IR 05000400/1993001
| ML18010A989 | |
| Person / Time | |
|---|---|
| Site: | Harris  |
| Issue date: | 01/25/1993 |
| From: | Blake J, Kleinsorge W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML18010A988 | List: |
| References | |
| 50-400-93-01, 50-400-93-1, GL-89-08, GL-89-8, IEIN-92-007, IEIN-92-7, NUDOCS 9302020017 | |
| Download: ML18010A989 (14) | |
Text
~PS REC0 (4 P0 UNITEDSTATES NUCLEAR REGULATORY COMMISSION
REGION II
101 MARIETTASTREET, N.W.
ATLANTA,GEORGIA 30323 Report Nos.:
50-400/93-01 Licensee:
Carolina Power and Light Company P. 0.
Box 1551 Raleigh, NC 27602 Docket Nos.:
50-400 Facility. Name:
Harris Inspection Conducted:
January 11-15, 1993 License Nos.:
NPF-63 Inspector:
W.
~
leinsorge Re t r Inspect Date Signed Approved by:J.J.
Bl e, Chief Mat ri s
and Process Section Engineering Branch Division of Reactor Safety Date igned SUMMARY Scope:
I This routine, announced inspection was conducted in the areas of Inservice Inspection (ISI), and followup on NRC Generic Letter (GL) 89-08:
"Erosion/Corrosion-Induced Pipe Wall. Thinning",
"Rapid Flow-Induced Erosion/Corrosion of Feedwater Piping",
and previous enforcement matters.
Results:
It appears that the licensee has established an effective program to maintain high energy carbon steel piping systems within acceptable wall thickness limits.
The licensee has'aken appropriate actions in response to IN Nos. 92-07.
9302020017 930128 PDR ADOCK 05000400
REPORT DETAILS 1.
Persons Contacted Licensee Employees E. Black, Nondestructive Examination (NDE) Unit
- J. Burns, Technicial Support
- R. Biggerstaff, Manager STSS/OEF
- J. Collins, Manager, Operations
- D. Knepper, Project Engineer-NRD Site Unit
- R. McKay, Manager Engineering and Technicial Support
- J. Nevill, Manager, Technical Support
- C. Osman, Principal'DE Specialist-NDE Service Unit
- W. Seyler, Manager-Outage Management 5 Modifications
- D. Sadler, Inservice Inspection
- G. Tucker, Specialist Technicial Support
- G. Vaughn, Vice President, Harris Nuclear Project
- M. Wallice, Regulatory Compliance Other licensee employees contacted during this inspection included craftsmen, engineers, technicians, and administrative personnel.
NRC Resident Inspectors
- D. Roberts, Resident Inspector (RI)
M. Shannon, RI
- J. Tedrow, Senior Resident Inspector (SRI)
R. Watkins, Intern Office of Research 2.
- Attended exit interview'nservice Inspection (ISI)
The inspector reviewed documents and records, and observed activities, as indicated below, to determine whether ISI was being conducted in accordance with applicable procedures, regulatory requirements, and licensee commitments.
The applicable code for ISI, for the plant is the ASME BE PV Code,Section XI, 1983 Edition with Addenda through Summer 1983 (83S83).
The plant is operating in the fifth fuel cycle, in the second 40 month period, of the first ten year ISI interval (II,P2).
The plant received its operating license January 12, 1987, and commenced commercial operations on May 2, 1987.'SI repair and replacement activities are conducted under the umbrella of the CPRL guality Assurance (gA) progra ISI Program Review, (73051)
The inspector reviewed the following documents relating to the ISI program to determine whether the plan had been approved by th'
licensee and to assure that procedures and plans had been established for the applicable activities.
The licensee has replaced a portion of the Auxiliary Feedwater (AF)
systems fittings and pipe, thinned by Flow Accelerated Corrosion (FAC).
The inspector reviewed the licensee's program for piping replacement.
Documents were reviewed for technical content.
