IR 05000400/1994009
| ML18011A427 | |
| Person / Time | |
|---|---|
| Site: | Harris  |
| Issue date: | 05/02/1994 |
| From: | Blake J, Kleinsorge W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML18011A426 | List: |
| References | |
| 50-400-94-09, 50-400-94-9, NUDOCS 9405160186 | |
| Download: ML18011A427 (13) | |
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UNITED STATES NUCLEAR REGULATORY COMMISSION
REGION II
101 MARIETTASTREET, N.W., SUITE 2900 ATLANTA,GEORGIA 303234199 Report Nos.:
50-400/94-09 Licensee:
Carolina Power and Li'ght Company P. 0.
Box 1551 Raleigh, NC 27602 Docket Nos.:
50-400 Facility Name:
Harris
Inspection Conduct'
'-
,
1994 License Nos.:
NPF-63 Inspector:
einsor P
Inspecto te Sig ed Approved by:
J ome
. Blake, Chief ater al and Process Section Engineering Branch Division of Reactor Safety
Date Signed SUMMARY Scope:
This routine, announced inspection was conducted in the areas of inservice inspection and erosion corrosion (E/C) induced wall thinning.
Results:
In each of the areas examined, the inspector discovered that nondestructive test (NDE) examiners have conducted conservative examinations in accordance with the appropriate test procedures.
NDE procedures were also noted to be appropriate to the circumstances.'upervisors, engineers, and NDE examiners contacted during this inspection were very knowledgeable in their areas of responsibility.
ISI records reflect the accomplishment of ISI activities consistent with procedural and regulatory requirements.
The licensee E/C program continues to maintain high energy carbon steel piping systems within acceptable wall thickness limits.
In the areas inspected, no violations or deviations were identified.
9405l60186 940505 PDR ADOCK 05000400 Q
REPORT DETAILS Persons Contacted Licensee Employees
- R. German, Manager Plant Support Services
- W. Harris, Harris Vice President
- M. Hill, Manager Management
& Organization
- W. Mercer, NDE Technician, ISI-NDE Unit
- R. Prunty, Manager Licensing
- G. Rolfson, Manager Nuclear Engineering Department
- G. Sinders, Director Nuclear Regulatory Issues
- G. Tucker, ISI M. Wallice, Regulatory Compliance Other licensee employees contacted during this inspection included craftsmen, engineers, technicians, and administrative personnel.
NRC Resident Inspectors
"J. Tedrow, Senior Resident Inspector (SRI)
D. Roberts, Resident Inspector (RI)
- Attended exit interview Acronyms and initialisms used throughout this report are listed in the last paragraph.
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 is ASME BEPV Section XI, 1983 Edition with Addenda through Summer 1983 (83S83).
The plant has complet-ed the fifth fuel cycle, and is in the third outage of the second
month period, of the first ten year ISI interval (II,P2,03).
The plant received its operating license January 12, 1987 and commenced commercial operations on May 2, 1987.
The licensee has contracted with Nuclear Energy Services Inc (NES) to perform liquid penetrant (PT), magnetic particle (MT), and ultrasonic (UT) examinations under the umbrella of CP8L Quality Assurance (QA) program.
a.
ISI Program Review, (73051).
The inspector reviewed the following documents relating to the ISI program to determine whether the plan had been approved by the licensee and to assure that procedures and plans had been estab-lished for the applicable activities.
Documents were reviewed for technical conten ID Procedures Reviewed Revision T-itle CP&L-ISI-100 4 w/Ch Control of Inservice Inspection Activ-4/1 ities 12/10/93 Inspection Plan NRC Inspection Report 50-400/92-24, for an October 1992 inspection identified the following:
The "ISI Component Listing and Ten Year Plan" is a computer data base, the PRISIH (Programmed Inservice Inspection Management)
system.
The original data base was the CP&L Ten Year Program Plan.ISI submitted to the NRC.
This data base has been changed a number of times since the programs inception, howev-er, no records exist describing the changes, the basis for those changes, when those changes were made, or who approved those chang-es.
