IR 05000416/1985019

Insp Repts 50-416/85-19 & 50-417/85-05 on 850528-31.No Violations or Deviations Noted.Major Areas Inspected: Turbine Bypass Line Indications,Rhr HX Vent Line Break & Inservice Testing of Pumps & Valves

ML20128H595
Person / Time
Site:	Grand Gulf
Issue date:	06/11/1985
From:	Blake J, Crowley B NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
To:
Shared Package
ML20128H577	List: IR 05000416/1985019 ML20128H573
References
50-416-85-19, 50-417-85-05, NUDOCS 8507100114
Download: ML20128H595 (12)

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jg3 Cteg UNITED STATES g 'o NUCLEAR REGULATORY COMMISSION

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t ATLANTA, GEORGIA 30323 s, v /

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Report Nos.: 50-416/85-19 and 50-417/85-05 Licensee: Mississippi Power and Light Company Jackson, MS 39205 Docket Nos.: 50-416 and 50-417 License Nos.: NPF-29 and CPPR-119 Facility Name: Grand Gulf I and 2 Inspection Conduc d: May 28 - 31, 1985 Inspector: 4*? x - d - #- 85'

[ '/ Date Signed Approved by:# -

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'E. J. 61ake, Secti ef [ #- N y Date Signed IM Engineering Bra Division of c Safety SUMMARY Scope: This routine, unannounced inspection entailed 27 inspector-hours on site in the areas of turbine bypass line indications (Unit 1), residual heat removal (RHR) heat exchanger vent line break (Unit 1), inservice testing (IST) of pumps and valves (Unit 1), ASME Code welding (Unit 2), nondestructive examination (NDE)

activities (Unit 2), safety-related piping activities (Unit 2), containment structural steel welding (Unit 2), and IE Bulletins (Units 1 and 2).

Results: No violations or deviations were identifie .

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REPORT DETAILS Persons Contacted Licensee Employees J. E. Cross, Grand Gulf Nuclear Station General Manager

• F. Rogers, III, Technical Assistant to Station General Manager S. F. Tanner, Manager, Nuclear Site QA

• L. F. Daughtery, Compliance Superintendent M. N. Bakarich, Nuclear Record Superintendent W. F. Adcock, Principal Mechanical Enginer-NPE

• B. C. Lee, QA Supervisor - Audits S. E. Thomas, Mechanical Systems Supervisor - NPE R. K. Dubey, Engineering Supervisor - Piping / Mechanical Analysis - NPE J. M. Feil, Materials Science Supervisor - NPE

• A. J. Malone, ISI Coordinator W. L. Justice, Materials Science Project Engineer - NPE M. D. Meier, Mechanical Systems Project Engineer - NPE J. D. Bailey, Compliance Coordinator Other licensee and contractor employees contacted included construction craftsmen, engineers, technicians, operators, security force members, and office personne Other Organization J. F. Hudson, Project QA Manager, Bechtel D. W. Watt, Lead Field Welding QC Engineer, Bechtel M. Shows, Lead Field Welding Engineer, Bechtel

• P. J. Collins, QA Supervisor, Bechtel D. A. Lindsey, Lead Piping / Mechanical QC Engineer, Bechtel T. D. Kinnebrew, Assistant Lead Piping QC Engineer, Bechtel NRC Resident Inspectors

• R. C. Butcher, Senior Resident Inspector

• J. L. Caldwell, Resident Inspector

• Attended exit interview Exit Interview The inspection scope and findings were summarized on May 31, 1985, with those persons indicated in paragraph 1 above. The inspector described the'

areas inspected and discussed in detail the inspection finding The licensee did not identify as proprietary any of the materials provided to or reviewed by the inspector during this inspectio (

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3. Licensee Action on Previous Enforcement Matters This subject was not addressed in the inspectio . Unresolved Items Unresolved items were not identified during the inspectio . Independent Inspection Effort (927068) (Units 1 and 2) General Inspection of Unit 2 The inspector conducted a general inspection of the Unit 2 reactor and auxiliary buildings to observe construction progress and general activities such as welding, material control, housekeeping, and storage. See paragraphs 6 and 10 for details of welding activities observe Indications in Main Steam Bypass Pipe (Unit 1)

In September 1984, during testing at approximately 18% power, two failures occurred in turbine bypass line "A" (see RII Report 50-416/

84-38 for a summary of these failures). After the second failure, the section of 18" diameter schedule 40 pipe between the bypass valve and the pressure breakdown assembly (PBA) was replaced with schedule 100 pipe. This modification was also accomplished on lines "B" and "C".

