IR 05000424/1992008
| ML20035D304 | |
| Person / Time | |
|---|---|
| Site: | Vogtle  |
| Issue date: | 06/15/1992 |
| From: | Julian C NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | Hairston W GEORGIA POWER CO. |
| References | |
| NUDOCS 9304130053 | |
| Download: ML20035D304 (1) | |
Text
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NUCLE AR REGULATORY COMMISSION
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101 MARIETTA STREET, N.W.
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June 15, 1992
Docket Nos. 50-424, 50-425 i
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Georgia Power Company ATTN:
Mr.
W. G. Hairston, III
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Senior Vice President Nuclear Operations P.O.
Box 1295 Birmingham, AL 35201 Gentlemen:
SUBJECT:
ERRATA LETTER FOR NRC INSPECTION REPORT NO. 50-424/92-08 AND 50-425/92-08
,
The above subject NRC Inspection Report No.
50-424-08 And 50-425/92-08 was transmitted to you by letter dated May 6, 1992.
It has come to our attention that the Inspection Report No. 50-424/92-05 AND 50-425/92-05 was inadvertently used. A corrected Inspection report is enclosed.
Please delete the superseded report and insert the corrected report.
If you have any questions concerning this matter, please contact us.
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Sincerely b'
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Caudle A.
Julian, Chief Engineering Branch Division of Reactor Safety 9304130053 920615 PDR ADOCK 05000424 PDR (
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,0, NUCLEAR REGULATORY COMMISSION
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101 MARIETTA STRE ET, N.W.
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,8 June 15, 1992 Docket Nos. 50-424, 50-425 License Nos. NPF-68, NPF-81 Georgia Power Company ATTN:
Mr. W.
G. Hairston, III Senior Vice President Nuclear Operations P.
O.
Box 1295 Birmingham, AL 35201 Gentlemen:
SUBJECT:
NRC INSPECTION REPORT NO. 50-424/92-08 AND 50-425/92-08 This refers to the inspection conducted by William P. Kleinsorge of this office on April 13-17, 1992.
The inspection included a review of activities authorized for your Vogtle facility.
At the conclusion of the inspection, the findings were discussed with those members of your staff identified in the report.
_
Areas examined during the inspection are identified in the report.
Within these area, the inspection consisted of selective examinations of procedures and representative records, interviews with personnel, and observation of activities in progress.
Within the scope of the inspection, violations or deviations were not identified.
In accordance with 10 CFR 2.790 of the NRC's " Rules of Practice,"
a copy of this letter and its enclosure will be placed in the NRC Public Document Room.
Should you have any questions concerning this letter, please contact us.
Sincerely, k'
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Caudle A. Julian, Chief Engineering Branch Division of Reactor Safety
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Georgia Power Company
June 15, 1995
Enclosure:
NRC Inspection Report
REGION 81 f"
101 MARIETTA STREET.N.W.
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AT LANTA, GEORGI A 30323 l
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Report Nos.:
50-424/92-08 and'50-425/92-08 Licensee:
Georgia Power Company
P.
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Box 1295 Birmingham, AL 35201 Docket Nos.:
50-424 and 50-425 License Nos.:
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Facility Name:
Vogtle 1 and 2 Inspection Co pril 13-17 1992 2f
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Inspector:
,
v. M. Kleina.g PE
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hake,
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Chief Date Signed J.
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Materi,als and Process Section Engineering Branch Division of Reactor Safety
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l SUMMARY Scope:
This routine, unannounced inspection was conducted in the areas of Inservice Inspection (ISI), closure of valve encapsulation
vessels, NRC Information Notice (IN) 92-22: " Criminal Prosecution
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and Conviction of The Wrongdoing Committed by a Commercial Grade Valve Supplier" and IN 91-31: " Nonconforming Magnetic Particle (14AM) Prepared Bath".
Results:
With the exception of a few procedural weaknesses discussed in
paragraph 2, ISI appeared to be conducted in a conservative manner by well trained personnel.
The licensee has taken
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aggressive and conservative actions in response to IN Nos. 88-48, 91-31 and 92-22.
