IR 05000413/1988001

Insp Repts 50-413/88-01 & 50-414/88-01 on 880105-07 & 19-22. No Violations or Deviations Noted.Major Areas Inspected: Inservice Insp & Maint/Mod Welding & NDE

ML20149M187
Person / Time
Site:	Catawba
Issue date:	02/10/1988
From:	Blake J, Crowley B NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
To:
Shared Package
ML20149M180	List: IR 05000413/1988001 ML20149M178
References
50-413-88-01, 50-413-88-1, 50-414-88-01, 50-414-88-1, NUDOCS 8802250396
Download: ML20149M187 (14)

Text

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ge Riog UNITED STATES

/ 'o NUCLEAR REGULATORY COMMISSION

[ *i n REGION ll 3 j 101 MARIETTA STREET. * i e ATLANTA, G EORGI A 30323

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Report Nos.

50-413/88-01 and 50-414/88-01 ,

licensee: Duke Power Company i 422 South Church Street Charlotte, NC 28242 Docket Nos.: 50-413 and 50-414 License Nos.: NPF-35 and NPF-52 ,

Fat.flity Name: Catawba 1 and 2 Inspection Conducted: January 5-7 and 19-22,1988 Inspector: , [- [ 1

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Date Si ned

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Approved by: ;L dB .l . aKe, Chief Dite Signed Ma r' ls and Processes Section Di i ion of Reactor Safety SUMMARY ,

Scope: This routine, unannounced inspection was in the areas of inservice

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inspection (ISI) (Units 1 and 2) and maintenance / modification welding and NDE -

(Unit 2).

Results: No violations or deviations were identified, p

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REPORT DETAILS t

' Persons Contacted Licensee Employees A. Allum, Senior Quality Control QC Supervisor

. *H. Barron, Superintendent of Operations

• T. Bumgardner, ISI Coordinator - Quality Assurance QA

• J. Cherry, QA Specialist - ISI .

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• R. Giles, ISI Coordinator - QA D. Mayes, Nuclear Production Engineer - Nuclear Maintenance

• W. McCollum, Jr., Superintendent of Station Services .

R. Petit, NDE Supervisor G. Robinson, Supervising QA Engineer - QA Technical Support

• G. Smith, Superintendent of Maintenance ,

• R. Wardell, Superintendent of Technical Services J. Willis, QA Station Manager Other licensee employees contacted included engineers, QA/QC personnel, 1 and office personne ;

NRC Resident Inspectors

• P. VanDoorn, Senior Resident Inspector

• Lesser, Resident Inspector

• Attended exit interview Exit Interview .

The inspection scope and findings were summarized on January 22, 1988, with those persons indicated in paragraph 1. The inspector described the

, areas inspected and discussed in detail the inspection findings. No . i dissenting comments were received from the license The licensee did not identify as proprietary any of the materials provided j to or reviewed by the inspector during this inspection.

Licensee Action on Previous Enforcement Matters

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This subject was not addressed in the inspectio . Unresolved Items

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Unresolved items were not identified during this inspection.- l l

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5. Inservice Inspection - Review of Program -(73051) (Units 1 and 2)

The inspector reviewed the licensee's inservice in:pection (ISI) program for the current Unit 2 outage (Outage 1) in the areas indicated belo With exception of Volume 3 of the ISI Plan and the Eddy Current (ET)

Plans, all documents reviewed were applicable to both Units 1 and 2. In accordance with Revision 2 of the ISI Plan (submitted to the NRC on August 18, 1986), the applicable code is the ASME Boiler and Pressure Vessel Code,Section XI,1980 Edition with Addenda through W81. The current ISI was being performed under the Duke Power Company (DPC) ISI Plan listed below with DPC having the primary responsibilit Both DPC and B&W examiners were being use Many of the documents listed below were reviewed during previous inspections (See RII. reports 50-413, 414/87-35; 50-413/86-34, 50-414/86-37; 50-413/86-42 and 50-414/86-4 During the current inspection, only changes since the last review were examine The following DPC and B&W documents were reviewed:

- DPC Inservice Inspection Plan, Catawba Nuclear Station Units I and 2, Revision 3. Volumes 1 and 3

- Eddy Current Inspection Plan, Catawba Unit 2, Steam Generator 8, December 1987 Refueling Outage

- Eddy Current Inspection Plan, Catawba Unit 2, Steam Generator C, December 1987 Refueling Outage

- D?C QA Department Quality Assurance Program, Revision 99

- Procedure QA-100, Revision 10, Preparation and Issue of Quality I

Assurance Procedures

- DPC QA-101, Revision 6, Quality Assurance Records Storage Area (General Office - Corporate Vault)

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- DPC QA-102, Revision 6, Storage of Special Processed Records

- DPC QA-107, Revision 3, Temporary Procedure Changes

- DPC QA-111, Revision 5, Transfer of QA Records

- DPC QA-113, Revision 7 Qualification and Training of Auditors

- DPC QA 116, Revision 11, Quality Assurance Records Collection, Storage and Retention

- DPC QA-123, Revision 1, Processing of Nonconforming Item Reports by Quality Assurance General Office Personnel

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- DPC QA-125, Revision 2, Problem Investigation Process

- DPC QA-130, Revision 16, Qualification and Training of Auditors

- DPC QA-131, Revision 10, Quality Assurance Training

- DPC QA-132, Revision 0, Qualification and Training of Operations Division Surveillance Personnel

- DPC QA-140, Revision 13, Quality Assurance Inspector Training

- DPC QA-160, Revision 2, Performance of Corporate Quality Assurance Audits

- DPC QA-210, Revision 20, Departmental Audit Procedure

- DPC QA-230, Revision 10, Departmental Audit Scheduling and Followup

- DPC QA-301, Revision 9, Management of Project QA Records

- DPC QA-500, Revision 20, Operations Division Surveillance Program

- DPC QA-502, Revision 5, Evaluating and Approving Quality Control Inspection Records

- DPC QA-513, Revision 5, Control of Inservice Inspection Plans and Reports

- DPC QA-516, Revision 0, Evaluation of ISI Indications

- DPC QA-517, Revision 0, Control of Technical Specification Surveillances Assigned to Quality Assurance (McGuire and Catawba)

- DPC QA-601, Revision 14, Vendor Evaluation

- DPC QA-602, Revision 10 Vendor Surveillance Procedure

- DPC QCL-5, Revision 8, Control of Preservice and Inservice Inspection Activities

- DPC QCK-1, Revision 23, Control of Nonconforming Items

- DPC NDE-A, Revision 9, Nondestructive Examination Program Procedure

- OPC NDE-B, Revision 12, Training, Qualification and Certification of NDE Personnel

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- B&W Quality Assurance Manual .Special Products and Integrated Field Services (SPIFS), Revision 4

- B&W SPIFS 1986 Administrative Manual, Revision 0 The documents were reviewed in the areas of:

- Conformance with ASME B&PV, Code,Section XI and applicable code cases

- Approval of code cases

- Use of an authorized nuclear inservice inspector (ANII) and

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approval of plan and procedures by the ANI Review and approval of the ISI' plan and procedures

- Identification of connitments and regulatory requirements .

- Procedures for preparing plan and schedules and filing with enforcement and regulatory authorities

- Sufficient organizational staff to ensure performance of acceptable ISI work

- Site administrative procedures to define -authorities and  !

responsibilities for final evaluation and acceptance of ISI

' results

- Maintenance and retention of appropriate ISI records

- QA review including assurance that plans and procedures have ,

been reviewed by appropriate personnel and meet regulatory I requirements j

- Establishment of procedures for-corrective action

- Procedures for auditing ISI activities by qualified QA personnel

- Corrective action of conditions adverse to quality

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Audits or surveillance of ISI activities

- Oversee contractor activities concerned with ISI

- Personnel qualification requirements

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- Reporting requirements per ASME code and Technical Specifications

