IR 05000413/1990007
| ML20012C326 | |
| Person / Time | |
|---|---|
| Site: | Catawba  |
| Issue date: | 03/05/1990 |
| From: | Blake J, Newsome R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML20012C325 | List: |
| References | |
| 50-413-90-07, 50-413-90-7, 50-414-90-07, 50-414-90-7, NUDOCS 9003210036 | |
| Download: ML20012C326 (11) | |
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.,8p* *f og'o, NUCLEAR REGULATORY COMMisslON
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t ATLANT A GEORGI A 30323
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Report Nos.: 50-413/90-07 and 50-414/90-07
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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 Inspection Conducted:
February 12 - February 16, 1990 0 nebef (A).
2-11 TO Inspector:
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Date Signed
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Approved by.
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Blake, Chief Date Signed fia rials and Processes Section En ineering Branch Division of Reactor Safety SUMMARY Scope This routine, unannounced inspection was conducted on site in the area of Inservice Inspection (ISD and included a review of the ISI program implementing procedures and the Unit 1 ISI plan for this outage; reviews of nondestructive examination (NDE) procedures; observations of in-progress NDE examinations; independent examination verifications; reviews of NDE personnel cualifications; revicws of NDE equipment calibration and material certification cocumentation; and, a review of completed NDE examination data.
Results In the areas inspected, violations or deviations were not identified.
This inspection indicated that ISI nondestructive examinations were being
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REPORT DETAILS
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Persons Contacted Licensee Empicyees
- R. Glovt.r, Technical Support (TS), Compliance T. Hilderbrand, QA Supervisor
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V. King. TS Compliance R. Pettet, NDE Supervisor
e Other licensee employees contacted during this inspection included l
craftsmen, engineers, technicians, and administrative personnel.
NRC Resident Inspectors
- W. Orders, Senior Resident Inspector M. Lesser, Resident Inspector
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- P. Hopkins, Resident Inspector
- Attended exit interview Acronyms and initialisms used throughout this report are listed in the
last paragraph.
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2.
Inservice Inspection The inspector reviewed documents and records and observed activities, as indicated below, to determine whether ISI was being conducted in
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accordance with applicable procedures, regulatory requirements, and licensee commitments. The applicable code for ISI is the American Society of Mechanical Engineers Boiler and Pressure Vessel (ASME B&PV) Code,Section XI,1980 edition with addenda through Winter 1981.
Duke Power
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Company (DPC) nondestructive examination personnel are performing the liquid penetrant (PT), magnetic particle (MT), radiography (RT),
ultrasonic (UT), and visual (VT) examinations.
tubing eddy current (EC) examination data collection was being accomplished by Duke Power personnel with Babcock and Wilcox (B&W)
performing the primary data analysis and Duke Power personnel performing a tecondary data evaluation.
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ISI Program Review, Units 1 and 2 (73051)
The inspector reviewed the following documents relating to the ISI program. to determine whether tiie plan had been approved by the licensee and to assure that procedures and plans had been established (written, reviewed, approved and issued) to control and accomplish
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organizational structure including qualifications, training, responsibilities, and duties of personnel responsible for ISI; audits including procedures.
frequency, and qualification of personnel; general Quality Assurance requirements including examination reports, deviations from j
previously established program, material certifications, and identification of components to be covered; work and inspection procedures; control of processes including suitably controlled work conditions, special methods, and use of qualified personnel; corrective action; document control; control of examination
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equipment; quality records including documentation of indications and
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NDE findings, review of documentation, provisions to assure legibility and retrievability, and corrective action; scope of the inspection including description of areas to be examined, examination
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category, method of inspection, extent of examinations, and justifi-
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cation for any exception; definition of inspection interval and extent of examination; qualification of NDE personnel; and, controls of generation, approval, custody, storage and maintenance of NDE records, Duke Power Company ASME Section XI Manual
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Section A Purpose, Organization, and Responsibility Section B Control Of Manual Section F Records Section G Control Of Measuring And Test Equipment Section I Audit And Surveillance Activities Inservice Inspection Plan Catawba Nuclear Station
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4th Refueling Outage NDE-A(R9)
Nondestructive Examination Program Procedure
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NDE-B(R14)
Training, Qualification And Certification Of
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NDE Personnel NDE-C(R3)
Calibration / Verification of NDE
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Equipment b.
