IR 05000413/1993032

Insp Repts 50-413/93-32 & 50-414/93-32 on 931117-19 & 1129-1203.Violations Noted.Major Areas Inspected:Observation of Eddy Current (ET) Exam of SG Tubes,Inservice Activities Including Surface & Volumetric Exams,Review of Radiographs

ML20059G178
Person / Time
Site:	Catawba
Issue date:	12/30/1993
From:	Blake J, Economos N NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
To:
Shared Package
ML20059G151	List: IR 05000413/1993032 ML20059G150 ML20059G159
References
50-413-93-32, 50-414-93-32, NUDOCS 9401240026
Download: ML20059G178 (15)

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UNITED STATES jP'@ RFoN - NUCLEAR REGULATORY COMMISSION

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E REGloN li 101 MARIETTA STREET, N.W., SUITE 2900 %

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Report Nos.: 50-413/93-32 and 50-414/93-32 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 a 2 Inspection Con c .

>mber 17-19 and November 29 - December 3,1993 l

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Date Signed a tor Inspec Approved by: k /m /{JatehMNd S6 ned J. J. Blake, Chief U p' 9 Materials and Processes Section Engineering Branch Division of Reactor Safety-SUMMARY Scope:

This routine, announced inspection was conducted onsite in the following areas: observation of Eddy Current (ET) examination-of steam generator (S/G)

tubes; observation of inservice activities including surface and volumetric examinations; and review of radiographs of welds from valve replacement in the Safety injection (SI) Syste Results:

ET activities including S/G tube examination / acquisition, analysis, disposition and plans for repairs, i.e. tube plugging, were consistent' with

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technical specification requirements, regulatory guides and commitments. The licensee demonstrated significant strength in the training of analysts and exercised notable conservatism in ident1 tying and evaluating ET indications.-

A violation (N0V) was issued for failure to include in the Inservice Inspection (ISI) plan, code required surface examinations on safe-end to nozzle welds in the four SI' accumulators in Units 1 and 2, (see paragraph 2c.2). In addition, one unresolved item was identified for using grey powder to perform magnetic particle examination on a bright metal carbon steel weld, Red powder would have provided more adequate color contrast under the circumstances (see paragraph 2c.3). Also a weakness was identified with 9401240026 931230 PDR G ADOCK 05000413 pyg

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regards to Catawba's referencing system used for the lay out of ISI weld This appears to be the result of an inconsistency in two related procedures on this subjec Except as noted above no violations or deviations were identifie ,

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,i REPORT DETAILS

. Persons Contacted Licensee Employees

• J. Baumann, Supervisor Eddy Current

• J. Cherry, Quality Assurance Technical Services (QATS)

• J. Forbes, Engineering Manager

• R. Giles, ISI Coordinator, QA >

• R. Kaye, S/G Station Sponsor

• J. Lowery, Regulatory Compliance Specialist t

• D. Mayes, Engineering Consultant, Nuclear Services Division

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• McCollum, Station Manager

• D. Rehn, Vice President Catawba Nuclear Station

• T. Tucker, level III NDE Examiner  ;

Other licensee employees contacted included engineers, technicians, and office personnel ,

NRC Resident Inspectors

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• R. Freudenberger, Senior Resident Inspector J. Zieler, Resident Inspector

• Attended exit interview Inservice Inspection (ISI)

The inspector reviewed documents and records, and observed activities, ,

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as indicated below, to determine whether ISI was being conducted in

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accordance with applicable procedures, regulatory requirements, and licensee commitment The applicable code for ISI, for both Unit 1 and Unit 2, is the ASME B&PV Code,Section XI, 1980 edition with addenda through winter 1981 (80W81). Unit 1, was in the seventh refueling outage; in the third 40 month period, of the first ten year ISI interval (P3,II). Unit I received their operating license on January 17, 1985 and commenced commercial operations on June 29, 198 The licensee's nondestructive examination personnel were performing the liquid  ;

penetrant (PT), magnetic particle (MT), ultrasonic (UT), and eddy current (ET) examination ISI Program Review, Unit 1 (73051)

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The inspector reviewed the following documents relating to the ISI l program to determine whether the plan had been approved by the licensee and to assure that procedures and plans had been -

established for the applicable activitie Unit 1, ISI Plan for Outage 2, Period 3, Interval 1-Volume 1, i Rev. 6  !

