IR 05000414/1985034

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Insp Rept 50-414/85-34 on 850812-16.No Violation or Deviation Noted.Major Areas Inspected:Fabricating & Welding of Supports,Pressure Insp Program,Reexam of Welds Using Region II Personnel & Equipment
ML20135F934
Person / Time
Site: Catawba Duke Energy icon.png
Issue date: 09/05/1985
From: Blake J, Coley J
NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
To:
Shared Package
ML20135F913 List:
References
50-414-85-34, NUDOCS 8509180023
Download: ML20135F934 (19)
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o NUCLEAR REGULATORY COMMisslON

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Report No.: 50-414/85-34 Licensee: Duke Power Company 422 South Church Street Charlotte, NC 28242 Docket No.: 50-414 License No.: CPPR-117 Facility Name: Catawba Inspection C : gust 12 - 16, 1985 Inspec r: E 9DAte Signed

.L C ley Approved by:

J. J. Jrlake, Section Chief Datd Signed E gf eering Branch iv sion of Reactor Safety SUMMARY Scope: This routine, unannounced inspection entailed 38 inspector-hours on site in the areas of fabrication and welding of supports, preservice inspection -

review of. program, preservice inspection - review of procedures, preservice inspection - data review and evaluation, and preservice inspection - independent re-examination of welds using Region Il personnel and equipmen Results: No violations or. deviations were identifie i e

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REPORT DETAILS Persons Contacted Licensee Employees

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  • L. Vincent, Construction Engineer - Civil
  • J. Whichard, Electrical Engineer
  • J. Cherry, Operation Quality Assurance - Inservice Inspection (ISI)
  • B. Throneburg, Status and Control
  • R. Giles, ISI Coordinator - Operations
  • E. Williams, Project Quality Assurance Technician Other licensee employees contacted included construction craftsmen, engineers, technicians, mechanics, and office personne NRC Resident Inspector
  • P. K. Van Doorn - Senior Resident Inspector

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  • Attended exit interview Exit Interview The inspection scope and findings were summarized on August 16, 1985, with those persons indicated in paragraph 1 above. The inspector described the areas inspected and discussed in detail the inspection finding No dissenting comments were received from the license Unresolved Item 50-414/85-34-03, Apparent Failure of Babcock and Wilcox to Perform Audits of Their Inspection Services Division, Work Activities on Unit 2, paragraph Unresolved Item 50-414/85-34-02, Clarification of Procedure NDE-11 and NDE-12 Needed, paragraph Inspector Followup Item 50-414/85-34-01, Demonstrate Ability of Ultrasonic Equipment to Discern Crack in Centrifugally Cast Stainless Steel, paragraph Inspector Followup Item 50-414/85-34-04, Technical Review of Preservice Records, paragraph The licensee did not identify as proprietary any of the materials provided to or reviewed by the inspectors during this inspectio . Licensee Action on Previous Enforcement Matters This subject was not addressed in the inspectio e

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4. Unresolved Items Unresolved items are matters about which more information is required to detemine whether they are acceptable or may involve violations or deviations. New unresolved items identified during this inspection are discussed in paragraphs 6.b and . Fabrication and Welding of Supports (55050)

On August 12, 1985, the inspector made a general inspection of the licensee's pipe fabrication shop, machine shop, and metal fabrication shop to determine through direct observation whether welding activities were performed in accordance with American Society of Mechanical Engineers (ASME)

Boiler and Pressure Vessel (B&PV) Code and Catawba's Unit 2 Safety Analysis Report (SAR) commitment In the metal fabrication shop, the inspector observed journeymen metal workers fabricating sway struts to be used on safety-related piping system at the Catawba and McGuire site The applicable code for the sway struts fabrication was the 1974 edition of the ASME Code, Subsection NF, with addenda through Summer 197 The inspector reviewed the fabrication drawings, work instructions, documentation, observed module assembly of the end bracket detail to assure clearances were maintained for welding, and verified control of filler materials from the fabrication area to and including the weld rod issue station. During the inspection the inspector questioned why visual inspection was the final acceptance criteria in lieu of magnetic particle examination when the struts observed were to be used on Class A, 8, and C piping systems. The inspector was referred to the licensee's engineering group for resolution of the inspection requirements. The inspector held discussions with the cognizant engineers and found that these struts were linear type pipe supports and that full penetration welds on linear type supports only required final visual inspection in accordance with subsection NF of the ASME cod .