Documents Reviewed ID
'W-01-NW-02 WH-03 WH-04 WH-06 WPS 05 3 33 WPS
1
WPS
3 04 PQR
PQR 28(B)
PQR 28(C)
PQR 193(B)
Revision (R3)
(R2)
(R2)
(R3)
(R4)
(RO)
(R2)
(RO)
8/22/78 8/22/78 4/30/82 6/22/82 8/7/84 8/21/84 12/17/90 12/17/90 Title Qualification of Welding and Brazing Procedures Qualification of Welders and Welding Operators Welding Material Control Permanent Marking of Plant Materials, Components and Weld Joints General.Welding Procedure for Carbon and Low-Allow Steels, Stainless Steels and Non Ferrous Alloys
Procedure gualification Record (P(R) supporting Welding Procedure Specification'(WPS)
3 33 RO PgR supporting-WPS Ol 1 04 R2 PgR supporting WPS
3 04 R2 The above procedures were appropriate for their intended applications.
b.
ISI Records Review, (73755)
Auxiliary Feedwater Pipe Replacement The licensee has replaced pipe and fittings in the Auxiliary Feedwater system in accordance with their repair and replacement program and ASME B8PV Code Subsection IWA 7000.
This matter is discussed further in paragraph 3c.
The inspector reviewed records associated with this replacement to ascertain whether the activities were accomplished in accordance with procedural and regulatory requirements, as indicated below.
The inspector examined Plant Change Request PCR 6622 with the associated Installation Package including Work Requests/Job Orders, Weld Data Reports, Nondestructive Examination (NDE)
Reports
[Radiography (RT) Magnetic Particle (MT), Liquid Penetrant (PT), Visual (VT), and Ultrasonic (UT) Examinations],
and Plant Maintenance Pipe Hanger-Process Control Installation Verification Sheets.
The inspector examined:
welder qualification and welder qualification maintenance records; welding filler material certification and receiving inspection documentati'on; NDE personnel qualification certification and visual acuity records; and NDE equipment and consumables certification records, for the personnel and materials involved in the replacement as indicated below.
With regard to the Weld Data Reports examined, a number of minor data errors were noted related to equipment identification and welding filler material heat numbers.
Welders GJ HF C2 NJ G19 GF G48 G14 A48 C39 A5 A10 G4 A43
Wel ding Fi 1 1 er Mater ial E-7018 E-7018 E-9018-B3 E-9018-B3 E-9018-B3 ER-70S-6 ER-70S-6 ER-905-B3 ER-905-B3 3/32" 3/32"
'1/8" 3/32" 3/32" 1/8" 3/32" I/8ll 3/32 II 34934 34945 432T1431 411T6781 89046 52386 B12995 G66766 F61757 KD RT-II PM RT-II HE RT-II BW RT-II DP VT,HT-II GL VT-II TB VT-II GSL HT-II RC PT-II NDE Examiners DO RT-I I I MH RT-II LH RT-T VS RT-II JKH PT,NT-II-JM PT,VT-II DW HT-II DH HT-II CA NT-III SJ RT-II JK RT-T EB RT-II WR PT,VT-II SJ HT) PT~VT II AB PT VT-II TD MT-II RS MT-II Penetrant Materials Penetrant:
90H03K 90L02K Cleaner/Remover:
92C02K Developer:
92J05K 92E02K Thermometers S/N:
HR 92-05 MT Yokes CT-14811 423 Dry Powder Nagnaflux 8A Red:
88L063 Ten Lbs. Test Weights SRO-MT-001 I
The inspector reviewed the radiographic film packages for the AF system replacement welds listed below.
The film was reviewed for both acceptance and film qualit Meld Radiographs Reviewed 1-AF-17-01-FW-1'-AF-17-01-FW-2 1-AF-17-01-FW-3 1-AF-17-01-FW-4
'he Radiographic NDE Report for weld 1-AF-17-Ol-FW-1 erroneously indicated that a
No
Image guality Indicator ( I(I) was used when in point of fact the appropriate No
I(I was actually used.
The licensee indicated that they would make the necessary changes to the records.
The inspector reviewed records for the AF system pressure test performed to satisfy the requirements of ASHE B&PV Code paragraph IWA-5214 as permitted by ASHE B&PV Section XI Case N-416.
The inspector determined that the AF system pipe and'itting replacements were made by properly qualified welders using certified welding filler material in accordance with qualified welding procedure specifications, and examined and tested in accordance with appropriate procedures by qualified personnel..