Unit 1, Steam Generator Inspection Plan for Outage 2, Period 3, Interval !

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b. Review of NDE Procedures, Unit I and 2 (73052)

The . inspector reviewed the procedures listed below to determine whether these procedures were consistent with regulatory requirements and licensee commitments. The procedures were also-  !

reviewed for technical conten '

Procedure Reviewed

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ID Revision Title NDE-10 (R18) Radiographic Examination Procedure NDE-25 (R15) Magnetic Particle Examination Procedure

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and Techniques NDE-35 (R14) Liquid Penetrant Examination NDE-90 Referencing System for Identification of Layout-of Welds and' System Components ,

NDE-B (R18) . Training, Qualification and Certification of NDE Personnel NDE-C (R4) Calibration, Verification of NDE Equipment NDE-600 (R2) Ultrasonic Examination ,

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of Similar Metal Piping Welds in Wrought Ferritic and Austenitic

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NDE-630 (R2). Ultrasonic Examination of Welds in Wrought Ferritic and Austenitic :

' Pressure Vessels 2" in -

Thickness and Under ,

NDE-640 (RO) Straight Beam Ultrasonic-Examination of Welds and Base Material in *

Pressure Vessels and Piping

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Procedure Reviewed 10 Revision Title NDE-701 (R1) Multifrequency Field Changes: Eddy Current Examination 92-04, 92-11, 92-24 of Steam Generator Tubing at MCGuire, Catawba, and Oconee Nuclear Stations NDE-702 (RO) Eddy Current Field Changes: Examination Data 93-12 Screening Program NDE-703 (R3) Evaluation of Eddy Field Changes:

93-12 Current Examination Data for Steam Generator Tubing NDE-705 (RO) Multifrequency Eddy Current Examination of Non-Ferrous Tubing The above procedures contained the necessary elements for performing the applicable examinations and were consistent with code requirement Observation of Work Activities (IP73753)

The inspector observed work activities, reviewed certification records of NDE equipment and materials, and reviewed NDE personnel qualifications for personnel utilized for ISI examinations observed. The observation and reviews conducted by the inspector are documented belo (1) Ultrasonic Examination (UT)

Item N Weld Component Comment CO2.021.051 1ACCB-02-13 Safety *See Note Accumulator Below Tank IB Outlet Nozzle to Lower Head C05.021.060 ICF34-03 Pipe to Valve *See Note

1. 1CF042 Main Below Feedwater C05.021.061 1CF34-04 Pipe to Valve ICF042 *See Note Main Feedwater Below

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• Note: These welds exhibited several low amplitude indications which were evaluated as fabrication related root condition that were I subsequently verified by review of construction radiographs.

(2) Liquid Penetrant Examination (PT)

Item N Weld Component Comments CO2.021.051A 1ACCB-02 *See note above No relevant-13 indications C02.021.301 INIl7-06 Safety No relevant Injection indications Tank 1B Terminal End in reference to these examinations the inspector noted the following:

• The liquid penetrant examination of weld INIl7-06 was identified in the ISI plan under item C05.011.301. The weld was described as a 10" diameter terminal weld to the Safety accumulator (NI), tank 18. In the field, the inspector noted the presence of a short pipe section about 11" long thought to be a safe-end attached between the NI tank nozzle and the 10" diameter pipe. The weld surface between this short pipe section (safe-end) and the nozzle appeared to be in the as welded condition while the weld between the safe-end to pipe had been ground smooth in preparation for ,

inservice inspection. Prior to the inspection, the NDE technicians and the inspector attempted to locate the weld number of either or both of these welds, but were unsuccessful. Because of the apparent inability to verify, in the field, which one of the aforementioned two welds was item CO2.021.301 (terminal weld INIl7-06) the technicians decided to PT both welds rather than take a chance of examining the wrong weld. Following. completion of the examination, the inspector asked the ISI coordinator, about the examination status of the subject safe end weld In .