Within the area examined, no violations or deviations were observed, 6. Preservice Inspection - Review of Program (73051B) Unit 2 The inspector reviewed the licensee's preservice inspection (PSI) program to ascertain whether the -licensee's program pertaining to the preservice inspection of Unit 2 was complete and in conformance with regulatory requirements and licensee commitment In accordance with these requirements,Section XI, of the ASME B&PV code (74S 75) is the applicable code. Babcock and Wilcox (B&W) was used by the licensee to perform the ultrasonic examinations of piping and component Radiography required by the program was per'ormed by the licensee and i surface and visual examinations were performed by both the licensee and B& !

Eddy current examinations were performed by CONAM for Unit 2; however, CONAM's program and procedures were not reviewed by the inspector.-

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The following specific areas of the program were reviewed for compliance; Program had been approved by the licensee Quality Assurance (QA) plans and procedures had been established (written, reviewed, approved and issued) to assure that the following activities are controlled and accomplished:

(1) Qualifications, responsibilities and duties of QA personnel responsible for PSI activitie (2) Indoctrination / training program for QA personnel responsible for PSI activitie (3) Audit procedure and/or checklists develope (4) Scope and purpose of audits to be performed are defined, including audits of the status and adequacy of the PSI progra (5) Frequency (or schedule) of audits, audit criteria, basis for re-audit, management review and assessment, corrective action and followup of corrective actio (6) Qualifications and responsibilities of auditors, including those of contractor (7) Quality requirements developed, including appropriate examination reports, acceptance criteria, and required documentation are specified in PSI progra (8) Deviations from previously established PSI programs and procedures are controlled and reviewed by cognizant personne (9) Quality documentation, including material certifications, examination reports, evaluations, and auditing results are generated and maintained to indicate whether PSI quality require-ments have been me (10) Identification of components, and systems covered by the PSI progra (11) Work and inspection procedures pertaining to the PSI are establishe (12) Inspection and work procedures are completed, reviewed, approved and controlled; and that those performing QA and inspection (QC)

activities have available the most recent and approved procedures and instructions pertinent to activities they are to monitor or inspec .

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(13) Procedures are provided to assure suitably controlled PSI work and inspection condition (14) Procedures are provided for the control of special methods, techniques and examination equipmen (15) Special methods, techniques and examination equipment are used by

. qualified personnel using qualified procedures in accordance with applicable requirement .

(16) Procedures are established for identification and correction of conditions adverse to -quality as detected during examination, including provisions to preclude repetition of such adverse activities.

'l (17) Documents relating to PSI activities are adequately controlle (18) PSI related documents are reviewed by cognizant personnel for adequac *

(19) Provisions to . assure appropriate identification / listing and control of aggregate collection of-quality assurance instructions and procedures, including future revision (20) Provisions to assure periodic review of the adequacy of document control procedure (21) Procedures to assure that acceptance criteria are specified, examination requirements-(including prerequisites) have been met, evaluation of results documented and deficiencies detected and reported to the appropriate level of management.

