IR 05000424/1993006

Insp Repts 50-424/93-06 & 50-425/93-06 on 930329-0402.No Violations or Deviations Noted.Major Areas Inspected: Inservice Insp & Flow Accelerated Corrosion

ML20035F185
Person / Time
Site:	Vogtle
Issue date:	04/08/1993
From:	Blake J, Kleinsorge W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
To:
Shared Package
ML20035F182	List: IR 05000424/1993006 ML20035F180
References
50-424-93-06, 50-424-93-6, 50-425-93-06, 50-425-93-6, NUDOCS 9304210013
Download: ML20035F185 (11)

Text

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4, UNITED STATES

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.., g NUCLEAR REGULATORY COMMisslON l

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REGION 11 g

r 101 MARIETTA STREET.N.W.

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AT LANT A, GEORGI A 30323

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Report Nos.:

50-424/93-06 and 50-425/93/06 l

Licensee: Georgia Power Company P. O. Box 1295 Birmingham, AL 35201 Docket Nos.: 50-424 and 50-425 License Nos.: NPF-68 and NPF-81 Facility Name:

Vogtle 1 and 2 I

9 - April 2, 1993 Inspection Conducted-

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pf ff f/

l Inspector:

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, Date signed

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W j.jt sinY6rge PV.

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l Rgact w s t,W Approved by: \\

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J. J.

lake,' Chief Date Signed Mat ia/sandProcessSection E

neering Branch Dfvision of Reactor Safety SUMMARY

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Scope:

This routine, announced inspection was conducted in the areas of Inservice Inspection (ISI) and Flow Accelerated Corrosion (FAC).

Results:

ISI procedures were well written and appropriate for their intended application, with the exception of a few minor discrepancies.

ISI examinations were performed properly in accordance with regulatory and

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procedural requirements.

ISI records supported the accomplishment of activities consistent with regulatory and procedural requirements.

To date the licensee's FAC program has been effective in maintaining high energy carbon steel piping systems within acceptable wall thickness limits.

In the areas inspected, violations or deviations were not identified.

9304210013 930415 PDR ADOCK 05000424 G

PDR

l REPORT DETAILS 1.

Persons Contacted

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I Licensee Employees

• S. Chesnut, Manager Engineering Technical Support

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• C. Christiansen, SAER Supervisor

• J. Churchwell, Senior Engineer ISI/SNC

• D. Cordes, Senior Nuclear Specialist SNC

• J. Edwards, Senior Nuclear Specialist SNC/NMS

• G. Frederick, Manager Maintenance

• W. Gabbard, Nuclear Specialist Technical Support

• G. Hooper, Engineering Supervisor Technical Support

• D. Hudson, Senior Engineer

• W. Kitchens, Assistant General Manager Plant Support

• E. McClain, Senior Nuclear Specialist SNC

• M. Sheibani, Nuclear Safety and Compliance Supervisor

• W. Shipman, General Manager Nuclear Plant

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• W. Smith, Senior Plant Engineer Technical Support Other licensee employees contacted during this inspection included

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craftsmen, engineers, operators, mechanics, security force members, technicians, and administrative personnel.

NRC Resident Inspector (s)

P. Balmain, Resident Inspector B. Bonser, Senior Resident Inspector

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• R. Starkey, Resident Inspector

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• J.

Starefos, Intern

• Attended exit interview 2.

Inservice Inspection (ISI)

The inspector reviewed documents and records, and observed activities, as indicated below, to determine whether ISI was being conducted in accor-dance with applicable procedures, regulatory requirements, and licensee commitments.

The applicable code for ISI, for both Units is the ASME B&PV Code,Section XI,1983 Edition with Addenda through Summer 1983 (83S83). Unit 1 is in refueling outage (RF0) 4, the second outage of the second 40 month period of the first ten year interval (02,P2,II).

Unit 2 is operating in the second 40 month period, of the first ten year l

interval (P2,II). Unit I received its Operating License March 16, 1987, and commenced commercial operations on May 31, 1987. Unit 2 received its Operating License on March 31,1989, and commenced commercial operations on May 20, 1989. The licensee, Georgia Power Company (GPC), has contracted with the Southern Nuclear Operating Company (SNC) to provide ISI services. SNC's nondestructive examination personnel, provided by Lambert McGill and Thomas (LMT) and Sonic Systems International Inc.

