IR 05000368/1988003

Insp Repts 50-368/88-03 on 880223-0303.Violation Noted.Major Areas inspected:safety-related Piping Weldments & Components & Supports Selected from Svc Water,Chemical Vol Control & Pressurizer Sys

ML20153E268
Person / Time
Site:	Arkansas Nuclear
Issue date:	04/12/1988
From:	Harris R, Kerch H, Oliveri M, Strosnider J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I)
To:
Shared Package
ML20153E255	List: IR 05000368/1988003 ML20153E251 ML20153E265
References
50-368-88-03, 50-368-88-3, NUDOCS 8805090443
Download: ML20153E268 (9)

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U.S. NUCLEAR REGULATORY COMMISSION

REGION I

Report N /88-03 .

Docket N License N NPF-6 Licensee: Arkansas Power and Light Ninth and Louisiana Street Little Rock, Arkansas 72203 Facility Name: Arkansas Nuclear One Inspection At: Russellville, Arkansas Inspection Conducted: February 23 through March 3, 1988

1 Inspectors:

, ki W. Kerth, Senior Reactor Engineer fNb dste

. LW HE Hartis, NDE Technician

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. A. OlivFr",' NDE TechnMian ' /

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Approved by: _ , 4/fd.//B6 J. R. Strosnider, Chief, Materials and date Processes Section, EPB, DRS, RI Inspection Summary: A routine announced inspection conducted on February 23 through March 3, 1988. (Report No. 50-368/88-03)

Areas Inspected: A routine announced inspection was conducted at Arkansas Nuclear Power Station Unit 2. Included in this independent measurements inspection were safety-related piping weldments, components, and supports selected from the Service Water (SW), Chemical Volume Control (CVC), and Pressurizer (PZR) Systems. The inspection included the review of associated documents and procedures. See attachments for specific items inspected and results. Three regional-based NRC Nondestructive Examination (NDE) personnel were utilized during this inspectio Results: Two violetions were identified regarding failure to provide adequate reviews of drawings and inadequate identification of part PDR ADOCK 05000313 Q DCD

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DETAILS

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1- 0 Persons Contacted

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Arkansas Power and Light (AP&L)

S. McGregor ~ Inservice Inspection (ISI) *

• J. Taylor-Brown- Quality. Control Superintendent J. McWilliams Maintenance Manager S. Quennog Plant Manager D. Graham Quality Control Engineer J. Ray Quality Engineer Level III

• P. Milchal Plant Licensing L. Humphry General Manager, Nuclear

• B. Durst Plant Modifications G. Goodson Project Engineer Supervisor H. Greene Quality Assurance Supervisor D. Lomax Plant Licensing Supervisor .

P. Lane Manager Engineer United States Nuclear Regulatory Commission

• W. Johnson Senior Resident Inspector, RIV L. Gilbert Inspector, RIV  !

• Denotes those attending the exit meetin l

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The inspector also contacted other administrative and technical personnel :

during the inspectio .0 Independent Measurements - NRC Nondestructive Examination and Quality Records Review of Safety-Related Systems

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i During the period of February 23 through March 3,1988 an onsite t independent measurements inspection was conducted at Arkansas Nuclear One Power Station Unit 2. This inspection was conducted by NRC regional-based

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inspectors. The purpose of this fnspection was to verify the adequacy of f

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the licensee's nondestructive examination program during p1' ant modifica-

. tion. This was accomplished by duplicating, as near as possible, those j examinations required by code and regulations and evaluating the results.

i The NRC examinations were performed on randomly selected samples from the

,~ Chemical Volume Control (CVC), Pressurizer Spray (PZR) and Service Water !

(SW) System Included in this sample were safety-related piping com-

, ponents and associated hanger / supports fabricated to ASME Section III and

! examined in accordance with the ASME Section XI, 1974 Edition with Summer .

1975 addenda and 1975 Winter addenda when required by the area specific procedure. The items selected were previously inspected and accepted by

,- the licensee as indicated by onsite QA/QC record l

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' 3.0 Nondestructive Examination Liquid Penetrant Examination Thirty-three (33) safety-related pipe weldments and adjacent base material (1-inch on either side of the weld) were' examined using the-

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solvent removable, visible dye penetrant technique per NRC Procedure NDE-9,-Rev. 0, and the licensee's Procedure 4678-ESS-093, Liquid Penetrant for Preservice and Inservice Inspectio Included in this inspection 1were ASME Code Class 1, stainless steel weldments,' pipe.to pipe, pipe to elbow and weldolet to pipe weldments selected from the Chemical. Volume Control (CVC), Pressurizer (PZR) and Service Water System Results: No violations were identifie Visual Examination

