IR 05000348/1993024

Insp Repts 50-348/93-24 & 50-364/93-24 on 931012-15.No Violations or Deviations Noted.Major Areas Inspected:Isi, Including Nondestructive Exam Procedures & Observation of Work & Work Activities

ML20059L002
Person / Time
Site:	Farley
Issue date:	11/01/1993
From:	Blake J, Kleinsorge W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
To:
Shared Package
ML20059K997	List: IR 05000348/1993024 ML20059K990
References
50-348-93-24, 50-364-93-24, NUDOCS 9311160268
Download: ML20059L002 (7)

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UNITED STATES '

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. NUCLEAR REGULATORY COMMISSION

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REGION 11 101 MARIETTA STREET, N.W.. SUITE 2900 y ATLANTA, GEORGIA 30323-0199

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Report No.: 50-348/93-24 and 50-364/93-24 Licensee: Southern Nuclear Operating Company, In North 18th Street Birmingham, AL 35291-0400 Docket No.: 50-348 and 50-364 License No.: NPF-2 and NPF-8 Facility Name: Farley 1 and 2 InspectionConducted:/dcio -1 1993 /

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Inspector: /

illiam / .

Kleinsor

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/eactor, B Inspector #ge P,EC/ ~

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Approved by: // 3 Jer 'e .' Bldke, Chief Date Signed Ma ri is and Process Section En in ering Branch ,

Division of Reactor Safety <

SUMMARY Scope: '

This routine, announced inspection was conducted in the area of Inservice Inspection (ISI), including review of Nondestructive Examination (NDE)

procedures, and observation of work and work activitie Results: '

Examination of the licensee's ISI program in action indicates adequate management control of the program currently in place. NDE procedures were noted to be adequate, well organized and technically effective in implementing the applicable code requirements. The licensee's ISI Coordinator, and Level III examiner were actively involved in the resolution of technical issues and ,

ensuring that all quality- objectives were properly. addressed by examiner One weakness was identified in the ISI program. The licensee does not have '

adequate drawings to locate some' branch connection and nozzle welds. This issue-was subsequently identified as an unresolved ite .

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

i 9311160269 931108 PDR ADOCK 05000348 G PDR e

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REPORT DETAILS Persons Contacted Licensee Employees

• R. Bathem, Inservice Inspection (ISI)

• W. Bayne, Supervisor Safety Audit and Engineering Review (SSAER)

• D. Hartline, ISI

• R. Hill, Nuclear Plant General Manager e

• L. McCain, ISI i

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Other licensee employees contacted during this inspection included engineers, security force members, technicians, and-administrative personne p NRC Resident Inspectors  ;

• Morgan, Resident Inspector M. Scott, Resident Inspector '

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• Attended exit interview Inservice Inspection (ISI)

The inspector reviewed documents and records, and observed activities, as !

indicated below, to-determine whether ISI was being conducted in accor-dance with applicable procedures, regulatory requirements, and licensee commitments. The applicable code for ISI, for both Units is the ASME B&PV Code,Section XI, 1983 Edition with Addenda through Summer 1983 (83S83). Unit 1 is operating in the second 40 month period, of the :

second ten year interval (P2,I2). Unit 2 is in refueling outage (RFO) 9, -'

the second outage of the first 40 month period of the second ten year j interval (02,PI,12). Unit I received its Operating License June 25, ;

1977, and commenced commercial operations on December 1,1977. Unit 2 ;

received its Operating License on March 31, 1981, and commenced commer-cial operations on July 30, 1981. The licensee, Alabama Power Company (APC), has contracted with Westinghouse (W) to conduct liquid penetrant (PT), magnetic particle (MT), and ultrasonic (UT) examinations. All the above activities are being accomplished under the umbrella of the W i Quality Assurance (QA) Progra ! Review of NDE Procedures, Units 1 and 2 (73052)