(SSI) are performing liquid penetrant (PT), magnetic particle (MT),

visual (VT), and ultrasonic (UT) examinations. Steam Generator (S/G)

tubing eddy current (ET) examination data acquisition and analysis is l

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l being accomplished by Dynacon Systems a subsidiary of Westinghouse (W).

All the above activities are being accomplished under the umbrella of the SNC Quality Assurance (QA) Program with the exception of the S/G work l

which is worked to the W QA program.

a.

ISI Program Review, Units I and 2 (73051)

l The inspector reviewed the following documents relating to the ISI program to determine whether the plan had been approved by the

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i licensee and to assure that procedures and plans had been estab-

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lished for the applicable activities, procedures were also reviewed for technical content.

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Vogtle Electric Generating Plant Unit 1 - Inservice Inspection Plan Fourth Refueling outage Plan (Period 2 / Interval 1)

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Review of NDE Procedures, Units 1 and 2 (73052)

The inspector reviewed the procedures listed below to determine

whether these procedures were consistent with regulatory require-

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i ments and licensee commitments.

The procedures were also reviewed for technical content.

t Procedures Reviewed i

ID Revision Title SNC-AUX-H/F/V-300 (R8)

Procedure (Written Practice) for Qualification and Certification of Nondestructive Examination Personnel

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SNC-UT-V-404 (RS)

Manual Ultrasonic Examination of Full-l Penetration Welds

SNC-UT-V-406 (R3)

Manual Ultrasonic Examination of Cast

Stainless Steel Full-Penetration Welds

i SNC-UT-V-411 (R4)

Manual and/or Mechanized Ultrasonic Examination of Pressure Vessel Welds (2 Inches to 12 Inches in Thickness)

SNC-UT-V-413 (RI)

Manual Examination of Main loop Branch Connected Welds SNC-UT-V-416 (R3)

Manual Ultrasonic Examination of Nozzles Inner Radius SNC-UT-V-417 (R2)

Manual Ultrasonic Examination of Reactor Coolant Pump Motor Flywheels

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Procedures Reviewed Cont'd ID Revision Title SNC-UT-V-422 (R2)

Manual Ultrasonic Examination of Bolts and Studs Greater than 2 Inches in Diameter SNC-MT-V-505 (R2)

Magnetic Particle Examination H-MRS-2.4.2 GPC-3 (RI)

Eddy Current Inspection of Preservice and Inservice Heat Exchanger Tubing H-MRS-2.3.2 GPC-1 (R2)

Mechanical Plugging of Steam Generator Tubes H-DAT-GYD-001 (R6)

Eddy Current Data Analysis Site Specific Guidelines The following items were noted relative to the review of procedures.

o In April of 1992 this inspector noted several minor procedural deficiencies relating to the ASME B&PV Code Section V Article 4 paragraph T-424-(h) requirement for the specification of UT transducer cable type and length, the metric conversion of ten and 40 pounds into kilograms, the lack of a reference to the SNC reference system procedure, and that post examination cleaning was optional. The licensee satisfactorily addressed all the discrepancies with the following exceptions.

Proce-dures SNC-UT-V-407 and SNC-UT-465 have not been revised or used since the April 1992 inspection, therefore the discrepancies remain. SNC-MT-V-505, Revision 2, dated January 29, 1993 does not reference the reference system procedure SNC-AUX-V-306.

o In Revision 2 to SNC-MT-V-505, the licensee added fluorescent MT examinations, however the accepted industry practice of prohibiting the of wearing photosensitive eye glasses (by the examiner) while performing fluorescent examinations, is not included.

It should be noted that although this an accepted industry practice, it is not a requirement for the licensee as the prohibition was not codified until the Winter of 1983.

o SNC-AUX-H/F/V-300, identifies, among others, " Personnel desig-nated by ITS NDE Supervisor" as qualified to administer visual acuity examinations. There is no written guidance for the ITS NDE Supervisor to use in determining the qualification of the personnel that the ITS NDE Supervisor designates.

Except as noted above the procedures reviewed, were well written and appropriate for their intended applicatio.

c.

