/G"B".
Eddy Current Examination planned for the present outage was outlined in document ESI-ET-93-01.
Accordingly, the population of tubes to be'xamined, with differential bobbin coil, included all non-plugged tubes with previously identified degradation measuring
&0% of tube wall thickness.
Also a sample of tubes with no history of degradation would be examined with bobbin coil at this time.
Additionally, the licensee scheduled for examination, with the motorized rotating pancake coil (NRPC), the expansion transition region of the tubes at the top of the tube sheet.
This examination will include 100% of hot leg tubes and a
3% sample of cold leg tubes.
These NRPC examinations will look at the tubes from approxim'ately 2" above to about 1" below the expansion transition region.
Also, HRPC examinations were scheduled for 20%
of dented 'hot leg tube support intersections.
The sample for this examination, included dents measuring a 5 volts as determined by bobbin coil and were biased towards the largest dents.
At PSL-1 denting has been detected primarily at the
and
supports and to a lesser extent at the egg crates.
Applicable documents governing the subject activity were as follows:
St. Lucie Unit-1 Plant Technical Specifications License No.
2.
ASHE Boiler and Pressure Vessel Code Section XI 1983 Edition with Addenda through the Summer of 1983, including the
3.
C provisions. of Code Case 401-1 (Digital Equipment)
and N-356 (5 years certification for Level III personnel).
USNRC Regulatory Guide 1.83, "In-service Inspection of Pressurized Water Reactor Steam Generator Tubes",
Rev.
1, July 1985.
4.
JPN-QI 2.14 (latest revision), Nuclear Engineering Quality Instruction for "ASME Section XI In-service Inspection".
5.
Examination Procedure NDE 1.3, (latest revision),
"Eddy Current Examination of Nonferromagnetic Tubing with Multi-frequency Techniques-MIZ-18".
6.
ECT Data Analysis Guidelines, April 1993 St. Lucie 81.
At the time of this inspection, standard bobbin examinations were approaching completion in both S/Gs and by the end of the inspection almost all results had been analyzed including those acquired with MRPC.
Preliminary results provided by the licensee and verified by record review were as follows:
Tubes to be Plugged S/G IIB II
S/G IIAII
A sample of tubes which had been examined and the results reviewed by the primary and secondary analysts and had been flagged for resolution were selected for data review.
The tubes and inspection results 'are presented below for informat'ion.
46 1.67
5
7
1
0.51
0.47
0.57
0.71
0.48
0.44
0.88
2.05 Steam Generator
"B" Row Line Volts Cold Leg Phase
~An le 140 139 129
141 133 135 138 130
~p'/
h
~Th h
22
001
28
23
1 02H 1 04H 1 05H 1 01H 1 03H 1 03H 1 01H 1 02H
03H Bobbin Coil Examination
The inspector performed a historical data review and evaluation on tube 1-47 above, to compare results from the present, 1991 and 1990 outage examinations.
This effort was in response to differing evaluations reported, on percent of throughwall degradation, between the analysts and resolution.
By comparison the inspector noted only minor changes had taken place in terms of voltage, phase angle and percent throughwall, over the last three outages.
Therefore it would appear that tube integrity is relatively stable.
Additional work performed in this area included review of personnel certifications for 18 ET examiners and analysts, dent code calibration standards and MRPC dual guide tube standards, data acquisition and analysis equipment.
Within the areas inspected violations or deviations were not identified.
Pressurizer Safety Relief Valve Discharge Piping Modifications (Unit 1)
(IP-37700)
a.
~Sco e
The purpose of the subject modification was to minimize seat leakage by optimizing support type and applied forces to reduce end loads on the outlet flanges of the pressurizer safety relief valves (PSRVs)
V1200, V1201 and V1202.
This would be accomplished by replacing two variable support springs, RC-005-12C and RC-005-34C, with constant support springs, on the PSRV discharge piping.
b.
En ineerin and Safet Anal sis As ects Ebasco, under contract from the licensee, performed the necessary engineering work and safety analysis.
Results of this work effort was issued, with licensee approval, as a safety related Plant Change Modification (P/CM), number 008-193 Rev.0, 3/13/93 and Rev. 1, 4/7/93.
By review of the subject documents/engineering packages (EPs),
and through discussions with cognizant licensee personnel the inspector ascertained that, a pipe stress analysis has been performed and affected supports/restraints modified; NUREG 0737 submittal has been reviewed and found not to have been affected.
Results of the safety evaluation showed the modification did not constitute an unreviewed safety question and as such prior NRC approval would not be required for implementation.
Also changes to Plant Technical specifications would not be required.
Associated piping in this modification was designed to the original code of record, NSAS B31. 1, 1967 Edition.
Fabrication and installation requirements would be controlled by site procedures and the licensee's Welding Control Manual which identifies ANSI B31. 1, 1983 Edition as the applicable code for non-safety related piping fabrication, installation and testing.