Procedure CP&L-ISI-100 requires that changes to PRISIH be controlled but does not specify how.that is to be accomplished.
The licensee indicated that they would compare the current data with the original submittal to assure that PRISIH is still in compliance with ASME B&PV Code Section XI.
To date the licensee has ammended CP&L-ISI-100 to establish a more definitive change control system for PRISIM, but the data comparison indicated by the licensee in October 1992 has not been completed.
The inspection plan was appropriate to the circumstances.
b.
Review oF NDE Procedures, (73052)
The inspector reviewed the procedures listed below to determine whether these procedures were consistent with regulatory require-ments and licensee commitments.
The pr'ocedures were also reviewed for technical content.
ID Procedures Reviewed Revision Title ISI-400T ISI-401T ISI-404T 0/ACO PSI/ISI Examination Areas and Volumes (NES-83A0283 R1)
Ultrasonic Examination of Studs and Bolting (High Gain Technique)
(NES-83A0286 R1)
Ultrasonic Examination of Piping Sys-tems for Shearon Harris Nuclear Power Plant (NES-83A6013 R2)
ID Procedures Reviewed Revision Title ISI-405T IS I-406T ISI-407T ISI-408T ISI-409T',
ISI-410T Hagnetic Particle Examination for Shearon Harris Nuclear Power, Plant (NES-83A6113 R3)
Ultrasonic Instrument Linearity Veri-fication (NES-80A9053 R9)
Liquid Penetrant Examination (NES-83A6103 R1)
Calibration of Hagnetic Particle Exam-ination Equipment (NES-80A9054 R5)
Calibration of Thermometers (NES-80A9055 R5)
Procedure for Certifying Nondestruc-tive Examination Personnel (NES-80A9068 R10)
The procedures were appropriate for their application.
Observation of Work and Work Activities, (73753)
The inspector observed work activities, reviewed certification records of NDE equipment and materials, and reviewed NDE personnel qualifications for personnel who had been utilized in the ISI examinations during this outage.
The observations and reviews conducted by the inspector are documented below.
Activities Observed Liquid Penetrant Examination (PT)
.The inspector observed PT examinations of the weld listed below.
The observations were compared with the applicable procedures and the Code.
The inspector performed an independent evaluation of the indications obtained to confirm the NDE examiner's evaluation.
Liquid Penetrant Examinations Observed Weld No.
System I-CS-FW-220 Chemical and Volume Control The PT examiner appropriately rejected the weld for inadequate preparatio The inspector reviewed. the certification documentation for the PT cleaner, penetrant and developer.
The inspector reviewed the certification, qualification, and visual acuity documentation for the PT examiners (See paragraph 2.d below).
The partial examination was performed satisfactorily.
Nagnetic Particle (NT) Examination The inspector observed NT examinations of the weld listed below.
The observations were compared with the applicable procedures and the Code.
The inspector performed an independent evaluation of the indications obtained to confirm the NDE examiner's evaluation.
Hagnetic Particle Examinations Observed Weld No.
System 1-FW-FW-J5 Feedwater The inspector reviewed the certification documentation for the HT powder, the yoke, and the 10 Lbs. test weight (See Paragraph 2.d below).
The inspector reviewed the certification, qualification, and visual acuity documentation for the NT examiners (See paragraph 2.d below).
The examination was performed satisfactorily.
Ultrasonic (UT) Examination The inspector observed UT examinations of the welds listed below.
The observations were compared with the applicable procedures and the Code.
The inspector performed an independent evaluation of the indications obtained to confirm the NDE examiner's evaluation.
U1trasonic Examinations Observed Weld No.
System 1-AF-FW-248 1-AF-FW-247*
1-AF-FW-246*
1-AF-FW-245*
1-AF-SW-A3*
Auxiliary Feedwater Auxiliary Feedwater Auxiliary Feedwater Auxiliary Feedwater Auxiliary Feedwater The UT examiners appropriately rejected the welds marked with an asterisk (*) for inadequate preparatio The inspector reviewed the certification documentation for the UT instruments, transducers, and couplant (See paragraph 2.d below).
The inspector reviewed the certification, qualification, and visual acuity documentation for the UT examiners (See paragraph 2.d below).