After replacement of the pipe, Wyle Lab recorded vibration measurements on line "A" using six accelerometer From the accelerometer data, calculated stresses and displacements were very small. On March 6, 1985, after removal of an accelerometer block, nondestructive examina-tion (NDE) of line "A" identified a 1 1/2 long indication in the 18" diameter, schedule 100 pipe near the pipe to PBA weld. This indication was identified after approximately 1740 hours0.0201 days <br />0.483 hours <br />0.00288 weeks <br />6.6207e-4 months <br /> of bypass operation with the thicker wall pip The indication was not thru wall and was repaire After the repair, an inservice monitoring program was developed for the three 18" schedule 100 bypass lines consisting of 100% visual (VT), magnetic particle (MT) of the welds and 6" of base material on each side of the welds, and ultrasonic (UT) for mapping any ,

questionable indication '

On May 8, 1985, as part of the inservice monitoring program, a 10" long MT indication was identified in line "A" near the 18" pipe to valve wel This occurred after approximately 116 hours0.00134 days <br />0.0322 hours <br />1.917989e-4 weeks <br />4.4138e-5 months <br /> of turbine bypass operation since identification of the 1 1/2" indication. The presence of a flaw was verified using ultrasonic (UT) examination. The actual depth of the flaw could not be determined due to difficulty of UT on the pipe surface at a high temperature. However, the data did provide approximate flaw depths and profil Line "A" was isolated and MP&L and General Electric (GE) performed analysis to show that the plant could be safely operated without the "A" bypass lin , _ __

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On May 18, 1985, the schedule 100 pipes on all three bypass lines were VT and MT inspected 100%. The MT revealed that the 10" flaw previously identified on May 8,1985, continued as a broken flaw for a total of 27 7/8". The flaw ran in a spiral around the pipe starting about 2 o' clock near the pipe to valve weld and extending to about 6 o' cloc Four other linear indications, ranging in length from 3/8" to 7/8" were identified. The flaw areas were UT inspected and the deepest area was approximately 1/4". No similar indications were identified on lines

"B" and "C".

The licensee is continuing to evaluate the flaws in bypass line "A" to try to determine the nature of the flaws and thus the failure mechanis c. On May 21, 1985, during steam condensing mode, a 3/4" drain line on RHR heat exchanger 1B broke. The failure was a clean break in the drain pipe at the toe of the socket weld connecting the line to the heat exchanger nozzle. The licensee indicated that the failure appeared to be caused by high-cycle fatigue due to flow-induced vibration. MNCR 0277-85 was issued to document corrective actions. The licensee determined that the drain line support system was not adequately designed due to a misapplication of the piping specification. The line was too flexible. The licensee's investigation revealed that the misapplication of the piping specification was a personnel error and an isolated case. Design Change Package 85/4032 was issued to repair the drain line and add and modify pipe supports to control pipe vibratio The inspector discussed the problem with responsible licensee personnel and reviewed MNCR 0277-85 and Design Change Package 85/403 d. Inservice Testing (IST) of Pumps and Valves (Unit 1)

The inspector discussed the IST program with licensee personnel as indicated below. Based on the Operating License date of June 16, 1982, the applicable code for IST, as required by 10 CFR 50.55(a)g and Technical Specification 4.0.5, is ASME Section XI,1977 Edition, S79 Addend However, the licensee has updated their program to ASME Section XI, 1980 Edition, W80 Addenda as allowed by 10 CFR 50.55(a) The IST program is prescribed by MP&L Specification, MP&L-M-189.1, Revision 0, "MP&L Pump and Valve Inservice Inspection Program."

Revision 1 to the program, incorporating the latest NRC comments and MP&L's submittal to NRC, is being reviewed for issuanc (1) The below listed implementing procedures were reviewed to verify that the licensee had assigned responsibilities for: preparation, review, and approval of ISI procedures; scheduling of IST; performance of test functions; performance of maintenance; and'

performance of calibration Administrative Procedure 01-S-06-12, R9, "GGNS Surveillance Program"

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Administrative Procedure 01-S-01-1, R13, TCN #3, " Grand Gulf Nuclear Station Organization"

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Administrative Procedure 01-S-07-1, R14, TCN #24, " Control of Work on Plant Equipment and Facilities"

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Administrative Procedure 01-1-07-10, R2, "Preservice and Inservice Inspection"

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Administrative Procedure 01-S-07-7, R8, " Planning and Scheduling Plant Maintenance Work"

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Administrative Procedure 01-S-07-3, R7, TCN #2, " Calibration and Control of Measuring and Test Equipment"

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Administrative Procedure 01-S-07-08, R6, " Control of Permanent Plant I&C Equipment Calibration" (2) The inspector reviewed the two administrative procedures listed below and a sample of the change and issue records for the four surveillance procedures listed below to verify adequate control of issue and revision of test procedur Administrative Procedure 01-S-06-12, R9

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Administrative Procedure 01-S-02-2, R20, " Control and Distribution of GGNS Operations Manual"

