IR 05000413/1986034
| ML20215H033 | |
| Person / Time | |
|---|---|
| Site: | Catawba  |
| Issue date: | 10/02/1986 |
| From: | Blake J, Crowley B, Newsome R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML20215H031 | List: |
| References | |
| 50-413-86-34, 50-414-86-37, NUDOCS 8610210379 | |
| Download: ML20215H033 (18) | |
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NUCLEAR REGULATORY COMMISSION g'
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j 101 MARIETTA STREET.N.W.
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Report Nos.:
50-413/86-34 and 50-414/86-37 Licensee:
Duke Power Company
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422 South Church Street Charlotte, NC '28242 Docket Nos.:
50-413 and 50-414
- License Nos.:
NPF-35 and NPF-52 Facility'Name:. Catawba 1 and 2 Inspection-Conducted: September 8-12, 1986 Inspector :
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Crowley Date Signed l0 >
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ess e Date Signed
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' Approved by:
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J. J/ Blake, Section Chief Date. Signed g(neering Branch ivision of Reactor Safety
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SUMMARY Scope:
This routine, unannounced-inspection was conducted in the areas of inservice inspection (ISI) (Units 1_ and 2) and maintenance / modification welding and nondestructive examination (NDE) (Units 1 and 2).
Results:
No violations or deviations were identified.
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P REPORT DETAILS 1.
Persons Contacted
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t Licensee Employees
'J. W. Hampton, Station Manager J. W. Willis, Senior Quality Assurance (QA) Engineer
- F.
P. Schiffley, Licensing Engineer
- T. A. Bumgardner, ISI Coordinator
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R. G. Rouse, QA Specialist W. D. Cabe, Radiography. Supervisor, NDE P. J. Helton, QA Planning and Scheduling J. W. Huffstickler,. Welding Engineering Technician
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J. E. Cavender, NDE Level III Examiner
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Other licensee employees contacted included construction craftsmen, QC personnel, engineers, technicians, mechanics, security force members, and office personnel.
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Other Organization R. J. Patterson, Group Lender, ISI Babcock and Wilcox (B&W)
NRC Resident Inspectors
- P. K. VanDoorn, Senior Resident Inspector
- M. Lesser, Resident Inspector
- Attended exit interview 2.
Exit Interview The inspection scope and findings were summarized on September 12, 1986, with those persons indicated in the paragraph above.
The inspector described the areas inspected and discussed in detail the inspection
~ findings.
No dissenting comments were received from the licensee.
The following new items were identified during this inspection.
(0 pen) Inspector Followup Item 413/86-34-01, 414/86-37-01, Clarification of Responsibilities for Evaluation of ISI Results paragraph 5.a.
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(0 pen) Inspector Followup Item 413/86-34-02, 414/86-37-02, Liquid Penetrant Procedure NDE-98, Clarification of Controls for Procedure Implementation -
paragraph 5.b.
The licensee did not ident'ify as proprietary any of the materials provided to or reviewed by the inspectors during this-inspection.
i 3.
Licensee Action on Previous Enforcement Matters This subject was not addressed in the inspection.
4.
Unresolved Items Unresolved items were not identified during the inspection.
5.
Inservice Inspection (ISI)
The inspectors examined documents, activities, and records as indicated below to determine whether ISI was being conducted in accordance with
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applicable procedures, regulatory requirements and licensee commitments.
The applicable code for ISI is American Society of Mechanical Engineers Boiler and Pressure Vessel (ASME B&PV) Code,Section XI,1980 edition with addenda through W81.
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The ISI was being performed under the Duke Power Company (DPC) ISI plan listed below.
DPC was responsible for performing all examinations except ultrasonic and eddy current, which were being performed by B&W.
a.