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R.EPORT DETAILS
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Persons Contacted
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Licensee Employees
- H. Beacher, Senior Engineer Technical Support
- J. Beasley, Assistant General Manager - Operations
- S. Chesnut, Manager, Engineering Technical Support-
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- D. Cordes, Senior Nuclear Specialist-SNC/ITS
- W. Copeland, Supervisor-Materials
- R. Healey, Senior Nuclear Specialist-SNC/ITS-r
- G. Hooper, Engineering Supervisor Technical Support
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- W. Kitchens, Assistant General Manager - Plant Suppport
- C. Meyer, Operations Superintendent
- W. Shipman, General Manager - Nuclear Plant
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- C. Tippins, Nuclear Specialist SNC/SAER
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Other licensee employees contacted during this inspection
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included craftsmen, engineers, operators, mechanics, techni-
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cians, and administrative personnel.
Other Organizations
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- T. Mozingo, Superintendent Nuclear Operations-Ogelthorpe Power Corp.
t NRC Resident Inspectors i
- B.
Bonser, Senior Resident Inspector R.
Starkey, Resident Inspector
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P. Balmain, Resident Inspector i
- Attended exit interview
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2.
Inservice Inspection (ISI)
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The inspector reviewed documents and records, and observed
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activities, as indicated below, to determine whether ISI was l
being conducted in accordance with applicable procedures, i
regulatory requirements, and licensee commitments.
The i
applicable code for ISI is the American Society of Mechani-cal Engineers Boiler and Pressure Vessel (ASME B&PV) Code, t
i Section XI, 1983 edition with addenda through Summer 1983 (83S83).
Unit i received its Operating Licensee on March
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16, 1987, commenced commercial operations on May 31,1987 l
and is currently operating in the second 40 month period of
the first ten year interval.
Unit 2 is in the second outage
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of the first 40 month period of the first ten year. interval.
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The licensee, G2org ' Power Co., contract for the Southern I
Nuclear Operating Co. (SNC) to provide inservice inspection services.
SNC's nondestructive examination personnel, i
rovided by Lambert McGill and Thomas (LMT) and TKS l
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International Incorporated (TKS), are performing the l
liquid penetrant (PT), magnetic particle (MT), visual
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(VT), and ultrasonic (UT) examinations.
UT examina-
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tions of the reactor vessel flange to vessel weld and the threads in the flange were performed by Dynacon i
Systems a subsidiary of Westinghouse (H)..
Steam
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generator tubing eddy current (EC) examination were
accomplished by W.
All work is being performed under
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the envelope of the SNC Quality Assurance (QA) program with the exception of W which worked to the H QA
program.
a.
ISI Program Review, Units 1 and 2 (73051)
The inspector reviewed the following' documents relating I
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to the ISI program to determine whether the plan had i
been approved by the licensee and to assure that proce-dures and plans had been established for the applicable
activities.
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Vogtle Electric Generating Plant Unit 2 - Inservice Inspection Plan Second Refueling Outage Plan (Period i
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1/ Interval 1)
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Review of NDE Procedures, Units 1 and 2 (73052)
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The inspector reviewed the procedures listed below to
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determine whether these procedures were consistent with I
regulatory requirements and licensee commitments.
The j
procedures were also reviewed for technical content.