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(22) Procedures to assure adequate control, calibration, and adjustment of measuring and examination equipmen (23) Procedures to assure that evidence of indications and NDE findings are documented by qualified personne (24) Procedures to assure that specified NDE documentation for PSI examinaticns have been received and have been reviewed by the cognizant personne (25) Provisions to assure that PSI activity records are legible, adequate, retrievable and refer to markings, identifications or other means of-identifying materials and components important to safet (26) Review of PSI activity records by qualified personnel, including records of appropriate subsequent corrective action if neede _

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In order to verify the program areas listed above, the following licensee and B&W procedural documents were reviewed by the inspector:

- Babcock and Wilcox Quality Assurance Manual, Revision 2

- Duke Power Company Quality Assurance Program

- B&W Procedure NPG-1719-21, Quality Assurance Audits of NPD Activities, Revision l'

- B&W Procedure 01-1280, Qualification of Quality Assurance Audit Personnel, Revision 1

- B&W Procedure ISI-1, Administrative Procedure for Control of Inservice Inspection Procedures, Revision 4

- B&W Procedure ISI-2, Administrative Procedure for Records Manage-ment, Revision 4

- B&W Procedure ISI-20, Personnel Qualification - Magnetic Particle Examination, Revision 4

- B&W Procedure ISI-21, Personnel Qualification - Ultrasonic Examination, Revision 4

- B&W Procedure ISI-22, Personnel Qualification - Liquid Penetrant Examination, Revision 3

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B&W Procedure ISI-23, Personnel Qualification - Radiographic Examination, Revision 3

- B&W Procedure ISI-24, Personnel Qualification - Eddy Current Examination, Revision 4

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B&W Procedure ISI-25, Personnel Qualification - Visual Examina-tion, Revision 5

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B&W Procedure ISI-50 Technical Procedure Describing Surface Requirements of Welds, Adjacent Base Metal, and Components for Nondestructive Examination, Revision 8

- B&W Procedure ISI-51, Technical Procedure for Macro-Etching, Revision 4

- B&W Procedure 151-55, Technical Procedure for Sulfur Content Analysis, Revision 0

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B&W Procedure ISI-56, Technical Procedure for Halogen Content Analysis, Revision 0

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- B&W Procedure ISI-60, Administrative Procedure for the Use of Consumables, Revision 5

- B&W Procedure ISI-61, Administrative Procedure for Control of Manuals and Reports, Revision 16

- B&W Procedure ISI-62, Administrative Procedure for Control of Documents, Revision 3

- B&W Procedure ISI-63, Administrative Procedure for Approval of Manuals and Reports for Baseline and Inservice Inspection-Programs, Revision 5

- B&W Procedure ISI-64, Administrative Procedure for Handling Nonreportable Nondestructive Examination Data, Revision 15

- B&W Procedure ISI-65, Administrative Procedure for Use of the Data Base System, Revision 12

- B&W Procedure ISI-67, Administrative Procedure for Preparation of Non-NDE Data for the Data Base System, Revision _4

- B&W Procedure ISI-69, Administrative Procedure. for Reporting of Nondestructive Examination Indications and Data to the Customer, Revision 9

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B&W Procedure ISI-76, Administrative Procedure for the Design, Fabrication, and Certifications of Calibration Standards, Revision 9

- B&W Procedure ISI-77, Administrative Procedure for Procurement, Revision 3

- B&W Procedure ISI-78, Administrative Procedure for Tagging and Correction of Nonconforming Items, Revision 6

- Bail Procedure 151-80, Administrative Procedure for Preventive Maintenance of Nondestructive Examination Equipment, Revision 13

- B&W Procedure ISI-83, Measurement of Ultrasonic Instrument Performance Characteristics, Revision 1

- B&W Procedure ISI-119, Ultrasonic Examination of Stainless Steel ant Nickle Base Alloy Weld Seams

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B&W Procedure 151-120, Ultrasonic Examination of Piping and Vessel Welds Joining Similar and' Dissimilar Materials

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B&W Procedure 1S1-1310. Ultrasonic Examinations of Vessel Welds and Nozzle Inside Radius Sections

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7 B&W Procedure ISI-240, Penetrant Examination of Weld and Base .