Inservice Inspection - Review of Program (73051) (Units 1 and 2)
The inspectors reviewed the following ISI program documents:
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Inservice Inspection Plan, Catawba Nuclear Station Units 1 and 2, Revision 2, Volumes 1 and 2 Procedure QCL
.5, Revision 5, Control of Preservice and Inservice
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Inspection Activities j
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QA Department Quality Assurance Program, Revision 84
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Procedure QA-100, Revision 9, Preparation and Issue of Quality Assurance Procedures
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Procedure QA-113, Revision 14, Qualification and Training of Auditors
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Procedure QA-132, Revision 0,
Qualification and Training of Operations Division Surveillance Personnel
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Procedure 9A-140, Revision 12, Quality Assurance Inspector Training
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Procedure NDE-A, ' Revision 7, Nondestructive Examination Program Procedures
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Procedure NDE-B, Revision 11, Training, Qualification and Certification of NDE Personnel
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Procedure QA 160, Revision.2, Performance of Corporate Quality Assurance Audits
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Procedure QA 210, Revision 19, Departmental Audit Procedure
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Procedure QA 230, Revision 10, Departmental Audit Scheduling and Followup
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Procedure QCK-1, Revision 13, Control of Nonconforming Items The documents were reviewed in the areas of:
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Use of an authorized nuclear inservice inspector (ANII) and approval of plan and procedures by the ANII
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Review and approval of the ISI plan and procedures
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Identification of commitments and regulatory requirements
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Procedures for preparing plans and schedules and filing with
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enforcement and regulatory authorities
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-Sufficient organizational staff to ensure performance of acceptable ISI work
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Site administrative procedures to define authorities and responsibilities for final evaluation and acceptance of ISI results
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QA review including assurance that plans and procedures have been reviewed by appropriate personnel and met regulatory requirements
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Establishment of procedures for corrective action
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Procedures for auditing ISI activities by qualified QA personnel During review of the above documents, the inspectors noted that
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authorities and responsibilities were not clearly defined for evaluation and acceptence of ISI results. An examole of an area where more detail is needed is for pipe supports. When pipe support problems are found that require corrective action, ASME Section XI, IWF-2000, requires that the scope of inspection be increased and that the problem support be reinspected during the next period.
The program does not define how these requirements are to be implemented or who is responsible.
The licensee pointed out that procedure QA-516 had been
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~ drafted, but.not yet issued' to more clearly cover the area in question.
Pending issue and review of procedure QA-516, Inspector Followup Item 413/86-34-01, 414/86-37-01, Clarification of Responsibilities for Evaluation of ISI Results, is identified.
b.
Review of Procedures (73052) (Units 1.and 2)
(1) The following procedures were reviewed in the areas of procedure i
approval and qualification of NDE personnel:
Procedure ID Title t
(Duke) NDE-35 R7 Liquid Penetrant Examination Technique (Color Contrast, Solvent Removable Method) for pre-service and inservice inspection (Duke) NDE-98 R3 Liquid Penetrant Examination Technique (Color Contrast, Solvent Removable Method) for pre-service and inservice inspection (1980)
(Duke) NDE-25 R8 Magnetic. Particle Inspection Technique (Yoke Method)
for preservice and inservice inspection (1980)
(Duke) NDE-26 R8 Wet Non-Fluorescent and Fluorescent Magnetic Particle Examination Techniques for Examination of Pressure Retaining Bolting (B&W) ISI-1 R6 Administrative Procedure for Control of Inservice Inspection Procedures and Procedure Qualifications (B&W) ISI-120 R25 Ultrasonic Examination of Piping and Vessel Welds Joining Similar and Dissimilar Materials (B&W) 151-104 R24 Ultrasonic Examination of Threads In Flanges and of Studs and Bolts (Duke) NDE-12 R5 General Radiography Procedure for Preservice and Inservice Inspection (Duke) NDE-44 R6 Ultrasonic Examination of Bolts, Studs, Bushings, and Threads in Flanges for Preservice and Inservice Inspection
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s (B&W) ISI-423 R9 Multifrequency Eddy Current Examination of.750' OD X. 044" wall RSG Tubing In Westinghouse Steam Generators (B&W)'ISI-424 R8 Multifrequency Eddy Current ' Examination of.750' OD X.044" wall RSG Tubing In Westinghouse Steam Generators for Detection of Tube Wear at Support Plates (Duke) QCL-13,R4 ISI Visual Examination, VT-1 (Duke) QCL-14,R6 ISI Visual Examination, VT-4 (Duke) QCL-15,R3 ISI Visual Examination, VT-2 (2) The inspectr>rs reviewed the ultrasonic procedures to ascertain whether they had been reviewed and approved in accordance with the licensee's established QA procedures. The. above procedure were reviewed for technical adequacy and conformance with ASME,Section V, Article 5 and other license commitments / requirements in the below listed areas:
type of apparatus used; extent of
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coverage of weldment; calibration requirements; search units; beam
. angles; DAC curves; reference level for monitoring disconti-nuities; method of demonstration of penetration; limits for evaluating and recording indications; recording significant indications and; acceptance limits.
