IR 05000413/1987004
| ML20207T658 | |
| Person / Time | |
|---|---|
| Site: | Catawba  |
| Issue date: | 03/02/1987 |
| From: | Blake J, Crowley B NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML20207T641 | List: |
| References | |
| 50-413-87-04, 50-413-87-4, 50-414-87-04, 50-414-87-4, NUDOCS 8703240220 | |
| Download: ML20207T658 (12) | |
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/ p Et toq*o UNITED STATES NUCLEAR REGULATORY COMMIS$10N
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REGION 11
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lj 101 MARIETTA STREET.N.W.
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ATLANTA, GEORGI A 30323
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Report Nos.:
50-413/87-04 and 50-414/87-04 Licensee:
Duke Power Company 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 Inspectio ted February 2 - 6, 1987 Inspect
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. Blake, Section Chief Date Signed
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ireering Branch D vision of Reactor Safety SUMMARY Scope:
This routine, unannounced inspection was conducted in the areas of inservice inspection (ISI) (Units 1 and 2), inservice testing (IST) of pumps and valves (Units 1 and 2), maintenance / modification welding and nondestructive testing (NDE) (Units 1 and 2), and inspector followup items (Units 1 and 2).
Results:
One violation was identified - Failure of installed equipment to meet drawings and procedures paragraph 7.f.
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REPORT DETAILS 1.
Persons Contacted
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Licensee Employees
- J. W. Hampton, Station Manager
- H. B. Barron, Superintendent of Operations
- R. F. Wardell, Superintendent of Technical Services
- G. T. Smith, Superintendent of Maintenance
- T. E. Crawford, Superintendent of Scheduling
- W. F. Bradley, QA Surveillance Supervisor A. E. Allum, Senior QA Engineer J. A. Kammer, Unit 2 Test Engineer Z. L. Taylor, Unit 1 Test Engineer D. Mason, Associate QA Engineer M. A. Cote', Licensing Engineer Other licensee employees contacted included construction craftsmen, engineers, technicians, operators, security force members, and office personnel.
NRC Resident Inspectors
- P. K. VanDoorn, Senior Resident Inspector
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- P. Skinner, Senior Resident Inspector
- M. Lesser, Resident Inspector
- Attended exit interview 2.
Exit Interview The inspection scope and findings were summarized on February 6,1987, with those persons indicated in paragraph 1 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 item was identified during this inspection.
(0 pen) Violation 414/87-04-01, Failure of Installed Equipment to Meet Drawings and Procedures paragraph 7.f.
The licensee did not identify as proprietary any of the materials provided to or reviewed by the inspector during this inspection.
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Licensee Action on Previous Enforcement Matters (Closed) Unresolved Item 413/85-55-10, 414/85-68-05, Apparent Inadequacies in NDE-B, Nondestructive Examination Program.
This item identified five areas where procedure NDE-B, Training Qualification and Certification of NDE Personnel, did not agree with the wording of SNT-TC-1A.
The current site requirement is to use the 1980 edition of SNT-TC-1A.
Procedure NDE-B has been revised and now agrees with the 1980 edition of SNT-TC-1A.
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Unresolved Items Unresolved items were not identified during this inspection.
5.
Inservice Inspection - Review of Procedures (73052)(Units l'and 2)
The inspector reviewed the ISI procedures indicated below to determine whether the procedures were consistent with regulatory requirements and licensee commitments.
The applicable code for ISI is the American Society of Mechanical Engineer Boiler and Pressure Vessel (ASME B&PV) Code,Section XI, 1980 edition with addenda through W81.
Magnetic Particle (MT) procedures NDE-25, Revision 8, Magnetic Particle Inspection Technique (Yoke Method) for Preservice and Inservice Inspection (1980) and NDE-26, Revision 8, Wet Non-Fluorescent and Fluorescent Magnetic Particle Examination Techniques for Examination of Pressure Returning Bolting were reviewed in the area of:
Review and approval in accordance with licensee's QA procedures
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Examination method
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Contrast of dry powder particle color with background Surface temperature
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Suspension medium for wet particles
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Viewing conditions
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Examination overlap and directions
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Pole or prod spacing
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Current or lifting power (Yoke)
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Acceptance criteria Within the areas inspected, no violations or deviations were identified.
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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 and regulatory requirements were being met.
