IR 05000335/1993029
| ML17228A412 | |
| Person / Time | |
|---|---|
| Site: | Saint Lucie  |
| Issue date: | 12/22/1993 |
| From: | Blake J, Crowley B NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML17228A411 | List: |
| References | |
| 50-335-93-29, 50-389-93-29, NUDOCS 9401040139 | |
| Download: ML17228A412 (10) | |
Text
gA< RECy
~o O
i.
o.
ky*y+
UNITED STATES NUCLEAR REGULATORY COMMISSION
REGION II
101 MARIETTASTREET, N.W., SUITE 2900 ATLANTA,GEORGIA 30323.0199 Report Nos.:
50-335/93-29 and 50-389/93-29 Licensee:
Florida Power and Light Company 9250 West Flagler Street Hiami, FL 33102 Docket Nos.:
50-335 and 50-389 License Nos.:
DPR-67 and NPF-16 Facility Name:
Saint Lucie 1 and
Inspection Conducted:
December 13 - 15, 1993 Inspectors:
Approved by; B.
R. Crowley lake, Chief erials and Processes Section Engineering Branch Division of Reactor Safety
/~ ~c
<~~
D te igned w z>
Date Signed SUMMARY Scope:
This routine, announced inspection was conducted on site in the areas of preparation for Unit 1 Steam Generator Replacement (SGR), preparation for inservice inspection (ISI) of Unit 2 during the upcoming refueling outage (RFO),
and corrective actions for previous inspection findings.
Results:
In the areas inspected, no violations or deviations were identified.
Relative to SGR, it appears that detailed plans and preparations are being made.
Contractors have been procured.
A SGR Project (SGRP)
has been formed and the SGs have been ordered and are being fabricated.
The licensee is very involved with the process rather'han relying totally on their contractors.
gA is heavily involved in the fabrication of the new SGs and planning for SG replacement.
940i040i39 93l222.
PDR ADOCK 05000335-
REPORT DETAILS Persons Contacted Licensee Employees S
L. Bladow, Quality Assurance Hanager
- R. Gross, Duty Project Hanager, SGR Project
- J. Holt, Licensing Engineer L. Lostocco, Engineer SGR Project
- H. Hacleod, Lead Steam Generator Fabrication Engineer K. Hayhew, Site ISI Coordinator J.
Hoaba, Engineering Supervisor, SGR Project F. Shiffley, Lead Licensing Engineer, SGR Project
- R. Sipos, Project Hanager, SGR Project Contractor Personnel H. Cepkauskas, SGRP Project Director - HK-Ferguson Other licensee and contractor employees contacted during this inspection included engineers, QA/QC personnel, security force members, technicians, and administrative personnel.
NRC Employees S. Elrod, Senior Resident Inspector H. Hiller, Resident Inspector N. Stinson, NRC Intern
".Attended exit interview Acronyms and initialisms used throughout this report are listed in the last paragraph.
Steam Generator Replacement (50001) (Unit I)
The purpose of this inspection was to review the status of plans and preparations for replacement of the Unit I Steam Generators.
The inspector met with key SGR Project personnel, reviewed the status of the project, reviewed the planned schedule for SGR, and observed scaled mockups being used for planning.
The following summarizes the inspection activities:
a.
Review of Project Documents In order to determine the scope and status of the SGR activities, the inspector discussed the project with licensee personnel and performed an ove'rview of the following documents:
e Steam Generator Replacement Project Plan, Revision 0.
This document describes the total controls for development and implementation.of the Steam Generator Replacement Project (SGRP).
Project approach; organization and interfaces between licensee, contractors and sub-contractors; project controls; work processes; contingency planning; licensing plan; quality assurance (gA) program; engineering self assessment; ALARA program; training plan; safety and security; and system testing're covered in detail in the Project Plan.
Stand Alone Safety Evaluation (SASE)
The licensee plans to replace the SGs using a
CFR 50.59 review.
The SASE is a detailed safety, evaluation and is divided into 4 volumes as noted, below.
The document has not been issued as a number of the sections are still being prepared.
The background work for the safety evaluation has been done and a Technical Specification (TS) -change is not anticipated.
Volume 1 is the overall safety evaluation for the replacement.
Volume 2 is the Steam Generator Equivalency Report, which
'rovides an analysis to show that the replacement SGs are equivalent to the old SGs.
Volume 3 provides Design Basis Documents for: Rigging and Handling, Transportation of SGs, Cutting and Beveling, Melding, Temporary Supports and Restraints, Blowdown System Interface, SG Insulation, Temporary SG Storage (old SGs),
Hanway Platforms, and Reactor Coolant System (RCS) Decontamination.
All of these documents have been approved, except welding.