(3) The inspectors reviewed the eddy current procedures for technical content relative to multichannel examination unit, multichannel examination indication equipment is specified, maximum examination sensitivity, material permeability, method of examination, method of calibration and calibration sequence, and acceptance criteria.
(4) The inspectors reviewed the liquid penetrant procedures to ascertain whether they had been reviewed and approved in accordance with the licensee's established' QA procedures.
The above procedures were reviewed for technical adequacy and conformance with ASME,Section V, Article 6, and other licensee commitment / requirements in the below listed areas:
specified method; penetrant materials identified; penetrant materials analyzed for sulfur; penetrant materials analyzed for total halogens; acceptable pre-examination surface; drying time; method of penetrant application; surface temperature; solvent removal; dry surface prior to developing; typed of developing; examination technique; and evaluation technique.
Liquid penetrant procedure NDE-98 is a special examination procedure that allows an abbreviated penetrant dwell time and an
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abbreviated development time prior to evaluation. This procedure may be used in areas where the radiation background level exceeds 100 MR/ hour or for other areas and locations when specifically
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specified by management or NDE Level III personnel.
The inspectors questions the use of this abbreviated procedure for those areas where the only requirement for implementation is that the background radiation area exceeds 100MR/ hour. There are many areas where the radiation level might allow the use of this procedure when the normal liquid penetrant procedure could be used by having personnel exit the high radiation. area while the liquid penetrant dwell and the development wait times are. allowed to
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terminate. Discussions with the licensee regarding this concern indicated that this procedure is not used only because the background radiation level exceeds 10MR/ hour, but that other factors, such as access limitations, must also be a problem before the procedure is allowed to be used.
The inspectors pointed out that the procedure does not specify these additional controlling factors and that these controls should be included in the text of the procedure.
The licensee agreed to revise the procedure and further clarify when the procedure may be implemented.
Pending
issuance of the procedure revision and subsequent review by the a
NRC, this item-will be identified as Inspector Followup Item 413/86-34-02, 414/86-37-02.
Liquid ~ Penetrant Procedure NDE-98, Clarification of Controls for Procedure Implementation.
(6) Visual Inspection Procedures QCL-13, QCL-14 and QCL-15 were reviewed in the areas of:
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Agreement with licensee commitments
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Methods of recording, evaluating and disposition findings
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Technical content relative to: method direct visual, remote visual or translucent visual; how visual examination is to be performed; type of surface condition available; surface preparation, if any; whether direct or remote viewing is used; special illumination, instruments, or equipment to be
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used, if any; sequence of performing examination, when applicable; data to be tabulated, if any; acceptance criteria is specified and consistent with the applicable code section or controlling specification; and report form completion.
c.
Observation of Work and Work Activities (73753) (Unit 1)
The inspectors observed work activities and reviewed certification records of equipment, materials, and NDE personnel which had been and will be utilized during the required ISI examinations during this outage. The reviews and observations conducted by the inspectors are documented below.
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(1) Examiner Qualification The inspectors reviewed the qualification documentation for the below listed B&W and Duke Power Company (DPC) examiners in the following areas: employer's name; person certified; activity qualified to perform; effective period of certifi-cation; signature of employer's designated representatives; basis used for certification; and annual visual acuity, color vision examination and periodic recertification.
Method - Level Exam'iner (B&W)
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(2) The inspectors observed the ultrasonic examinations and calibration activities for the ' welds indicated below.