(2)
Auxiliary Feedwater System Baseline Data The inspector reviewed the Preservice 'Inspection baseline HT and UT examination reports for the welds listed below:
NT Examination Reports Examined 1-AF-2-01-FW-1 1-AF-2-01-FW-3 1-AF-2-01-FW-5 1-AF-2-01-FW-7 1-AF-2-01-FW-23 1-AF-2-01-FW-26 I-AF-2-01-FW-18 1-AF-01-FW-2 1-AF-01-FW-4 1-AF-01-FW-6 1-AF-01-FW-22 1-AF-01-FW-24 1-AF-01-FW-17 I-AF-01-FW-19 UT Examination Reports Examined 1-AF-17-01-FW-1 1-AF-17-01-FW-3 (3)
System Leakage Test 1-AF-17-01-FW-2 1-AF-17--01-FW-4 The inspector reviewed records attesting to the accomplishment of the system leakage test on the Class 1 portion of the Chemical and Volume Control system (Item Nos B15.50 nd B15,70) to satisfy the requirements of ASME B&PV Code paragraph IWA-522 Records reflected the accomplishment of activities in accordance with procedural and regulatory requirements.
J With in the areas examined no deviations or violations were identified.
3.
Followup (92701)
a ~
(Closed)
Unresolved Item 400/89-31-01:
"Visual Examination of Snubbers" b.
This item concerns the intent of the Technical Specifications (TSs)
as implemented by proc'edure PLP-106, related to the inspection of snubbers.
This item was examined during the inspection documented in NRC Inspection Report 50-400/92-24.
At that time, this item was left open pending NRC review of the operability of support MS-H-345.
This inspector reviewed the licensee's calculations supporting the operability of support HS-H-345.
The inspector concurs with the licensee's determination of operability.
This matter is considered closed.
r NRC Generic Letter (GL) 89-08:
"Erosion/Corrosion-Induced Pipe Wall Thinning" The licensee has established a Flow Accelerated Corrosion (FAC)
inspection program which uses the CHECHATE EPRI (Electric Power Research Institute)
computer code, industry experience, and previous inspection data as predictive tools for the determining and prioritizing inspection locations, The licensee's procedure for performing UT thickness examinations of carbon steel piping is approved by the management review committee defined in Section 6.0 of the licensee's Technicial The licensee's CHECHATE~ electronic model includes the systems that have been predicted to be susceptible to FAC, which ranks the systems components according to their FAC susceptibility.
The licensee's primary basis for the selection of components for ultrasonic (UT) examination during the next refueling outage is the results of'redictive analyses.
In addition to the results of predictive analyses the licensee uses:
the results of previous UT examinations including sample expansion points; engineering judgement, including plant specific design characteristics; and industry and operating experience.
The licensee has criteria for excluding a system from the FAC program.
The licensee's FAC pro'gram includes the following systems:
Feedwater; Condensate; Steam Generator Blowdown; Feedwater Heater Drains; Hoisture Separator Drains; Hoisture Separator Reheater Drains; Extraction Steam; Steam Generator Blowdown; Hain Steam,'ain Steam Drains; Auxiliary Steam; Auxi'liary Feedwater Pump Supply; Crossover and Crossunder piping.
Components in the licensee's program include: control/check valves; tees and branches; expanders and reducers; flow nozzles and orifices; exit nozzles; elbows and reducing elbows; and steam trap Specifications.
The licensee's procedures define the method for the following:
performing UT measurements; grid marking the inspection zone; ensuring location repeatability on followup UT examinations; ensuring certified UT examiners perform the examinations; and establishing acceptance criteria for evaluating UT data.
The, licensee has no documented guidelines for analyzing results of UT measurements, The licensee uses hoop stress calculations and system stress analysis data when available to establish minimum wall thickness (t ) requirements for both safety-related (SR)
and Balance of Plant (BOP) piping.
The point to point method is used to calculate wear rate (wr).
The predicted thickness (t,)=[t,,~-(wr x current operating cycle time)] for previously measured components and t,=[t,;-(wrx total operating time to date)] for first time examined components.
Component acceptabil-ity at the next outage is determined by the following method:
t, > t. and tp p > t
-,.
Remaining life (rl)
calculations are not made by the licensee.
To date no repairs have been made to ASME Code class 1, 2, or 3 components identified by-the FAC program.
Replacement of ASME Code class 1, 2, or 3 components identified by the FAC program are being accomplished in accordance with ASME B&PV Code Section XI Subsection IWA 7000.