The examinations were performed satisfactorily.
The inspector made a number trips into the containment building with NDE examiners to observe NDE examinations (PT, HT, and UT) in prog-ress.
During these trips the examiners repeatedly rejected welds scheduled for examination due to inadequate surface preparation or inadequate scaffolding.
The lack of scaffolding would have necessi-tated the examiners, to climb or stand on small bore piping or snubbers, in'order to accomplish the examinations.
This climbing or standing has the distinct potential of damage to important plant equipment.
The preceding demonstrates both a strength and a weak-ness.
A strength for the NDE examiners, in that they were assuring high quality examinations without damaging important plant equip-ment.
The weakness is in the area of communications between the ISI organization and the groups responsible for examination area prepa-ration.and scaffold building, in that there were multiple examples of inadequate examination area preparation and scaffolding.
Repair and Replacement The inspector observed repair and replacement activities associated with the Auxiliary Feedwater (AF) system,- which is discussed further in paragraph 3 below.
d.
Data Review and Evaluation Unit
(73755)
The inspector reviewed completed ISI examination records and the supporting certification for:
examiner qualification, certification and visual acuity; PT cleaner, penetrant and developer; HT powder, yokes and 10 Lbs. test weights; and UT instruments, transducers, and couplant.
The inspector also reviewed baseline data of the welds to determine whether the indications were previously recorded and if so, were there any noticeable differences in the recorded informa-tion.
Records for the following welds and the supporting data were reviewed:
Examination Records Examined Exam Item Iso)Drawing No System Hethod 1-BD-FW-2 1-IS I-BD-1 1-CT-FW-2 1-ISI-CT-2 I-CS-FW-219 1-ISI-CS-1 Blowdown Chemical and Volume Control Containment Spray HT PT PT
Examination Records Examined Exam Item Iso)Drawing No System method 1-CT-FW-2 1-CT-FW-2 1-CT-FW-2 1-ISI-CT-2 1-IS I-CT-2 1-ISI-CT-2 1-CT-FW-80A, 1-ISI-CT-7 1-CT-FW-80B 1-CT-SW-F3 1-ISI-CT-7 1-ISI-SI-9 1-FW-FW-485 1-IS I - FW-HS-RC-3 1-CT-SW-F3A-1-ISI-SI-9 Containment Spray Containment Spray Containment Spray Containment Spray Containment Spray Containment Spray Containment Spray Feedwater PT PT'T PT PT PT PT UT 1-FW-FW-491 1-ISI-FW-HS-RC-2 Feedwater UT 1-FW-FW-497 1-FW-SW-G10 I-IS I-FW-HS-RC-I Feedwater I - IS I - FW-HS-RC-I Feedwater UT MT I-HS-SW-f3 I-MS-SW-E3A I-ISI-FW-HS-RC-I Hain Steam I-ISI-FW-HS-RC-I Hain Steam I-ISI-FW-NS-RC-I Hain Steam I-HS-SW-E3B 1-RC-SW-A5 1-ISI-SI-26 1-ISI-SI-26 1-ISI-SI-25 1-ISI-SI-25 1-ISI-SI-25 1-ISI-RH-4
Reactor Coolant Reactor Coolant
- Reactor Coolant Reactor Coolant Reactor Coolant 1-RC-SW-A6 1-RC-SW-J3 1-RC-SW-J4 1-RC-SW-J5 Heat Removal 1-RH-FW-66 Residual Residual Residual Residual Residual Residual Residual Residual Residual Residual Heat Removal 1-RH-FW-66A 1-ISI-RH-4 Heat Removal 1-ISI-RH-2 1-RH-SW-E3 Heat Removal 1-RH-SW-E3A 1-IS I -RH-2 1-RH-SW-E3B 1-IS I-RH-2 1-RH-SW-E3C 1-IS I-RH-2 1-RH-SW-EB
.
