IR 05000370/1980008
| ML19344F531 | |
| Person / Time | |
|---|---|
| Site: | Mcguire |
| Issue date: | 07/18/1980 |
| From: | Herdt A, Zajac L NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML19344F522 | List: |
| References | |
| 50-370-80-08, 50-370-80-8, NUDOCS 8009150377 | |
| Download: ML19344F531 (1) | |
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Report No. 50-370/80-08 Licensee: Duke Power Company 422 South Church Street
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Charlotte, NC 28242 Facility Name: McGuire Docket No. 50-370 License No. CPPR-84 Inspection a.McGui site near Charlotte, North Carolina
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Inspector:
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U Date signed
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Approved by:
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,s A.
. lie'rdt, Section Chief, RCES Branch D4te Signed
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SUMMARY Inspection on June 16-19, 1980
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Areas Inspected This routine, unannounced inspection involved 28 inspector-hours on site in the creas of Preservice Inspection including observation of ultrasonic examination cf piping welds, review of procedures, and review of data and evaluction records; cbservation of radiographic examination including review of radiographic films, cnd review of facilities and equipment used; and visual examination of safety-related welds.
Results Of the seven areas inspected, no items of noncompliance or deviations were identified in six areas; one item of noncompliance was found in one area (Deficiency - Failure of ultrasonic procedures to complete instructions for
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performing and recording examinations paragraph 6b(2)).
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DETAILS 1.
Persons Contacted Licensee Employees
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- T. E. Tcuchstone, Senior Construction Engineer
- E. B. Miller, Senior QA Engineer
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N. Starnes, Senior QC Engineer Other licensee _ employees contacted included construction craftsmen, eight technicians, operators, mechanic, security force members, and office personnel.
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Other Organizations P. Pitz, Level II Examiner (UT) Babcock & Wilcox Construction Company (B&W)
- Attended exit interview
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2.
Exit Interview The inspection scope and findings were summarized on June 19, 1980 with those persons indicated in Paragraph I above. The one item of noncom-pliance described in paragraph 6 b (2) and the three unresolved items
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described in paragraph 5.b, 5.d and 6.b.(1) were discussed in detail.
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Licensee Action on Previous Inspection Findings
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Not inspected.
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Unresolved Items Unresolved items are matters shout which more information is required to determine whether they are acceptable or may involve noncompliance or deviations.
New unresolved items identified during this inspection are discussed in paragraph 5.b, 5.d and 6.b.(1).
5.
Independent Inspection Effort Radiographic Examination of Safety-Related Piping Weld a.
The inspector observed (on the back shift) the radiographic examina-tion of 4" carbon steel pipe weld CA2-FW50-5 of the auxiliary feedwater system to ascertain if code requirements were being met. The applicable code for this testing is ASME Boiler and Pressure Vessel Code Section V, 1971. Edition. Areas observed were: type and placement of penetra-meters, type and placement of radiographic film, placement of radiation
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source, use of backing lead and lead letter "B", and the roping-off of the radiation area.
It was noted that "High Radiation Area" signs were attached to the radiation perimeter barrier ropes. These signs -
are not the type specified for use; " Caution Radiation Area" signs are the ones specified. This was brought to the attention of the Duke Power Company Safety Officer who agreed to evaluate this condition.
No items of noncompliance or deviations were identified.
b.
Radiographic Facilities and Equipment The inspector toured (on the back shift) the radiographic facilities and checked radiographic equipment to ascertain if they met applicable code requirements, as identified in paragraph 5.a.
Areas observed were: film processing equipment, film cassettes, lead screens, penetra-meters, film storage area and shim material. It was noted that numerous penetrameters were damaged by, bending or crimping, most of which had permanent bends or crimps. The inspector was advised by radiographic personnel that the penetrameters were purposefully bent in an attempt to fit them to the curvature of the item (normally pipe) being radio-graphed. The inspector pointed out that some of the permanently bent penetrameters may have been bent sufficiently to cause an elongation or distortion of the penetrameter hole, which could effect its percep-tibility on the radiographic film. The inspector advised that radiographic personnel should consider placing the penetrameter perpendrcular to
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the weld during radiography which would eliminate the need for bending the penetrameter, and to even leave them flat when placed parallel to the weld on large' diameter pipe.
It was agreed that several of the most deverely damaged penetrameters would be re-calibrated to ascertain if the diameter of the penetrameter holes conform to the dimensional tolerances specified by the code.