Because there is a potential for cold spring in the PSRV
piping, the subject P/CH provides specific guidelines for removing existing cold spring.
c.
Observation of Work Activities At the time of this inspection, replacement spool fabrication was complete but welding of field joints was in progress.
The inspector observed field activities around the Pzr i.e.,
process control, material control, cleanliness around work area, weld appearance and posting of fire watch.
Records/travelers of completed welds reviewed for content, completeness and accuracy were as follows:
Weld¹ Line Size 601, 603 827 6" x 0.280" 601, 606 Descri tion Pipe to Elbow 602 828 6" x 0.280 Pipe to Elbow 604 828 1.25" x 0.422 Pipe to Coupling 601, 603 829 6" x 0.280" Pipe to Elbow 604, 606 608 829 1.25" x 0.422 Pipe to Coupling In addition to review of these fabrication records, the inspector reviewed the following material certifications and personnel qualifications.
Filler Metal:
ER-308 ER-308 HT-63391 HT-8E5483
)gll x 36 Il 3/32" x 36" QC-¹0346 QC¹-0448'e lacement Material:
Pipe Pipe Flange Elbow, 90" Elbow, 45'oupling A-312 A-312 A-182 A-403 A-403 A-182 6" x Sch.
40s 10" x Sch.
6
> 300 lb 6" x Sch.
40s 6" Sch 40s Ij" 3000¹ PO ¹C93732-90663 PO ¹C93732-90663 PO ¹C93732-90663 PO ¹C93732-90663 PO ¹C937312-90663 PO ¹C93732-90663 Weldin Procedure S ecification:
WPS-43-Rev.3 GTA-Manual Open butt P8 to P8 Applicable procedure qualification records included PQR-8.8-3,
-8.8-4 and N140.
The procedure was qualified to weld material ranging from 1/16" to 8" thickness with SFA 5.9 stainless steel filler meta In addition, the inspector reviewed qualification records for the welder observed.fabricating one of the field welds in the 6" discharge lines.
His stencil number was identified as TFGF and his qualification record appeared to be in order.
Within the area inspected violations or deviations were not identified.
Followup (IP92701)
Erosion Corrosion Honitoring Program The licensee's erosion corrosion program was reviewed and the results documented in Region II Report No. 92-09.
The report indicated that, at the time, the licensee's program deviated from the Electric 'Power Research Institute (EPRI) computer code program recommendations in three different areas which are summarized below:
a b.
C.
EPRI recommends that inspection data be collected at intersections of a standard grid pattern which allows for reinspection of identical points during subsequent inspections.
The inspector of record reported that the licensee's method of marking grid lines did not assure a parallel pattern and that subsequent reinspections were not likely to be at identical points.
Through discussions with cognizant
'iicensee personnel, the inspector determined the licensee issued procedure JI-CPS 2.3-6 Rev 0, 2/17/93 entitled Harking and Gridding for Erosion/Corrosion.
Section 5.3 Permanent Harking, addresses the above observation in a satisfactory manner.
EPRI recommends that inspections cover an area from two inspection grids up stream of a component, to two diameters down stream of the component.
The inspector of record, reported that the licensee did not examine two grids upstream of the component as recommended.
Through discussions with cognizant licensee personnel the inspector ascertained that the licensee, based on engineering judgement, currently grids upstream piping for expanders and orifices, but does not find it necessary to grid upstream of each component tested.
EPRI recommends the use of Tppy data to enhance correlation between field conditions and the electronic model.
The inspector of record, reported that the licensee did not use TOY data.
Approved procedure JI-CPS 2.3-4 Rev. 0, 2/12/93 Evaluation of Examination Data, Section 5.5 Checmate Line Specific Hode, addresses the use of To~ and provides specific guidelines for its application.
This review indicates the licensee has taken appropriate action to address the aforementioned comments on the use of EPRI's recommendations.
The action taken demonstrates managements active involvement and interest in improving programs which could impact safe plant operatio Exit Interview The inspection scope and results were summarized on April 23, 1993, with those persons indicated in paragraph 1.
The inspector described the areas. inspected,and discussed in detail inspection results.
Although reviewed during this inspection, proprietary information is not contained in this report.
Dissenting comments were not received from the licensee.
10.
Acronyms and Initialisms ABB-CE ASHE 88cPV CE DAC EP EPRI ESI ET ISI HRPC HT NDE P/CH PSRV Pzr S/G UT Assea Brown Boveri, Combustion Engineering American Society of Hechanical Engineers Boiler and Pressure Vessel Combustion Engineering distance amplitude correction engineering packages Electric Power Research Institute Equipment Support Inspections eddy current Inservice Inspection motorized rotating pancake coil magnetic particle examination Nondestructive Examination Plant Change Hodification pressurizer safety relief valves pressurizer steam generator ultrasonic examination