The inspector reviewed the procedures listed below, to determine whether these procedures were consistent with regulatory require-ments and licensee commitments. The procedures were also reviewed i for technical conten ,

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Procedures Reviewed l ID Revision Title l FNP-0-NDE-157.11 3 Magnetic Particle Examination -

FNP-ISI-70 1983 Code FNP-0-NDE-15 Liquid. Penetrant Examination - 1983 :

FNP-ISI-11 Code l FNP-0-NDE-157.12 5 Manual Ultrasonic Examination of l FNP-ISI-206 Welds - 1983 Code i

, i I NDE procedures were noted to be adequate, well organized and techni- l l cally effective in implementing the applicable code requirement ;

l b. Observation of Work and Work Activities, Unit 2 (73753)

The inspector observed work activities, reviewed certification l records of NDE equipment and materials, and reviewed NDE personnel i

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qualifications for personnel who had been utilized in the ISI I l examinations during this outage. The observations cnd reviews j conducted by the inspector are documented belo :

I Activities Observed i Liquid Penetrant Examination (PT)

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The inspector observed PT examinations of piping welds listed below.

l The examinations were observed to determine whether approved proce-dures were being followed, if examination personnel were knowledge- l able of the examination method and operation of the test, and !

whether examination results and evaluations of the results were 1 recorded, and dispositioned correctly. The applicable procedure for i the examinations was FNP-ISI-11/FNP-0-NDE-157.4 Revision Person- i nel and equipment certifications were verified by the inspecto The following ISI examinations were observed by the inspector:

Liquid Penetrant Examinations Observed i Drawing No Weld N System l

APRI-4106 10 3 Reactor Coolant APRI-4106 11 Reactor Coolant i APRI-4105 1, Reactor Coolant 1 APRI-4105 2 Reactor Coolant APRI-4105 3 Reactor Coolant APRI-4105 4 Reactor Coolant APRI-4105 5 Reactor Coolant APRl-4105 6 Reactor Coolant APRI-4105 25BC Reactor Coolant  !

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Relative to the examinations above, the inspector noted the follow-ing:

o The PT examiners were unable, with certainty, to show the inspector the location of branch connection to pipe weld No. I on drawing APRI-4105, and branch connection to pipe weld No. 10 on drawing APRI-4106. These welds are marked , above. The examiners indicated that they had examined a large area to assure that the Code required area of interest would be exam- '

ined. This matter, an example of Unresolved Item 50-364/93-24-01, is discussed further in the MT section belo O The scaffolding installed, in the containment, adjacent to the main loop piping, approximately eight feet above the-floor, to facilitate the examination of the reactor coolant system welds indicated above, was not provided with a ladder access. This lack of a ladder caused the examiners to climb on installed equipment, piping, insulation and pipe supports in order to reach the welds requiring examination. This is of concern because of the potential for damage to important reactor plant equipment from indiscriminate climbin o The waist high hand rail installed on the scaffolding discussed above, was inadequately supported thus making it both a nuclear and industrial safety hazard. The rail was not strong enough '

to restrain personnel to prevent falls. The rail, a wooden 2"x4", was secured, by nails, to the upper end of two vertical wooden 2"x4"s, the bottom end of which were nailed to the toe board of the scaffold. No upper lateral support was provided to the hand rail rendering it extremely flimsy. Aside from the potential for personnel injury, this is of concern because of the potential for damage to important reactor plant equipment upon which the rail and personnel might fal The inspector reviewed the certification documentation for penetrant Batch No. 88E038, developer Batch No. 88B019 and cleaner Batch N B02 The inspector reviewed the certification, qualification, and visual acuity documentation for PT-II examiners RSC, JSC, KHB, MRP and WE Except as noted above, the examinations were performed satisfactori-l Magnetic Particle (MT) Examination ,