Observation of Work and Work Activities, Unit 1 (73753)

Because the window of opportunity to observe the majority of active examination activities had past, the inspector observed the active work activities available, and in addition reviewed records of work activities accomplished this outage, 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 reviews conducted by the

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inspector are documented below.

Work Activities Observed

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The inspector observed the UT examination of 29) inch diameter Main Steam (MS) system butt weld 11301-004-5, including the calibration activities.

The inspector observed the MT examination of weld 11301-004-4 an intregal attachment weld to a 291 inch MS system pipe. The inspec-tor performed an independent evaluation of the indications obtained to confirm the NDE examiner's evaluation.

The inspector independently examined two MS system pipe supports, 11301-004-H002 and 11301-004-H003, to evaluate the indications obtained and to confirm the NDE examiner's evaluation.

The inspector observed ET data acquisition and analysis activities associated with S/G Nos. 2 and 3.

The licensee is performing the

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following bobbin coil examinations this outage.

S/G-2 S/G-3 AVB Indications

36 Previous >19%

5 UDS Tubes

11 Random Tubes 2232 2225 Additional 10%

563 567 C/L Untested from 1R3

84 H/L Untested From 1R3

0 Possible Loose Parts C/L

3 Possible Loose Parts H/L

3 The examinations were performed properly in accordance with regula-tory and procedural requirement. _.

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i Work Activity Records Reviewed l

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PT Examination Records j

11201-005-1 11201-008-1 11201-008-8 11201-012-1

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I 11201-012-4 11204-012-6 11204-030-1 11204-049-1 j

11204-049-4 11204-049-5~

11204-049-6 10305-058-8

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l 11204-127-19 11204-127-20 11204-127-22 10301-004-8

10301-004-10 10304-004-12 10305-058-2 10305-058-3 10305-058-5 10305-058-6 10305-058-7 11201-001-5

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11201-004-2 11201-004-3 11201-004-1 l

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Relative to the above PT examinations, the inspector reviewed j

certification documentation for the following penetrant materials i

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j and thermometers.

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f Penetrant Material Records

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Penetrant:

90G0lP Cleaner / Remover:

90C01K, 89LO1P, and 89H03S i

Developer: 90F07P, 870014, and 90F08P

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Thermometers l

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Serial Nos.:

1388, 1389, 1390, 1391, 1395, and 1423 MT Examination Records Reviewed 11305-156-1 11305-156-2 10301-004-9 10301-004-3 l

10301-004-5 10301-004-7 10301-004-8 10301-004-10

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10301-004-12 10305-058-2 10305-058-3 10305-058-5

10305-058-6 10305-0'9-7 10305-058-8 Relative to the above MT examinations, the inspector reviewed certification documentation for the following MT Yokes, dry powder, and ten Lbs. test weights.

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Yokes Serial Hos.: 2363, 2827, LMT YK-10, and LMT YK-Il Dry Powder Magnaflux 1 Gray Batch No.90A008 Ten Lbs. Test Weights i

Serial Nos.: VEGP-MAG-1 and VEGP-MAG-2 i

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f UT Examination Records Reviewed

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11305-156-1 11305-156-2 11305-058-1 11301-004-9

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11301-016-1 11301-004-2 11301-004-12 11305-058-2

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11305-058-5 11305-058-6 11305-058-7 11305-058-8

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Relative to the UT examinations the inspector reviewed certification

documentation for the following UT calibration blocks and standards,

UT instruments, transducers, and couplant.

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UT Calibration Blocks and Standards.

l IIW-86-4245 IIW-86-4246 5-Step 87-3543 Rompas LMT-030

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Rompas LMT-048 j

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UT Instruments Serial Nos.:

6225E, 784523, 92038103, 91043406, and 92068401

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Transducers

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I 00959 00654 00833T 0131 01396

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016251 24362 75113 85-808 91-26

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Couplant Batch Nos. 8982 Visual Examination Records Examined

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11201-053-H002 11204-024-H035 11204-024-H011 i

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11204-076-H012 11204-076-H013 11204-076-H15

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Il204-076-H016 ll204-076-H017 11204-076-H018

ll204-076-H020 ll204-076-H021 ll204-076-H022 l

11204-076-H023

ET Records Examined

l The inspector reviewed records for the following ET calibration standards:

ET Calibration Standards

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Serial Nos.:

ISI-806B, ISI-806C, 151-808B and ISI-808C.

