IR 05000483/1987029

Insp Rept 50-483/87-29 on 870921-1203.No Violations or Deviations Noted.Major Areas Inspected:Inservice Insp Work Activities,Training & Qualification Effectiveness & Facility Mods (73501,73057,73753,73755,41400,37701,55700 & 57700)

ML20237C497
Person / Time
Site:	Callaway
Issue date:	12/16/1987
From:	Danielson D, David Jones NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
To:
Shared Package
ML20237C483	List: IR 05000483/1987029 ML20237C482
References
50-483-87-29, NUDOCS 8712210341
Download: ML20237C497 (9)

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U.S. NUCLEAR REGULATORY COMMISSION

REGION III

Report No. 50-483/87029(DRS) l Docket N License No. NPF-30 Licensee: The Union Electric Company Post Office Box 149 - Nail Code 400 St. Louis, MO 63166 Facility Name: Callaway Plant, Unit 1 Inspection At: Callaway Site, Callaway County, Mist.ouri Inspection Conducted: September 21-24, October 5-8, 13-16, and November 30 through December 3, 1987

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Inspector: E. Jones /2-/[- 8 7 Date ob79,bwat k~

Approved By: D. H. Danielson, Chief '#/kP 7 Materials and Processes Section Date Inspection Summary Inspection on September 21-24, October 5-8, 13-16, and November 30 through December 3, 1987 (Report No. 50-483/87029(DRS))

Areas Inspected: Routine, unannounced inspection of inservice inspection (ISI)

work activities, training and qualification effectiveness, and facility modifications (73501, 73057, 73753, 73755, 41400, 37701, 55700, 57700).

Results: No violations or deviations were identifie % 2g 0 gg PDR ADOCK PDR G

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DETAILS 1. Persons Contacted Union Electric Company (UE)

• W. Witt, Supervisor Engineer, NSS Systems

• T. McFarland, Superintendent, Systems Engineering 1

• J. Laux, Superintendent, Technical Support C. Slizewski, Supervisor Engineer, QA Technical Support

• R. Huber, Supervisor Engineer, Performance /ISI J. Davis, Superintendent, Compliance B. Newton, Welding Engineer T. Pettus, System Engineer (Steam Generators)

• D. Stepanovic, ISI Engineer J. Ostroot, QA Engineer

• R. Myatt, QA Engineer

• L. Zahara, Assistant QC Supervisor

• J. Cassmeyer, Assistant Engineer

• T. Shaw, QC Supervisor

• T. Moser, Supervisor, Engineer Systems Combustion Engineering (CE)

P. Lancaster, Site Supervisor Nuclear Energy Services /Dynacon (NES/Dynacon)

P. Barry, Site Manager Nuclear Energy Services (NES)

A. Pennanen, Site Supervisor Westinghouse (W)

D. Hughes, Eddy Current Coordinator F. Garofalo, Lead Analyst Hartford Steam Boiler Inspection and Insurance Company A. Kim, Authorized Nuclear Inservice Inspector H. Potter, Authorized Nuclear Inservice Inspector Nuclear Regulatory Commission (NRC)

B. Little, Senior Resident Inspector

• C. Brown, Resident Inspector The NRC inspector also contacted and interviewed other Licensee and contractor employee * Denotes those present at the final exit interview on December 3, 198 l

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2. Inservice Inspection General This is the second refueling outage of the first ten year pla UE contracted with Westing current inspection, NES /0ynacon to perform the reactor vesselhouse (W)

outlet nozzle ultrasonic testing (UT), Combustion Engir.eering (CE)

to perform the primary loop UT, and with NES for.the balance of the ISI. The ISI was conducted in accordance with ASME Boiler and Pressure Vessel Code (ASME),Section XI, 1980 Edition, Winter 1981 Addend Steam generators A and D were eddy current inspected and the ,

following eight tubes were plugged:

Steam Generator A Steam Generator D Row Column Row Column 3 44 46 72 51 60 56 81 17 55 33 12 43 21 47 86 Program / Procedure Review The NRC inspector reviewed the following program / procedures:

• UE, Nondestructive Examination Inservice Inspection Program, EDP-ZZ-01003, Revision * UE, Qualification of Quality Control Personnel For Visual i Examinations to ASME Boiler and Pressure Vessel Code, QCP-ZZ-01004, l Revision * UE, Certification of Quality Control Personnel, QCP-ZZ-01001, Revision * UE, Qualification of Quality Control Personnel for NDE Activities, QCP-ZZ-01003, Revision * UE, Steam Generator Tubesheet Marking, ETP-ZZ-01303, Revision 1, (W, MRS 2.2.2, Gen-12, Revision 2).

• UE, Post-Activity Sign-Off For Area Cleanliness, ETP-ZZ-01304, Revision 1, (W, MRS 2.2.2, Gen-6, Revision 7). l

• UE, S/G Primary Nozzle Dam Installation / Removal Procedure, ETP-ZZ-01310, Revision 1, (W, SE-SG-83-084, Revision 5).