This is Unresolved Item Number 370/80-08-01, " Damaged Penetrameters". No items of noncompliance or deviations were identified.
c.
Radiographic Film Review The inspector reviewed the radiographic films, for the pipe welds listed below, to ascertain if they met the code requirements identified in paragraph 5.a.
The films were reviewed for: proper film density, discernibility of the penetrameter outline and penetra-meter hole, the correct penetrameter, the correct film density between the weld and penetrameter, placement of location markers, correct film identification and correct identification and evaluation of weld defects.
Weld Identification (ID) Pipe Size & Material System ID CA2FW-50-5 4" Carbon steel Aux. Feedwater CA2FW-52-16 6" Carbon steel Aux. Feedwater VP2W-1-4 12" Carbon steel Containment Purge Ventilation
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No items of noncompliance or deviations were identified.
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d.
Visual Examination of Welds Tne inspector performed a visual examination of the welds identified belew, to ascertain if they met code requirements identified in para-graph 5.a.
The welds were examined for: weld thickness, weld undercut, surface marking, and surface defects, such as, cracks, slag, porosity, laps, etc.
Weld ID Pipe Size & Material System ID 2D-SGE-2 Carbon Steel Steam Generator Outer Containment -
Circumferential Weld 2A-SGE-2 Carbon Steel Circumferential Weld VP-2W-1 -6 1/2" Carbon steel Containment (Branch Boss Purge Ventilation Weld)
VP2W-1-8 1/2" Carbon steel Containment (Branch Boss Purge Ventilation Weld)
It was noted during this examination that branch boss welds VP2W-1-6 and VP2W-1-8 contained, what appear to be, incomplete penetration and/or sharp machine grooves on the inside surface of the bored-out waterway. Weld VP2W-1-6 had already been visually accepted.
It is questionable if either of these welds meet code requirements. The visual examiner, who accompanied the NRC inspector, did not have a mirror or other device small enough to slide into the pipe bore to-properly evaluate the indications.
In discussion with the visual examiner, it was determined that they are not issued instruments small enough to slide into a.1/2-inch pipe for visual examination. The visual examiner stated that normally the conditions in question would be requested to be faired-in by mini grinding. The NRC inspector also pointed out that visual examining the inside surface of the bored-out area without the aid of a mirror or other instrument, such as a borescope, did not appear to meet the requirements of Article 9 of Section V of the ASME Code wherein a surface h to be examined at an angle of not lets than 30 degrees to the surface being examined.
It was agreed that weld VP2W-1-6 would be re-examined and evaluated for accepta-bility and that VP?W-1-8 would be visually examined with proper instruments.
This is Unresolved Item Number 370/80-08-04, " Branch Connector Welds Appear to be Unacceptable".
.No items of noncompliance or deviations were identified.
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6.
Preservice Inspection - Review of Procedures The preservice (baseline) inspection for Unit 2 is approximately 50%
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cos.plete.
Babcock and Wilcox Construction Company (B&W) is under contract to Duke Power Company to perform the preservice inspections.
The applicable coqe for preservice $nspect{ ops is (S$ Boiler apd
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9 Pressure Vessel Code Section XI,1974 edition thru summer 1975. The inspector reviewed ultrasonic procedures ISI-120, Rev.
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" Ultrasonic Examination of Piping Welds Joining Similar and Dissimilar Materials" and ISI-131, Rev 5, used for the automatic ultrasonic examination of vessels, and visual procedure ISI-350, Rev.
8, titled,
" Visual Examination of Welds and Surface Conditions". Areas reviewed included the following:
(1) Technical content of the procedures (2) Procedure approval by the licensee (3) Qualification requirements for nondestructive examination personnel (4) Records required to be maintained such as:
(a) examination results and data sheets (b) examination equipment data (c) calibration data sheets (d) calibration block data for UT (e) couplant material data for UT b.
As a result of the review, the following conditions were noted:
(1) The visual procedure ISI-350 Rev 8, paragraph 2 specifies that a visual examiner shall be qualified to at least Level II in accor-dance with B&W procedures 9A-167 or 9A-168 which are for liquid penetrant (PT) and magnetic particle (MT) qua]Ifications respec-tively.
It was determined by a review of the training outline and qualification requirements for these two nondestructive tests (PT and MT) that specific visual requirements, as delineated in the ASME code, were not included.