ReviewofNDEProcedures, Units 1and2(73052)
(1) The inspector reviewed the procedures listed below to determine l
whether these procedures were consistent with regulatory requirements and licensee commitments. The procedures were also reviewed in the areas of procedure approval, requirements for qualification of NDE personnel, and compilation of required records; and, if applicable, division of responsibility between the licensee and contractor personnel if contractor personnel are involved in the ISI effort.
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NDE-35(R12)
Liquid Penetrant Examination j
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NDE-25(R14)
Magnetic Particle Examination
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Procedure and Techniques i
NDE-12(R7)
General Radiography Procedure for i
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Preservice And Inservice Inspection QCL-14(R9)
ISI Visual Examination, VT-3 and VT-4
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QCF-9(R8)
Piping Support Installation Inspection
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Eddy Current Analysis Guidelines For Catawba Nuclear
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Station Unit #1 NDE-703(R3)
Evaluation Of Eddy Current Data For
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Steam Generator Tubing All procedures listed above have been reviewed during previous NRC inspections.
Only current revisions were reviewed during
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this inspecticn.
(2) The inspector reviewed the Liquid Penetrant procedure to ascertain whether it had been reviewed and approved in accordance with the licensee's established QA procedures.
The procedure was also reviewed for technical adequacy and conformance with ASME,Section V, Article 6, and other licensee commitments / requirements in the following areas:
specified method; penetrant material identification; penetrant materials
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analyzed for sulfur; penetrant materials analyzed for total halogens; surface temperature; acceptable pre-examination surface conditioning; method used for pre-examination surface
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cleaning; surface drying time prior to penetrant application; method of penetrant application; penetrant dwell time; method used for excess penetrant removal; surface drying prior to developer application, if applicable; type of developer; examination technique; evaluation techniques; and, procedure
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requalification.
(3) The inspector reviewed the Magnetic Particle procedure to ascertain whether it had been reviewed and approved in accordance with the licensee's established QA procedures. The procedure was reviewed for technical adequacy and for conformance with the ASME Code Section V, Article 7, and other licensee commitments / requirements in the following areas:
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examination methods; contrast of dry powder particle color with
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background; surface temperature; suspension medium and surface temperature requirement for wet particles; viewing conditions; examination overlap and directions; pole or prod spacing; current or lifting power (yoke); and, acceptance criteria.
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(4) The inspector reviewed the Radiographic procedure to determine whether it contained sufficient information to assure that the
following parameters were specified and controlled within the limits permitted by the applicable code, or any other specification requirement:
type of material to be radiographed;
material and weld surface condition requirements; type of radiation source, effective focal spot or effective source size;
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film brand or type; number of films in cassette; minimum source l
to film distance; type and thickness of intensifying screens and
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filters; quality of radiographs; film density and contrast for f
single and composite viewing; use of densitometers for assuring compliance with film density requirements; system of radiograph
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identification; use of location markers; methods of reducing and f
testing for back-scatter; selection of penetrameters including penetrameter placement; number of penetrameters; shims under penetrameters; radiographic technique for double wall viewing; and, evaluation and disposition of radiographs.
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While reviewing RT procedure NDE-12, the NRC inspector noted that there was no requirement stipulated in the procedure for the radiographic film to be evaluated 2 times by 2 different qualified film interpreters.
The licensee is, however, evaluating the film twice, as is industry practice, and does stipulate in one of their other RT procedures that the film is required to be evaluated. twice by two different interpreters.
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The NRC inspector brought this to the attention of licensee personnel and the licensee has agreed to correct this oversight
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in their next revision of the procedure.
(5) The inspector reviewed the Visual examination procedures to determine whether they contained sufficient instructions to assure that the following parameters were specified and controlled within the limits permitted by the applicable code, i
standard, or any other specification requirement:
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direct visual, remote visual or translucent visual; application
- hydrostatic testing, fabrication procedure, visual examination
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of welds, leak testing, etc.; how visual examination is to be performed; type of surface condition available; method or implement used for surface preparation, if any; whether direct or remote viewing is used; 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 comple-tion.
i While reviewing some of the completed visual examination records, the NRC inspector noted that some of the items had been accepted which should have been rejected when applying procedure QCL-14 acceptance criteria.
The inspector discussed these findings with knowledgeable licensee personnel and found that in many cases the final acceptance of the item is based on criteria
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contained in Form QCF-9A, Support Inspection Instructions, of procedure QCF-9 which are special design considerations documented during the plant construction phase.