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- B&W Procedure ISI-270,' Wet or Dry Methods of Magnet Particle i Examination of Welds, Studs, Nuts, Bolts, and Pump Motor Flywheels

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B&W Procedure 1S1-350 Visual Examination" of Welds and Surface Conditions

- B&W - Procedure -ISI-353, Visual Examination of Pipe Hangers, Supports, and Restraints

- Duke Power Company (DPC) Procedure NDE-A, Nondestructive Examination Program Procedure, Revision 5

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DPC Procedure NDE-B, Training Qualification and Certification of NDE Personnel, Revision 9

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DPC Procedure NDE-11, General Radiography Procedure for Preservice and Inservice Inspection, Revision 4

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DPC Procedure NDE-12, General Radiography Procedure for Preservice and Inservice Inspection, Revision 4

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DPCProcedureNDE-24,MagneticParticleInspectionTechnique(Yoke

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Method) for Preservice and Inservcie Inspection,. Revision 6

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DPC Procedure NDE-25, Magnetic Particle Inspection Technique l(Yoke method) for Preservice and Inservice Inspection (1980), Revision 6

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- DPC Procedure NDE-26, Wet Non-Fluorescent and Fluorescent Magnetic Particle Examination . Techniques - for Examination of Pressure Retaining Bolting, Revision 6 J

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DPC Procedure NDE-33, Liquid Penetrant Examination . Technique (Color Contrast,- Solvent Removable Method) for Preservice and Inservice Inspection, Revision 5

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DPC Procedure NDE-44, Ultrasonic Examination of Bolts and Studs for Preservice and Inservice Inspection, Revision 5 DPC Procedure NDE-46, Ultrasonic Examination of Reactor Vessel

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Closure. Nuts for Preservice and Inservice Inspection, Revision 4 As a result of the above document reviews the following area of concern -

was identified:

Babcock and Wilcox's Quality Assurance Manual,Section XV, requires

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that, audits of the Inspection Service activities, typically performed at the job site, provide verification of compliance with the QA progra Discussions with cognizant B&W personnel both onsite and off

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site indicated that B&W has- not audited the inspection service

> activities as required for Catawba Unit In addition, there was no documentation available at the site to indicate that Unit I received an i audit of the inspection service activities by B& B&W's QA Manual

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further states that, the audits conducted under the QA audit program

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include an objective evaluation of- quality-related _ practices, i

! procedures and instructions; the effectiveness of implementation, work i

! areas, activities, processes, and the review of documents and records.

B&W sent the inspector an audit (Audit No.157) that had been performed
in June of 1985 on the Nuclear Power Division's, Special Products and i Integrated Field Services in Lynchburg, Virginia. However, the scope of this audit was restricted to documents and records, not inspection
activities relating to the effectiveness of examiners and examination t The inspector tried to contact cognizant licensee personnel to deter-mine if the -licensee had a contract exception with B&W that would

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relieve B&W from their QA manual requirements- by designating the

! licensee responsible for auditing B&W's site activities. Cognizant

Duke personnel in Charlotte, North Carolina, could not be reached for .

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confirmation of the above. This item will be reported as an unresolved j j item until the inspector can verify any contract exception to B&W's QA >

i program and will be tracked as Unresolved Item 50-414/85-34-03,

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Apparent Failure of Babcock and Wilcox to Perform Audits of Their Inspection Services Division, Work Activities on Unit 2.

! Scope of Preservice Plan

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i The inspector reviewed the licensee's PSI program for Unit 2 to l ascertain whether the program included the following: ,

I (1) Description of areas to be' examined in accordance to ASME BPVC '

l Section XI, Articles IWB-2000 and IWC-2000 ,

(2) Examination category for each area
(3) Method of inspection for each area

L (4) Extent of examination for each area i (5) Justification for exceptions to codes.and standards.

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qualification requirements were consistent with Regulatory Guide-1.58, i Qualification of Nuclear . Power Plant Inspection, Examination and Testing Personnel, American National Standard Institute (ANSI) N45.2.6

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i and the - American Society - for Nondestructive _. Testing, recommended practice no. SNT-TC-1A.