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• UE, Digital Multi-Frequency Eddy Current Inspection of Preservice I

and Inservice Heat Exchanger Tubing, ETP-ZZ-01300, Revision 2, l (W, MRS 2.4.2, Gen-28, Revision 2).

• UE, SM-10W Operating Procedure, E1P-ZZ-01302, Revision 1, (W, MRS 2.4.2, Gen-30, Revision 1).

• UE, Visual Examination To ASME VT-1, QCP-ZZ-05040, Revision * UE, Visual Examination To ASME VT-2, QCP-ZZ-05041, Revision * NES, Quality Assurance Program Plan for Inservice Inspections.,

No. 80A2929. Revision 1 * NES, Inservice Inspection Program Plan General Reference Text, No. 83A0977, Revision * NES, Inservice Inspection Quality Assurance Inspection Manual, No. 80A9021, Revision * NES, Ultrasonic Examination Procedure General Requirements, No. 83A1005, Revision * NES, Ultrasonic Examination Procedure For Austenitic Piping Welds, No. 83A1006, Revision * NES, Ultrasonic Examination Procedure For Ferritic Piping Welds, No. 83A1007, Revision * NES, Liquid Penetrant Examination, No. 83A1009, Revision * NES, Procedure For Magnetic Particle Examination, No. 83A1010, Revision * 'NES, Ultrasonic Examination Procedure For Pressurizer Welds, No. 83A1011, Revision * NES, Ultrasonic Examination Procedure For Fitting To Fitting Welds, No. 83A1012, Revision * NES, Ultrasonic Examination Procedure For Pressurizer and Steam Generator Nozzle Inner Radius Areas, No. 83A1013, Revision * NES, Ultrasonic Examination Procedure For Steam Generator Welds, No. 83A1014, Revision * NES, Ultrasonic Examinations Systems Performance Procedure, No. 83A1676, Revision * NES, Ultrasonic Examination Procedure For Studs and Bolts, No. 83A1016, Revision _ _ _ _ _ _ _ _ _ _ _ _ _

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• NES, Ultrasonic Examination Procedure For Accumulator Safety l Injection Tank Welds, No. 83A1018, Revision l

• NES, Procedure For Ultrasonic Examination of Studs From The 3 Heater Hole, No. 83A1020, Revision I

• NES, Ultrasonic Examination Procedure For Nozzle To Safe End Welds, No. 83A1021, Revision * NES, Supplemental 0 Ultrasonic Examination Of Studs and Bolting, <

No. 83A1023, Revision l

• NES, Ultrasonic Examination Procedure For Reactor Pressure Vessel Stud Hole Threads and Closure Head Nuts, No. 83A1025, Revision * NES, Ultrasonic Examination Procedure For Reactor Pressure Vessel Closure Head Welds, No. 83A1666, Revision * NES, Visual Examination Procedure, No. 83A1667, Revision * NES, Visual Examination Scan Plan, No. 83A1668, Revision * NES, Manual Ultrasonic Examination Procedure For Reactor Pressure Vessel To Flange Weld, No. 83A1677, Revision * NES/DYNACON, General Examination Requirements For The Mini-Scanner Examination Of The Reactor Pressure Vessel For Callaway Nuclear Power Plant, No. 83A1674, Revision * NES/DYNACON, Ultrasonic Examination Requirements For The Inner Radius / Nozzle Bore, Nozzle to Shell Weld, Nozzle to Safe End Weld, and Safe End to Pipe Weld From The Outlet Nozzle Bore With The Mini-Scanner System, No. 83A1669, Revision ,

• NES/DYNACON, Mini-Scanner Syrtem Scan Plan, No. 83A1675, Revision * CE, Introspect Ultrasonic Imaging System Procedure For Inspection Procedure For Statically and Centrifugally Cast Stainless Steel Piping and Components, STD-410-018, Revision No violations or deviations were identifie c. NDE Personnel Certifications and Observations of Work Activities The NRC inspector reviewed NDE Personnel Certifications in accordanco with SNT TC-1 The NRC inspector also observed the work and had discussions with personnel during the following examinations:

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• Eddy current examination in accordance with UE Procedure No. ETP-ZZ-01300, Revision 2, " Digital Multi-Frequency Eddy Current Inspection of Preservice and Inservice Heat Exchanger Tubing" of the following tubes:

Steam Generator A Row Column Row Column 45 38 51 39 46 38 50 39 47 38 48 39 48 38 47 39 49 38 45 39 50 38 44 39 51 38 43 39 Steam Generator D Row Col umn Row Column 19 11 24 14 17 11 23 13 21 12 17 15 7 12 19 15 5 12 9 17 9 13 11 17 11 13 23 17

• Liquid penetrant examination, in accordance with NES procedure 83A1009, Revision 5, " Liquid Penetrant Examination", of the following stainless steel pipe welds:

Weld Identification 2-EM-05-FWO25 (2-inch)