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W-GBE-ISI-10 (RO)
Qualification of Ultrasonic Manual Equipment for Vogtle Unit 2 l
W-GBE-ISI-54 (RO)
Manual Ultrasonic Examination for the l
Reactor Vessel Upper Shell to Flange
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Weld for Vogtle Unit 2
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i W-GBE-ISI-55 (RO)
Manual Ultrasonic Examination of Reactor i
Vessel Threads in Flange for Vogtle l
i Unit 2 l
W-MRS 2.4.2 GPC-3 (R1)
Eddy Current Inspection of Preservice
and Inservice Heat Exchanger Tubing
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SNC-AUX-H/F/V-300 (R6)
Procedure (Written Practice) for Quali-
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fication and Certification of Non-
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i destructive Examination Personnel
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SNC-AUX-H/F/V-303 (RO)
Control of Measuring and Test Equipment j
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SNC-AUX-V-306 (R1)
Reference System for Marking, Measuring, l
and Recording
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SNC-AUX-V-307 (R3)
Pre-service and Inservice Documentation
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SNC-AUX-V-308 (R1)
Pre-service and Inservice Handling'and Care of Calibration Blocks Under SCS i
Control SNC-UT-V-404 (R4)
Manual Ultrasonic Examination of Full-Penetration Welds i
SNC-UT-V-406 (R2)
Manual Ultrasonic Examination of Cast Stainless Full-Penetration Welds SNC-UT-V-407 (R2)
Manual Ultrasonic Examination of Full-Penetration Welds (.15 Inches to.5
Inches)
SNC-UT-V-411 (:R4)
Manual and/or Mechanized Ultrasonic l
Examination of Pressure Vessel Welds (2
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Inches to 12 Inches in Thickness)
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SNC-UT-V-413 (RO)
Manual Ultrasonic Examination of Main i
Loop Branch Connected Welds
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SNC-UT-V-416 (R2)
Manual Ultrasonic Examination of Nozzle
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Inner Radius
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a SNC-UT-V-417 (:R1)
Manual Ultrasonic Examination of Reactor Coolant Pump Motor Flywheels i
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SNC-UT-V-422 (R1)
Manual Ultrasonic Examination of Bolts and Studs Greater than 2 Inches in Diameter Containing Access Holes
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i SNC-UT-V-423 (R1)
Manual Ultrasonic Examination of Bolts and Studs
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SNC-UT-V-455 (R1)
Qualification of Manual Ultrasonic In-struments
SNC-UT-V-465 (R1)
Ultrasonic Thickness Examination Proce-i dure SNC-UT-V-855 (RO)
Qualification of Mechanized Ultrasonic l
i Instruments SNC-MT-V-505 (R1)
Dry Powder Magnetic Particle
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Examination: Yoke Method F
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SNC-MT-V-506 (:R2)
Wet Florescent Magnetic Particle Exami-j nation
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SNC-PT-V-605 (R2)
Color Contrast, Solvent-Removable' Liquid Penetrant Examination Procedure i
SNC-VT-V-715 (R1)
Visual Examination (VT-1)
SNC-VT-V-725 (R1)
Visual Examination (VT-2)
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SNC-VT-V-735 (R2)
Visual Examination (VT-3, VT-4)
.9 The following items were noted relative to the review of procedures.
o ASME B&PV Code Section V Article 4 paragraph T-424 (h) requires the transducer cable type and
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length to be specified in UT procedures.
The transducer cable type and length specification was missing from the following UT procedures: H-GBE-
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ISI-54, W-GBE-ISI-55, SNC-UT-V-406, SNC-UT-V-417, and SNC-UT-V-423.
It should be noted that-the H data sheets for exams performed this outage contained the required cable data.
The SNC procedures identified above were not used during this outage.
o ASME B&PV Code Section V Article 7, Paragraph T-733 requires AC and DC Yokes to be calibrated by l
lifting 10 and 40 Lbs weights respectively.
The
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metric equivalent weight of magnetic particle test plates as specified in procedure Nos SNC-MT-V-505 and SNC-MT-V-506 are 4.5 kg = 9.9 lbs # 10 lbs and
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18.1 kg = 39.9 lbs # 40 lbs.
In addition the two SNC procedures indicated above state "Each weight
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shall be weighed on a scale from a reputable manufacturer..."
no reference is made to traceable standard weights which conflicts with the notion of " calibration".
It should be noted i
that the certification documentation reflect test plate weights greater than 10 and 40.lbs for the
actual weights used.
The scales used to verify those weights are traceable to standard weights.
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Although the licensee has an excellent reference system procedure, used for marking, measuring and
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recording, it is only referenced in a few examina-
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tion procedures.
o Post examination cleaning is optional in all the i
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o The recording criteria for reflectors with ampli-i tudes of from 1% to 49% of DAC is not clear in the following UT procedures:
SNC-UT-V-406 and SNC-UT-V-423.