~ Thirty-five (35). safety-related pipe weldments and adjacent base material were. examined for cracks, gouges,-linear ~ indications, reinforcement and any surface conditions that may interfere with the performance of pre-service or inservice inspection. Visual examinations were performed using NRC Procedure NDE-10, Appendix A, the licensee's Procedure 00000-ESS-066 and associated isometrics and drawing Included in this sample were ASME Code Class I components selected from the Chemical Volume Control (CVC), Pressurizer Spray (PZR) and Service Water System Results: No violations were identifie Ultrasonic Examination Two (2) safety-related pipe weldments were ultrasonically examined using a Sonic Mark II ultrasonic flaw detector per NRC Procedure NDE-1, Rev. O, in conjunction with the licensee's Procedure 4678-ISI-019 and associated ultrasonic data report The instrument calibration (linearity veri-fication) was performed per NRC Procedure NDE-2, Rev. O, a distance amplitude correction curve (DAC) was constructed using the licensee's calibration blocks UT-45 and UT-46. The instrument setting and search unit (transducer) were matched as near as possible to those indicated by the licensee's ultrasonic data reports in order to attempt to duplicate tne original ultrasonic examinatio Resu11s: No violations were identifie . - _ - . . . . . . . .-. . . . . - - = ..

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Hanger Support Examination Nineteen (19) safety-related hanger / supports were visually examined per NRC Procedure NDE-10, Rev. O, Appendix B, in conjunction with the licensee's Procedure 00000-ESS-066 associated isometrics and "as-built" drawings. Included in this examination were-components selected frcm the Service Water System. The purpose of this examination is to provide a check that support members have not been damaged, misaligned or otherwise adversely affecte Specific attributes looked for were evidence of cracking, erosion /

corrosion, wear, misalignment, welding, loose or broken members, missing or bent parts and improper installatio Results No violations were identified; however, Drawing 2-HCC-264-1-HS, issued

"as-built" had a discrepancy in the dimensions as shown from the center ,

to center of the anchor placement holes. The dimension shown on the

"as-built" is 11-1/2 inches, the actual dimension is 7-3/4 inche A further investigation of documentation show that a nonconformance ;

report had been written for this item and dispositioned "use-as-is" ;

(NRC-8?.-236-2). The inspector has no further concerns about this ite "

4.0 Review of Site Procedures The following procedures were reviewed to verify their technical adequacy and conformance to regulatory and code requirements.

i Arkansas Power and Light ,

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APL-M-2410 TECHNICAL SPECIFICATION FOR INSTALLATION, i MODIFICATION, INSPECTION, AND DOCUMENTATION OF !

PIPING SYSTEMS AND PIPE SUPPORTS, HANGERS, AND !

RESTRAINT QC010 CERTIFICATION AND QUALIFICATION OF NDE PERSONNE .02 WELDING AND LOGGING PROCEDURE.

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Combustion Engineering, In ESS-093 LIQUID PENETRANT EXAMINATION FOR PRESERVICE AND INSERVICE INSPECTION.

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4678-ISI-019 ULTRASONIC EXAMINATION PROCEDURE FOR CLASS I & II AUSTENITIC PIPIN ISI-029 GENERIC MANUAL ULTRASONIC EXAMINATION PROCEDUR ESS-066 VISUAL EXAMINATION PROCEDURE FOR PRESERVICE AND ^

INSERVICE INSPECTIO P NQAI 2.2, Rev. 3 CERTIFICATION FOR INSPECTION / TESTING PERSONNE '

NQAI 2.4, Rev. 4 CERTIFICATION FOR NDE PERSONNE Independent Testing Laboratories ITL-UT-A-6 AUTOMATED STRAIGHT BEAM ULTRASONIC EXAMINATION OF PIPIN Results: No deficiencies were identifie .0 Welder Qualifications The NRC inspector conducted an indepth review of the welder qualification system. The purpose of the review was to determine if the licensee had an effective, accurate system that met applicable code requirements for test-ing, recording, and updating welder qualifications. Procedure 1092.012 and NCR 85-130, both dealing with recording and updating welder qualifi-

- cations, were reviewed. The inspector made the following two comments to the ANO welding clerk that maintains the welding qualifications record * That the welding supervisor be notified seven days in advance when his welders are due for requalification, rather than two day * This notification should be in a memorandum, not a phone cal The welding clerk and welding engineer indicated they would take action to address the above comment Results: No violations were identifie .0 Review of Licensee's Radiographs A sample of the licensee's site safety-related radiographs was reviewed to verify the adequacy of the radiographic program. Radiographs were reviewed for technique, film quality and weld integrity. The following is a list of the weld radiographs reviewed.

l * Welds FW23 C2, FW24 C1, FW29 C1 and FW38 C1 on isometric drawing 2CCA-15- .

rwwi-V y-w-+ g- r-yy- v-vy,..wm-e----t-w -

vv v- yy'1==rer er g f' wa-=y'- tg - - 91- 9 -*gdis- --M~9 9ggha

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Welds FW22 C1 and FW21 C1 on isometric drawing 2CCA-15- * Welds FW25 C1 (undergoing repair) and FW19 C1 on isometric drawing 2CCA-15- * Welds FW11 on isometric drawing 2CCA-14- *