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9 Nondestructive Examination (NDE) Records The inspector reviewed the PSI program and reference documents to ascertain whether adequate provisions relating to the control of NDE records included the following:

(1) Administrative controls have been established for control of the generation, approval, and custody of the following records:

- Examination results and data sheets including film and tape records for automated examination Listing of NDE equipment and instrumentation which are used during examinations, including make, model and serial numbe Calibration data sheet Listing of calibration blocks by identification number and material identificatio Personnel qualification records and certificate Drawings, sketches, and work order Listing c f welds for Class I and II component (2) Responsibilit es assigned for maintenance of NDE records identified in (1) above which defines storage, designates a custodian, and describes the filing syste Within the areas examined, no violation or deviation was identifie . Preservice Inspection - Review of Procedure (73052) Unit 2 The inspector reviewed the licensee's examination procedures for procedure approval, qualification of NDE personnel, procedure scope and technical content to determine whether these procedure pertaining to PSI are consistent with regulatory requirements and licensee commitments. The applicable code for this review is delineated in paragraph 6 abov Ultrasonic Examination The inspector reviewed the following ultrasonic examination procedures for technical content:

- B&W Procedure ISI-119, Ultrasonic Examination of Stainless Steel and Nickle Base Alloy Weld Seams

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B&W Procedure ISI-120, Ultrasonic Examination of Piping and Vessel Welds Joining Similar and Dissimilar Materials

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- B&W Procedure ISI-130, Ultrasonic Examination of Vessel Welds and Nozzle Inside Radius Sections

- Duke Power Procedure NDE-44, Ultrasonic Examination of Bolts and Studs for Preservice and Inservice Inspection, Revision 5

- Duke Power Procedure NDE-46, Ultrasonic Examination of Reactor Vessel Closure Nuts for Preservice and Inservice Inspection, Revision 4 The above procedures were compared to ASME Code requirements in the following areas:

(1) The type of apparatus to be used including frequency range as well as linearity and signal attenuation accuracy requirements is specifie (2) The extent of coverage (beam angles, scanning surface, scanning rate and directions) as well as the scanning techniques are specified and are consistent with the ASME Code.

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(3) Calibration requirements, methods and frequency including type, size, geometry and material of calibration blocks as well as location and size of calibration reflectors within the block are clearly specified and consistent with the applicable ASME Cod (4) The sizes and frequencies of search units are specified and are consistent with the ASME Cod (5) Beam angle or angles are specified and are consistent with the ASME Cod (6) Methods of compensation for the distance traversed by the ultra-sonic beam as it passes through the material including distance -

amplitude correction curves, electronic distance - amplitude correction and transfer mechanisms, if used, are specified and are consistent with the ASME Cod (7) The reference level for monitoring discontinuities is defined and the scanning gain setting specified and that these values are in accordance with the ASME Cod (8) Methods of demonstrating penetration are establishe (9) Levels or limits for evaluation and recording of indications are specified and are in accordance with ASME Code,Section X (10) Method of recording significant indications are established and the reporting requirements are in accordance with licensee requirement _ ._. . . . ,

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(11) Acceptance limits are specified or referenced and are in accordance with the ASME Code,Section X b. Radiographic Examination The inspector reviewed the following radiographic examination procedures for technical conten Duke Power Procedure NDE-11, General Radiography Procedure for Preservice and Inservice Inspection, Revision 4 (In accordance with 1974, ASME Code)

Duke Power Procedure NDE-12, General Radiography Procedure for

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Preservice and Inservice Inspection, Revision 4 (In accordance with 1980, ASME Code)

The above procedures were compared to ASME Code requirements in the following areas:

(1) Type of material to be radiographed (2) Material thickness range (3) Type of radiation source, effective focal spot or effective source siz (4) Film brand, type and number of films in cassette.