QCL-14 has no documented path to QCF-9 although it is common knowledge with the DPC visual inspectors that if the item examined does not meet the acceptance criteria of. QCL-14 an automatic review of
Form QCF-9A is to take place to see if these special design considerations allow the item to be accepted.
Following discussions with licensee personnel, the licensee agreed that a
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documented link between procedures QCL-14 and QCL-9 needs to be incorporated into QCL-14. This oversight will be corrected with
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the next revision to procedure QCL-14.
(6) The inspector reviewed the Eddy Current procedures for technical content relative to:
multichannel examination unit, multichannel examination irdication equipment is specified,
examination sensitivity, method of examination, method of l'
calibration and calibration sequence, and acceptance criteria.
All procedures reviewed appeared to contain the necessary elements for conducting the specific examination. The minor discrepancies
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noted above in the RT and VT procedures did not have any significant impact on the acceptability of the examint.tions conducted while using these procedures, c.
Observation of Work and Work Activities Unit 1(73753)
The inspector observed work activities, reviewed certification records of NDE equipment and materials, and reviewed NDE personnel qualifications for personnel that had been utilized during the required 151 examinations during this outage.
The observations and reviews conducted by the inspector are documented below.
(1) The inspector observed calibration activities and the in-process ultrasonic (UT) examinations being conducted on 4 Safety Injection System welds.
These observations were compared with the applicable procedures and the ASME B&PV Code 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; type of apparatus used; calibration requirements; search units; beam angles; DAC curves;
reference level for monitoring discontinuities; method of demonstrating penetration; extent of weld / component examination coverage; limits of evaluating and recording indications; recording significant indications; and, acceptance limits.
The inspector conducted an independent ultrasonic verification examination, using DPC equipment, on portions of 2 of the Safety Injection System welds previously observed being examined by the ultrasonic examiners.
These examinations were conducted in order to evaluate the technical adequacy of the ultrasonic
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examination procedure being used by the licensee and to assess
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the validity of the information being reported by the ultrasonic examiners.
The verification ultrasonic examinations conducted by the inspector indicated that the procedure being used to conduct the t
examinations is adequate and the verification examination results compared favorably with the information being reported by the ultrasonic examiners.
The following listed ultrasonic equipment and materials certification records were reviewed:
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Ultrasonic Instruments Manufacturer Serial No.
Panametrics 1080 Panametrics 1219 The inspector reviewed spectrum analysis data for the ultrasonic transducers listed below:
Serial No.
Size Frequency 42951
.5" 2.25 MHz 42966
.5" 2.25 MHz C31227
.25" 5.0 MHz Ultrasonic Couplant Batch Numbers 8981, 8558, and 8767 Ultrasonic Calibration Block 6" Dia. Stainless Steel No. 50308 (2) The inspector observed the in process liquid penetrant (PT)
examinations of 2 integrally welded attachments to piping in the Safety Injection System.
The observations were compared with the applicable procedure and the ASME B&PV Code in the following areas:
specified method, penetrant materials identified; penetrant materials analyzed for halogens and sulfur; acceptable pre-examination surface; surface temperature; surface drying time prior to penetrant application; method of penetrant application; penetrant dwell time; method used for excess penetrant removal; surface drying prior to developing, if applicable; type of developer; examination technique; evaluation technique; and, reporting of examination results.
The NRC inspector re-evaluated both of the above attachment welds following the PT examiners evaluation of the welds but prior to the developer being removed from the weld surfaces.
This re-evaluation was conducted in order to determine if the evaluations performed by the PT examiners was in accordance with
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the applicalle procedure acceptance criteria and to determine if the examination results were being reported as required.
The re-evaluations conducted by the NRC inspector indicated that the proper evaluation was made by the PT examiners and that the examination results were being reported as required.
The inspector's review of the below listed liquid penetrant materials certification records indicated that the sulfur and halogen content of the material was within acceptable content limits.
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Materials Batch Nepber Liquid Penetrant 78E084 Cleaner / Remover 88F051, 880039, 89E0Ag Developer 830033, 86B076 (3) Tne inspector reviewed documentation indicating that a 10 pound lift test had been performed on magnetic particle alternating current (AC) yokes CN016 and ES-6-1, which had been used to conduct ISI examinations.
The certification record for the lift test plate that was used to conduct the tests, MTC-1, was reviewed to confirm the weight of the test plate.
A review of the magretic particle material certification record for batch number 87F008 indicated the particles met the applicable specifications requirements.
(4) The inspector evaluated 16 radiographic films for 1 of the 3 pipe welds that are scheduled to be radiogra)hed under the licensee's ISI program.
