IR 05000382/1986031
| ML20212L127 | |
| Person / Time | |
|---|---|
| Site: | Waterford  |
| Issue date: | 03/04/1987 |
| From: | Harris R, Kerch H, Strosnider J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML20212L120 | List: |
| References | |
| 50-382-86-31, NUDOCS 8703100227 | |
| Download: ML20212L127 (15) | |
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APPENDIX B U.S. NUCLEAR REGULATORY COMMISSION
REGION I
NRC Inspection Report:
50-382/86-31 License: NPF-38 Docket:
50-382 Licensee:
Louisiana Power & Light Company (LP&L)
N-80 317 Baronne Street New Orleans, Louisiana 70160 Facility Name: Waterford 3 Inspection At: Taft, Louisiana Inspection Conducted: December 1-11, 1986 Inspectors:
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H. W. Kerch, Lead Reactor Engineer Date'
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. HarrTs,'NDE Technician Date
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Approved:
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2d5/67 R. Strosnider, Chief, M & P.S., EB, DRS Date Inspection Summary Inspection Conducted December 1-11, 1986 (Report 50-382/86-31)
Areas Inspected: A special, announced independent verification inspection of plant modifications and inservice inspection was performed using the NRC Nondestructive Examination Mobile Van. Two Regional based inspection personnel assisted by two contractor NDE personnel were utilized during this inspection.
The purpose of this inspection was to evaluate the plant modification program and ascertain the condition of plant materials through various NDE techniques.
Results: Within the two areas inspected, two violations were identified (failure to follow instructions and failure to control nonconforming components, paragraph 3).
8703100227 870304 PDR ADOCK 05000382 G
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DETAILS 1.
Persons Contacted Louisiana Power & Light-(LP&L)
- D. Schultz, Station-Supervisor
- G. Forgala, Shift Supervisor
- A. S. Lockhart, Nuclear Support Manager
- K. W. Cook, Licensing
- J. D. Dewease, Senior Vice President -_ Nuclear
- R. C. Barkhurst, Vice President - Nuclear
- N. S. Carns, Plant Manager - Nuclear
- R. F. Burski, Engineering Manager
- G. W. Robin, Inservice Inspection
- T. F. Gerrets, Nuclear QA Manager
- J. G. Dickinson, NDE Level III J. R. McGaha, Assistant Plant Manager G. E. Wisler, Licensing L. L. Bass, Nuclear Operations Engineer T. H. Smith, Maintenance Superintendent U.S. Nuclear Regulatory Commission
- L. D. Gilbert, Reactor Inspector, RIV
- B. A. Breslau, Reactor Engineer, RIV
- T. R. Staker, Resident Inspector, RIV
- J. I. Tapia, Reactor Inspector, RIV
- Denotes those present at exit meeting.
2.
Purpose of Inspection-The purpose of this inspection was to evaluate the licensee's modification program and its implementation as demonstrated by the installation of a supplemental fuel pool heat exchanger performed during the plant outage.
The inspection included review of procedures, review of modification records, review of the ISI program, and review of quality assurance activities.
The inspection activities included various independent nondestructive examinations (NDE), observations of work in progress, and
- review of records.
3.
NRC Conducted Nondestructive Examinations During the period of December 1-11, 1986, an onsite inspection was conducted at Waterford Power Plant Unit 3.
The inspection included independent nondestructive examinations of safety related piping and supports to verify their acceptability and the effectiveness of the licensee NDE and QA/QC program _
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A random sample of f safety related pipe weldsents and associated ' supports was selected from the plant modification package (SMP-107)Lfor installation'of a supplemental fuel pool cooling heat exchanger.
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addition to the above,;other safety related' piping included in the. plant Inservice Inspection Program was selected for independent' inspection by the NRC.
All items selected were previously inspected and accepted by the licensee, based on information_ supplied (QA/QC records) by the licensee.
Nondestructive. examinations were performed'using NRC procedures.
Isometrics and drawings supplied by-the licensee were used in conjunction
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with the procedures.
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The following examinations were performed by two NRC-inspectors and two contracted NDE personnel.+
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It was intended that, to'the extent practicable,.these inspections would be conducted in a similar manner, i.e., using the same. techniques and code specified procedures and acceptance criteria, as the original examinations.