response to this question, the licensee's representative stated that a record review showed the safe-end welds in each of the four NI accumulator tanks in Unit I and 2 had been examined during the preservice inspection effort, but for some unknown reason they had been left off the ISI Pla The inspector informed the licensee that failure to include code required inspections in the ISI plan is in violation of

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IWA-1400 of ASME Code Section XI 1980 Edition and was reported to the licensee as violation 50-413,414/93-32-01, Failure to Include Code Required Welds Subject to Examination in Facility ISI Pla _ . .

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e Weld Identification & Referencing System Procedure NDE-90 describes methods to be used for marking / identifying welds and for laying-out referencing of welds subject to UT examination per the ISI plans. In the field, the inspector noted that weld C02.021.051 scheduled for UT had not been laid out with center line referencing marks as described in the above procedure. The reason given was that the weld had been previously stamped around its circumference for radiography and those numbers could be used for this purpose. However, these numbers were located on the edge of the weld and not include in the geometric center as described in the procedure. In reference to the PT'd welds, the inspector and the NDE technician tried '

unsuccessfully to locate the identification number for each !

of the subject weld Discussions with the NDE technicians ,

disclosed that site / Duke fabricated welds were required to be identified using either low stress punches or vibrio tools for numbering purposes. Vendor welds retained the identification number stamped on the component / weld by the ;

manufacture. However, in the case of the subject welds, the >

inspector noted that neither the Duke weld (terminal weld) ,

nor the safe-end weld (vendor weld) were clearly identifie l In the inspector's view this lack of. clear weld  ;

identification contributed in part to the confusion over '

which of the two welds were to be liquid penetrant examined as discussed earlier. With regards to the lack of-centerline referencing marks on weld 002.021.051, it appears that the level II examiners decided the RT referencing j numbers provided adequate referencing points for plotting i purpose Because the subject weld had been ground flush, t and the weld edges were readily visible, the inspector agreed with the examiner's decision. However, the inspector cautioned against following this practice since weld edges ;

are not as easily discernable in many similarly finished ;

welds. The described lack of consistency in weld l identification and referencing was identified to the j licensee as a programmatic weakness requiring appropriate I action to preclude possible problems in this are (3) Magnetic Particle (MT) Examination The inspector observed MT examination performed on the welds 'l listed below: '

Item N Weld Component Comments C051.021.060A ICF34-03 Pipe to Valve No relevant indications

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C051.021.061A ICF34-04 Pipe to Valve # No relevant indications-

ICF042 (opposite side)

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The observations were compared with the applicable procedures and the Code in the following areas: examination methods; contrast' of dry powder particle color with background; surface temperature; viewing conditions; examination overlap and directions; pole or prod spacing; lifting power.(yoke); and acceptance criteri Although the examinations met applicable procedure and code requirements, the inspector noted the following technique weaknesses:

e On previous ISI inspections, NRC inspectors have noted that the licensee's MT examiners prefer to use gray magnetic particles (powder), when performing the subject. examinations. During this inspection, the inspector noted that the above welds had been ground *

smooth.to a bright metal finish. As such the inspector observed that the hue / tint of the weld and the powder were similar in that both were in the gray color range which did not appear to meet the intent of adequate contrast with the surface being examined as stated in T-753, of the ASME Code V. In this inspector's view, the better color selection would have been red powder which would have provided significantly better contrast. This inspector discussed this concern with the licensee's level III examiner responsible for this activit He acknowledged that this matter had been discussed previously with other NRC inspectors and reiterated the position taken on this matter. Basically, the position stated in part that gray magnetic particles were acceptable provided it (powder) provided adequate contrast to distinguish indication from the surface background. The choice of particle color was left to the technician. In most cases the color chosen has ,

been gray. This inspector disagreed with this position because the position was not a documented part of the approved procedure. The position provides no specific instructions to the technician, as to the color of powder to be used for specific conditions i.e., bright metal, mill surface et This inspector's position is that these decisions should be made at the corporate level (i.e. Level III corporate)

and implemented by approved procedure (s), rather than letting them be made at the technician level The inspector suggested that if the licensee wished to continue the present practice they should be prepared to prove, by demonstration, the adequacy of using gray magnetic particles over a wide color spectrum of welds and materials under field conditions. The licensee agreed to pursue this matter further, and report back during a future RII, inspection. This matter was