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(5) Minimum source to film distanc (6) Blocking or masking technique, if use (7) Type and thickness of intensifying screens and filters, and use therefor (8) Exposure condition (9) Material and weld surface condition requirements (irregularities,

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weld ripples, surface finish, etc.)

(10) Radiographic film processing requirement (11) Quality of radiographs - limits on mechanical, chemical or other blemishes, such as fogging, process marks, scratches, finger marks, loss of detail or false indications.

(12) Film density limits or sufficient contrast for single and composite viewin (13) Use of densitometers for assuring compliance with film density requirements.

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(14) Method of radiograph identificatio (15) Use of location marker (16) Methodology for showing film location with reference to the part being radiographe (17) Selection and use of penetrameters including:

Penetrameter design Selection of essential hole Penetrameter thickness including special requirements for single and double wall viewing

Penetrameter placement including special requirements for single and double wall viewing

Number of penetrameters

Shims under penetrameters (18) Radiographic technique requirements for double wall viewin The inspector noted during the review of the above radiographic procedures, that the maximum source size was not define The reader could assume from charts depicting various source sizes and their minimum source to film distance, that these source sizes would cover the range used. However, the procedures also described a method for determining source sizes when unknown. The licensee was notified of the unclarity of the procedures and agreed to identify specifically the maximum source size that would be used with these procedure This item will be identified as Unresolved Item 50-414/85-34-02, Clarifica-tion of Procedure NDE-11 and NDE-12 Neede c. Liquid Penetrant Examination The inspector reviewed the following liquid penetrant examination procedures for technical content:

B&W Procedure ISI-240, Penetrant Examination of Weld and Base Materials Including Studs and Nuts Duke Power Procedure NDE-33, Liquid Penetrant Examination Technique (Color Contract, Solvent Removable Method) for Preservice and Inservice Inspection, Revision 5 The above procedures were compared to the ASME code requirements in the following areas:

(1) The specified test method is consistent with AMSE Code require- '

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(2) Brand names and specific types (number of letter designation if available) of penetrant, penetrant, remover, emulsifier and developer are specifie (3) Penetrant materials used for nickel base alloys are required to be analyzed for sulfur using method prescribed in the ASME Code and allowed residual total sulfur do not exceed the established limit (4) Penetrant materials used for the examinations of austenitic stainless steel are required to be analyzed for total halogens using method prescribed in the ASME Code and the total residual halogen content do not exceed the specified limit (5) Fluorescent penetrant examination method (if used) is not permitted to follow color contrast examination and that penetrant materials are used only in combinations recommended by the penetrant manufacture (6) Methods for acceptable preexamination surface preparation are specified and that these methods are consistent with the applicable ASME Cod (7) The procedure establishes a minimum drying time following surface cleanin (8) The method of penetrant application and the penetration time are specified and the penetration time is consistent with the penetrant manufacturer's recomendatio (9) The examination surface temperature is specified and the specified range is between 60 and 125 F. (If temperatures outside this range are permitted, has the examination procedure been specially qualified.)

(10) Procedures specify acceptable methods of removing water washable penetrant and that the water pressure and temperature are not permitted to exceed 50 psi and 110 F, respectivel (11) The method of applying emulsifier (when applicable) is specified and that emulsification time is not permitted to exceed 5 min, without a special procedt.re qualificatio (12) Methods for removal of solent removal penetrant (when applicable)

are specified and that these methods do not permit flushing the examination surface with solven (13) Method of surface drying prior to developing is specifie .

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(14) The type of developer to be used, method of developer application and the time interval between penetrant removal and developer application are specifie (15) Examination technique is specified and the permitted time interval during which the " final interpretation" is made falls within 7-30 min. after developer applicatio (16) Examination conditions for fluorescent penetrants (when applicable) are specified and are in accordance with the applicable ASME Code requirement (17) Technique for evaluation of indications is specified, acceptance standards are referenced, and are consistent with applicable ASME Cod (18) Requirements exist (and are followed) for procedure requalifica-tion when changes are encountered in any of the following parameters:

- Surface treatments which may alter the condition of surface openings (blast cleaning, acid etching).