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Thirty-six safety-related pipe weldments and adjacent base material (1/2 inch on either side of:the weld) were examined by.the visible dye
method per NRC procedure NDE-9, Revision 0, and' Westinghouse procedure WTR-ISI-11, Revision 0.
Samples' included in this selection were ASME Code Class 1, 2, and 3 carbon and stainless steel weldments.
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Results:
No violations were identified.
Thickness Measurements:
Seventeen safety-related pipe weldments and adjacent base material (1/2. inch on either side of the weld) were examined using a NOVA-D 100 digital thickness gauge per NRC procedure NDE-11, Revision 0.
The
' required minimum wall thickness was determined by use of an ASTM standard pipe size and nominal thickness chart.
Results:
No violations were identified.
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Ferrite Measurements:
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Ten' safety-related pipe weldments were examined for delta ferrite content
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using a type II ferrite indicator (Severn Gauge).
This test is intended to ' verify that the welding filler metal composition had achieved an as-deposited delta ferrite content sufficiently high to eliminate hot cracking.
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Results:
No violations were identified.
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Hardness Test:
Seven safety related pipe weldments and adjacent base material were tested using the'Equo-Tip, hardness tester per NRC procedure NDE-12, Revision 0.
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Measurements taken;from the impact. device are processed into "L" values as a digital readout; the "L" valuesf are then converted to Brinell hardness
- values and approximate tensile strengths by means of a conversion table.
'Results:.No violations were identifie'd.
. Ultrasonic Examination:
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Ten safety-related pipe weldments were ultrasonically examined using a Sonic Mark'1 ultrasonic flaw detector per NRC-procedure NDE-1, Revision 0, Westinghouse procedure WTR-ISI-206, Revision 0, and associated ultrasonic data reports. LInstrument calibration (linearity-verification) was performed using NRC procedure NDE-2, Revision 0, and the distance amplitude correction (DAC) function was constructed using the licensee's calibration blocks,.UT-115, UT-105, UT-119 and UT-141 for this examination.
Instrument settings and search unit (transducer) were matched as nearly as possible to those indicated by the licensee's ultrasonic data reports in order to attempt to duplicate the original ultrasonic examinations.
Results: Welds61-073 and 61-080 on drawing WTR-2-4107, welds56-040 and 56-042 on drawing WTR-2-4211 and weld 52-019-900 on drawing WTR-2-4205 could not be examined ultrasonically with complete coverage due to physical restrictions. These restrictions were noted in the' licensee's ultrasonic data reports and verified during the NRC inspection.
No violations were identified.
Visual Examination:
l Forty-six safety-related pipe weldments and adjacent base material were examined for cracks, gouges, linear indications, reinforcement and surface condition that could interfere with the performance of inservice inspection.
Visual examinations were performed using NRC procedure NDE-10, Revision 0, in conjunction with site documents.
Samples in this examination include ASME Code Class 1, 2, and 3 carbon and stainless steel piping.
A sample of 14 supports that were part of the supplemental Fuel Pool Heat Exchanger modification were selected for detailed review (see attachment 2).
The supports had been installed and quality control (QC)
accepted.
The supports selected were ASME III Class 3, Seismic Category I.
The Supports were examined for member size; configuration and
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dimensions; installation of pins and locknuts; weld appearance and clearances.
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'.Results_
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.In general, the modifications met the requirements for design drawings.
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.However, discrepancies were identifiedLon the following hardware:
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1 upport number FSRR-4001: - Drawing required lock nut missing S
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. Support number FSRR-4004:
Locknuts not engaged-per specification.and
~ Cotter, Keys'not installed properly.
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-' Support number FSRR-4010:
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_ Required weep hole not drilled.
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Support number.CCRR-4521:. Locknuts not engaged per specification and Cotter keys.not installed.
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These-items are considered a violation of 10 CFR,. Appendix'B, Criterion'V'
-(382/8631-01).-
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Also, the following discrepancies in documentation were identified:
. Welds FSRR-4002-FW1 and FSRR-4002-FW2 were rejected by QC, however,
-the' weld records indicated that the completed welds were acceptable
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without having been reinspected by-QC for the rejectable attribute.