- Identification and process of relief requests

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5 During review of the steam generator (S/G) eddy current (ET)

inspection plans and the inspection results (see paragraph below), the inspector questioned whether Technical Specification (TS)

sample requirements had been met. The original ET plans specified inspection of 650 tubes in S/G "B" and 628 tubes in S/G "C" (S/G's

"A" and "D" were inspected during the Summer 1987 maintenance outage). The sample plan included 100% of the peripheral tubes in both "B" and "C" S/G's. Inspection of the original sample revealed a pluggable condition (wall degradation 77% vs. <40% allowed by TS) in a S/G "B" tub The affected tube was a peripheral tub DPC expanded the scope of the inspection to include 14 tubes adjacent to the affected tube to bound the defective condition. No other defective tubes were found. A later visual inspection revealed loose parts (2 jacking bolts) in the vicinity of the defect in the affected tub The defect was attributed to one of the jacking bolts wearing on the tub The TS (Surveillance Requirements 4.4.5.2) requires that the initial sample size (1S) be at least 3% of the total tubes in all S/G's or approximately 150 tubes per S/G. If one or more tubes are found to be defective (240% degradation), the inspection results are categorized as C-2 and an additional 25 (6%) sample of the tubes in that S/G are to be inspecte A strict interpretation of this requirement would mean inspection of an additional 300 tubes in the

"B" S/ DPC considered that the intent of the TS had been met since the original sample far exceeded the number of tubes required for the first and second sample and included 100% of the area (peripheral tubes) where the defective tube was foun *

After the inspector questioned TS compliance relative to the need to take an additional sample, OPC contacted the NRC's Office of Nuclear Reactor Regulation (NRR) for concurrence that the intent of the TS l had been met. After review of the matter, NRR concluded that the  :

intent of TS had been met based on the makeup of the original sample, ,

and identification of the cause (a loose part in the vicinity of the l tube defect) of the defective tub Within the areas inspected, no violations or deviations were identifie i Inservice Inspection - Observation of Work and Work Activities (73753)

(Unit 2)

The inspector observed the ISI cctivities described below to determine j whether these activities were being performed in accordance with  !

regulatory requirements and licensee procedure See paragraph 5 above  ;

for the applicable code, The inspector reviewed the examination plan for the current inspection to determine if changes were being properly documente :

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6 Qualification and certification records for the following NDE examiners involved in the examinations identified in paragraphs c.,

d., e., f.,'and 9. below were reviewe .

- Eddy Current (ET): B&W - 4 LIIA

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2 LII DPC - 9 LII

- Magnetic Particle (MT): DPC - 6 LII

- Liquid Penetrant (PT): DPC - 2 LII

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Ultrasonic (UT): B&W - 2 LII DPC - 3 LII

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- Visual (VT-1, 2, 3, 4): DPC - 1 LII In process MT inspection was observed for the following welds / components:

Weld 2SM-44-03 Weld 2SM-42-01 RV Nut 2RPV-NUT-02A RV Nut 2RPV-NUT-08A RV Stud 2RPV-STUD-02A The inspections were compared with applicable procedures in the following areas: ,

- Specification of procedure to be used and availability of procedure at inspection area

- Use of knowledgeable NDE personnel qualified to the proper level

- Specific areas, locations and extent of examination clearly defined

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Examination method

- Type and color of ferromagnetic particles - particle contrast

- Material surface preparation / cleanliness

- Material surface temperature

- Examination technique / coverage

- Magnetizing current

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Prod or pole spacing ,

- Yoke lifting power ,

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- Evaluation of indications  !

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d. In-process ultrasonic (UT) inspection was observed for reactor vessel -l stud 2RPV-STUD-02A. The inspections were compared with applicable procedures in the following areas-  ;

- Availability of and compliance with approved NDE procedures j

- Use of knowledgeable NDE personnel i

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- Use of NDE personnel qualified to the proper level-I

- Recording of inspection results  !