The observations were compared with the applicable procedures and the Code in the following areas:
availability of and compliance with approved Nondestructive Examination (NDE)
procedure; use of knowledgeable NDE personnel; use of NDE personnel qualified to the proper level; type of apparatus used; extent of coverage of weldment; calibration requirements; search units; beam angles; DAC curyas;
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reference level for monitoring discontinuities; metho'd of demonstrating penetration; limits of evaluating and recording
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indications; recording significant indications and;
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acceptance limits.
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Weld / Component Description ~
Class
' Scans I.D.
INI24-15 6" SS Safety II 45 -circ &
Injection System axial 606-axial 1CF27-01 16" CS Main II 0*,45 -circ &
Feedwater to SGIA axial 60 -axial INC31-01 6" SS Reactor I
45 -circ &
Coolant System axial 60 -axial INC31-02 6" SS Reactor I
45 -cire &
Coolant System axial 60* axial 1RPV-Stud-04 RPV Stud
During the observation of in-process ultrasonic examinations, in order to evaluate the technical adequacy of the ultrasonic examination procedure being used and to confirm the information being reported by the examiners, the NRC inspectors utilized the ultrasonic equipment being used by the examiners and performed independent verification examinations on portions of welds 1NI24-15 and 1CF27-01.
Weld 1CF27-01 had exhibited several reportable indications during the examination, however, most of the indications could be attributed to internal geometry conditions.
Final evaluation and disposition of.the reported indications had not been completed at the end of this NRC inspection.
(3) The following listed ultrasonic equipment and materials certification records were reviewed:
Ultrasonic Instruments Manufacturer /Model Serial No.
KK/USK-7 27276-732 TokyoKeiki/SM100DG 1287 TokyoKeiki/SM100DG 1288 TokyoKeiki/SM1000G 1289 Ultrasonic Couplant-Sonotrace 40 Batch 8552
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Ultrasonic Transducers
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Size Frequency Serial'No.
.5" 1.5 MHZ F01576
.5" 1.5 MHZ F01578
.5" 2.5 MHZ K83293
.5" 5.0 MHZ K83300 1.0" 1.0 MHZ F15232
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Ultrasonic Calibration Blocks
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Identification No.
Heat No.
Material 50373 NX4862 Inconel 50356 6X11237 CS 50330 LO3933 CS 50329 L64237 CS 50316 J7289 SS 50307 M1416 SS 50311 74356 SS (4) The ' inspectors reviewed the below listed liquid penetrant materials certification records to ascertain if the sulfur and halogen content of the material was within acceptable content limits.
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Materials Batch Number Liquid Penetrant 78E084 Cleaner / Remover 84M067, 85C029
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Developer 83G033 (5) The inspectors observed magnetic particle examination of reactor pressure vessel stud 1RPV - Stud-04. The inspection was compared with applicable requirements to determine whether:
Approval procedures were available, were being followed and
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specified N0E equipment was being used Examination personnel were knowledgeable and had the proper
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level of qualification and certification Examination results were being recorded and evaluated
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Procedure requirements were being met in the areas of: type
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and color of particular, surface preparation, surface
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temperature, examination technique / coverage, current and evaluation and acceptance criteria.
The inspectors reviewed documentation indicating that lift tests had been performed on yokes with Serial Nos. CN0-31 and CNO-32.
Certification records for Batch 86D062, type 14AM fluorescent magnetic particle material were reviewed.
(6) The inspectors observed visual inspection of flanged pipe joint INC55-MJ1.
The inspection was compared with applicable require-ments to determine whether:
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Approval procedures were available, were being followed and specified NQE equipment was being used
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Examination personnel were knowledgeable and had the proper level of qualification and certification Examination results were being recorded and evaluated
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d.
Inservict Inspection, Data Review and Evaluation, (73755) (Unit 1)
(1) Records of completed nondestructive examinations were selected and reviewed to ascertain whether: the method, technique and extent of the examination complied with the ISI plan and applicable NDE procedures; findings were properly recorded and evaluated by qualified personnel; programmatic deviations were recorded as required; personnel, instruments, calibration blocks and NDE materials (penetrants, couplants) were designated.
Records selected for this review are tabulated below:
Item No.
Wold I.D.