In general, the governing code is the 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:
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Section I, Revision 6, Identification and Control of class A, B, C, E and F-Piping Section III, Revision 4, Welding of Nuclear Structures (Containment and Canal Liner Plate, Structural and Miscellaneous QA Condition Steel) and l
Non-QA StructuresSection I identifies ASME B&PV Code Section III,1974 Edition, 574 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 In addition to 'the above documents, the following administrative and QC inspection procedures are applicable:
QCL-8, Revision 12, Procedure for the Inspection of QA Condition 2, 3, and 4 Field Fabricated Pipe Welds QCL-9, Revision 4, Procedure for the Inspection of Containment Plate, and Spent Fuel Pool liner Plate (McGuire and Catawba Nuclear Stations only)
QCL-10, Revision 9, Procedure for the Examination of Structural and Miscellaneous Steel Welds QCL-11, Revision 4, Procedure for the Inspection of Temporary Attachment Welds MM Procedure 1.0, Revision 20, Work Request Preparation a.
Welding (55050 and 55100)
(1) -Welder Performance Qualification
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The inspector reviewed the qualification status records for the below listed welders relative to the field welds listed in paragraph (2) below.
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(2) Production Welding i
(a) The inspector observed in process welding and reviewed l
in process records for welds 9,14,15 and 16 on ISO l
These are class H (QA condition 3) welds.
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l welding was observed and the records reviewed to determine whether:
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Work was conducted in accordance with a document which coordinates and sequences operations, references procedures, establishes hold points, and provides for production and inspection approval Weld identification and location were as specified
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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 Welding technique and sequence were specified and
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adhered to Welding filler materials were the specified type and
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traceable to certifications
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Weld joint geometry was in accordance with applicable procedure and was inspected Alignment of parts was as specified
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Preheat and interpass temperatures were in accordance
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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
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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 Gas purging, if specified, was used in accordance with
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applicable procedures
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Process control system had provisions for repairs 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 20, 21, and 22 on ISO CN-1WL-1542 were examined to verify by visual inspection that the characteristics listed below conformed to. ASME Code and AWS Standard, as applicable, and applicable procedures.
These welds are Class E (QA condition 2) welds.
Weld surface finish and appearance
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Transition between components of different diameter and
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thicknesse's Weld reinforcement
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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 Finish grinding absence of wall thinning
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Absence of surface defects b.
NDE (1) Liquid Penetrant (PT) Examination (57060)
The inspector examined the PT activities described below relative to maintenance / modification activities.
PT procedures NDE-31, Revision 17, Liquid Penetrant Examination Technique (Color Contrast, Water Washable Method and NDE-32, Revision 8, Liquid Penetrant Examination Technique Color Contrast, Post Emulsfying), were reviewed to determine whether the-procedures had been approved and issued in accordance with the QA program.
In addition, the procedures were reviewed to determine whether the following parameters were specified and controlled in accordance with applicable requirements:
Method consistent with applicable codes
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Specification of brand names and types of penetrant materials Specification of limits of sulfur and total halogens for
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materials Pre-examination surface preparation and cleaning
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Minimum drying time following surface cleaning
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Penetrant application and penetration time Temperature requirements
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Penetrant removal
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Method and time of surface drying prior to developing
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Type of developer and method of application
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Examination technique
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Time interval of interpretation Required lighting
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Technique for evaluation
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Acceptance standards
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Reporting requirements Requalification Requirements
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(2) Magnetic Particle (MT) Examination (57070)
The following MT procedures were reviewed:
NDE-21, Revision 13, Magnetic Particle Inspection Technique
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Direct Current Prod Method
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NDE-22, Revision 13, Magnetic Particle Inspection Technique Yoke Method NDE-23, Revision 3, Magnetic Particle Inspection Technique
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for Carbon Steel Bolts The procedures were reviewed to determine whether the following parameters were specified and controlled in accordance with applicable requirements:
Method - Continuous
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Surface Preparation Particle Contrast
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Surface Temperature Light Intensity
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Coverage
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Prod Spacing
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Magnetizing Current
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Yoke Pole Spacing
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Acceptance Criteria
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Within the areas inspected, no violations or deviations were identified.
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Inservice Testing (IST) Program For ASME Classes 1, 2, And 3 Pumps And Valves (61700 and 61725)(Units 1 and 2)
The inspector examined the IST activities described below to determine whether regulatory and code requirements were being met.
In accordance with the pump and valve programs listed below and as approved by NRC Safety Evaluation Report (SER), dated January 8,1987, the applicable code for IST is the ASME B&PV Code,Section XI, 1983 Edition with addenda through S83.
