IR 05000440/1979006
| ML19254C604 | |
| Person / Time | |
|---|---|
| Site: | Perry  |
| Issue date: | 08/27/1979 |
| From: | Danielson D, Ward K NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML19254C600 | List: |
| References | |
| 50-440-79-06, 50-440-79-6, 50-441-79-06, 50-441-79-6, NUDOCS 7910170031 | |
| Download: ML19254C604 (11) | |
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U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT
REGION III
Report No. 50-440/79-06; 50-441/79-06 Docket No. 50-440; 50-441 License No. CPPR-148; CPPR-149
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Licensee:
Cleveland Electric Illuminating Company P. O. Box 5000 Cleveland, OH 44101 Facility Name: Perry Nuclear Power Plant, Units 1 and 2 Inspection At: Perry Site, Perry, Ohio Inspection Conducted: August 8-10, 1979 k he Y &
Inspector:
K. D. Ward
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Approved By:
D. H. Danielson, Chief
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Engineering Support Section 2 Inspection Summary Inspection on August 8-10, 1979 (Report No. 50-440/79-06; 50-441/79-06)
Areas Inspected: Newport News-Industrial Corporation and Pullman Power Products nondestructive examination (NDE) procedures, personnel certifi-cations, equipment and review of radiographs. The inspection involved a total of 16 onsite inspector-hours by one NRC inspector.
Results:
Of the two areas inspected, no apparent items of noncompliance were identified in one area; one apparent item of noncompliance was identified in one area (infraction - failure to qualify liquid penetrant examination procedures - Paragraph 2.e.(6)).
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DETAILS Persons Contacted Cleveland Electric Illuminating Company (CEI)
- M. Edelman, Manager Nuclear QA Department
- Gy Groscup, Manager NED
- W. Kacer, General Supervisor Engineer
- P. Martin, General Supervisoc Program Quality H. Walls, Project Inspector Gilbert Associates Incorporated (GAI)
- T. Arney, Program Manager
- J.
Connelly, Lead Civil QE
- R. Crofton, Lead Piping QE J. Mehaffey, Lead Mechanical QE W. Pardee, Quality Engineer Kaiser Engineers Incorporated (KEI)
- D.
Fitzpatrick, Construction Manager
- P. Gibson, Construction QC Supervisor
- D. Cooper, CQSS - Supervisor Pullman Power Products (PPP)
J. Miller, QA Manager R. Walter, Resident Manager J. Steele, NDE Supervisor Newport News Industrial Corporation (NNIC:
T. Bond, QA/QC Operations Manager T. Payne, NDE Manager
- Denotes those present at the exit interview.
The inspector also contacted and interviewed other licensee and contractor employees.
Functional or Program Areas Inspected 1.
Review of Pullman Power Products NDE Activities a.
PPP was contracted to perform radiography (RT) and liquid penetrant examinations (PT) on Class II pipe welds in accordc.nce with ASME Section III, 1974 Edition, Winter 1975 Addenda.
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b.
GAI, PPP, and the Authorized Inspector (AI) have reviewed 100%
of S 3 Class II pipe welds to date.
c.
Ict.nspector reviewed audits performed by GAI on PPP and audits of PPP on PPP.
d.
The PPP QA Manual No. 10, May 16, 1978, was reviewed.
e.
Preservice inspection (PSI) may start the Summer of 1980.
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f.
The inspector reviewed the following procedures and NDE personnel certifications in accordance with SNT-TC-1A, ^975 Edition.
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Nondestructive Examination Personnel - Control and Administration of Training, Examination, Qualification and Certification, No. 11-2, November 12, 1976.
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Control and Administration of Examination, Qualification and Certification of Nondesturctive Examination of Level III Personnel, No. 11-3, April 8, 1978.
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Inspection and Test Personnel Qualification and Certification, No. 11-4, January 12, 1979.