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i It appears that the heat number for the Tube Support Simulation Ring

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indicated on Ztec drawing 2-4000 S/N Z-27709 associated with ISI-806B is in. error. The licensee indicated that they would verify the heat number on the calibration standard when it is removed from the Steam Generator, and have the necessary corrections made.

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NDE Examiners The inspector reviewed the following NDE examiner qualification, certification and visual acuity records.

M GCB ET-IIA RAC ET-I JAD ET-I WDG ET-II MJG ET-II CDH ET-I KPH ET-IIA GPJ ET-II DJJ ET-II DMM ET-II GPP ET-III JMR ET-III DLR ET-II MAR ET-III KLS ET-I CAS ET-IIA GMT ET-III TSB ET-III DJC ET-III SVR ET-IIA SSI HRB MT-II UT-IIR CPC MT-II PT-II VT-I-II VT-2-II VT-3-II SJF MT-I PT-II UT-IIR VT-I MG MT-II PT-II UT-II VT-1-II VT-2-II VT-3-II KR MT-II PT-II UT-I

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LMT KRL MT-II PT-III UT-III JER MT-1 PT-II UT-I SDS MT-I PT-I GJS MT-III PT-III UT-III LPH MT-II PT-II UT-I

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GPC DRC MT-III PT-III VT-II ET-I MLP MT-I PT-II VT-II LEM MT-III PT-III VT-III RT-III Records supported the accomplishment of activities consistent with

regulatory and procedural requirements.

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

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3.

Flow Accelerated Corrosion Units 1 and 2 (49001)

The licensee has established a Flow Accelerated Corrosion (FAC)

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inspection program which uses the CHECMATES EPRI (Electric Power Research Institute) computer code for Unit 1 and the CHECS EPRI computer code for Unit 2 (the CHECMATES model for Unit 2 is under construction and should be ready for the Unit 2 Fall refueling outage), industry experience, and previous inspection data as predictive tools for the determining and i

prioritizing inspection locations.

F The licensee's Unit 1 CHECMATES electronic model includes the systems that have been predicted to be susceptible to FAC, which ranks the systems components according to their FAC susceptibility. The licensee's primary basis for the selection of components for ultrasonic (UT)

examination during the next refueling outage is the results of previous

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ultrasonic examinations.

In addition to the results of previous ultra-J sonic examinations the licensee uses:

engineering judgement, including plant specific design characteristics; predictive analyses; and industry and operating experience. The licensee program does not currently have criteria for excluding a system from the FAC program. The licensee's FAC program includes the following systems:

Feedwater; Condensate; Feedwater Heater Drains; Moisture Separator Drains; Moisture Separator Reheater

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Drains; Extraction Steam; Steam Generator Blowdown; Main Steam Drains;

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Auxiliary Steam; and Crossover and Crossunder piping. Components in the licensee's program include: control / check valves; tees and branches;

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expanders and reducers; flow nozzles and orifices; straight pipe sections; and elbows and reducing elbows.

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The licensee's procedure for performing UT thickness examinations of carbon steel piping is not approved by the management review committee defined in Section 6.0 of the licensee's Technical Specifications. The

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licensee's procedures define the method for the following: performing UT measurements; grid marking the inspection zone; ensuring location repeatability on followup UT examinations; ensuring certified UT examin-ers perform the examinations; and establishing acceptance criteria for evaluating UT data. The licensee program provides guidance only for analyzing results of UT measurements (there are no firm requirements in this area).

The criteria for establishing minimum wall thickness (t,,,,)

requirements for safety-related (SR) piping is to set t, to code s

minimum allowable thickness. The criteria for establishing t, require-

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mi ments for Balance of Plant (B0P) piping is to set t, to code minimum j

mi allowable thickness.

The wear rate (wr) calculation method is determined on a case by case basis. The predicted thickness (t,,,a)=[t,,,,,,o-(wr x current operating m

cycle time)) for previously measured components and t,,3=[t,%,a (wr x y

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total operating time to date)] for first time examined components.

Component acceptability at the next outage is determined by the following method:

t,,,,,,,,, >

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a nd t,,,, > t o. The licensee's method for calcu-lating remaining life (rl) = (t,,,,,,o-tmio)/wr.