Class NDE Method C05.021.223 1NI24-15 II UT B09.011.035 1NC27-02 I
- B09.011.200 1ND37-03 I
- B09.011.201 IND37-04 I
UT B09.011.310 INI149-03 I
- B09.011.336 INI166-09 I
- B09.011.337 1NI166-10 I
PT B09.011.035A INC27-2 I
PT B09.011.317A INI148-6 I
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B09.011.354A INI241-04 I
PT B09.021.001 INC40-2 I
PT CO2.011.001 1RHRA-W1 II PT C03.010.007 1RHRA-W5
~II PT C03.020.060 1R-SM-1577 II MT C05.011.010 1CA67-3 II MT C05.011.013 ICA67-7 II MT C05.011.017 1CA67-16 II.
MT C05.011.021 1CA68-05 II MT C05.011.024 1CA69-14 II MT C05.011.100 IFW12-03 II PT C05.011.150-IND1-01 II PT C05.011.153 1ND1-10 II PT C05.011.159 1N02-06 II PT
- The inspectors compared the preservice examination results with the current ISI examination results. No major discrepancies were noted.
(2) The inspectors discussed the results of the recently completed Steam Generator Tubing Eddy Current examinations with the licensee and reviewed a summary of the examination findings. A summary of the Eddy Current examination results is listed below:
Number of Tubes Steam Total Tubes Having Indications Generator Examined s20%
>20% to <40%
s40%
A 534
1
8 522
0
C 526
0
4
521
0
The total numbers of tubes in each steam generator is 4674.
Within the areas examined, no violations or deviations were identified.
6.
Maintenance / Modification Welding and NDE (Units 1 and 2)
The inspector examined the welding and NDE activities described below relative to maintenance / modification to determine whether applicable code
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and regulatory requirements were being met. In general, the governing code i
is ASME Boiler and Pressure Vessel Code (B&PV),Section XI,1980 Edition, W81 Addenda. The General Controls are specified in the following Sections of the Catawba Nuclear Station Maintenance Welding Manual:
Section I, Revision 6, Identification and Control of Class A, B, C, E,
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and F piping
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Section III, Revision 4, Welding of Nuclear Structures (Containment and
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Canal Liner Plate, Structural and Miscellaneous QA Condition Steel) and Non-QA StructuresSection I identifies ASME B&PV Code Sections III,1974 Edition, S74 Addenda as the applicable code for pipe welding.
In addition various editions and addenda of the following codes are being used:
ASME B&PV Code Section V ASME B&PV Code Section IX AWS Structural Welding Code D1.1 i
a.
Welding (55050 and 55100)
(1) Welding Material Control (a) The inspector verified that the filler. materials used for the welds observed (see paragraph (3)(a) below) were the correct materials specified by the Welding Procedure Specification
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(WPS) and that in general, filler materials specified on WPSs were compatible with specified base materials.
(b) The inspectors performed the following verifications related to control and. handling of welding material:
That the licensee had established procedures for
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receiving, storing, disbursing, and handling of welding materials. The applicable procedures is:
CNS Maintenance Welding Manual,Section VIII, Revision 2, Issue, Control and Care of QA Condition Welding Material
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That receiving operations were conducted in accordance
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with aoplicable procedures.
Purchasing and receiving records for the welding materials listed below were reviewed.
That welding material storage and handling procedures
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contained requirements for environmental control and that actual practice followed these requirements.
Issue Station Number 3 was inspected and weld material control observed during observation of welding (see para-graph (3)(a) below).
That there were effective procedures for maintaining
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identification of welding materials and that procedures are enforced.
Identification control was inspected during observation of welding (see paragraph (,3)(a)
below).
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requirements for the most restrictive application and personnel involved were knowledgeable of the. system.
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That the method of disbursement of welding materials was
effective and controlled in accordance with approved
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procedures.
That required ASME Code tests were performed on each lot
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of welding material.
The receiving inspection and material certification documentation were reviewed for
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the following welding materials used for the welds listed is paragraph (3)(a) below.
3/32" ER308 Ht. No. 464177 1/8" ER308 Ht. No. 467832 5/32" Consumable Insert Ht. No. E4252T308 (2) Welder Performance Qualification The inspectors reviewed the qualification status records for the-
t below listed welders relative to the field welds 1.isted in paragraph (3) below.