- Welds FS-SM-107-M3-FW6'and FS-SM-107-M4-SW8 were rejected due to'
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excessive _ fit up gap (greater than 5/32 of an inch).
Proper disposition was not documented for these nonconforming conditions in
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accordance.with. site administrative' procedure QP-015-001, Revision 3, Nonconformances and Corrective Actions.
Results:
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These items'are considered a violation.of 10 CFR, Appendix B, Criterion XV (382/8631-02).
4.
Review of Procedures
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The procedures listed in Attachment Number 3 were reviewed to verify their technical adequacy and conformance to regulation and code requirements.
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Results:
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Review of Procedure QA.2.4, Revision 0, Qualification and Certification of
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Visual Examination Personnel for Preservice and Inservice Inspections,
-indicated the procedure does.not meet the industry standard nor are there
. precedents within the referenced ASNT and ANSI documents for the liberties taken.
The following are examples:
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The procedure allows reduction of experience by 33-1/3 percent in
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accordance with ANSI 45.2.6 (1978).
However, the procedure permits further reduction of the required experience by an additional
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m L50 percent :if the individual 'is certified to Level II for'at 'least three NDE methods.
There is no apparent basis why an-individual who is certified Level II in PT, MT, and UT should have the required.
experience' level for VT3 and VT4 reduced by 50 percent.
- iFurthermore, the p'rocedure eliminates the requirement for an
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individual to take a practical-exam if he has a specified amount of
' training.. There is no basis presented for this relaxation in requirements.
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This-issue is considered unresolved pending the licensee's evaluation and justification and subsequent NRC review (382/8631-03).
5.
-Review of Modification SM-107 Inspection was concentrated on the installation of a Backup Spent Fuel Fool Cooling heat exchanger.
Cooling water lines and related accessories on the 35-foot elevation in the Fuel Handling Building were inspected.
-The heat exchanger and its interconnecting piping are safety-related equipment and were designed to ASME Section III, Class-3 requirements.
The backup spent fuel pool cooling system is a Seismic Category I installation.
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The following documents were reviewed in order to-determine if the licensee's program for control of design changes and modifications-had been adequately implemented.
Ebasco's independent design verification for modification SM-107.
- Ebasco's Quality Assurance review of the independent design verification for modification SM-107.
- Ebasco's procedure control for design changes and modifications E69.
The NRC inspectors examined the as-built configuration of the system and compared this configuration to the piping and hanger isometric drawings and specifications.
Several discrepancies were noted as discussed in Section 3.
The type of discrepancies found indicate that site
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installation procedures were not properly implemented to ensure that quality requirements were met.
6.
Review of the Inservice Inspection (ISI) Program The Waterford 3 ISI program was prepared and is implemented by the licensee. The plan meets the requirements of ASME Section XI 1980 edition including addenda through Winter 1981.
This outage was the first in the first 10 year interval of the ISI program.
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Organization and Staffing of ISI Program The Waterford 3 Plant Manager - Nuclear has the prime responsibility for coordinating and conducting the ISI Program.
The inspector concluded that Waterford 3 has adequate staff comprised of site personnel, augmented by contract personnel, to properly execute the ISI program.
Quality Assurance Audits of ISI The inspector reviewed the documents. listed below to. ascertain that ISI vendors are audited by the QA department prior to their being considered as a-qualified supplier of ISI services.
LP&L Audit report on Westinghouse for ISI Contract (dated January 8-10, 1985).
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LP&L Audit report on Westinghouse for ISI Contract (dated August 29, 1986).
The audit reports indicated that various aspects of the ISI Program were examined, audit findings were properly closed out, and that the licensee's ISI vendor was properly qualified as a supplier of ISI services.
ISI Personnel Record Review The inspector reviewed 24 nondestructive examination ~(NDE) personnel qualification and certification records.- One individual was identified for which additional information was required to justify marginal experience at the' time of his certification. The individual had received adequate experience since his certification.
The inspector had no further concerns on this item.
Inservice Inspection (ISI) Data Review During this inspection the inspector reviewed all the ISI data that had been taken as of December 9, 1986.