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To date no repairs or replacements have been made to ASME Code class 1,

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2, or 3 components identified by the FAC program.

For B0P components

which fail to meet the licensee's FAC acceptance criteria, the licensee

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has a repair and replacement program.

It should be noted that the i

program is not contained in a single document. Welding and nondestructive examination (NDE) of SR and B0P piping replacements are

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being accomplished by qualified personnel and suitable procedures.

i Corporate Nuclear Engineering Department is responsible for the i

implementation of the FAC prograr. The licensee does not have formal programmatic requirements assigning the responsibility for oversight of the FAC program. The licensee's FAC program is not covered by their QA program.

i To evaluate the licensee's performance in this area the inspector conducted interviews and reviewed Minor Departure from Design (MDD)

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package 92-V2M040, Nuclear Plant Maintenance Work Order (NPMWO) 19200346

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dated 2/17/92, NPMWO 29201408 dated 4/16/92, NPMWO 19202802 dated 10/27/92 and Request for Engineering Review (RER) 91-0471. The inspector reviewed welding material certification documentation, and welder qualification, and qualification maintenance records associated with the above MDD, NPMWO and RER documents.

In addition the inspector reviewed the below listed procedures.

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ID Revision Title (R4)

Erosion / Corrosion Program

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83301-C (RO)

Review and Processing of Erosion / Corrosion Data

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UT-V-466 (RO)

Ultrasonic Erosion / Corrosion Examination Proce-

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The Licensee's FAC program document, " Erosion / Corrosion Program",

Revision 4 dated June 1991, is based on CHECS EPRI computer code, and is therefore out of date. The licensee indicated that the document is

currently being revised.

The licensee does not currently use the T-Dat portion of the CHECMATES program and therefore has missed out on the iterative benefits built into the program.

The calculations used in the program are not proceduralized.

UT-V-466 specifies that the grid pattern for expanders and expanding elbows, shall extend from 12 inches upstream of the fitting to 12 inches downstream of the fitting. The preceding is not consistent with EPRI recommendations for pipe sizes over six inch diameter.

EPRI recommends that the grid pattern extend two pipe diameters above the upstream weld for expanders and expanding elbows to two pipe diameters beyond the downstream weld.

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The licensee indicated that their program has identified a number of fittings that have experienced FAC, to date three of those fittings have been or will be replaced this outage.

To date the licensee's program has been effective in maintaining high

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energy carbon steel piping systems within acceptable wall thickness l

limits.

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

4.

Exit Interview The inspection scope and results were summarized on April 2, 1993, with those persons indicated in paragraph 1.

The inspector described the

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areas inspected. Although reviewed during this inspection, proprietary

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information is not contained in this report. No dissenting comments were received from the licensee.

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Acronyms and Initialisms 83S83

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1983 Summer 1983 ASME

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American Society of Mechanical Engineers

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AVB

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Anti Vibration Bar i

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Balance of Plant B&PV

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Boiler and Pressure Vessel C/L

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Cold Leg

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MDD

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Minor Departure from Design EPRI

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Electric Power Research Institute i

ET Eddy Current FAC

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Flow Accelerated Corrosion l

GPC

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Georgia Power Company H/L

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Hot Leg ID

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Identification ISI

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Inservice Inspection KLT

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Lambert, McGill and Thomas

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MS

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Main Steam i

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MT

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Magnetic Particle

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NDE

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Nondestructive Examination

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NPF

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Nuclear Power Facility NPMWO

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Nuclear Plant Maintenance Work Order j

NRC

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Nuclear Regulatory Commission l

P.E.

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Professional Engineer PT

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Liquid Penetrant QA

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Quality Assurance R

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Revision RER

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Request for Engineering Review

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RF0

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Refueling Outage rl

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Remaining Life i

RT

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Radiography

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S/G

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Steam Generator

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SR

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Safety Related i

SNC

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Southern Nuclear Operating Company SSI

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Sonic Systems International Inc.

t,o,_,a

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Measured Thickness t,

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Minimum Wall Thickness o

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Nominal Thickness o

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Predicted Thickness

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VEGP

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Vogtle Electric Generating Plant UT

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Ultrasonic VT

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Visual W

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Westinghouse company

wr

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Wear Rate l

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