Volume 4 is SGR Supple'mental Documents (SDs)
and includes analysis and checklists for various documents, such as, FSAR, Technical Specifications, Procedures (Plant, EOP's, ONOPs, and SU), Industry SGRP Issues
- Lessons Learned, and the PSL SER.
. Also included are sections on Disposition of Old SGs and Code Reconciliations.
Specification No.
F-MECH-SP-002, Revision 01, Replacement Steam Generator Assemblies For Florida Power and Light Co.
ST. Lucie Unit No. l.
SGRP 6.0, Revision 0, Contract Administration Plan
b.
SGRP Detail s The above discussions and reviews revealed the following:
Schedule
- The schedule calls for SGR during the Fall 1997 outage.
The contract for the new SGs was placed in June 1992.
Delivery of the SGs is expected in November of 1996.
Contractors
- The HK-Ferguson (HK-F) Group of Horrison Knudsen Corporation from Cleveland, Ohio, has the implementation contract, including construction, with sub-contracts to: (1)
Duke Engineering and Services, Inc.
(DE&S) for engineering, including Volumes 1, 3, and 4 of the SASE, and (2)
BW Nuclear Technologies (BWNT) from Lynchburg, Virginia, for, the cutting and welding processes.
HK-F previously replaced SGs at D. C.
Cook and Point Beach plants.
A second contract is with Babcock and Wilcox International (BWI) of Canada for fabrication of the new SGs with a subcontract to BWNT for developing Volume 4 of the SASE.
Fabrication of the SGs at BWI is in process with most of the SG sub-assemblies in the shop with pre-assembly fabrication work on-going.
All known potential industry problem areas were considered in the design of the new SGs and design measures taken to preclude or minimize the problems.
The following problem areas are highlighted in the SASE as having had design improvements made:
Tubesheet Cladding Separation Tube-to-Tubesheet Crevice IGA Tube-to-Tubesheet Crevice and Primary Side SCC Tube Sensitization at the Tube-to-Tubesheet Weld Tubesheet Sludge Pile Hinimized Tube Support Crud Accumulation Denting by Tube Supports Tube Vibration Fretting Wear U-Bend Cracking of Inner Row Tubes
'ater Hammer Loose Parts Steam Separator Hoisture Carryover Pressure Boundary Weld Cracking The tubing for the new SGs is Inconel 690, thermally treated as described in Electric Power Research Institute (EPRI) Guideline NP-6743-L, Volume 2.
The requirements of ASHE SB-163 Ally N06690, Code Case N20-3 are incorporated.
The SGs are being fabricated to the 1986 Edition of the ASHE Boiler and Pressure Vessel (BEPV) Code,Section II The inspector noted a discrepancy in the Code dates referenced for ASHE Section XI.
The SG Specification, F-HECH-SP-002, specifies the 1986 Edition with no Addenda.
The SGRP Plan specifies the 1983 Edition, S83 Addenda, which agrees with the current Code being used for ISI of Unit 1.
It is not clear which Edition of the Code the Preservice inspection of the new SGs will be performed to.
SGR Project Engineering personnel had noted this discrepancy and initiated actions to resolve the issue.
The SGs will be shipped by barge from Canada to the St.
Lucie site and off-loaded to a crawler for movement to the Unit
containment.
Special lifting equipment, independent of plant equipment, will be used inside and outside the containment for
'removal of the old SGs and installation of the new SGs.
A temporary Hoist and Lifting Device will be erected inside the containment, This will allow handling the SGs without using the Polar Crane.
The SGs will be removed and installed as complete units through the Containment Construction Hatch.
The hatch is large enough to accommodate the full diameter of the SGs.
Reactor Coolant (RC), Hain Steam (HS),
piping will be cut at the SG nozzles.
Narrow Gap welding will be used for replacement welds.
The old SGs will be stored on site.
Ground core samples have been taken at possible sites being considered for the on-site storage facility.
Quality Assurance (QA)
The Site QA Hanager is responsible for QA ove} view of fabrication of the SGs at BWI.
There is a full time FP&L Resident Inspector at BWI.
For SG installation, site QA/QC will be performed under the site QA program with Site QA performing QA/QC functions.
The inspector discussed the QA aspects of the project with the Site QA Hanager and reviewed the following documents:
List of Completed Audits for the SGRP Joint Audit Schedule for 1993 and 1994 (FP&L, Duke Power, and Rochester Gas
& Electric participating)
Audit No. 08.03BABCA.93.5* - Vertical Slice Audit Performed Prior to Gun-Drilling of the RSG Tubesheets
- June 21-23, 1993 Audit No. 08.03.BABCA.93.4* - Special Processes Audit-Hay 7-31, 1993 QA Resident monthly Report for November 1993 -
e Based on the above discussions and reviews, the inspector determined that licensee gA is heavily involved in the SGRP.