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identified to the licensee as an unresolved item pending NRC review of the licensee's action (s) on this matter. This issue was identified as unresolved item ;

50-413.414/93-32-02, Use of Gray Magnetic Particles on Bright Metal Finish Weldment (4) Eddy Current Examination of Steam Generator (S/G) Tubes Background

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The four S/Gs at Catawba Unit 1 are Westinghouse D-3 !

models with 4,674 tubes per S/G. The tubing materia )

is mill annealed inconel 600, with 0.750" OD and 0.43" l nominal wall thickness. The tubes are hard rolled for !

the full length of the tube sheet on both ends i hot and cold legs. Primary Water Stress Corrosion )

Cracking (PWSCC) - ID originating cracking in the ,

rolled tube sheet area has been responsible for many i plugged tubes at Catawba Unit 1. In general the area of concern is about 3" from the tube end to the last main roll expansion at or near the top of the tube sheet. Peripheral tubes in the pre-heater region of the generator are susceptible to support plate wea Antivibration Bar (AVB) wear in the U-bend area ,

throughout the generators has been observe Examination Program As stated earlier, ISI activities during this outage included eddy current examination of tubes in the four steam generators. Data acquisition and analysis were being performed in accordance with procedures identified earlier in this report. Controlling documents / code by reference, include ASME Code Section XI (80W80), Regulatory Guide 1.83 July 1975, Code Case N-401, Digitized Data Collection for Eddy Current Examination, and proposed amendments to Technical Specifications (T.S.) 4.4.5.2, dated October 5, 1993, renewal of Steam Generator Tube Interim Plugging Criteria for Unit 1 Cycle The submittal, requests renewal of the voltage based steam generator tub interim plugging criteria (IPC) for use during cycle This submittal was undergoing NRR staff review during the time of this inspection effor For this outage, adoption of the T.S. amendment means that tubes with flaw 1.idications, with a bobbin coil measured voltage less than or equal to 1.0 volt, can remain in service without further action. Tubes with flaw indications (bobbin coil measured value) in excess of 1.0 volt but less than 2.7 volts, can remain

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in service provided a rotating pancake coil (RPC)

inspection of the indication does not detect Outer Diameter Stress Corrosion Cracking (0DSCC) or any other degradation mode. Crack indications, in tubes (bobbin coil measured value), above 2.7 volts will be plugged or repaired by. sleeving, and do not require RPC confirmation. As such the licensee was performing a 100% bobbin coil inspection for all tube support plate (TSP) intersections and all cold leg TSP intersections down to the lowest cold leg tube support  ;

plate with ODSCC indications. An inspection using the i RPC probe was being performed on tubes with flaw like l bobbin coil signal amplitudes > 1.0 volt but < l volts. RPC data was being evaluated to establish l whether principal indications could be characterized i as ODSCC. Also, the subject proposed T.S. amendment 1 requires the licensee to report, to the commission, results for all tubes, in which the TSP intersection  !

IPC has been applied together with location of tube degradation, and the extent of the degradation in terms of voltage. Tubes planned for examination and the types of examinations performed are as follows:

TYPE S/G A S/G B S/G C S/G D INSPECTION HL/CL HL/CL HL/CL HL/CL Number of Tubes BOBBIN 4442/4468 4601/4601 4386/4395 4414/4487 l MRPC, U-BEND 320 332 316 317 Rows 1-3 U-BEND 168 372 427 156  ;

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MRPC HL 4442 4601 4386 4414 Tubesheet MRPC Plugs 109/109 36/36 120/122 79/80 MRPC 627/584 779/437 928/808 826/327  ;