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Change in precleaning materials or method Changes in the type of penetrant materials (including developer, etc.) or in processing technique d. Magnetic Particle Examination The inspector reviewed the following magnetic particle examination procedure for technical content:

B&W Procedure ISI-270, Wet or Dry Methods of Magnet Particle Examina-tion of Welds, Studs, Nuts, Bolts, and Pump Motor Flywheels Duke Power Procedure NDE-24, Magnetic Particle Inspection Technique ,

(Yoke Method) for Preservice and Inservice Inspection, Revision 6 Duke Power Procedure NDE-25, Magnetic Particle Inspection Technique (Yoke Method) for Preservice and Inservice Inspection (1980),

Revision 6 Duke Power Procedure NDE-26, Wet Non-Fluorescent and Fluorescent Magnetic Particle Examination Techniques for Examination of Pressure Retaining Bolting, Revision 6 The above procedures were compared with the ASME code in the following areas:

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(1) Examinations are done by the continuous method (current on while particles are being applied) and adequate material surface preparation are specifie (2) If dry particles are used, the particle color provides good contrast with, background and component surface temperature is less than 600 F. '

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(3) If wet particles are used they are suspended in suitable liquid medium and component surface temperature is below 135 (4) Viewing conditions for fluorescent particles consistent with paragraph T-725.3 of ASME Section V (Article 7).

i (5) Examination is conducted with sufficient overlap to achieve 100%

coverage and two separate examinations are made with field directions perpendicular to each othe (6) When prod method is used, prod spacing does not exceed 8-in. and provisions are made to reduce arcin (7) Magnetizing current for the prod method urges between 100-125 amps per inch of prod spacing for section thickness more than 3/4 i and 90-100 amps /in. for sections less than 3/4 in thic (8) If coil or direct contact methods are used, current and technique are consistent with paragraph T-732 and 733 of ASME Section (9) If yoke method is used, pole spacing is within 3-6 inches and minimum lifting power is 10 lb. for alternating current and 40 l for direct curren (10) Acceptance criteria are specified or referenced and are consistent with the applicable ASME Code Sectio Within the areas examined above, no violation or deviation was identifie . Preservice Inspection - Data Review and Evaluation The inspector reviewed data described- below to ascertain whether the NDE data covers the scope of examinations required in the applicable ASME Code, the SAR and the licensee's PSI Program. Files were reviewed for complete-ness and acceptability, and the licensee's disposition of adverse findings and subsequent re-exdaination, were reviewed for consistency with regulatory requirement The applicable code for this review is delineated in para-graph 6 of this repor n

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a. The inspector selected the following component welds for review:

ITEM N WELD ID N METHOD COMP 0NENT B2.01.001 2PZR-W8A UT Pressurizer Lower Head to Shell Circumferential Weld B3.01.002 2SGB-01-02 UT Steam Generator 2B Channel Head to Tube Sheet i

B4.01.002 2NC9-01 UT Reactor Pressure Vessel Outlet Nozzle Safe-end to Pipe NDE records for the above welds were reviewed to determine whether the selected records contain or provide reference to the following documents:

(1) Examination results and data sheets (2) Examination equipment data (3) Calibration data sheets (4) Examination evaluation data (5) Records on extent of examination (6) Records on deviation from program and procedures including justification for deviation (7 Records on disposition of findings (8 Re-examination data after repair work (9 Identification of NDE material such as penetrant, penetrant cleaner, couplant, films, tapes, et b. The inspector selected the following reactor pressure vessel welds for review:

Item N Weld ID N Method B1.02.001 2RPV-101-151 UT Bl.02.004 2PRV-102-101 UT Bl.01.001 2RPV-101-171 UT NDE records for the above welds were reviewed to ascertain whether the following requirements were me (1) The method, extent and technique of examination comply with licensee's PSI program and applicable NDE procedur (2) The examination data are within the acceptance criteria as oatlined in applicable NDE procedure and applicable code require-ment =

(3) The recording, evaluation and disposition of findings are in

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compliance with the applicable NDE procedure and applicable code requirement .