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Surveillnce Procedure 06-0P-SP21-Q-0001, R22, " Makeup Water Treatment Quarterly Valve Test"

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Surveillance Procedure 06-0P-SP64-Q-0009, R21, "Fi re Protection System Quarterly Valve Testing"

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Surveillance Procedure 06-0P-1C41-M-0001, R22, " Standby Liquid Control Operability"

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Surveillance Procedure 06-0P-1E12-Q-0023, R23, "LPCI/RHR, Subsystem A, Quarterly Functional Test" (3) Through discussions with test and scheduling personnel and reviewing of the following documents, the inspector verified that, in general, tests are scheduled at the required frequenc MP&L Specification M-189.1, R0

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Administrative Procedure 01-S-06-12, R9

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Technical Section Procedure 09-S-05-8, R0, " Surveillance Procedure Scheduling"

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The four Surveillance Procedures listed in paragraph (2)

abov Within the areas inspected, no violations or deviations were identifie . Nuclear Welding (55050) (Unit 2)

The inspector examined the licensee's program for ASME Code welding as indicated below to determine whether application code and regulatory requirements were being met. The applicable code is the ASME Boiler and Pressure Vessel Code,Section III,1974 Edition including Addenda through the Summer of 197 Welder Performance Qualification The inspector reviewed the qualification records and status records for the below listed welders relative to the field welds listed in paragraph b. belo P177 P2381 P2509 P822 P294 Production Welding The inspector observed the below listed welds at the indicated stage of completion:

ISO Weld Size Status Q2P41-G005-C01 1 Lugs Fill welding in process M-2544C 2 2" Socket Fill welding in process M-2358C 8 2h" Sch. 40 Fitup in process M-2358C 23 2h" Sch. 40 Fitup in process M-2358C 24 2 " Sch. 40 Final weld in process M-2358C 7 2 " Sch. 40 Final weld in process M-2548E & 81 1 " Sch. 80 Observed fitup and first FCN-PR2-0098 pass welding M-2548E 38 1h" Sch. 80 Fill welding in process The welding was observed to determine whether:

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Work was being conducted in accordance with a document which coordinates and sequences operations, references procedures, establishes hold points, and provides for production and inspection approva Weld identification and location were as specifie Procedures, drawings, and other instructions were at the work station and readily availabl Welding procedures specification (WPS) assignment was in accor-dance with applicable code requirement Welding technique and sequence were the specified type and traceable to certification Welding _ filler materials were the specified type and traceable procedure and was inspecte Weld joint geometry was in accordance with applicable procedure and was inspecte Aligrment of parts was as specifie Preheat and interpass temperatures were in accordance with

. procedure Electrodes were used in positions and with electrical charac-teristics specifie Shielding gas was in accordance with the welding procedur Welding equipment was in good conditio Interpass cleaning was in accordance with applicable procedure Temporary attachments were removed in accordance with applicable procedure Gas purging, if specified, was in accordance with applicable procedure Process control system had provisions for repair Welders were qualifie No peening performed on root and surface layer Inspection personnel were qualifie __ _ _-_, _

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7 Welding Material Control Receiving inspection and material certification documentation were reviewed for the following welding materials being used for the welding

, observed (see paragraphs 6b and 10b).

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3/32" E7018 -

3/32" ER70S-2 -

3/32" ER308L Ht. 411S61181 Ht. 5772 Ht. 776292

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1/8" E7018 -

1/8" ER70S-2 -

1/8" ER308L Ht. 74619 Ht. 401K0151 Ht. 741119 Weld material issue activities were examined for the Unit 2 weld material issue station in the areas of:

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Storage of materials - identification, segregation and cleanliness

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Temperature control

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Issue control

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Handling of returns Within the areas inspected, no violations or deviations were iden-tifie . Visual Examination (57050) (Unit 2)

The inspector examined the VT examination activities described below to determine whether applicable code and regulatory requirements were being me See paragraph 6 above for the applicable cod The inspector observed the following in process VT examinations:

Dwg. M-2548E: Welds 38, 45, and 49 observed VT of final weld i

Dwg. M-2358C: Welds 7 and 24 observed VT of final weld Dwg. M-2548E: Weld 81 observed fitup The examinations were observed to verify that:

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

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Personnel performing the examinations were qualified

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Required tools and aids were available l

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Specific areas, locations and extent of examination were clearly defined

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Test attributes were specified and consistent with applicable procedures

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Defects were evaluated in accordance with applicable procedure and inspection results were reported as required Personnel qualification / certification records for NDE personnel who performed the VT inspections of the welds in paragraphs a. above were reviewe Within the areas inspected, no violations or deviations were identifie . Liquid Penetrant Examination (57060) (Unit 2)