It is noted that paragraph IWA-2300 of Section XI requires that personnel performing NDE operations be qualified with a procedure prepared in accordance with SNT-TC-1A for the applicable examination technique and methods. This paragraph further requires that for NDE methods not covered by SNT-TC-1A documents (of which visual examination is not), personnel shall be qualified by the owner or his agent to comparable levels of competency by subjection to comparable examinations on the particular method involved.
In addition, paragraph IWA-2210 of Section XI delineates general surface conditions required to be reported by the visual examiner dad specifies that visual examination shall be conducted in accordance
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with article 9 of Section V.
Article 9 of Section V delineates specific requirements for visual examinations. A review of B&W's qualification requirements for visual examiner indicates a lack
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of adherence to the above code requirements. In discussion with I
B&W personnel, the inspector was advised that other documents l
containing code requirements were thought to be available at
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their headquarters in Virginia.
However, at the time of the I
inspection the B&W Level III examiner, who would have such documents,
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was not available. This item will be carried as Unresolved Item Number 370/80-08-02, " Inadequate Certification of Visual Examiners".
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.v (2) A review of ultrasonic procedures ISI-120 and ISI-131 disclosed
_that both procedures did not provide complete instructions.
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Examples are:
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(a) ISI-120, paragraph 11 indicates that reporting of recordable indications shall be done in accordance with ISI-69. However, ISI-69 has not been issued.
Furthermore, two reporting forms are used in conjunction with ISI-120, but neither are included, or mentioned in the procedure. One of these forms (no form number or title) is used to provide a graphic illustration of the indication with respect to the cross-section of a weld.
The other form, no form number, is
' titled, " Ultrasonic Data Evaluation Report".
It should be noted that before the inspector departed the site on 6/19/80, B&W prepared a field change (which was approved by Duke Power Co.) to delete reference to ISI-69 in the procedure.
However, the other two forms have not yet been incorporated.
(b) ISI-131 includes Form 105 for recording ultrasonic data. A review of Form 105 representating completed examinations for a reactor vessel nozzle, W11, disclosed that data recorded did not correlate with any information or instructions in the procedure. For example, recordings on Form 105 refer to Segments A, B, C and D and Subscans 1, 3 and 4, but there is no sketch or description of scan paths in the procedure to identify these items.
Consequently it cannot be determined where or how these inspections were conducted.
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The above descrepancies are indications of inadequately documented instructions which are in noncompliance with Criterion V of Appendix B, 10 CFR 50, as implemented by paragraph 17.1.5 of DCP Topical Report Duke 1-A. This noncom-pliance is categorized as a deficiency and is item number 370/80-08-03, Failure of Ultrasonic Procedures to provide adequate instructions for performing and recording examinations.
Within the areas examined, no items of noncompliance or deviations were noted except for the deficiency noted above.
7.
Preservice Inspection - Observation of Ultrasonic Examination The inspector. observed the ultrasonic examination, using both shear and
- longitudinal wave, of 12 inch stainless steel circumferential weld NI2FW22-27 of the Safety Injection System. This observation was made to ascertain if the code requirements, indicated in paragraph 6.a were being met.
No items of noncompliance or deviations were identified.
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8.
Preservice Inspection - Data Review & Evaluation
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The inspector reviewed completed records, for the welds listed below, to determine whether they met the code requirements indicated in paragraph 6.a.
Areas reviewed included:
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a.
Examination results and data sheets b.
Examination equipment data c.
Calibration data sheets d.
Extent of examination e.
Disposition of indications f.
Identification of NDE material such as, penetrant, penetrant remover, developer and ultrasonic couplant
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Check of initial and final calibration data sheets for major deviations
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Weld ID.
Size & Mat'l System ID.
Type of NDE Performed Vessel Stainless Steel Pressurizer Visual Cladding (36 sq. in, patch)
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NC2F1-2 Stainless steel Reactor Liquid Penetrant to carbon steel coolant W-09 Carbon steel Reactor Ultrasonic Vessel Head Weld
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NT2FW-53-8 8 1/2 " Stainless Safety Ultrasonic-steel Injection NI2FW-56-12 8 1/2 ' Stainless Safety Ultrasonic steel Injection ND2F-43 14 " Stainless Residual Ultrasonic steel Heat removal ND2F-27 14" Stainless Residual Ultrasonic steel Heat Removal No items of noncompliance or deviations were identified.
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