The total count was:
24 ultrasonic examinations
117 visual examinations l
19 liquid penetrant examinations
i 2 magnetic particle examinations The inspector verified that the examinations were done in compliance with governing procedures and that applicable ASME code and Regulatory requirements were met. The review also was undertaken to verify that the licensee had properly recorded the evaluations.
A licensee employee with a Level III NDE certification reviewed all NDE ISI data and his signature on each of the NDE data reports was required for acceptance of those reports.
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Overall, the. inspector found that the Inservice Inspection Pro' gram at
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Waterford 3 including its documentation,is being performed adequately and that the_ objectives of the ISI program are being met.
No violations were identified.
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Attachments:
Attachment No.'1 is a tabulation of piping weldments inspected and the results.
Attachment Nc. 2 is a tabulation of_ specific pipe supports inspected during this inspection and the inspection results.
Attachment
.No.' 3 is a list of procedures reviewed during this inspection.
8.
Unresolved Items Unresolved' items are those for which more information is necessary for the
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NRC to determine whether the item or items are acceptable, a violation or a deviation.
An unresolved item is contained in Section 4.
9.
Exit On December 11,-1986, the NDE Van personnel attended an exit meeting with the. licensee: staff.
The findings of this' inspection were described' at
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'this meeting.
No written material was~provided;to-the licensee during this inspection.
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Pag 3 3 cf 4 SITE: 'Wat; o rd 3,
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I WELD NUMBER CLASS l ALLOY FERRITE THICK
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HARDNESSl VISUAL REMARKS.
'LlNE/ ISO I ANAL.
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N/A N/A N/A N/A N/A ACC N/A
.N/A ACC due.to weld.
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N/A N/A N/A N/A N/A ACC l' N/A-N/A ACC
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WTR-2-4211
N/A N/A N/A N/A N/A ACC N/A N/A ACC A6180' f rom i
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- 56-043
N/A N/A N/A N/A N/A ACC N/A N/A ACC: i
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WIR-2-4205 i
52-017-900
N/A N/A-N/A N/A N/A ACC.
N/A N/A.
ACC i
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N/A ACC
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ACC-due to poor i
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WTR-2-4211 Limited exam.
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.ACC due to
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Attachment No. 3:
List of Procedures Reviewed
'
.
Title (We'stinghouse Procedures)
Preservice and Inservice Examination Documentation WTR-0PS-101, Revision 0 Qualification of Ultrasonic Manual WTR-ISI-10, Revision 0
" Equipment
. Manual Ultrasonic Examination of Welds WTR-ISI-206, Revision 0 Manual Ultrasonic Examination of Welds WTR-ISI-47, Revision 0 in Vessels Manual Ultrasonic Examination of Vessel WTR-ISI-247, Revision'0 Nozzle Inside Radius (Training) Qualification and WTR-QA-2.2, Revision 1 Certification of NDE Personnel Visual Examination WTR-ISI-8, Revision 0 Magnetic Particle Examination WTR-ISI-70, Revision 0 Liquid Penetrant Examination WTR-ISI-11, Revision 0 Qualification and Certification of Combustion Engineering Procedures Visual Examination Personnel for PSI QA.2.4, Revision 0 Certification of NDE Personnel NQA 1 2.4 (Louisiana Power and Light Company Procedures)
Section IV Repairs and Replacement PE-1-001 Modification MP-107, Revision 0, 1, 2 Control of Inservice Inspection PE-1-003 l
Modification SM-107, Revision 0, 1, 2 l
Penetrant Examination PT QI-009-011, Revision 3 Administration Control of ISI PE-003, Revision 2-(Louisiana Power and Light Company Procedures)
Administration Plant Engineering PE-2-006, Revision 8 Station Modification
'
(EBASCO Procedures)
!*
I
!
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.
-.
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n
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.-
-
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2-Structural Steel LOU 1564.723 Specification Station Piping, Hanger
' LOU 1564.100 and Supports Welding
- M 1-050, Revision 3 -
PC-I General Power Piping hCR-MP-2050 (GE0 Proce'dures)
'
- Penetrant Examination PT-23, A. 58, Revision 23
.
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