The licensee indicated that they would consider the above observations and make necessary changes to the procedures.
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All procedures reviewed appeared to contain the neces-sary elements for conducting the specific examination.
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(Except as noted above)
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Observation of Work and Work Activities, Unit 2 (73753)
i The inspector observed work activities, reviewed certification records of NDE equipment and materials, and reviewed NDE personnel qualifications for personnel who had been utilized in the ISI examinations during this outage.
The observations and reviews conducted by the inspector are documented below.
This inspection was conducted late in the refueling
outage and only one examination remained to be per-
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formed.
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The inspector observed the PT examination of a 14" pipe to tee weld in an ASME class 2 system.
The inspector
performed an independent evaluation of the indications obtained to confirm the NDE examiner's evaluation.
a The inspector examined the records of approximately 90%
to 95% of the 180 UT, MT, PT, and VT examinations
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conducted during this outage.
In addition the inspector reviewed records of the EC and UT
i examinations performed by W.
These records included l
examination reports and associated evaluation and i
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notification documents, certification documentation for MT yoke calibrations, MT test weights, MT prepared bath, dry MT particles, PT cleaner developer and penetrant, longwave ultraviolet intensity meters, UT
reference blocks (step, rompas and IIW), UT. instrument calibrations, UT transducers, and NDE examiners i
qualification and certification data.
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A random sample of. current examination results were I
compared with historical examination results.
No major discrepancies were noted during the comparison. (five linear and one rounded indication not previously seen were identified during this outage)
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No steam generator tubes were plugged during this out-
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age.
In the areas examined, no violations or deviations were
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identified.
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3.
Followup (92701)
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a.
NRC Information Notice (IN) 92-22: " Criminal Prosecution and Conviction of The Wrongdoing Committed by a Commercial Grade Valve Supplier".
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In IN 88-48, and the two associated supplements,
" Report of Defective Refurbished Valves" the staff
discussed the problem that Pacific Gas and Electric j
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Company found with what they believed to be a valve manufactured by Henry Vogt Company in a non-safety l
related system.
IN 92-22 discusses the prosecution of
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the wrongdoer, the president of CMA, and the resulting
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sentence of three years imprisonment and the payment of l
$213,825.03 in restitution to the NRC's licensees,
which includes $34,784.00 due to GPC.
On March 7, 1989, Vogtle discovered non-safety related valve 2-1305-U4-654 leaking, and a repair kit was ordered to effect repairs.
The replacement parts would not fit the valve.
This occurrence initiated an investigation that determined that the valve, thought to be manufactured by Pacific Valve was in fact counterfeit.
The same valve in Unit 1, 1-1305-U4-654, was identical though not leaking.
On May 5, 1989, the licensee stopped the leak on the valve in unit 2, and replaced it October 8, 1989.
The Unit i valve was replaced March 27, 1990.
The NRC resident inspector was notified on April 28, 1989.
The licensee has apparently taken aggressive and conservative action in response to these Information Notices.
IN 88-48 is further discussed in NRC report 50-424,425/91-22, paragraph 11 a.
b.
NRC Information Notice (IN) 91-31: " Nonconforming Magnetic Particle (14AM) Prepared Bath" This IN transmitted a Magnaflux Notice which recalled three batches.of 14AM MT aerosol prepared bath, and included a warning for six others.
The licensee deter-mined that they had used one of the recalled batches in several examinations conducted during the first Unit 2 refueling outage.
None of the recalled or warning material was used in Unit 1 examinations.
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Magnaflux, the Vogtle site has a 98.5%
probability of not having used an effected can of the product.
Reactor head closure studs No. 1 through 18 and reactor head closure nuts No. 1 through 9'and 19 through
27 were the specific items examined with the recalled material.
The licensee decided to i
reexamine, during the second Unit 2 refueling outage, reactor head closure studs No. 1 through 18 and reactor head closure nuts No.
1 through 9 with a new examination of reactor
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head nuts No. 10 through 18.