Name Methods Level J. Steele VT-RT-UT-PT-MT III J. Miller VT-RT-UT-PT-MT-LT III D. Denlinger PT II I. Havard PT-VT II J. Wilcox LT-PT-VT II J. Wilcox RT I
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The inspector made a tour of the PPP facilities escorted by the GAI Lead Civil QC and the PPP Manager. The following are the inspector's findings.
(1) Radiograph Examination (RT)
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The NRC License expires May 31, 1984, No. 37-08042-01 and covers IR 192 up to 100 curies and CO 60 up to 50 curies.
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PPP does not have a CO 60 source or a X-ray machine on site.
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The lab has one IR 192 source stored in a locked, brick, lead lined box in a storage area.
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A hand film processing tank and an automatic processor
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are used to process film.
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Survey meters are calibrated every three months.
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Pocket dosimeters are read and recorded every day when performing RT.
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Film badges are processed and recorded every ',eek.
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Acceptable color rope and signs were available for securing areas when RT is being performed.
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Decay n ves of the IR 192 source are posted for the NDE persocnel to use.
The lab uses Kodak industri21 radiographic film only,
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Types I and II.
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No outdated film was observed.
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Filt cassettes were in acceptable condition.
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Lead screens are checked and replaced when needed.
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Flourescent screens are not used nor are there any onsite.
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The films are streed in the dark room prior to exposure.
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PPP uses lead numbers for the number belt and a flasher for the identification.
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The lab uses a Macbeth densitometer.
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PPP uses a film density step wedge traceable to the Bureau of Standards for the calibration of the densitometer.
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ASTM penetrateters are the only penetrameters used onsite. They were in acceptable condition and had certifications.
PPP had various thickness of shims to be used under
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the penetrameters.
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The lab uses a high intensity viewer for interpreting radiograpits.
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The inspector also reviewed Radiographic Inspection
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of Weldments, Procedure No. IX-RT-5, February 12, 1979.
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PPP has radiographed only the following nine welds to date.
ISO No.
Weld No.
Thickness Diameter Date RT 1-E21-6
.500" 14" 5/1/79 1-E22-7
.625" 16" 5/14/79
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1-P11-8
.500" 18" 4/24/79 1-P11-8
.500" 18" 4/5/79 1-P11-8
.500" 18" 4/5/79
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1-P11-8
.500" 16" 4/5/79 1-P11-8
.500" 16" 2/16/79 1-Pl? 8
.500" 16" 3/5/79 1-P11-8
.375" 16"
- 5/14/79 The above systems are:
E21 - Low Pressure Core Spray (LPCS).
E22 - High Pressure Core Spray (HPCS).
P11 - Condensate Transfer and Storage.
In reviewing the above radiographs, the inspector fcund that the welds had heavy root reinforements.
In most cases the result of this heavy root reinforce-ment in the weldment was because of an offset or mismatch of the pipes and fittings when welded together.
The above welds are acceptable, but if a slight more reinforcement was induced the welds coild be unaccept-able and be judged as to have an, " elongated indication,"
which is unacceptable in accordance with the Code.
An excessive root reinforcement results in a rolled edge of the root bead possibly masking a real defect, an " abrupt change," is also unacceptable in accordance with the Code. We3ds with excessive root reinforcement have been cut out at nuclear power plants trying to prove the acceptability of the weld to the NRC, AI and Licensees.Metallographic examinations have revealed minor imperfections associated with the rolled edge of the root bead where it joined unfused base material and had the appeareance of a very small tear / crack.
The depth of the imperfections ranged up to 0.010 Tches. Welders can be trained or upgraded to put in
?lat root bead and eliminate potential problems.
The intpector discussed this matter in detail at the exit.
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(2) Liquid Penetrant Examination (PT)
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The lab uses Magnaflux and Turco materials and receive certifications.
Reviewed procedures, Liquid Penetrant Examination
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IX-PT-1, Fe bruary 12, 1979, and NDE Procedure Qualification Record Liquid Penetrant No. PQP-PT-1, March 1, 1976.
