IR 05000348/1987027
| ML20236Q086 | |
| Person / Time | |
|---|---|
| Site: | Farley  |
| Issue date: | 11/12/1987 |
| From: | Blake J, Newsome R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML20236Q084 | List: |
| References | |
| 50-348-87-27, 50-364-87-27, IEB-87-001, IEB-87-1, IEIN-87-036, IEIN-87-36, NUDOCS 8711190172 | |
| Download: ML20236Q086 (12) | |
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UiBITED STATES pm Riooq'o NUCLEAR REGULATORY COMMISSION g
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REGION 11 n
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. j 101 MARIETTA STRE ET, N.W.
- ATLANTA. GEORGI A 30323
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Report Nos.:
50-348/87-27 and 50-364/87-27 Licensee:
Alabama Power Company 600 North 18th Street Birmingham, AL 35291-0400 Docket Nos.: 50-348 & 50-364 License Nos.:
Farley 1 and 2 Inspection u
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ober 19-23, 1987 Inspector:
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R Ne om Date S'igned Approved by:
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Biake, Section Chief Date Signed
,a _ rials and Processes Section Di ision of Reactor Safety SUMMARY Scope:
This routine, announced inspection was in the areas of inservice inspection (ISI) including review of docure* ' 1 tion and observation of NDE activities, and independent verification of a iected ISI ultrasonic results.
Activities relative to Bulletin 87-01, were examined including independent verification of ultrasonic thickness measurements relating to BU 87-01.
Also, radiographs and reports associated with Unit 2, Loop "B",
safety injection system thermal sleeve were reviewed.
Results:
No violations or deviations were identified.
8711190172 871113 PDR ADOCK 05000348 PDR G
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REPORT DETAILS
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Persons Contacted J
l Licensee Employees
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- J. D. Woodard, General Manager, Farley Nuclear Plant (FNP)
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- D. N. Morey, Assistant General Manager, FNP, Operations
- W. B. Shipman, Assistant General Manager, Support
- R. D. Hill, Operations Manager j
- J. K. Osterholtz, Supervisor Safety Audit and Engineering Review l
- L. W. Enfinger, Manager Plant Administration
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- C. D. Nesbitt, Technical Manager l
- t. M. Coleman, Systems Performance Supervisor l
- D. B. Hartline, Systems Performance, General Plant Engineer Supervisor l
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l Other licensee employees contacted included construction craftsmen,
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l engineers, technicians, mechanics, security force members, and office I
l personnel.
l Other Organizations
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R. T. Davis, Southern Company Services (SCS), Lead Level III l
J. Campbell, ISI Coordinator, Westinghouse Electric Corp. (W)
l C. G. Ward, Authorized Nuclear Inservice Inspector (ANII)
- J. R. Allen, Southern Company Services, Senior Engineer j
i NRC Resident Inspectors l
"W. H. Bradford, Senior Resident Inspector
- Attended exit interview 2.
Exit Interview
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l The inspection scope and findings were summarized on October 23, 1987, with those persons indicated in paragraph 1 above.
The inspector
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described the areas inspected and discussed in detail the inspection findings.
No dissenting comments were received from the licensee.
The licensee did not identify as proprietary any of the materials provided to i
or reviewed by the inspector during this inspection.
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3.
Licensee Action on Previous Enforcement Matters
(Closed) Unresolved Item 50-348, 364/87-09-01, Adequate Conformance to Administrative Procedures. This item identified an omission of specified details concerning documentation of in process inspections of groove welds
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l which were included in Figure 1 of Section.5.7 of procedure
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FNP-0-SPP-WD-001, Revision 4.
A random check of this procedure indicated that Figure I was not included in two of the control copies.
The-licensee has since issued Revision 5 of ENP-0-SPP-WD-001 and has physically verified the content of each individual controlled copy.
The inspector reviewed Revision 5 of the procedure and reviewed the-verification documentation.
This matter is considered closed.
4.
Unresolved Items Unresolved items were not identified during this inspection.
5.
Inservice Inspection (ISI)
The inspector examined documents, activities, and records as indicated
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below to determine whether ISI was being conducted in accordance with applicable procedures, regulatory requirements, and licensee commitments.