The licensee has a repair and replacement program for BOP components which fail to meet the licensee's FAC acceptance criteria.
It should be noted that the program is not contained in a single document.
Welding and NDE of SR and BOP piping replacements are being accomplished by qualified personnel and suitable procedures.
The Site Inservice Inspection Department is responsible for the implementation of the FAC program.
The licensee has not assigned the responsibility for oversight of the FAC program.
A self assessment was performed in September 1992 and an audit of the FAC program is scheduled for spring 1993.
The licensee's FAC program is covered by their Quality Assurance (QA) program.
The licensee currently does not use the T-Dat portion of the CHECMATE~ program and therefor misses out on the iterative benefits of the built into the program.
The licensee indicted that they intend to implement T-Dat prior to RF05.
The calculations used in the program are not proceduralized.
The remaining life of components is not calculated.
This calculation if done would provide an effective means to schedule reinspection of components to achieve maximized results.
Notwithstanding the above the licensee has established an apparently effective program to maintain high energy carbon steel piping systems within acceptable wall thickness limit c ~
"Rapid Flow-Induced Erosion/Corrosion of Feedwater Piping" NRC Information Notice (IN) 92-07, dated January 9,
1992 documented a pipe wall thinning condition identified in Auxiliary Feedwater'AF)
system preheater bypass piping at Catawba Unit 2.
Although some wall thinning was predicted at Harris, in the AF system, by the CHECMATE code applied to the Harris electronic model, the thinning rate was relatively low.
Notwithstanding, the licensee elected to volumetrically examine a portion of the safety related AF system in locations similar to those identified in IN 92-07.
The examinations identified apparent FAC wall thinning rates approximately double the rates predicted by CHECMATE.
The licensee expanded the areas of the examinations, to determine the extent of, the wall thinning.
The expansion carried over into the BOP Feedwater (FW) system.
In the end, the licensee replaced 47 fittings and 233'f piping.
The licensee conducted an investigation to determine why the accelerated thinning rate occurred, why the CHECMATE code apparently failed to predict the accelerated thinning rate, and what could be done to prevent a recurrence.
This investigation included analysis by CPRL engineering and metallurgical personnel as well as EPRI.
Corrective action included pipe and fitting replacement and material upgrade in some cases.
The licensee established a
FAC Task Force.
Sections of all three trains of schedule 120 carbon steel FW system piping from the AF/FW split to the first isolation valves were upgraded with 2j Cr I Mo material, and the excessively thinned material in the schedule 80 carbon steel AF system.both inside and outside of containment, was replaced with like material (carbon steel).
EPRI determined that the licensee had modeled the AF and FW systems lines properly.
In the modeling of piping systems, the licensee assumed the initial material wall thickness to be the nominal thickness as indicated by the material specification.
EPRI, in their evaluation, postulated that the wall thickness of some the material at installation, was in actuality close to the material specification wall thickness minimum of 87j% of nominal wall.
This would explain the apparent under estimate by 50% of the FAC rate.
The licensee has taken appropriate actions in response to this Notice.
Within the areas examined, no violations or deviations were identifie Exit Interview The inspection scope and results were summarized o'n January 15, 1993, with those per sons indicated in paragraph 1.
The inspector described the areas inspected.
Although reviewed during this inspection, proprietary information is not contained in this report.
Dissenting comments were not received from the licensee.
Acronyms and Initialisms AF ASME BOP BE(PV CP5L EPRI FAC GL ID IQI ISI IN MT NDE No.
NPF NRC P.E.
, RIrl RT SR SRI mlfr Tpred TS UT VT wr WPS gineers the next fuel cycle Auxiliary Feedwater System American Society of Mechanical En Balance of Plant Boiler and Pressure Vessel Carolina Power and Light Electric Power Research Institute Flow Accelerated Corrosion NRC Generic Letter Identification Image Quality Indicator Inservice Inspection NRC Information Notice Magnetic Particle Nondestructive Examination Number Nuclear Power Facility Nuclear Regulatory Commission Professional Engineer Procedure Qualification Record Liquid Penetrant Quality Assurance Revision Resident Inspector Remaining Life Radiography Safety Related Senior Resident Inspector Code Minimum Thickness Predicted Thickness at the end of Technicial Specification Ultrasonic Visual Wear Rate Welding Procedure Specification