If no indications were identified in reactor head closure nuts No. 1 through 9, then only
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reactor head closure nuts No. 1 through 18
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would be reexamined.
If indications were
identified in reactor head closure nuts No. 1 l
through 9, then reactor closure nuts No. 1 through 27 would be examined.
Reactor head closure nut and stud Nos. 1 through 18 were
examined during the second Unit 2 outage with no indications identified.
The licensee has j
taken effective conservative action in
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response to this IN.
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In the areas examined, no violations or deviat.4ons were
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identified.
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4.
Closure of Valve Encapsulation Vessels The licensee has experienced continuing problems with the sealing of the eight encapsulation vessels, in both units, j
associated with both trains of the Residual Heat. Removal l
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(RHR) and the Containment Spray (CS) systems.
The problems
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have caused the licensee to exceed the vendor drawing i
specified torque of 125 ft-lbs on the closure fasteners in many cases to effect a seal.
This was done after performing j
calculations and consulting with the vendor, Richmond i
Engineering Company (RECO).
The calculations were to l
determine the torque required to crush the vendor supplied gasket, without exceeding the allowable stress in the fasteners, in order to effect a seal.
Torque values have been as high as 240 ft-lbs in the RHR vessels and 255.ft-lbs on the CS vessels.
A Bechtel Power Corp. (BPC) review of l
the last calculations indicated that appropriate torque
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levels should be somewhat less than 125 ft-lbs for all the
-vessels, to ensure that allowable stresses are not exceeded.
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It was determined that the allowable stress level in the weld (and the adjacent base material) that attached
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the flanges to the vessel shells and heads was exceeded.
With a change in gasket material type and i
thickness an effective seal was achieved at torque
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values of 80 ft-lbs and less.
To reestablish integrity of the vesse3s, in view of the over l
stressing of the weldments, the licensee and RECO performed i
a visual exemination of the flanges and found no visual
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plastic deformation.
The weld and heat affected zone on the
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Unit i vessels and the weld and one inch of adjacent base
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material on the Unit 2 vessels were PT examined with the
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l solvent removable visible dye method with no indications
identified.
Weld No. 7 on vessel 2-1205-V4-002 was radio-
graphically reexamined.
Those radiographs were compared
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with the original construction radiographs, with no anoma-
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lies noted.
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The inspector conducted interviews with licensee personnel, reviewed the radiographs, reviewed documentation including
work orders, inspection reports, and calculations; and pre-l formed a walkdown inspection of two of the Unit 2 vessels.
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The cause of the above problems appear to be the failure of f
the licensee and vendor (RECOs) to consider the stress'
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report for the vessel when calculating the appropriate torque value required to achieve a seal; and the choice of a j
gasket material that required excessively high torques to l
achieve a seal.
t To prevent recurrence of similar circumstances an appropri-j ate cautionary note was added the licensee's " Bolt-i ing/ Torquing Manual".
This matter is further discussed in
NRC Report 50-424,425/92-04.
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In the areas examined, no violations or deviations were
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identified.
6.
Exit Interview
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The inspection scope and results were summarized on April 17, 1992, with those persons indicated in paragraph 1.
The
inspector described the areas inspected and discussed in
detail the inspection results.
Although reviewed during
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this inspection, proprietary information is not contained in
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this report.
No dissenting comments were received from the l
licensee.
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I 7.
Acronyms and Initialisms
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83SB3 -
1983 edition summer 1983 addenda AC
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Alternating Current l
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American Society of Mechanical Engineers j
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Boiler and Pressure Vessel
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Bechtel Power Corp.
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Distance Amplitude Curve i
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Direct Current EC
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Eddy Current ID
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Identification
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NRC Information Notice
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Inservice Inspection LMT
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Larabert, McGill and Thomas
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Magnetic Particle j
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Number NPF
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Nuclear Power Facility i
NRC
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Nuclear Regulatory Commission
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P.E.
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Professional Engineer
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Quality Assurance i
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Richmond Engineering Co.
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Southern Nuclear Operating Co TKS
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TKS International Inc.
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Ultrasonic VT
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Visual Westinghouse i
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