The inspector observed the MT examination of the welds' listed belo ,

The inspector performed an independent evaluation of the indications obtained to confirm the NDE examiner's evaluation. The examinations were observed to determine whether approved procedures were being followed, if examination personnel were knowledgeable of the exami-

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nation method and operation of the test equipment, and whether examination results and evaluations of the results were recorded, and dispositioned correctly. The applicable procedure for the examinations was FNP-ISI-70/FNP-0-NDE-157.11, Revision Personnel and equipment certifications were verified by the inspector. The following ISI examinations were observed by the inspector:

Magnetic Particle Examinations Observed Drawing No Weld N System APR2-4150 16 Feedwater APR1-2100 92 Reactor Coolant Relative to the examinations above, as discussed in the PT section above, the inspector noted that the MT examiners also were unable, with certainty, to show the inspector the location of nozzle to vessel weld No. 9 on drawing APR1-2100 marked 2 The examiners indicated that they had examined a large area to assure that the required area of interest had been examined. The inspector dis-cussed with the licensee, the H examiners inability to point out the exact location of this weld as well as the two reactor coolant system welds discussed in the PT section above. During the time period of this inspection the licensee was unable to provide draw-ings that would precisely locate the three welds. The licensee is in the process of acquiring the necessary drawings to assure that the Code required area of interest for these welds will be properly examined. The licensee's lack of drawings, which locate the exact position of welds requiring examination, is a weakness of the ISI program and is identified as Unresolved Item 50-364/93-24-01:' "Un-available Drawings Required to Locate ISI Welds" The inspector reviewed the certification documentation for Red MT powder Batch No. 85J080, and yoke S/N A99904 The inspector reviewed the certification, qualification, and visual acuity documentation for MT-II examiners RSC and JS Except as noted above, the examinations were performed satisfactori-l !

Ultrasonic Examination (UT)

The inspector observed examiners perform equipment calibrations and 'l ultrasonic examinations for the welds listed below. The examina-tions were observed to determine whether approved procedures were

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being followed, if examination personnel were knowledgeable of the examination method and operation of the test equipment, whether welds were properly scanned, and whether examination results and evaluations of the results were recorded, plotted, and dispositioned correctl The applicable procedure for the examinations was FNP-l

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ISI-206/FNP-0-NDE-157.12, Revision Personnel and equipment certifications were verified by the inspector. The following ISI l examinations were observed by the inspector:

Ultrasonic Examinations / System Calibrations Observed Drawing No Weld N System t APR2-4150 16 Feedwater The inspector reviewed the certification documentation for the following UT equipment and materials: Transducer S/N 031296; .

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Instrument S/N 136-904; Couplant Batch No. 8874; Thermometers S/N 10071 and 1007 ;

The inspector reviewed the certification, qualification, and visual -

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acuity documentation for UT-II examiner RSC and UT-Trainee JS The examination was performed satisfactoril . Exit Interview _;

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The inspection scope and results were summarized on October 15, 1993, 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 report. No dissenting comments were received from the license ,

On November 1, 1993, the licensee was informed, by an NRC representative on site, that the weakness to the ISI program, related to the lack of drawings which locate the exact position of welds requiring examination, will be identified as Unresolved Item 50-364/93-24-01: " Unavailable Drawings Required to Locate ISI Welds"  : Acronyms and Initialisms '

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APC -

Alabama Power C ASME -

American Society of Mechanical Engineers ,

B&PV -

Boiler and Pressure Vessel FNP -

Farley Nuclear Mant ,

ISI -

Inservice Inspection ,

MT -

Magnetic Particle .

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NDE -

Nondestructive Examination NPF -

Nuclear Power Facility NRC -

Nuclear Regulatory Commission i Professionai Engineer PT -

Liquid Penetrant QA -

Quality Assurance RF0 -

Refueling Outage

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Acronyms and Initialisms Cont'd S/N -

Serial Number SSAER -

Supervisor Safety Audit and Engineering Review UT -

Ultrasonic H -

Westinghouse

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