1-ISI-RH-2 1-RH-SW-EBA 1-IS I-RH-2 Heat Removal Heat Removal Heat Removal Heat Removal Heat Removal 1-RH-SW-L3 1-RH-SW-L3A 1-ISI-RH-2 1-IS I-RH-2 Heat Removal 1-FW-SW-G10 I-IS I-FW-HS-RC-I Feedwater UT UT UT UT UT UT PT PT PT PT PT PT PT'T PT PT
Exam Item Examination Records Examined Iso(Drawing No
, System Method 1-RH-SW-M6 1-ISI-SI-8 Residual Heat Removal PT 1-RH-SW-M6B 1-ISI-SI-8 1-SI-FW-284 1-ISI-SI-9 1-RH-SW-M6A 1-ISI-SI-8 Residual Heat Removal PT Residual Heat Removal PT Safety Injection PT gualification, Certification, and Yisual Acuity Records'xamined Examiner.
Method-Level CAF SPW BS ASB HDH PT-II I PT-I I PT-I I PT-II HT-I I I MT-I I MT-II HT-II UT-III UT-1 UT-II UT-II UT-II UT-I IT NDE Equipment and Consumables Records Examined Equipment/Consumables Serial No/ Heat No./ -Lot No./
Batch No.
PT Cleaner PT Developer PT Penetrant HT Red No.
8 Powder MT 10 LBS. Test Weight MT Yoke UT Instrument UT Transducer UT Couplant Thermometers 92C02K 92E02K 90L02K 88L063 and 92G027 SRO-HT-001 423 1009L, 1010L and 1011L 031243, J09185, D10970 3026, E18404, E26683)
B07680, H12411, C31627, 2211-89002, 092121 and 9092 94-23, 94-24, 94-25 and CT.-
834 Records support examinations conducted in accordance with applicable procedures and regulatory commitments.
Within the areas examined no violations or deviations were identifie.
Followup (92701)
(49001)
NRC Generic Letter (GL) 89-08:
- "Erosion/Corrosion-Induced Pipe Wall Thinning"
'This GL requested licensees to provide assurances that a long term Erosion/Corrosion (E/C) monitoring program, has been established to ensure that E/C does not lead to degradation of carbon steel piping in single and two phase high energy piping systems.
The licensee has established an E/C inspection program which uses the CHECMATE EPRI (Electric Power Research-Institute)
computer program, industry experience, and previous inspection data as predictive tools for determining and prioritizing inspection locations.
The licensee has received but not implemented EPRI's latest E/C software package CHECK WORKS.
Observations/Findings The inspection sample is selected on an outage by outage basis, based on the data from previous outages.
The licensee has tested approximately 214 test locations during Refueling Outage 5 (RF05).
These examinations resulted in the replacement of three pipe sections and four fittings and the repair to a fifth fitting in the balance of plant systems.
In addition the licensee replaced approximately 200 feet of pipe and ten fittings, (an eleventh fitting was repaired),
in the safety related AF system.
To evaluate the licensee's implementation of the E/C program the inspec-tor interviewed licensee and contractor personnel, reviewed procedures and records, and observed repair activities.
Procedures Reviewed ID CP&L-IS I -107 CPKL-NDEP-427 CPKL-NDEP-1012 Revision
0 IC1 Title HNP Flow Accelerated Corrosion (FAC) Moni-toring Program Digital Ultrasonic Thickness Measurement (Panametrics Model 26DL Plus)
For Erosion/Corrosion Detection and Monitoring Gridding Of Components For Erosion/Corrosion The licensee identified 22 examination locations as Category 1, the most critical of the 214 FAC locations examined.