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L The IST programs are implemented by the following Catawba documents:
Inservice Testing Program for Pumps and Valves - Unit 1, Revision 12
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Pump and Valve Inscrvice Testing Program - Unit 2, Revision 3
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Catawba Nuclear Station (CNS) Directive 3.2.2, Revision 8, Development and Conduct of the Periodic Testing Program a.
The above documents and the below listed procedures were reviewed for general content and to the extent necessary to verify that the licensee had assigned responsibilities for:
preparation, review and approval of IST procedures; scheduling of IST; performance of test functions; performance of maintenance; and performance of calibrations.
Administrative Policy Manual (APM), Revision 24
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Section 3.2.2 Section 3.3 Section 4.1 Section 4.2 Section 4.3 CNS Directive 2.3.1, Revision 9, Control of Test and Measuring
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Equipment
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CNS Directive 4.2.1 (TS), Revision 23, Development, Approval and Use of Station Procedures Maintenance Management Procedure (MMP) 1.0, Revision 20, Work
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Request Preparation
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Performance Procedure (PP)
5.2, Revision 6/1:e 82, Valve
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Inservice Testing Statement
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PP-5.4, Revision 6/7/83, Documentation of Periodic Test Development b.
Issue and change records for the test procedures listed below were reviewed to the extent necessary to verify adequate control of issue and revision of test procedures.
PT/1/A/4200/04C, Condition Spray Pump 1B Performance Test
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PT/1/A/4200/13E, CA Valve Inservice Test (QU)
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PT/1/A/4200/13, ND Valve IST (CS)
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P1/1/A/4250/038, Auxiliary Feedwater Motor Driven Pump 1B Per-
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formance Test
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PT/2/A/4250/03B, Auxiliary Feedwater Motor Driven Pump 28 Per-l l
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'iPT/2/A/4200/04C, Containment Spray Pump 2B Performance Test
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PT/2/A/4250/03B, Auxiliary Feedwater Motor Driven Pump 2B Performance Test
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PT/2/A/4260/13F,3ND Valve Inservi.ce Test (CS)
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- Thetinspector reviewed Station Directive 3.2.2 and a sample of the
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Periodic. Test Scheduling Status for Units 1 and 2 generated by the 3:
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Catawba Periodic Test (CPT) program.
In addition?nthe current " Weekly
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Operations. Schedule" was reviewed.
These documents were reviewed and discussed with responsible personnel to verify that tests are scheduled
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The inspector reviewed a sample!'of the Units 1 and 2 Periodic Test ;P._
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Program Summary List to verify that status lists were maintained andi
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reflected properly scheduled tests.. The inspector pointed out to the W-licensee that,.althoegh it appears the Summary List meets ASME Sectioni n,
XI, which only requires'a summary list for recording' the current status n
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'of the program, the list is not very useful in its current form.
The t
? list is derived from the CPT and gives the component number, the test y
procedure, 'the last date the component was successfully tested (the F
last four dates in some cases), the next date the component is to be Q-tested and any outstanding work orders.
No details of unsuccessful
te ts are provided.
Essentially, the'same information is available in
- the Periodic Test Scheming Status.
Useful information for trending, a
preventive ' maintenance $and other purposes would' be available if the
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summary were a true summary of the test program. The licensee stated
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ii specific information is needed for a particular component, the test-
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packages in the' records vault for each component can be retrieved to
obtain the history for the component.
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The inspector verified that the licensee had developed prodedures for
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. pump-and valve testing by identifying and examining the 'following test -
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PT/1/A/4250/038
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PT/2/A/4250/038 PT/1/A/4200/13E
PT/2/A/4200/13E
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j (1) The pump test procedures were reviewed in(the areas of:
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p, General te.;hnical and administrative adequacy
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Plant equipment status evaluation and identification
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Description of hydraulic circuit to be used (
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W Location and type of measurement for each code test parameter
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function.
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-Minimum system' operation time for stabilization
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Realignment of hydraulic circuits
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Review of test results
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Recording requirements
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Establishment of pump measurement reference values
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(2) ~The valve procedures were reviewed in the area of:
General technical and administrative adequacy
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Plant equipment status evaluation and identification
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Identification of test instrumentation requirements
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Hydraulic circuit alignment Measurements required and location of measurements
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Exercising and timing requirements
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In process pump tests were observed to verify adequate implementation of procedures for the following two pumps:
Unit 2 ~ Auxiliary Feedwater Motor _ Driven Pump 2B, Procedure
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PT/2/A/4250/03B Unit 2 Containment Spray Pump 2B, Procedure PT/2/A/4200/04C
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During observation of the Auxiliary Feedwater Pump test, the inspector noted the following condition en the Containment Ventilation Condensate Drain Tank Foundation anchor colts (tank located ~ in the same room as the auxiliary feedwater pump):
On two studs on the north support, the primary nut was backed off
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approximately 2".