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(3) Magnetic Particle (MT), Ultrasonic (UT), Eddy Current (ET)
Leak Testing (LT)
To date PPP does not perform MT, UT, ET and LT onsite.
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The inspector reviewed the following procedures:
Magnetic Particle Examination Dry Power Continuous Prod Method, IX-MT-I, March 29, 1970.
Ultrasonic Examination of Weldments, IX-UT-1, August 14, 1975.
Ultrasonic Examination of Seamless and Welded Tubular Materials IX-UT-2, August 20, 1975.
Ultrasonic Thickness Measurement, IX-UT-3, September 1, 1976.
No items of noncompliance or deviations were identified.
2.
Review of Newport News Industrial Corporation NDE Activities a.
NNIC was contracted to perform rediography (RT) on containment welds in accordance with ASME cection III, Subsection NE, 1974 Edition, with no Addenda.
b.
The inspector reviewed audits performed by GAI on NNIC and audits performed by NNIC on NNIC.
c.
Reviewed QA Manual Rev. C, Copy 28.
d.
The inspector reviewed the fol.owing procedures and NDE personnel certificatiens in accordance with SNT-TC-1A, 1968 Edition.
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Qualification of Personnel, Rev. A, September 15, 1977 (ANSI N45.2.6).
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Qualification of Nondestructive Examination Personnel, Rev. E, August 30, 1977 (SNT-TC-1A, 1968 Edition).
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Name Methods Level T. Payne RT-MT-PT-UT-LT III D. Vigne RT-UT-MT-PT III J. Rodriguez MT-PT-RT II S. Land MT-PT-RT II J. Goodenough UT II L. Oberacker PT II
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T. Avelone RT-MT II K. Collins PT II J. Gester UT II J. Gester does not have previous experience documented in accordance with NNIC written procedures above or in accor-dance with SNT-TC-1A.
The licensee has requested Gester's resume which will be included as part of his certification.
Until Gester's previous experience is reviewed, this is an unresolved item.
(440/79-06-01; 441/79-06-01)
e.
The inspector made a tour of the NNIC facilities escorted by the GAI Quality Engineer and the NNIC Manager.
The following are the inspector's findings.
(1) Radiography Examinations (RT)
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The NRC license expires March 31, 1981, No. 34-16805-01 and covers IR 192 up to 100 curies and CO 60 up to 30 curies.
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NNIC does not have a C0 60 source or a X-ray machine onsite.
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The lab has one IR 192 source, stored in a locked 2" thick steel, 1200 lb. vault, located - a locked fenced in room in a warehouse.
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A hand film processing tank or an automatic processor is used to process film.
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Survey meters are calibrated every three months.
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Pocket dosimeters are used and recorded every day when performing RT.
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Film badges are processed and recorded every month.
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Acceptable color rope and signs were available for securing areas when RT is being performed.
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Decay curves of the IR 192 source are posted for the
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NDE personnel to use.
The lab uses Kodak industrial radio,caphic film only,
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Types I and II.
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No outdated film was observed.
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Film cassettes were in acceptable condition.
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Lead screens are checked and replaced when need(d.
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Flourescent screens are not used nor are there any onsite.
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The films are stored in the dark room prior to exposure.
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The exposed film is stored in the viewing room.
NNIC uses lead numbers or a flasher for the identification.
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The lab used a X-Ray - Model 301 densitometer.
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ASTM and ASME pen trameters are used onsite.
They were in acceptable condition.
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The lab uses a high intensity viewer for interpreting radiographs.
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NNIC had various +hickness of shims to be used under the penetrameters.
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The inspector also reviewed procedure, Radiograph Inspection, Rev. C, 465-NC-N002, November 18, 1976 (ASME Section III, NE, 1974 Edition with no Addenda).
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The following radiographs were reviewed.
Weld No.