The applicable code for ISI is American Society of Mechanical Engineers
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Boiler and Pressure Vessel (ASME B&PV) Code,Section XI, 1974 Edition with addenda through Summer 1975. Westinghouse (W).has the responsibility as
the ISI contractor with Southern Company Services (SCS) conducting
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overview functions.
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Inservice Inspection, Programmatic Review, Unit 2 (73051)
J (1) The inspector reviewed the ISI program, for the current outage, to determine whether the program - had been approved by the licensee and included a description of areas to be examined, examination category, method of inspection, extent of l
examination, and justification of any exceptions.
(2) The inspector reviewed administrative procedure FNP-0-AP-4, i
Revision 12, " Control of Plant Documents and Records" and W
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i procedure OPS-NSD-101, Revision 5, Field Changes 1, 2, 3, and 4, l
"Preservice and Inservice Inspection Documentation" to assure that a procedure had been established (written, reviewed,
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l approved, and issued) to control general quality assurance (QA)
requirements including examination reports and to establish controls for generation, approval, custody,. storage and maintenance of nondestructive examination (NDE) records.
b.
Review of Procedures (73052) Units 1 and 2 l
The inspector reviewed the procedures indicated below to determine whether the procedures were consistent with regulatory requirements and licensee commitments.
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, i
division of responsibility between the licensee and contractor personnel if contractor personnel are involved in the ISI effort.
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Procedure ID Title
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I ISI-8 (R7)
Visual Examination Procedure j
AM.-001 ISI-47 (R2)
Manual Ultrasonic Examination of Circumferential
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FC002 & Am.8 and Longitudinal-Butt Welds on Ferritic Vessels
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of 2-1/2" Thick and Greater ISI-70 (R1)
Magnetic Particle Examinations
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with Ch.1 & Ch.2
ISI-205 (R2)
Ultrasonic Examination of Full Penetration Am.03, Circumferential and Longitudinal Butt Welds FCs 01 thru 05
I MRS 2.4.2 (R2)
Digital Multi-Frequency Eddy Current Inspection
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APC-6 of Preservice and Inservice Heat Exchanger Tubing j
(1) The inspector reviewed procedures ISI-47 and ISI-205 to ascertain whether they had been reviewed and approved in accordance with licensee's established QA procedures. The above procedures were reviewed for technical adequacy and conformance with ASME,Section V and other licensee commitments / requirements in the below listed areas:
type of apparatus used; extent of coverage of weldment; calibration requirements; search units; beam angles; DAC curves; reference level for monitoring l
discontinuities; method for demonstrating penetration; limits i
for evaluating and recording indications; recording significant
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indications; and acceptance limits.
(2) The inspector reviewed procedure ISI-70 to ascertain whether it had been reviewed and approved in accordance with the licensee's established QA procedures.
The procedure was reviewed for
l technical adequacy and conformance with ASME,Section V,
Article 7, and other license commitments / requirements in the below listed areas: examination method; contrast of dry powder particle color with background; surface temperature; suspension medium and surface temperature fr;r wet particles; viewing
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i conditions; examination overlap and directions; pole or prod
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l spacing; current or lifting power (yoke); and acceptance criteria.
(3) The inspector reviewed procedure MRS-2.4.2 APC-6 for technical content relative to:
multichannel examination unit, multichannel examination indication equipment is specified, examination sensitivity, material permeability, method of examination, method of calibration and calibration sequence and acceptance criteria.
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(4) The inspector reviewed the visual. examination procedure to determine whether it contained sufficient instructions to assure j
that the following parameters were specified and cont _ rolled within the limits permitted by the applicable code, standard, or
any additional specification requirement; method - 'di rect -
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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 tool
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for surface preparation, if any, whether direct or remote viewing is used; special illumination, instruments, or equipment j
to be used, if any; sequence of performing examination, 'when j
applicable; data to be tabulated, if any; acceptance criteria is j
specified and consistent with the applicable code section or j
controlling specification; and report form completion, c.
Observation of Work and Work Activities Unit'2 (737538)
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The inspector observed a limited amount of work activities due.to the
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limited number of examinations scheduled and the early completion of j
the examination activities.