Weld FW24 C1 on isometric drawing 2CCA-15 Results: No violations were identifie .0 NDE and Visual Personnel Qualifications The following personnel records were reviewed:

• Wyle Scientific Services Laboratories visual personnel certification records were reviewed and found to meet ANSI-45-2-6 requirement * ANO visual personnel certification records were reviewed and found to meet ANSI 45-2-6 requirement * Combustion Engineering NDE and visual personnel certification records were reviewed and found to meet ANSI 45-2-6 and SNT-TC-1A requirement Results: No violatior.s were identifie .0 Review of Modification 82-2072 Pressurizer Spray Isolation Valve Inspection of the pressurizer spray isolation valve installation activities was performe The installation of this modification was started during this inspectio Pipe spool sections were being fabricated and preservice inspected on sit The following documents were reviewed to determine if the licensee's program for control of design changes and modifications had been adequately implemente *

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ISO 2CCA-15-1

ISO 2CCA-15-2

• Revised ISO 2CCA-15-1 March 1983

• Design change package Revision 1 (DCPRI),

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During this inspection, several problems found indicated that site modification 82-2077 Pressurizer Spray Isolation Valve Installation was not being properly implemented to ensure that quality requirements were me These problems are discussed below.

The controlling drawing for this modification was isometric drawing ISO 2CCA-15-1. A review of this drawing indicated that there were portions of two IS0s portrayed on the same drawing, ISO 2CCA-15-1 and Both IS0s lacked phantom lines to properly indicate the transition between isometric drawings. In addition, within the welding data package, at the work station, the installation ISO 2CCA-15-1 was illegible with areas of information missing. It was the opinion of the inspector that the craft could not effectively utilize these drawings to perform the subject modificatio The inspector also determined that the ISI coordinator used and supplied the ANII an outdated ISO 2CCA-15-1 that was used by the ANI to track this modification for code purpose Failure to provide proper and adequate reviews of drawings before they are distributed is a violation of 10 CFR, Appendix B, Criterion VI and Section 6.0 of the Arkansas Power and Light QA manua (88-03-01)

• During this inspection, it was disclosed that two subassemblies had been fabricated for the same line segment on ISO 2CCA-15-1. One subassembly was fabricated during the time frame of 1985, the other,

, January 1988. The two subassemblies were different designs, but both had been inspected and accepted by the licensee's QC group. At the time of the NRC inspection, ANO modifications engineering had made the decision to use the January 1988 design. Both subassemblies were undergoing fabrication and/or ISI during the inspection. In fact, the NRC inspected the subassembly of the 1985 modification and started the inspection of the 1988 subassembly when it was apparent that there was a duplication of subassemblies and weld designators. Further investigation revealed that the assigned modifications engineer was aware of the duplication of subassemblies. He was unaware of the materiel tagging and segregating requirements in the ANO QA manual Section 8.0, "Identification and Control of Materials, Parts and

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Components." Furthermore, engineering did not have a procedure that i reflected this requirement.

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Inadequate identification of parts is a violation of 10 CFR, Appendix B, Criterion VIII and the Arkansas Power and Light QA manual, Section i 8.0. (88-03-02)

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During this inspection, there was a meeting with the plant manager concerning the quality and material control for modification 82-2072, Pressurizer Spray Isolation Valve. Discussions included all the above items; ANO management wanted to review these findings and requested another meeting the next day. The inspector was informed of the following accomplishments during that meetin *

New correct and accurate drawings 2CCA-15-1 and 2CCA-15-2 had been prepared and issued to the work statio *

ANO walked down the modification and documented the correct weld identifications and corrected previous inspection report * Correct drawings were provided to the ISI coordinator and the AN * AND management recognized the need for an engineering procedure for controlling materia Summary and Conclusions

• Thirty-three (33) pipe weldments were Liquid Penetrant examine * Thirty-five (35) pipe weldments were Visual examine * Two (2) pipe weldments were Ultrasonicly examine * Nineteen (19) hanger / supports were Visually examine * Radiographs for ten (10) weldments were reviewe * Ten (10) procedures were reviewe * Welder qualification system was reviewe * NDE and Visual Personnel Qualification records were reviewe * Modification 82-2072 Pressurizer Spray Isolation Value was reviewe Based on our inspection, we have concluded that this licensee has problems in the areas of drawing and material control. Two violations were identified during the course of this inspectio .0 Attachments

• Attachment No. 1 is a tabulation of specific items examined and results achieve * Attachment No. 2 is a list of specific hanger / supports examine r-l

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10.0 Entrance / Exit Interviews Licensee management was informed of the scope and purpose of the inspection at the entrance interview on February 23, 1988. The findings of the inspection were discussed with licensee representatives during the course of the inspection and presented to licensee management at the exit interview (see paragraph 1 for attendees).

At no time during the inspection was written material provided to the licensee by the inspector. The licensee did not indicate that proprietary information was involved within the scope of this inspectio .

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