Thickness Date 1-77 1.5" 3/16/79 1-178 1.5" 7/29/79 WN2-33 1.5" 7/12/79 WN2-6 1.5" 2/5/79 WN2-125 1.5" 7/10/79 WN2-102 1.5" 3/26/79 1-54 1.5" 8/6/79 WN1-18 1.5" 6/26/79 WN1-40 1.5" 7/27/79 1-25 1.5" 5/30/79 Penetration 1-45 1.5" 6/4/79 NN1-42 1.5" 6/11/79-8-C'
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The lab has a film density step wedge that has been
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used every work day for approximately two and one half years. The film density step wedge is traceable to the Bureau of Standards for the calibration of the densitometer. The step wedge was last calibrated two and one half years ago.
The lab has a procedure that was approved for use May 1979. The procedure states in part, items which can be calibrated including reference s'.ndards, will be calibrated every 12
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months. The inspector was informed that there will
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be an annual calibration of the step wedge in accor-dance with the procedure, No. 701-NC-5001, Rev. F, April 23, 1979.
Until an NRC inspector has varified that the step wedge has been calibrated, this is an anret lved item.
(440/79-06-02 and 441/79-06-02)
(2) Magnetic Particle Examination (MT)
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The lab has eleven field prod units and eight yoke units.
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NNIC uses finely divided, red, gray and black mangetic particles.
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The inspector reviewed procedure, Magnetic Part:'.cle Inspection, 465-NC-N004, Rev. D, April 10, 1979, yoke, ASME Section III, 1974 Edition, with 1975 Addenda.
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Also reviewed was Magnetic Particle Inspection Procedure, 948-N-N003, Rev. D, April 11, 1979, Prod and Yoke, AWS D1.1-75.
(3) Ultrasonic (UT)
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The lab has four ultrasonic instruments and variou calibration blocks.
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The couplant onsite is celluose gum and exosen.
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NNIC has 2 and 2.25 MHZ transducers, various sizes, straight and angles.
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The inspector reviewed Liquid Penetrant Inspection Procedure, 948-N-N005, Rev. E, April 12, 1979.
(4) Leak Testing (LT?
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The lab performs vacuum box and pressure testing.
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Reviewed procedure, Instruction for Leak Testing of Welds, Rev. B, May 13, 1977.
(5) Visual (VT)
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The inspector reviewed the following procedures.
Visual Inspection of Welds, 701-N-N003, Rev. a, March 8, 1978, ASME Section III, 1974 Edition with no
addenda.
Visual Inspection, 948-N-N002, Rev. B, May 9, 1977 AWS D1.1-75-(6)
fiquid Penetrant (PT)
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The lab uses Magnaflux materials with certifications.
The in-rector reviewed the following procedures.
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Liquid Penetrant Procedure a48-4-N004, Rev. C, AWS D1.1 75.
Liquid Penetrant Procedure 465-NC-N003, Rev. 3, August 15, 1977, ASME Section V, 1974 Edition with ao Addenda.
In reviewing the above two liquid penetrant procedures, the inspector found that the procedures are not qualified down to a temperature of 40*F as required by ASME Section V and AWS. Tr.c Manager of the lab did not know if the procedure was qualified down to 40 F.
This is identified as an item of noncompliance in Appendiy A.
(440/79-06-03; 441/79-06-03)
3.
General The inspector reviewed several procedures and observed that various codes are specified or referenced withcut the applicable year and addenda. The personnel.'orking to the procedures are not sure of the code or addenda they are working too, but they are knowledgeable of procedure requirements. The above was discussed at the exit.
The Ferry PSAR, Volume 5, Paragraph 3.8.2.7 Materials Specifications, Quality Control and Special Construction Techniques for Steel Containment Vessel, state, "1971 ASME Codes with Summer 1972 Addenda and AWS D1.1-72."
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Unresolved Items Unresolved items are matters about which more information is required in order to ascertain whether they are acceptable items, items of noncompliance or deviations. Unresolved items disclosed during the inspection are discussed in Paragraph 2.d and 2.e.(1).
Exit Interview The inspector met with site representatives at the conclusion of the inspection and summarized the scope and findings of the inspection. The licensee acknowledged the information.
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