The inspector reviewed certification
records of equipment, materials, and NDE personnel which had been and will be utilized during the required ISI examinations during this outage.
The reviews conducted by the inspector are documented below.
(1) Examiner Qualifications The inspector reviewed the qualification documentation for the below listed Westinghouse examiners i. n the. following areas:
employer's name; person certified; activity' qualified to j
perform; effective period of certification; signature of j
employer's designated representatives; basis used for certification; and annual visual acuity, color vision examination and periodic decertification.
Method - Level Examiner UT MT EC VT PJK II
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GAM II
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II HMA
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II MES II II r
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RSC I
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II JDF
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III
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JCH
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JMZ
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IIA
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IIA
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IIA WJS
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ASN
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III
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JJC
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(2) The inspector observed calibration activities and the in process ultrasonic examinations indicated below.
The observations were compared with the applicable procedures and the Code in the
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following areas:
availability of and compliance with approved l
Nondestructive Examination (NDE) procedure; use of knowledgeable
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NDE personnel; use of NDE personnel qualified to the proper j
level; type of apparatus used; extent of coverage of weldment; I
calibration requirements; search units; beam angles; DAC curves; l
reference level for monitoring discontinuities; method of l
demonstrating penetration; limits of evaluating and recording indications; recording significant indications; and acceptance limits.
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Drawing System Weld ID j
l APR-2-2120 Main Steam 6" 2-44 APR-2-2120 Main Steam 6" 2-45 APR-2-2111 Main Steam 6" 1-44 APR-2-2111 Main Steam 6" 1-45 a
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The following listed ultrasonic equipment and materials certification records were reviewed:
Manufacturer /Model Serial No.
Sonic /MK1 08078E Sonic /MK1 05941E Sonic /MK1 06208E Sonic /MK1 08683E Ult-asonic Couplag Sonotrace 40, Batch No.-8662 l
l Ultrasonic Transducers with serial nos. G07311A, D15535,
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I and F-28239 Ultrasonic Calibration Blocks APR-7, ALA-12, and ALA-27 (3) The inspector conducted ultrasonic verification examinations using Westinghouse equipment on portions of the below listed welds. The examinations were performed in order to evaluate the technical adequacy of the ultrasonic examinations procedure
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being used by the licensee's contractor to perform ultrasonic examinations and to assess the validity of the information being reported by the ultrasonic examiners.
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l Weld ID Drawing System
i 2-45 APR-2-2120 Main Steam 1-44 APR-2-2111 Main Steam 1-45 APR-2-2111 Main Steam
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The verification ultrasonic examinations conducted by the inspector indicated that the procedure being used to conduct the
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ultrasonic examinations-is adequate and the' information being reported by the ultrasonic examiners compared favorably with the
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verification examinations.
(4) The inspector reviewed the certification documentation for two eddy current calibration standards identified with serial numbers 2-3152 and 2-2667.
d.
Inservice Inspection, Data Review and Evaluation, Unit 2 (73755)
(1) Records of completed nondestructive examinations 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 deviations were recorded as required; personnel, instruments, calibration blocks and NDE materials (penetrants, couplants) were designated.
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Records selected for this review are listed below.
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APR-1-2110 IR-1 UT IR-2 UT IR-3 UT IR-4 UT i
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APR-1-3100 1-IR1 UT l
2-IR2 UT APR-1-5110 Bolts B1 thru B12 UT/MT/VT APR-2-2110 4-14*
UT 4-16*
UT-APR-2-2310 34LSI UT 34LS2 UT 36LS1 UT 36LS2 UT APR-2-2313 43LS1 UT
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43LS2 UT
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APR-2-2316 2LS UT APR-2-2411 3LSI UT 3LS2 UT APR-2-2417 12LS UT
UT APR-2-2111 1-44 UT 1-45 UT APR-2-2120 2-44 UT 2-45 UT
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- Current examination.results were compared with preservice i
examination results.
No discrepancies were'noted.
(2) Steam Generator Tubing Eddy Current Examination Data Review l
(a) The' inspector reviewed records of the eddy current i
examinations indicated below.