The remaining two we'ds had not been radiographed at the erid of this inspection.
The radiographs were evaluated in order to determine if the radiographic quality was in accordance with the applicable procedure and ASME Code requirements and to specifically verify the following:
penetrameter type, size, and placement; penetrameter sensitivity; film density and density variation; film identification; film cuality; weld coverage; and, disposition of the welds radiographec
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The NRC inspector's review of the radiographs agreed with what was reported by DPC.
The inspector confirmed the calibration status for Densitometer 1788 to ascertain whether the documentation was retrievable, complete, and accurate.
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i (5) Steam Generator Tubing Eddy Current Examination
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The inspector observed the EC activities indicated below.
The observations were compared with the applicable procedures and the Code in the following areas:
method for maximum sensitive is applied; method of examination has been recorded; examination equipment has been calibrated in accordance with the applicable i
performance reference; amplitude and phase angle have been j
calibrated with the proper calibration reference and is
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recalibrated at predetermined frequency; required coverage of steam generator tubes occurs during the examination; acceptance criteria is specified or referenced and is consistent with the procedure or the ASME Code; and, results are consistent with the
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acceptance criteria.
(a) Steam generator in-process tube data acquisition, including i
calibration confirmation and tube location verifications,
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was observed for 18 SG tubes,16 in SG-A and 2 in SG-D.
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In-process eddy current data evaluation, including calibration confirmation, was observed for 59 SG tubes.
Primary data analysis, being conducted by B&W, was observed for 37 SG tubes and secondary data analysis, being conducted by DPC, was observed for 19 SG tubes.
The NRC inspector also observed the resolution of evaluations for 3
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SG tubes in SG-A as a result of differences noted between the primary and secondary evaluation of these tubes.
The NRC inspector co-evaluated 23 of the SG tubes during the observations of the primary and secondary analysts evaluations,11 in SG-A, 7 in SG-B, 4 in SG-C, and 1 in SG-D.
The sample of evaluations, some having reportable indications and some with no reported indicatior,s, was conducted in order to confirm the validity of the reported tubing condition.
The co-evaluation analysis conducted by the inspector agreed well with the reported results.
(c) Certification records for EC calibration standards 50388,
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50390, and 50391 were reviewed for material type, correct l
fabrication, and artificial flaw location and size.
(6) The inspector reviewed personnel qualification documentation for 23 NDE personnel including EC data collection and EC data analysis personnel.
These personnel qualifications were reviewed in the following areas:
employer's name; person certified; activity qualified to perform; current period of certification; signature of employer's designated representative; basis used for certification; and, annual visual acuity, color vision examination, and periodic recertificatio *
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The personnel qualifications reviewed indicated that all personnel were adequately qualified for the examinations conducted.
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Data Review and Evaluation, Unit 1(73755)
(1)
Records of 8 UT, 6 PT,13 MT,12 VT, and 1 RT completed ISI nondestructive examinations were selected dnd reviewed to ascertain whether:
the methods (s), 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.
(2) The inspector reviewed the eddy current data analysis results and a sample of associated completed records for more than 25 tubes from each of the 4 Steam Generators.
The reviews were compared with the applicable procedures and the ASME B&PV Code in the following areas: the multichannel eddy current examination equipment has been identified; material permeability has been recorded; method of examination has been recorded; and, results are consistent with acceptance criteria.
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All of the examination reports reviewed appeared to contain the required examination information including disposition of
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indications, if any.
A random sample of current ISI examination results were compared with historical examination results.
No major discrepancies were noted during the comparison.
In the areas inspected, violations or deviations were not identified.
3.
Exit Interview The inspection scope and results were summarized on February 16, 1990, with those persons indicated in paragraph 1.
The inspector described the areas inspected and discussed in detail the inspection results listed below.
Although reviewed during this inspection, proprietary information is not contained in this report.
Dissenting comments were not received
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Acronyms and Initialisms l
Alternating Current AC
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ASME American Society of Mechanical Engineers
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B&PV Boiler and Pressure Vessel
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B&W Babcock and Wilcox
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Distance Amplitude Curve DAC
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Diameter Dia.
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Duke Power Company DPC
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Eddy Current
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EC
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Inservice Inspection
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MT Magnetic particle
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Megahertz MH
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NDE Nondestructive Examination
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Nuclear Regulatory Commission NRC
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Radiographic Test
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Technical Support l
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UT.
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Ultrasonic
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VT Visual
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