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Previously installed sleeved tubes were plugged during this outage and therefore they were deleted from-inspection plan. Data acquisition was being performed ]

by licensee personnel. Data analysis was conducted by licensee and contractor personnel at the McGuire Nuclear Station. Examinations were being performed with a multifrequency bobbin coil technique, utilizing the computerized MIZ-18 syste Bobbin coil

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identified indications were confirmed with motorized :

RPC examinations. Data was evaluated and subsequently analyzed with the aid of documented detailed guidelines developed and approved for use during the ,

present outage. A list of these guidelines and ;

applicable appendices are as follows:  :

Catawba Unit 1 Eddy Current Analysis Guidelines '

October 26, 1993 Appendix A: MRPC Special Interest /Tubesheet Analysis Guidelines Appendix B: MRPC Plug Analysis Guidelines ,

Appendix C: Rotating Crosswound Sleeve Analysis ,

Guidelines Appendix D: Lead / Resolution Analyst Guidelines ;

In summary, the above guidelines and appendices provided for data analysis, data screening, reporting and recording criteria, monitoring probe wear, ;

calibrations, assignment of responsibilities, resolution and disposition of tubes with'pluggable ,

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indications. In addition the subject guidelines provided specific instructions for reporting: all signals indicative of degradation regardless of depth and minimum voltage; dents when voltage levels '

measured 2: 2.5 volts; and indications of Intergranular Attack (IGA) or ODSCC in the hot leg TSP intersections regardless of the voltage indicated depth (s).

In addition to reviews of the applicable requirements _ i procedures and guidelines, the inspector observed data'

acquisition activities including MRPC of inner-row tubes in the cold leg (C/L) and on the tubesheet on the hot leg (H/L) side of S/G B. The run'of tube '

examinations observed were identified as follows:

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S/G "B" U-Bend, MRPC Single Coil Examination

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C/L: Row Columns

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2 99-114 2 70-79 C/L: Row Columns 2 58-68

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Tubesheet, MRPC Three Coil Examination H/L: Row Columns 49 58-72 43 90-93 42 94-58 41 58-87 S/G "C" Special Interest, MRPC Three Coil Examina+ '.

C/L: Row Columns 22 43-45 and 49 25 50 In addition to these observations, the inspector witnessed in line system calibration performed at the following times.

DATE TIME DISC # CAL. GROUP #

11-17-93 09:44 06BHTS 219 15:55 03 BUB ---

11-19-93 09:40 02CSI 0605 These calibrations and results were consistent with applicable procedural requirements. They were performed in a timely manner by adequately trained and qualified personnel using equipment and calibration standards that were identifiable and traceable to appropriate QA documents. Calibrations were performed on a four' hour schedule. Tube position verification was performed once every twenty tubes and documented as required. During this time the inspector observed shift turnover and reviewed related log entries which were found in orde * Records Review:

Records review included qualification and/or certifications of equipment, calibration standards and personnel. Some but not all of the documents reviewed were as follows:

Remote Data Acouisition Unit (RDAU) S/N Certification MIZ 18-A 071 20504 MlZ 18 131 20494

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246800 Calibration Standards Serial Number Type Zetec-50446 Z-ll220 ASME/ WEAR, Combination Z-11387 Z-ll207 Personnel Qualification I II IIA III IIIA (QDA)*

Records Organization Duke 3 5 ABB (ASEA Brown Boveri) 3 1 B&W Nuclear Service 5 1 Company (B&W NCS)

Zetec In *This individual had taken ERI's data. analyst training and had successfully passed the examination which certified him as a qualified data analyst. This training and qualification is over and above the code prescribed training, experience and examination requirement e Tubes Removed from Service As stated earlier in this report, all S/G tubes planned for .l inspection were examined using site approved procedures, '

guidelines and the proposed APC/IPC voltage limit Discussions with the licensee's representative after the  ;

closing date of this inspection disclosed that approximately  ;

8300 bobbin indications were identified in total, in:the four steam generators. Those-indications with voltages  !