2-EM-05-FW016(2-inch)

2-EP-01-F010 (6-inch)

2-EP-01-FWO60 (2-inch)

• Ultrasonic examination of reactor outlet nozzle-to-vessel weld at 22 in accordance with NES/Dynacon Procedure No. 83A1669, Revision 2, " Ultrasonic Examination Requirements For The Inner Radius / Nozzle Bore, Nozzle To Shell Weld, Nozzle To Safe End Weld, And Safe End To Pip'e Weld From The Outlet Nozzle Bore With The Mini-Scanner Syste * Ultrasonic examination, in accordance with CE procedure STD-410-018, Revision 0, "Introspect Ultrasonic Imaging System Procedure For Inspection Procedures For Statically And

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Centrifugally Cast Stainless Steel Piping And Components", of the following primary loop welds:

Weld Identification S305-4, Loop 3 Pipe-to-Elbow F307, Loop 3 Pipe-to-Elbow (calibration & exam)

• Ultrasonic calibration and examination, in accordance with NES Procedure No. 83A104, Revision 2, " Ultrasonic Examination Procedure For Steam Generator Welds", of the following welds located in the shell of Steam Generator B:

Weld Identification 2-EBB 01B-Seam-2-W 2-EBB 018-Seam-3-W No violations or deviations were identifie d. Material and Equipment Certification The NRC inspector reviewed the certification documents, relative to the following items:

• Ultrasonic instruments, transducers, couplant, thermometers, calibration blocks

• Magnetic particle equipment and materials

• Liquid penetrant materials

• Eddy current calibration standards No violations or deviations were identifie e. Data Review The NRC inspector reviewed report documentation relative to the following:

• Ultrasonic examinations

• Liquid penetrant examinations

• Magnetic particle examinations

• Eddy current examinations

• Visual examinations No violations or deviations were identifie _ _ _ _ _ _ _ _ _ _ _ _ _ _ - _ _ - _ -

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3. Essential Service Water System Modification General This modification was performed to add 14" boundary valves and 1" drain valves to the Essential Service Water and Containment Cooling systems to facilitate local leak rate testing and valve repairs without taking the entire A or B essential service water train out of service, Procedure Review The NRC inspector reviewed the following procedures:

• UE, Maintenance Welding Procedure, MTW-ZZ-WP501, Revision * UE, Qualification Of Welding Procedures, MTW-ZZ-WP006, Revision * UE, Administration Of Welding, APA-ZZ-00661, Revision * UE, ASME/ ANSI General Welding Requirements, MTW-ZZ-WP001, Revision 1 * UE, Control Of Weld Filler Materials, MTW-ZZ-WP003, Revision * UE, Control Of Special Processes, Materials, And System Cleanness, APA-ZZ-00660, Revision * UE, Welder Performance Qualification, MTW-ZZ-WP002, Revision 1 No violations or deviations were identifie Personnel Certifications The NRC inspector reviewed the NDE personnel certifications in accordance with SNT-TC-1A, and the welder qualification record No violations or deviations were identifie Material and Equipment Certification The NRC inspector reviewed the certification documents, relative to the following items:

• Liquid penetrant materials

• Weld filler materials No violations or deviations were identified.

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. Data Review i'

The NRC inspector reviewed report documentation relative to the following:

• Liquid penetrant examinations

• Weld control records

• Storeroom issue requisitions

• Holding oven calibration records No violations or deviations were identifie . CVCS Letdown Heat Exchanger Nozzle Examinations In September 1987, the licensee was notified that it had received two CVCS letdown heat exchangers from a manufacturer of a heat exchanger that had developed a crack in the inlet nozzle, at another facility. The crack developed as a result of grinding grooves left by the manufacturer. The heat exchanger purchased under P.O. No. 546-CAZ-240543-BM was installed in Unit 1, and the heat exchanger purchased under P.O. No. 546-CAZ-240545-BM was sold to Anderson Underground Construction in Centerville, Missouri for scra The licensee initiated a program to inspect the Unit 1 inlet and outlet CVCS letdown heat exchanger nozzles. The acceptance criteria was based on the failure analysis of the cracked nozzle and the ASME code. Visual and liquid penetrant examinations revealed no indication . Training and Qualification Effectiveness An evaluation of training and qualification effectiveness was made during the inspection. The evaluation included discussions with ISI personnel and observations of ISI personnel performance during work activitie On occasions ISI personnel were observed during discontinuity evaluatio Their performance during such evaluation demonstrated ability to identify and evaluate discontinuities, and is indicative of effective trainin The ISI personnel appear to be knowledgeable of industry practice . Exit Interview The inspector met with the site representatives (denoted in persons contacted paragraph) at the conclusion of the inspection. The inspector summarized the scope and findings of the inspection noted in this repor The inspector also d u ussed the likely informational content of the inspection report with regard to documents or processes reviewed by the inspector during the inspection. The licensee did not identify any such documents / processes as proprietar