The inspector examined the liquid penetrant (PT) examination activities described below to determine whether applicable code and regulatory requirements were being met. See paragraph 6 above for the applicable cod The inspector observed in process PT inspection for the following welds:

Dwg. M-2548E: Welds 38 and 49 Dwg. M-2544C: Weld 2 The examinations were observed to verify that:

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Applicable instructions or travelers clearly specified the procedure to be used and that a copy of the procedure was available for the inspectio Sequencing of examinations relative to other operations were specified and in accordance with applicable code and procedures

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Personnel performing the examinations were qualified

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Materials used for the examinations were certified and the certifications met applicable requirements

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Areas, locations and extent of examinations were clearly defined

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The following attributes were as specified in the applicable procedure and consistent with applicable code:

(1) Surface preparation / cleaning method, type, time, et (2) Penetrant type (3) Penetrant application method

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f (4) Penetration time (5) Temperature of surfaces '

(6) Penetrant removal (7) Drying (8) Developer, application, type (9) Developing time (10) Evaluation technique ,

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(11) Acceptance criteria a (12) Reporting of results ,

, Personnel qualifications / certifications records for NDE personnel who performed the PT inspections of the welds listed in paragraphs a. above were reviewe Material certification records for the below listed PT materials, used to inspect the welds listed in paragraph a. above, were reviewe Remover - DR60 - Batch 33K4

, Penetrant - DP40 - Batch 26H1 Developer - D100 - Batch 41586 Within the areas inspected, no violations or deviations were identifie . Safety-Related Piping - Observation of Work and Work Activities .(490638)

(Unit 2)

The inspector observed the work activities below relative to safety-related piping to determine whether work was being conducted in accordance with applicable procedure and code requirements. See paragraph 6 above for the >

applicable cod Work activities listed below were observed to determine whether requirements were being met in the following areas, as applicable: ,

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Conformance with inspection (QC) and work performance procedures -

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Conformance with recordkeeping requirements

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Conformance with construction / installation specifications

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Issuance and use of materials as specified

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Performance of~ prescribed inspections

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Performance of prescribed NDE activities

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Calibration and use of proper measuring and test equipment

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Utilization of qualified inspection (QC) and NCE personnel w -

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Installation , activities, including idedtification and cleanliness

verification, of pipe spools Q2P41-G003-05, 06, 19 and 20 at field welds 7 and 24 on drawing M-2358 Installation activities, including identification and, cleanliness verification, of pipe spool Q2E12-G115-01H-20 at field weld 81 on drawing M-2548 ,

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' Installation activities of pips spool Q2E12-G115-14-20 at field weld 38 on drawing M-2548 >

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Laydown yard storage of pipe spools Q2P41-G008-04-24, Q2P41-G008-03-24, Q2E61-G001-06-23, Q2G41-G016-38-23, Q2E12-G017-01-23, Q2G41-G009-21-22, and in plant storage of stool Q2P41-G003-07-2 '

Within the areas inspected, no violations or deviations were identifie ,

1 Containment (Structural Steel Welding) - Observation of Work & Work

, Activities (55053B) (Unit 2)

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The inspector observed in process welding off' containment structures as indicated below to determine whether applicable code and procedure require-mentsi,were being met. The applicable codes for this welding are the AWS structural welding code D1.1, 1982 edition and Bechtel Specffication C-133.0, Revision 1 In process welding for the following structures inside the containment /

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ISI Platform P-4 , '

Dwg. C-2040A /

WP & IR Q2M20-Y-2317380A, Rpt. #5 .

FCN C2-0976 e '

Welding bracket to heam 614B3 at intersection of beams 61483 anc 112B1 .f >

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Main steam hanger and snubber supports Dwg. C-2086J '

Section J welds

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Use of applicable' weld procedure

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Welder qualified to perform weld

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Use of specified filler material .,

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IIDE performed at proper stage of fabrication

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Periodic che,cks of welding variables Weld material control w'as examined (see paracraph 6.c dbove).

c '. Work areas' were observed for .the presence of uncontrolled filler

materia '

j The inspector examined the 1bvel of OA/QC involvement in the above

,wel ding ~ activitie ' ' Welder qualification records and status records for the below listed a '

welders relative to the welds listed in paragraph a. above were

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reviewe I4b0 ,

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Within the areas inspected, no violations or deviations were identifie ,

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1 IE Bulletins (92703) (Units 1 and 2)

) (Closed) 416,' i417/83-BU-07, Apparently Fraudulent Products Sold By Ray Miller, Inc. : The inspector reviewed the licensee's internal correspondence and responses' to NRC, AECM-84/0391 dated August 16, 1984, AECM-84/0083 dated

March 13,1984, and AECM-84/0126 dated May 24, 1984. The licensee's and their contractor's investigations revealed that no Ray Miller products were

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purchased or installed at Grand Gulf Units 1 and 2.

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