IR 05000424/1990026
| ML20058F048 | |
| Person / Time | |
|---|---|
| Site: | Vogtle  |
| Issue date: | 10/17/1990 |
| From: | Blake J, Newsome R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML20058F040 | List: |
| References | |
| 50-424-90-26, 50-425-90-26, NUDOCS 9011080068 | |
| Download: ML20058F048 (10) | |
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UNITED STATES
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o NUCLEAR REGULATORY COMMISslON
-j REGION 11
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y 101 MARIETTA STREET,N.W.
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ATL ANTA, OEoRol A 30323
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Report Nos.:
50-424/90-26 and 50-425/90-26~
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Licensee: Georgia Power Com9any
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P.O. Box 1295
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Birmingham, AL 35201
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Docket Nos.:
50-424 and 50-425 License Nos.:
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i Facility Name:
Vogtle 1 and 2
Inspection Conducted: October 9-12, 1990 s
Inspectors:6 d
A -/7-96
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R. W. Newsome {
Date Signed i
I Approved by:
/o -/ 7 - 9 0 d
J'. Blake, Chief
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Date Signed arerials and Processes Section Engineering Branch-Division of Reactor. Safety
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SUMMARY
~ Scope This routine', unannounced inspection was conducted on site in the. area of:
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Inservice : Inspection -(ISI) and included a review of.the ISI program,
'l implementing procedures and the Unit 1 ISI plan for-this outage;. reviews of I
nondestructive examination- (NDE) procedures; observations of in-progress NDE
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examinations;. independent examination verifications; reviews of NDE personnel qualifications; reviews-of NDE equipment calibration and material certification
. documentation;'and, a review of completed NDE examination data.
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Results'
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This finspection. indicated that ISI nondestructive examinations ' were being.
I conducted adequately.-
Also, documentation of examination results, personnel qualifications, and material certification records were adequate.
'One Non-cited Violation (NCV) was identified:
Violation of precedure re
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failure to record reportable indications during preservice. inspection (garding PSI),
paragraph 2.c.(3).
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9011000068 901019 PDR ADOCK 05000242 G
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REPORT DETAILS 1.
Persons Contacted Licensee' Employees
'*S.-Chesnut, Manager, Technical Support H. Beacher, Senior Plant Engineer
- D. Hudson, Senior Plant Engineer
- W. Kitchens, Assistant General Manager, Operations
- R. Odem, Supervisor, Nuclear. Safety and Compliance
- W. Shipman, General Manager, Plant Support
- J. Williams, Supervisor, Plant Engiredring 0ther licensee employees contacted during this inspection ncluded engineers, security-force members, technicians, and administrative
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personnel.
Other. Organizations Southern Company Services R.'Healey, ISI Level III
- R. Keck, ISI Project Coordinator NRC Resident Inspector
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B. Bonser.-Senior Resident Inspector
P..Balmain, Resident Inspector
.D. LStarkey, Resident Inspector
- Attended exit interview Acronyms ~ tnd initialisms used throughout this report are listed in the
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-last-paragraph, 2.
- Inservice Inspection LThe inspector reviewed documents' and records and observed activities, as indicated below,-- to determine whether ISI was being conducted in 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, _1983 edition with addenda-through Sumer 1983; Westinghouse
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examination!of steam generator (SG) ponsibility for the eddy current -(EC)
Electric Corporation (W) had the res tubing and utilized a variety of.NDE laboratory personnel to' conduct both the primary and secondary, manual,
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data evaluations.
Southern Company Services (SCS) has the responsibility for the remainder of the ISI examination activities and is utilizing SCS personnel and a variety of other NDE laboratory personnel to conduct the examinations.
Examinations were being conducted by SCS personnel during this inspection, however, just prior to this inspection, the eddy current examinations of the steam generator tubing had been completed. The NRC inspector reviewed the preliminary results reports for the completed steam generator tubing examinations and reviewed quality a:surance documentation relative to the P;ocedures, personnel qualifications, and equipment used to conduct both the completed and on going NDE examinations.
a.
ISI Program Review. Units 1 and 2 (73051)
The inspector reviewed the following documents relating to the ISI program to determine whether the 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 the following applicable activities:
organizational structure including qualifications, training, responsibilities, and duties of personnel responsible for ISI; audits Mcluding procedures, frequency, and qualification of personnel; general % 11ty Assurance requirements including examination reports, deviations from 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 equipment; quality records including documentation of indications and NDE findings, review of documentation, pr cvisions to assure legibility and retrievability, and corractive action; scope of the inspection including description of arer.s to be examined, examination category, method of inspection, extent of examinations, and justifi-cation for any exception; definition of inspection interval and
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extent of examination; qualification of NDE personnel; and, controls of generation, approval, custody, storage and maintenance of NDE records.