The. reviews were compared i
with the applicable procedures and the Code in the
following areas: the multichannel eddy current examination equipment has been identified; method for maximum sensitivity is - applied; material permeability has been
recorded; method of examination has been recorded; examination equipment has been calibrated in accordance j
with the applicable performance reference; amplitude and phase has been calibrated with the proper applicable calibration reference and is recalibrates at predetermined frequency; 100% coverage of steam generator tubes occurs during the examination; and acceptance criteria is specified or referenced and is consistent with the procedure or the ASME B&PV Code.
Results are consistent with acceptance criteria.
Tube I. D. SG-A Tube I.'O.
SG-B Row Column Data Type Row Column Data Type
2 RPC
6 SB
40 RPC/S6
7 SB
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3 SB
9 SB
9 SB
13 SB
12 RPC/SB
38 RPC/SB
13 RPC/SB
41 SB
15 SB
57 RPC
15 SB
78 RPC
36 RPC/SB
81 SB
51 SB
84 SB
57 SB
84 SB
91 SB SB = Standard Bobbin RPC = Rotating Pancake Coil (b)
In association with the data review for the steam generator tubing listed in the above paragraph, the inspector:
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reviewed the below listed documents to confirm data analysis and records keeping were being accomplished as required by controlling entities.
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APR (J. M. Farley #2) Guidelines (analysis guidelines)
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Resolution of Analysis W__:.___-__________----_-_.--__
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Data Analysis Log Sheets for Tapes 21, 15, and 16
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SG-B Final Data for all Scheduled Tubes.
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(c)
In' addition to the reviews noted in the above paragraphs, I
the inspector confirmed printed indication lissajous I
against reported indications in steam generator B.
Some minor discrepancies were note; however, the lissajous were generally in agreement with the indications reported.
(d) At the conclusion of the NRC inspection, all examinations had not been completed.
The inspector discussed the
program and status with the licensee and the preliminary l
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examination status for steam generators A and B are listed below.
Examination of steam generator C had not yet started.
SG-A SG-B j
Tubes examined 3251 3275 i
Tubes with reportable indications
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Possible tubes to be plugged
35 Previously plugged tubes 124 113 l
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Within the areas inspected, no violations or deviations were identified.
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IE Bulletin 87-01, Thinning of Pipe Walls in Nuclear Power Plants, Units 1 and 2 j
The licensee has officially responded to the requirements of Bulletin j
87-01; however, a final review of the response has not yet been completed
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within the NRC.
The inspector conducted a review of documentation and J
data relative to the actions being generated as a result of this bulletin.
J The inspector also observed work being performed as a result of actions being taken by the licensee.
The documentation reviews and observations conducted by the inspector are documented in the following subparagraphs.
a.
The inspector reviewed ultrasonic procedure FNP-2-ETP-4260, Revision 0, " Pipe Wall Erosion / Corrosion Inspection". This procedure i
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is being utilized to obtain the thickness readings required by the licensee's inspection plan. The procedure was reviewed in the areas of procedure approval, requirements for qualification of NDE
personnel, and compilation of required records.
The procedure is being utilized to obtain data by both manual and automated, P-Scan
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techniques, b.
The inspector observed approximately 400 thickness readings being taken on the items listed below.
The inspector also reviewed certification records of equipment, materials, and NDE personnel being utilized during the examination of these items.
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Data Acquisition Type 2-84-4 Manual 2-83-3 Manual 2-133-1 Automated, P-Scan 2-13-10 Automated, P-Scan The inspector conducted an independent verification on several. of the c.
thickness readings taken on items 2-84-4, 2-83-3, and 2-13-10. The verification readings were made following the completion of the examinations conducted by licensee personnel and with the use of the licensee's equipment, couplant, and calibration block.
The verification readings obtained were within an acceptable tolerance range although minor deviations were noted that could be attributed to transducer placement.
d.
The inspector reviewed the thickness data and associated records for
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the Unit 2 test locations indicated below. The data was reviewed to'
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determine whethat the reported thickness was consistent.with the data being obtained in the field. The data was also reviewed to determine compliance with requirements for examination records.