The FP&L resident inspector has numerous assigned hold points. during SG fabrication steps, and also performs detailed inspections of the fabrication process on a daily basis.
The inspector is NDE certified.
The Honthly Reports give detailed writeups for the activities inspected during the month.
The audits are detailed, performance based, and the audit teams are joint teams made up of FP&L personnel and personnel from other utilities who also have SGs under construction.
Overall, it appears the licensee has a very aggressive gA program for the SGRP.
No violations or deviations were identified.
Based on the overview of SGR activities described above, it appears that detailed plans and preparations are being made for the SGR.
The licensee is very involved with the process rather than relying totally on their contractors. 'A i'
heavily involved in the fabrication of the new SGs and planning for SG replacement.
3.
Inservice Inspection (73753)
(Unit, 2)
P The inspector reviewed plans for the upcoming ISI inspection of Unit 2 during the Spring 1994 RFO.
The outage is scheduled for February
through Harch 31, 1994.
The applicable code for Unit 2 ISI is the ASHE B&PV,Section XI, 1989 Edition.
The beginning date for commercial service was August 8, 1983.
Unit 2 is operating in the first period of the second ten year ISI interval, which began August 8, 1993, and ends August 8, 2003.
The Second Ten Year Interval Inspection Program was forwarded to the NRC by FP&L letter L-93-191 dated August 4, 1993.
A SER has not been issued.
The inspector discussed the upcoming outage plans with the Site ISI Coordinator and reviewed the following documents:
PSL-200, Revision 0, Second Inservice Inspection Interval Program Plans and Schedule PSL-200-40-1, Revision 0/A, Second Inspection Interval, First Period Inservice Examination Plan No violations or deviations were identified.
4.
Licensee Actions on Previous Inspection Findings (92701, 92702)
(Closed) Violation 335, 389/92-09-01, Failure to Follow Liquid Penetrant Examination Procedure This violation involved failure to perform Liquid Penetrant (PT)
inspection of pipe welds in accordance with procedure requirements.
" The inspection coverage for one weld did not meet procedure requirements and
surface cleanliness was improper for another weld.
FPKL letter of response, L092-192, dated July 16, 1992, has been reviewed and found to be acceptable.
The cause of the.violation was determined to be personnel error, or failure to give appropriate attention to detail for procedure requirements.
Nonconformance Report (NCR)92-001 and NCR Corrective Action Requests (CARs) N-92-083 and N-92-084 document corrective actions, which included:
Counseling all ISI contract examiners on the importance of procedure compliance and attention to detail Counseling the ISI Supervisor Responsible for technical supervision of examination activities on the importance of proper contractor orientation and the need for an aggressive contractor surveillance program Development of a new contractor orientation procedure to place additional emphasis on attention to detail and procedure compliance Increased Surveillance of contractor examinations during the next refueling outage to ensure that the new contractor orientation was working The inspector reviewed the following to verify licensee corrective
.actions:
NCR 92-01 CAR N-92-083 CAR N-92'-084 Procedure JI-NDE-2. 1, Revision 0, Orientation Program for Contractor NDE Personnel Documentation of a sample of FPLL "Vendor Surveillance/Over-Check EBASCO Services INC - PSL-1 1993" for the last ISI outage, including the FPEL Auditor's Checklist Documentation of FPKL orientation tr'aining of vendor examiners on NDE procedures dated March 31, April 1, April 2, and April 5, 1993 Based on review of the above corrective actions, this violation is close Exit Interview The inspection scope
'and results were summarized. on December 15, 1993, with those persons indicated in paragraph 1.
The inspector described the areas inspected and discussed in detail the inspection'indings listed below.
Proprietary information is not contained in this report.
Dissenting comments were not received from the licensee.
(Closed)
VIO 335,389/923-09-01, Failure to Follow Liquid Penetrant Examination Procedure
- Paragraph 4.
Acronyms ALARA ASME BKPV BWI BWNT CAR DE&S EPRI FPKL FSAR FW HK-F HS NCR NDE NRC NRR PT gA gC
'C RFO RII SASE SD SER SG SGR SGRP TS As Low As Reasonably Achievable A'merican Society of Hechanical Engineers Boiler and Pressure Vessel Bobcock and Wilcox International BW Nuclear Technologies Corrective Action Request Duke Engineering and.Services Electric Power Research Institute Florida Power and Light Company Final Safety Analy'sis Report Feedwater System r
HK-Ferguson Group Hain Steam System Nonconformance Report Nondestructive Examination Nuclear Regulatory Commission Nuclear Reactor Regulation Liquid Penetrant Inspection guality Assurance guality Control Reactor Coolant System Refueling Outage NRC Region II Stand Alone Safety Evaluation Supplemental Documents Safety Evaluation Report Steam Generator Steam Generator Replacement Steam Generator Replacement Project Technical Specification