The inspector reviewed the examination data and the engineering evaluations for those 22 locations, as indicated belo Component ID Category I
System Size FAC Locations Type No. Times Disposition Examined ES074-011E ES073-013 ES070-013 ES070-004 ES072-009 ES074-011 HD124-005 HV033-004 HV029-009 HV033-008 Extraction Steam Extraction Steam Extraction Steam Extraction Steam Extraction Steam Extraction Steam Heater Drain Heater Vent Heater Vent Heater Vent ES070-006 ES069-006 ES074-003 HD169-007 HD170-014 HD204-013 HV076-001 Extraction Steam Extraction Steam Extraction Steam Heater Drain Heater Drain Heater Drain Heater Vent BD058-006 Blowdown 2pn Ipn 20" 2pn 12n
II 12n 2n 1)n 2 II
II 2pn 2pn 12n Ipn 1pn
II 2nx3 n
90'lbow 45'lbow 45'lbow 90'lbow 90'lbow Pipe 90'lbow Pipe Pipe Pipe 90'lbow 45'lbow 90'lbow 90'lbow 45'lbow 90'lbow 90'lbow 90'lbow Repair Replace Replace Replace Replace Acceptable Repair Replace Replace Replace Acceptable Acceptable Acceptable Acceptable Acceptable Acceptable Acceptable Acceptable
Component ID Category I
FAC Locations System Size Type No. Times Disposition Examined HV077-006 Heater.
Vent 3"
Pipe Acceptable HD169-002 ES075-006 Heater Drain Extraction Steam 10" 90'lbow 12" 45'lbow HV093-007 Heater 3"
45'entElbow Acceptable Acceptable Acceptable In addition to the balance of plant repairs and replacements listed above, the licensee made a repair to one elbow, installed one 6" x 4" tee, nine 90'lbows, and approximately 200 feet of pipe, with 40 butt welds which, are to be radiographically examined, in the safety related AF system.
The inspector observed the radiographic examination of the weld repair to the elbow, and welding activities associated with welds 1-AF-1-02-4 and 1-AF-1-02-1.
In addition the inspector visually inspected welds 1-AF-1-2-5, 1-AF-1-2-6, and 1-AF-1-2-8.
The inspector reviewed the welder qualification certification documentation, certified material test reports (CMTRs),
and welding procedure specifications (WPSs)
and their associated procedure qualification test records (P(Rs), for the welders, materials, and procedures employed to make the welds listed above.
The documents were reviewed for compliance with licensee procedures and sections II, IX and XI to the ASME'EPV Code.
Welding Filler Material CMTRs Examined Type Size Heat/Lot No.
ER-90S-.B3 1/8" G9893 E-9018-B3 3/32" 92166 E-309 1/8" 6011E-11A 8E-309 3/32" 50296-1 ER-309 1/8" 1831616 Welder's gualification Certification Documentation Examined GJ, G-85, G-45, G-14, C-2
WPS WPS-05-3-35 WPS-05-3-03 WPSs Examined PQR 240 241 The welds were made by properly qualified and certified welders, using appropriate welding materials in accordance with properly qualified welding procedure specifications.
The remaining life of components was not calculated, This calculation, if done, would provide an effective means to schedule the reinspection of components to achieve maximized results.
It appears that the licensee has established and continues to implement an effective program to maintain high energy carbon steel piping systems within Code allowable wall thickness limits.
Within the areas examined no violations or deviations were identified.
Exit Interview The inspection scope and results were summarized on April 8, 1994, 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.
Dissenting comments were not received from the licensee.
5.
Acronyms and Initialisms AF ASHE BKPV BD BOP CHTR CP&L CS CT E/C EPRI ES FAC FW FW GL HD HNP HV ID Auxiliary Feedwater System American Society of Hechanical Engineers Boiler and Pressure Vessel Blowdown System Balance of Plant Certified Haterial Test Report Carolina Power and Light Chemical and Volume Control System Containment Spray System Erosion Corrosion Electric Power Research Institute Extraction Steam System Flow Accelerated Corrosion Field Weld Feedwater NRC Generic Letter Heater Drain System Harris Nuclear Plant Heater Vent System Identification
NPF NRC P.E, PgR PT gA R
RC RFO RH RI SC SI SRI SW UT WPS Inservice Inspection Main Steam System Magnetic Particle North Carolina Nondestructive Examination
.
Nuclear Energy Services Number Nuclear Power Facility Nuclear Regulatory Commission Pr'ofessional Engineer Procedure gualification Record Liquid Penetrant guality Assurance Revision Reactor Coolant System Refueling Outage Residual Heat Removal System Resident Inspector South'Carolina Safety Injection System Senior Resident Inspector Shop Weld Ultrasonic Welding Procedure Specification