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(4) The method used for NDE was sufficient to determine the full extent of indication or acceptance, c. The inspector selected the following pressure retaining pipe welds for review:

Item N Weld ID N Method Pipe Diameter B4.05.399 2NC119-03 UT 6 inch B4.05.400 2NC119-04 UT 6 inch B4.05.401 2NC119-5 UT 6 inch B4.05.565 2ND67-11 UT 12 inch B4.05.566 2ND67-10 UT 12 inch B4.05.567 2ND67.09 UT 12 inch B4.05.677 2NI92-01 UT 8 inch

, B4.05.678 2NI94-01 UT 8 inch

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B4.05.679 2NI94-12 UT 8 inch C2.01.706 2SMI3-01 RT (Film Reviewed) 32 inch C2.01.703 2SM11-02 RT (Film Reviewed) 32 inch NDE records for the above welds were reviewed to ascertain whether the following requirements were met:

! The examination unit calibration data sheets show no l major deviations between initial and final calibration *

! Collected examination data and any recordable indications are properly recorded to permit accurate evaluation and documentatio Evaluation of examination data performed by a Level II or Level III examine *

Evaluation of examination data complies with the procedure Evaluation of indications (if applicable) comply with the criteria of the NDE procedure and ASME Section X During the technical review of NDE records in subparagraphs a and c above, the inspector noted the following:

The ultrasonic data sheet for figure no. B2.1.001, weld no. 2PZR-W8A had incorrect entries for -indication no. 200, throughwall dimension from surface one, minimum and maximu This error, however, did not affect the acceptance or rejection of the recorded indicatio The review also revealed that numerous NDE data reports of inside radii on welded elbows had deviation reports attached denoting limited scans for these areas of the weld. The reports however do not indicate whether

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coverage of the weld and base metal had been fully achieved from the pipe side of the weld using the 60 degree angle probe. B&W's ultra-

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sonic procedure ISI-120 would have allowed the examiner to use a smaller search init in curvatures such as elbow inter-radi The inspector discussed the above concerns with the licensee cognizant  !'

personnel in light of the fact that B&W has not performed an audit of site activities and that the delay of a technical review of data for

! accuracy and completeness could impact scheduled event The licensee's response to this concern will be tracked by Inspector

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Followup Item 50-414/85-34-04, Technical Review of Preservice Record '

Within the areas examined, no violations or deviations were identifie , Independent Re-Examination Of Welds Unit 2(73053)

i The inspector re-examined the following welds using Region II ultrasonic equipment to determine if B&W's recorded data for these welds had been properly documented and evaluate Weld ID No Scan Performed

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2NI94-01 Axials 2NI94-12 Axials 2NI32-2 Axials 2NI32-1 Axials

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The inspector's re-examination and evaluations of indications compared favorable with data recorded by B& i In addition to the above, the inspector held discussion with the~ licensee

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concerning ultrasonic equipment -that the licensee intends to use on '

Catawba's centrifugal cast stainless steel when inservice inspection

) requirements require the licensee to modify their calibration standards to

include notch type reflector Typical transducers presently used with side drill holes will not detect notch type reflector However, the equipment the licensee intends to use during ISI should provide satisfactory results on notch reflectors. The inspector, however, requested that the licensca demonstrate their complete ultrasonic system including instrument, transducers and recorders (if applicable) on Region II cracked centrifugal cast stainless steel specimens prior to the first refueling outag This item will be tracked as Inspector Followup Item 50-414/85-34-01, Demonstrate
Ability of Ultrasonic Equipment to Discern Crack in Centrifugally Cast

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Stainless Steel.

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Within the areas examined above, no violations or deviations were identified.

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