Vogtle Electric Generating Plant Unit 2 Inservice Inspection
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Outage Plan First Refueling Outage (Period 1/ Interval 1)
with Deviations 001 and 002 SCS/ Inspection and Testing Procedures Manual, Revision 1
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Section Ti tle 2-1 (R-0)
Program - Including Relief Requests with Dev. 001 2-2 (R-0)
Examination and Testing Plan with Dev. 001 4-3 (R-0)
Receipt and Control of Equipment and Naterials AUX-V-307 (R3) Preservice and Inservice Inspection Documentation
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Review of NDE Procedures, Units 1 and 2 (73052)
(1) The inspector reviewed the procedures listed below to determine whether these procedures were consistent with regulatory requiremtnts 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; ard, if applicable, division of responsibility between the licensee and contractor personnel if contractor personnel i
are involved 13 the ISI effort.
UT-V-407 (R2)
Manual Ultrasonic Examination Of
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Full-Penetration Welds (.15" to.5")
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UT-V-411(R3)
Manual Ultrasonic Examination Of
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Pressure Vessel Welds (2 Inches to 12 Inches in Thickness)
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UT-V-413(RO)
Manual Ultrasonic Examination Of Main
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Loop Branch Conn 9ction Welds UT-V-422(R1)
Manual Ultrasonic Examination Of Bolts
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And Studs Greater Than 2 Inches In Diameter Containing Access Holes
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UT-V-423(R1)
Manual Ultrasonic Examination Of Bolts
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And Studs Without f.ccess Holes UT-V-855(RO)
Qualification er Mechanized Ultrasonic
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Instruments
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PT-V-605-(R2)
Color Cont.ast, Solvent-Removable
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Liquid Penetrant Examination Procedure r
VT-V-735(R2)
Visual Examination (VT.-3).-
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All: procedures listed above have been reviewed during previous
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NRC inspections.
Only current revisions were reviewed during this inspection.
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(2) The inspector reviewed the Ultrasonic (UT) procedures to ascertain whether-they had been reviewed and approved in-accordance with the licensee's established QA. procedures.
The procedures were also reviewed for technical adequacy and conformance with ASME,Section V, Article 5 and other licensee commitments / requirements in-the following areas:
type of i
apparatus used; extent of coverage of weldment; calibration requirements; search units; beam angles; DAC curves; reference level for monitoring discontinuities; method for demonstrating penetration; limits for evaluating and recording indications; recording significant indications; and, acceptance limit *
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(3) The inspector reviewed the Liquid Penetrant (PT) procedure to ascertain whether it had been reviewed and approved in
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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 ccmmitments/ requirements in the following areas:
specified method; penetrant material identification; penetrant materials analyzed for sulfur; penetrant materials analyzed for total haiogens; surface temperature; acceptable pre-examination surface conditioning; method used for pre-examination surface cleaning; surface drying time prior to penetrant application; method of penetrant application; penetrant dwell time; method used fe* excess penetrant removal; surface drying prior to developer application, if applicable; type of developer; examination technique; evaluation techniques; and, procedure requalification.
(4) The inspector reviewed the Visual (VT) examination procedure to determine whether it contained sufficient instructions to assure that the following parameters were specified and controlled within the limits permitted by the applicable code, standard, or any other specification requirement:
method - direct visual, remote visual or translucent visual; application - hydrostatic testing, fabrication procedure, visual examination 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 to 'ilated, if any; acceptance criteria is specified and consistent w1th the applicable code section or controlling specification; and, report form completion.
All procedures reviewed appeared to contain the necessary elements for conducting the specific examination, c.
Observation of Work and Work Activities, Unit 2 (73753)
The inspector observed work activities, reviewed certification records of NDE equipment and materials, and eviewed NDE personnel qualifications for personnel that had been utilized during the required ISI 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) examination being conducted on weld 21301-001-7, a 6" carbon steel, outlet to flange, SG-1 main steam system wel d.
This observation was compared with the applicable procedures and the ASME B&PV Code in the following areas:
availability of and compliance with approved NDE procedures; use
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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
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This examination was conducted in order to evaluate the technical adequacy of the ultrasonic examination procedure being used by the licensee and to assess the validity of the information being reported by the ultrasonic examiners.
The verification ultrasonic examination conducted by the inspector indicated that the procedure being used to conduct the.
examination 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:
Ultrasonic Instruments Manufacturer /Model Serial No.
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KB/USK-7 27276-4317-2 KB/USK-7 27276-4302-2 KB/USK-7 27276-4314-2 The inspector reviewed spectrum analysis data for the ultrasonic transducers listed below:
Serial. No.
Size Frequency 021693
.25" 2.25 MHz 031294
.375" 2.25 MHz 031328
.375" 2.25 MHz 30297
.375" 2.25 MHz Ultrasonic Couplant Batch Number 8982 Ultrasonic Calibration Blocks ISI-D-303A, ISI-D-413A, ISI-D-307A, ISI-D-309A, and ISI-0-311A l
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(2) 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 acceptab'e content limits.