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Welder 513 j
549 P64
530 i
j Welder qualification test coupon 5467 was visually inspected and
the RT film reviewed for a 3/8" carbon steel coupon for. welder
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e (3) Production Welding l
(a) The ' inspectors observed in process welding and reviewed j
in process records for welds INV632-1 and INV632-3.
The welding was observed and the -records reviewed to determine whether:
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4 Work was conducted in accordance with a document which
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coordinates and sequences operations, -references procedures, establishes hold points', and provides for production and inspection approval
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Weld identification and location were as specified i.
Procedures, drawings, and other instructions were at the
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work station and readily available WPS assignment was in accordance with applicable code
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requirements
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Welding technique and sequence were specified and adhered to
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Welding filler materials were the specified type and traceable to certifications
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Weld joint geometry was in accordance with applicabla procedure and was inspected Alignment of parts was as specified
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Preheat and interpass temperatures were in accordance with procedures Electrodes were used in positions and with electrical
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characteristics specified Shielding gas was in accordance with the~ welding
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procedure Welding equipment was in. good condition i
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Interpass cleaning was in accordance with applicable procedures Temporary attachments were removed in accordance with
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applicable procedures
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Gas purging, if specified, was used in accordance with applicable procedures Process control system had provisions for repairs
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Welders were qualified
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No peening performed on root and surface layers
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Weld inspection personnel were qualified
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(b) Completed welds INV632-5 and NV632-17 were examined to verify by visual inspection that the following characteristics conformed to ASME Code and' AWS ' Standard, as applicable, and applicable procedures.
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Weld surface finish and appearance
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Transition between components of dif ferent diameter and thicknesses Weld reinforcement
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Shape and~ size of fillet and socket welds
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Weld reinforcement Shape and size.of fillet and socket welds
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Weld reinforcement Removal of temporary attachments, arc strikes and weld
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spatter
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Finish grinding - absence of wall thinning
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Absence of surface defects b.
Radiographic (RT) Examination (57090)
The inspectors examined the RT activities described below relative to
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modification activities:
(1) The following procedure was reviewed to determine whether the procedure had been approved and issued in accordance with the QA program:
NDE-10, R16, General Radiography Procedure
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In addition, the procedure was reviewed to determine whether the following parameter were specified and controlled in accordance with applicable requirements:
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Material and weld surface condition requirements
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Types of material to be radiographed Paterial thickness range
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Type of radiation source and effective source size
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Film brand or type and number of films in cassette
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Minimum source to film distance Blocking or masking technique, if used
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Type and thicknesslof intensifying screens and filters
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Radiographic film processing requirements
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Quality of radiographs
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Film density limits for single and composite viewing Use -of densitometers for assuring compliance with. film
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density requirements
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System of radiograph identification Use of location markers
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Use of intensifying screens
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Methods of reducing and testing of backscatter Material type and thickness restrictions for isotope
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radiography
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Geometrical unsharpness limitations Selection and use of penetrometers including:
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panetrometer design Selection of essential hole Penetrameter thickness including special requirements for single and double wall viewing Penetrameter placement including special requirements for single and double wall viewing Number of penetrameters Shims under penetrometers
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Radiographic technique requirements for double wall viewing
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Requirements for evaluation and disposition of radiographs
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Records requirements (2) The inspectors observed in process radiography for weld INV638-1.
The RT was observed to determine whether:
Applicable drawings or instructions specified the examination
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procedure to be used and the procedure was available at the work area Personnel performing radiography and evaluating results were
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qualified Required equipment was available and calibrated
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Areas to be examined were clearly defined
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Examination attributes were as specified
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RT film was being processed in accordance with applicable
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procedure Within the areas inspected, no violations or deviations were identified.
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7.
Inspector Followup Items (927018)
(Closed) Inspector Followup Item 424/85-11-08.
IST Plan Change Control.
The licensee had indicated-earlier that a review of Revision 9 of the
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Catawba IST program would be made to determine if this document should have a listing of effective pages:
The inspector reviewed the IST program and established that all pages that were affected by the most recent revisions had been identified in the front of the document. This item is hereby closed.
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