Item No.
Data Type 2-141-2 Manual 2-22-5 Manual 2-141-1 Manual 2-97-1 Manual 2-29-1 Manual and Automated P-Scan i
2-25-1 Manual and Automated P-Scan 2-128-1 Manual
2-127-2 Manual and Automated P-Scan e.
Discussions with licensee personnel and a review of the completed data shows that replacement of some components will be necessary.
All scheduled examinations have not yet been completed, In this area of inspection, no violations or deviations were identified.
7.
NRC Information Notice No. 87-36, Significant Unexpected Erosion of Feedwater Lines (August 9, 1987)
Discussions with site personnel indicated that they currently had no plans to examine piping inside containment.
The inspector strongly suggested that they make an effort to obtain at least a sample thickness determination on these pipes since the areas highlighted by the Notice are on straight runs of pipe in safety-related portions of Class 2 piping l
inside containment.
Further, with Unit 2 down for refueling, this would be an opportune time to examine the piping in that unit.
The licensee indicated they would take the suggestion under consideration.
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inspector indicated that their actions relating:to this Notice would be reviewed during a future inspection.
8.
Dislodged Safety Injection Nozzle Thermal Sleeve - Unit 2 On October 2,1987, the licensee discovered a thermal sleeve, six inches in diameter, one foot long, and approximately 1/4 inch in thickness, loose inside the reactor vessel.
The thermal sleeve had come loose from the nozzle to which it had been attached by two 5/32" fillet welds-approximately 3/8" in length and at location 180 degrees apart using a gas-tungsten-arc welding procedure during the construction phase of the
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plant. The sleeve appears to have been dislodged from the
"B" loop safety
injection nozzle and flow through reactor coolant system piping carried it into the bottom portion of the reactor vessel.
The NRC inspector reviewed radiographs and associated reports generated in 1983 relative to the thermal sleeves in Unit 2.
These radiographs and-
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reports were generated as a result of dislodged thermal sleeve incidents experienced in Unit 1.
The 1983 radiographs were taken for information purposes only and are of poor quality and do not meet ASME code
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requirements. The radiographs and reports relative to the Unit 2, loop
"B" six inch safety injection thermal sleeve, indicated that this thermal
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sleeve appeared to have a broken weld and that it.had slipped downward out j
of position approximately 1-1/4 inch. The remaining two six inch thermal
sleeves in Unit 2 did 'not appear to be in difficulty.
Radiographs and
reports generated as a result of the most recent discovery of the thermal sleeve displacement and subsequent migration indicate that the loop "B" thermal sleeve does not appear to be in place. The NRC inspector reviewed the current information only, poor quality, non-ASME code radiographs of the loop "B", six inch safety injection nozzle and the report accompanying these radiographs. The conclusion reached as a result of the review of the informational radiographs is that the six inch thermal sleeve in loop
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"B" could not be seen in the radiographs although there appears to be a j
broken weld evident in one of the radiographs.
i Discussions with licensee personnel at the conclusion of this inspection
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indicated that the thermal sleeve had been removed from the reactor vessel and a remote visual examination of the lower section of the reactor vessel
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and associated components inside the vessel was conducted which indicated that no damage had occurred to the vessel or the surrounding components where the thermal sleeve had been located.
No further action is anticipated by the licensee at this time regarding the remaining Unit 2 thermal sleeves.
9.
Inspector Followup Items (IFIs) (92706)
(Closed) IFI 50-348, 364/86-21-01, Procedure Revisions to Include ANII Functions This item concerns inclusion of functions associated with an Authorized j
Nuclear Inservice Inspector (ANII) within the licensee's ISI program. The L
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licensee has issued administrative procedure FNP-0-AP-80, "ASME Section XI and Section III Code Required Authorized Nuclear Inspection," that assigns staff responsibilities and administrative controls relating to the ANII.
Also, a recent revision to procedure FNP-0-SPP-GW-001,. Revi sion 5,
" General Welding Standard for Repairs, Replacements, and Modifications,"
assigns specific criteria relating to the ANII.
Following review of the aforementioned procedures and discussions with onsite ANII by the inspector, this item is considered closed.
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