Materials Batch Number Liquid Penetrant 87A045 Cleaner / Remover 89H03S Developer 88H043, 870014 (3) The inspector observed the in-process magnetic particle (MT)
examinations of 4 steam generator number 1 main steam system circumferential pipe welds and 2 integrally attached pipe support welds.
These 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; suspension medium for wet particles, if applicable; viewing conditions; examination overlap and directions; pole or prod spacing; current or lifting power (yoke); and acceptance criteria.
During the examination of support weld 21301-001-9, 5 short linear indications were detected by the examiners.
These-indications ran parallel with the weld and were located at the toe of the weld where it met the base metal on the support side of the weld.
The indications were determined to be 1/8 inch to 5/16 inch in length and acceptable to ISI acceptance criteria.
The inspector examined these indications and determined that the indications were a result of the welding process used during fabrication of the weld and were not service induced flaws.
Because these indications were not service induced they should have been detectable during the preservice inspection (PSI).of the weld.
The inspector requested the PSI examination report-for this weld and found -that the report did not contain any record of indications in the MT report.
Having determined that the PSI MT examiner had not recorded the indications, as required by the MT procedure, the inspector requested that all the PSI MT reports be searched to determine how many additional welds the MT examiner had inspected during PSI.
This records search indicated that the PSI MT examiner-had examined a total of 11 welds, of which 6 welds, including the weld in question, had already been re-examined during this ISI and that none of the remaining 5 welds re-examined had revealed any reportable conditions.
The inspector further suggested that the remaining 5 welds, which were not scheduled to be re-examined during this ISI, be re-examined at this time to insure that +5ere were no more discrepancies associated with the examinations conducted by the PSI MT examine,_
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The licensee re-examined the remaining 5 welds prior to the end of this NRC inspection, under the observation of 2 NDE Level III examiners, and no additional reportable conditions were found.
Because the licensee took immediate action to assure the integrity of the questionable welds and the results of the re-examinations did not reveal any further reportable conditions, this apparent failure by the PSI MT examiner to record reportable indications, as required by the examination procedure, is identified as a non-cited violation, NCV 50-425/90-26-01: Failure To Record Reportable Indications During PSI.
This NRC identified violation is not being cited because criteria specified in Section V. A of the NRC Enforcement Policy were satisfied.
The inspector conducted MT verification examinations, using SCS equipment, on portions of 5 of the welds previously observed being examined including the area of support weld 21301-001-9 that contained the linear indications.
These examinations were conducted in order to evaluate the technical adequacy of the examination procedure being used by the licensee to perform examinations-and to assess the validity of the information being reported by the MT examiners.
The information reported by the MT examiners compared favorably with the verification examinations.
The inspector reviewed documentation indicating that a 10 pound lift test had been performed on magnetic particle alternating current yokes 6661 and 2363.
The certification record for the lift test plate that was used to conduct the tests, SCS-112, was reviewed to confirm the weight of-the test plate.
A review of the magnetic particle material certification records for batch numbers 87A035, 90A008, and 89D095 indicated the particles met the applicable specifications requirements.
(4) Certification records for EC calibration standards ISI-D-806A'
and ISI-D-806C were reviewed for material type, correct fabrication, and artificial flaw location and size.
(5) The inspector reviewed personnel qualification documentation for 6 UT examiners, 7 PT examiners, 3 MT examiners, 5 VT examiners, and 8 EC 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 recertification.
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Data Review and Evaluation, Unit 2 (73755)
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(1) Records of completed ISI nondestructive examinations for 32 UT, 33 PT, 28 MT, and 20 VT examinations were selected and reviewed
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to ascertain whether:
the method (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
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materials-(penetrants, couplants) were designated.
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(2) The inspector reviewed the preliminary EC data analysis results and a sample of associated completed records for over 800 SG tubes, approximately 200 tubes from each of the four 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.
All of - the examination reports reviewed appeared to contain the required-examination information including disposition ' of-indications, if any.
t A random sample of current examination _results were compared with historical examination results.
No major discrepancies -sere noted during the comparison.
In the areas inspected, violations o'.-deviations were not identified except as noted-in paragraph 2.c(3).
3.
Exit Interview The inspection scope and results were summarized on October 12,-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 rrom the i
licensee.
NCV 50-425/90-26-01, Failure To Record Reportable Indications During PSI, paragraph 2.c(3).
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- Acronyms-and Initialisms
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American Society of Mechanical Engineers
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B&PV- -
Boiler =and Pressure Vessel
Distance Amplitude Curve L,
- DAC
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Deviation
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-Eddy: Current-EC.
--Inservice -Inspection ISI
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Krautkramer/Branson KB
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B ffF Magnetic Particle
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- NCV-Non-Cited Violation
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Nondestructive Examination-
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Number:
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- -- Preservice Inspection
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' Quality Assurance QA.
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Southern Company Services SCSE :-
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Ultrasonic
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