exceeding IPC voltage limits were examined with MRPC for I confirmation and further analysis. A summary of the S/G tubes plugged is presented for information'below. As required by the proposed T.S. amendment, the licensee has provided the NRR staff, a report with details of their findings prior to returning to powe .I

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Type Indications and Tubes Plugged From RF0 12-10-93 STEAM HL TUBE COLD HOT GENERATOR SLEEVED SUPPORT TUBE- LEG LEG WEAR OTHER TOTAL PLATE SHEET FREE- FREE-SPAN SPAN A 26 8 34 18 6 12 15 119 B 0 18 23 16 6 0 26 89 C 47 123 26 18 5 4 20 243 D 104 101 39 18 9 0 13 284 TOTAL 177 250 122 70 26 16 74 735 PER IN TYPE The total number of tubes plugged prior to this outage for Unit-1 is as follows:

S/G "A" S/G "B" S/G "C" S/G "D" Total Tubes Previously 206 73 279 187 745 Plugged Within the areas inspected no deviations or violations were identifie . Review of Radiographs (37700/57090)

Unit-1 pressurizer is equipped with three Rockwell equi-wedge gate Power-Operated Relief Valves (PORVs), INC31B, INC33A and INC35 These valves were replaced during this outage for maintenance, as minor modification No. CE395 The modification was performed under ASME Code Section XI Repair and Replacement program. At the time of this inspection, welding and NDE work was completed. As such, the inspector performed a review of related radiographs to determine their adequacy in terms of procedural and code requirements. The welds were shot using the film side penetraimeter technique per DPC radiographic procedure NDE-10 Rev. 18A. The following weld radiographs were reviewe Welds Size Description ' Condition INC257-7 3" x 0.438" Valve, ET 347-1-3 to pipe Acceptable INC257-8 3" x 0.438" Valve, ET 347-1-3 to pipe Acceptable

• lNC257-ll 3" x 0.438" Valve, ET 347-1-4 to pipe Acceptable INC257-12 3" x 0.438" Valve, ET 347-1-4 to pipe Acceptable INC257-16 3" x 0.438" Valve, ET 347-1-5 to pipe Acceptable INC257-17 3" x 0.438" Valve, ET 347-1-5 to pipe Acceptable

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Minor porosity indications were observed on interval 3-4 of this weld which had not been documented on the reader sheet. This observation was communicated to the licensee representative for further review by the NDE examine Except for the condition noted, the inspector found the radiographs to be of good quality and satisfactory sensitivity. The film packages contained all 1 the necessary information for reviewing the subject fil '

Within the areas inspected No violations or deviations were identifie ) Equipment Certification Records Review Equipment / material certification records, listed below, for equipment / materials used in the inspections detailed in paragraphs 2c, 2d, and 2e above were reviewed to ensue compliance with applicable requirement Equipment Type Eauipment Identification i

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Penetrant Cleaner Batch 91F02P Penetrant Batch 78E084 Penetrant Developer Batch 92D06K Magnetic Particles Batch 91J047 UT Transducer Serial C11843 UT Transducer Serial 42683  ;

UT Transducer Serial F03822 I UT Transducer Serial 43062 UT Transducer Serial 42689 UT Instrument Serial 32810-922 UT Instrument Serial 32810-873 UT Couplaint Batch 093001 Temp. Indicator Serial 716388 Magnetic Yoke Serial ES-6-1 Within the areas inspected no violations or deviations were identifie . Exit Interview The inspection scope and results were summarized on December 3,1993, with those persons indicated in paragraph 1. lhe inspector described the areas inspected and discussed in detail the findings listed belo Although reviewed during this inspection, proprietary information is not contained in this report. Dissenting comments were not received from the license Violation: 50-413,414/93-32-01, Failure to Include Welds in ISI Plan, paragraph 2 Unresolved Item: 50-413,414/93-32-02, Use of Gray Magnetic Powder on Bright Metal finish Weldments, paragraph 2 _ _ _ - - _ _ _ - _ - _ _ _ _ - _ _ _ _ _ _ - _ _ _ _ - _ _ _ _ _ _ _ - - -