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On two studs on the north support and four studs on the south support, the jam nuts were missing.
_ On two studs on the north support and four studs on the south
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l support, the jam nuts were backed off approximately 2".
There are eight anchor bolts on each support or a total of 16.
The north support' has sliding feet while the south support has non-sliding p
feet.
The support is a QA condition four support.
In accordance with i
drawing CN-1222-4 and referenced sketch CN-1222-4Aa, each anchor bolt
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requires two nuts.
Paragraph 4.1 of Procedure M-10 provides process instructions for non pressure retaining items in accordance with
Construction Procedures.
Paragraph 4.2.2 of Construction Procedure 117
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requires that nuts on sliding feet anchor bolts be finger tight while non-sliding feet anchor bolt nuts be finger tight plus 1/4 turn.
This failure of equip:nent to meet drawings and procedures is in violation of 10 CFR 50, Appendix B, Criterio, V, as implemented by Section 17.2.5 of l
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DPC Topical Report Duke 1.
The violation is identified as Violation 414/86-04-01, Failure of Installed Equipment to Meet Drawings and Procedures.
When notified of the problem by the inspector, the licensee immediately issued Problem Investigation Report (PIR)
No. 2-C87-0025 to document investigation and correction of the problem.
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Instrumentation used in testing the Auxiliary Feedwater Pump in paragraph f. above was inspected in the areas of:
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Recording of instruments used
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Calibration frequency
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Accuracy as required by IWP-4000 Proper scale range
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Within the areas inspected, no violations, except as noted in paragraph f.,
or deviations were identified.
8.
Inspector Followup Items (IFIs)(92701B)(Units 1 and 2)
(Closed) IFI 413/85-11-08, IST Plan Change Control.
This item was closed in report 50-413/86-34, but was erroneously referred to as number 424/85-11-08.
(Closed) IFI 413/85-49-02, Scheduling of Pump Tests.
This item is relative to the licensee's method of scheduling pump bearing temperature measurements.
The method previously used could allow the test to exceed the 3.25 time limit for three consecutive test as required by the Technical Specification.
Since this item was written, i.he licensee's pump procedures have been revised to require the annual pump run test, including bearing temperature measurement, if the annual pump test has not been conducted in the last ten months.
This should preclude the problem identified by the IFI.
(0 pen) IFI 413/86-34-01, 414/86-37-01, Clarification of Responsibilities for Evaluation of ISI Results.
This item pertains to the issue of procedure QA-516 to better define responsibilities for evaluation of ISI Results.
At the time of the current inspection, the procedure was in the implementation stage and was expected to be issued in February 1987.
(Closed) IFI 413/86-34-02, 414/86-37-02, Liquid Penetrant Procedure NDE-98, Clarification of Controls for Procedure Implementation.
This item pertains to the use of a special PT procedure in lieu of the normal PT procedure.
The only limit, specified in the procedtre, for use of the procedure was that the area to be inspected be in a radiation area greater than 100 MR/ hour.
The inspector questioned the need to use a special procedure if the only factor is radiation levels above 100 MR/ hour.
Revision 4 to the procedure has been issued identifying accessibility as well as radiation levels as limiting factors for use of the procedure.
(0 pen) IFI 413/86-42-01, 414/86-45-01, Review of Section XI Manual. Writing and review of the Section XI manual is still in progress.
A number of sections base been written and are in revie '
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(Closed) IFI 413/86-42-02, 414/86-45-02, Revision of Welder Qualification Procedure.
This item pertained to the need to revise the licensee welder qualification procedure to require positive identification of welders in the qualification process to insure that a welder does not take a test for another velder.
Revision 3 to procedure L-1000 has been issued to require positive identification of welders.
(Closed) IFI 413/86-42-03, 414/86-45-03, Review of Revised PT Procedure.
This item pertains to the need to clarify the drying time before penetrant application and the maximum evaluation time for procedure NDE-30.
Revision 17 to NDE-30 has been issued and clarifies the drying time before penetrant application.
A new generic PT procedure, NDE-35, has been written and at the time of this inspection, was in the process of being issued.
This procedure clarifies both the drying time before penetrant application and the maximum evaluation time.