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- Type of apparatus used

- Extent of coverage of weldment j

- Calibration requirements

- Search units

- Beam angles

- DAC curves (

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- Reference level of monitoring discontinuities  ;

- Method of demonstrating penetration l

- Limits of evaluating and recording indications l l

- Recording significant indications j i

- Acceptance limits  !

I In-process liquid penetrant inspection was observed for welds l 2NV323-16, -20, -22 and -2 The inspection was compared with 4 applicable procedures in the following areas:

- Availability of and compliance with approved NDE Procedures

- Use of knowledgeable NDE personnel

- Use of NDE personnel qualified to the proper level ,

- Recording of inspection results l

- Method consistent with procedure

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Penetrant materials identified and consistent with ASME Code j i

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- Certification of sulfur and halogen content for penetrant materials

- Surface preparation

- Drying of surface prior to developing

- Developer type, application and' time interval after penetrant removal

- Time interval between developer application and evaluation

- Evaluation technique

- Reporting examination results In-process visual (VT) inspection was observed for the following components:

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Washer: 2RPV-WASHER-02

- Hangers: 2R-KD-99 2R-KD-81 2R-LD-29 2R-LD-21 2R-LC-30 2R-LD-19 2R-LD-17 The inspections were observed to verify that:

- Applicable instructions or plans clearly specified the procedure to be used and that a copy of the procedure was available for the inspection

- Personnel performing the examinations were qualified

- Required tools and aids were available

- SpGific areas, locatior.s, and extent of examination were clearly defined

- Test attributes were specified .and consistent with applicable procedures

- Defects were evaluated in accordance with applicable procedure and inspection results were reported as required In addition, functional testing of snubbers was observed for the following snubbers:

2-R-NC-1690 2-R-NC-1703 2-R-CA-1648 2-R-NV-0073

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g. In-process eddy current (ET) inspection was observed for the following steam generator tubes:

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Steam Generator "B" Row Column 3 87 3 97 4 -85 4 65 4 59 3 59

- Steam Generator "C" Row Column 2-~ 4 2 5 2 6 The inspections were compared with the requirements of applicable procedures in the areas of:

- Equipment

- Sensitivity

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Test Method

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Calibration

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Acceptance Criteria In addition to the above observations, the inspector discussed with the licensee the ET inspection program and inspection results for Unit 2 S/G tubes. In order to assess the condition of the Unit 2 tubes and address known problem areas, the licensee's program for the current outage specified testing 650 tubes in S/G "B" and 628 tubes in S/G "C". The sample included 100% of the peripheral tubes in both S/G's. "A" and "0" S/Gs were inspected earlier durirg the Summer 87 outage. The sample consisted of 370 tubes in S/G "A" and 405 tubes in S/G "D". Only one defective tube (degradation 40% wall thickness) was identified. The tube was a peripheral tube in S/G "B" located at Row 41 Column 20 and the indication was near the tube sheet on the hotleg side. Only one other indication greater than 20%

wall degradation was identified. This was a 26% indication at row 45 column 59 in S/G "C", 6" from the 13th tube support plate. Based on the defective tube in S/G "B", an additional 14 tubes near the defective tube were inspected. Also, since the wall degradation was on the outside of the tube, the licensee performed a fiberoptics visual inspection of the peripheral of the tube bundle. Two jacking screws (21" dia, by 3" long) were found in the vicinity of the defective tube. An additional jacking screw was found in the other hot leg quadrant. As a result of the loose parts in S/G "B" and as part of the S/G inspection program, the other S/G's were visually inspected. A block of metal, 3-1/2" x 2" x l'-1/2" was found on the tube sheet of S/G "A". A sliver of metal approximately 8" long by 3/8" x 1/16" was found in S/G "D". In addition, other small parts

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(pieces o'f wire _etc.) were found in all S/Gs. All loose parts were located on the. tube sheet. After sludge-lancing, VT inspection revealed a damaged tube in S/G "D" in the vicinity of where the sliver of metal had been found. The licensee plans to ET inspect all peripheral tubes in S/G's "A" and "D" prior to returning to powe Certification records for the following materials / equipment used for the inspections noted above were reviewed:

- ET Equipment: MIZ 18 R.D.A.U. - Serial 074 MIZ 18 R.D.A.U. - Serial 131 Data Recorder - Serial 8708-002 Data Recorder - Serial 8708-079 ,

MIZ 18 Computer - Serial 24404A10016 MIZ 18 Computer - Serial 2314A07406 ET Calibration Block 50285 ET Calibration Block 50379-

- MT Materials / Equipment: Dry Particles - Batch 85C012 MT Yoke - Serial ES6-1 Fluorescent Particles - Batch 860062 i

~ Light Meter - CNQUA 18395

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PT Materials: ' Cleaner - Batch 86J005 Developer - Batch 83G033 Developer - Batch 868076 Penetrant - Batch 78E084 Within the areas inspected, no violations or deviations were ,

identifie . ISI Data Review and Evaluation (73755) (Units 1 and 2)

The inspector reviewed the ISI NDE records indicated below to determine whether the records were consistent with regulatory requirements and licensee procedures. See paragraph 5 above for the applicable cod :

l The following records were reviewed: i Unit 1 - Pipe Support Visual Records Supports -

1-R-KC-1006 1-R-KC-1036 1-R-KC-1038 1-R-KC-1039 1-R-KC-1033 l

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1-R-KC-1034 1-R-KC-1065 1-R-KC-0447 1-R-KC-0457 1-R-RN-0735

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1-R-RN-0599 1-R-RN-0600 1-R-RN-0126 1 1-R-RN-0105 1-R-RN-0135

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1-R-RN-0120 1-R-RN-0337 Unit 2 - Pipe Weld UT Data Welds -

2NC24-07 2NC24-08 L

2NC24-11 2NC24-17 2NI55-02 2NI55-04 j- 2NI55-06

.; 2SV8-02 The records were' reviewed to determine whether the following records were included or referenced:  ;

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Examination results and data sheet l

- Examination equipment data, j

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Calibration data sheet ]

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Examination evaluation dat Records on extent of examinatio j

- Records on deviation from program ar d procedures including i

justification for deviation, if applicabl Records on disposition of finding Re-examination data af ter repairwork, if applicabl Identification of NDE material such as penetrant, penetrant cleaner, couplant, films, tapes, et Within the areas inspected, no violations or deviations were identified.

l 8. Maintenance / Modification Welding and NDE (Unit 2) (55050)(57090) j a

l The. inspector examined the welding and NDE activities described below 1 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 l 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 Structure (Containment and Canal Liner Plate, Structural and Miscellaneous QA Condition Steel) and Non-QA StructuresSection I identifies the ASME B&PV Code Section 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

> In addition to the above documents, the following administrative and QC inspection procedures are applicable:

QCL-8, Procedure for the Inspection of QA Condition 2, 3, and 4 Field Fabricated Pipe Welds QCL-9, Procedure for the Inspection of Containment Plate, and Spent Fuel Pool Liner Plate (McGuire and Catawba Nuclear Stations only)

QCL-10, Procedure for the Examination of Structural and Miscellaneous Steel Welds

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QCL-11, Procedure for the Inspection of Temporary Attachment Welds MM Procedure 1.0, Work Request Preparation The inspector reviewed completed radiographic film for the following pipe welds:

Weld ID Pipe Size Class 2NV-629-7 3" x .438" II 2NV-631-26 2" x .344" II 2NV-630-3 3" x .438" II 2NV-83-35 3" x .438" II 2NV-629-2 3" x .438" II The radiographs were reviewed to detennine if radiographic quality was in accordance with applicable procedure and code requirements and specifically to verify:

- Penetrameter type, size and placement

- Penetrameter sensitivity

- Film density and density variation

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Film identification

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Weld quality Weld Process Control Sheets for the welds listed in paragraph above v> e reviewed and compared with applicable procedures, c Welder qualification records (welder qualification printout) for the following welders who performed the welds listed in paragraph above were reviewed:

E81 EIS Y81 X36 530 Within the areas inspected, no violations or deviations were identified. .