IR 05000483/1998009

Insp Rept 50-483/98-09 on 980428-30.No Violations Noted. Major Areas Inspected:Maint & Plant Support

ML20247M432
Person / Time
Site:	Callaway
Issue date:	05/19/1998
From:	NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
To:
Shared Package
ML20247M431	List: IR 05000483/1998009 ML20247M424
References
50-483-98-09, 50-483-98-9, NUDOCS 9805260272
Download: ML20247M432 (9)

Text

.. - _ _ - _ _ _ __ _- .

EfiCLOSURE U.S. NUCLEAR REGULATORY COMMISSION

REGION IV

t l

Docket No.: 50-483

,

License No.: NPF-30 l

l Report No.: 50-483/98-09 Licensee: Union Electric Company Facility: Callaway Plant l Location: Junction Hwy. CC and Hwy. O Fulton, Missouri Dates: April 28-30,1998 Inspector: William P. Ang, Senior Reactor Inspector, Maintenance Branch Approved By: Dr. Dale A. Powers, Chief, Maintenance Branch Division of Reactor Safety

l ATTACHMENT: Supplemental Information l

l 9805260272 980519 I PDR ADOCK 05000483 l G PM l

_ _ _ - _ - - - - _ - _ _ _ - -

- _ _ _ _ _ _ _ _ _ _ _ _ _ - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ .

.

.

-2-EXECUTIVE SUMMARY Callaway Plant NRC Inspection Report 50-483/98-09 A routine, announced inspection of the implementation of the inservice inspection program was performed at the Callaway Plant. The inspector used NRC Inspection Procedure 73753,

" Inservice Inspection," 'o determine whether the inservice inspection, repair, and replacement of Class 1,2, and 3 pressure retaining components were performed in accordance with applicable requirements. The inspector determined, by review of records of completed inservice inspection, repair, and replacement activities, that the inservice inspection program was being appropriately implemented in accordance with licensee procedures, ASME code requirements, and NRC regulatory requirement Maintenance

.

The inservice inspection program implementing procedure provided good detail for implementation of the inservice inspection plan (Section M1.1).

. Visual inspection of the replaced Essential Service Water Valve EFHV0041 indicated that the valve had been appropriately replaced in accordance with the work document  ;

(Section M2.1).

. The procedures and records for inservice inspections, examiner qualifications, and repair and replacement of ASME Code Class 1,2, and 3 components that the inspector reviewed were good, and indicated that the inservice inspection program was being appropriately implemented (Section M3.1).

. Allowing Level ll examiners to review the work of Level ill examiners was identified as a poor practice (Section M3.1).

Plant Sucoort

. Housekeeping in the essential service water pipe chase, in general, was good, but three distinct areas were observed that needed further cleanup (Section M2.1).

l l

i l

i

- _ _ _ - _ _ - - _ _ _

.

.

-3-Report Details Summarv of Plant Status Callaway Plant was in Mode 5 and was completing its ninth refueling outage at the start of the inspection period. The plant entered Mode 4 on April 29,1998, and was preparing to go to Mode 3 on April 30,199 II. Maintenance M1 Conduct of Maintenance M1.1 Inservice Insr,ection Proaram Insoection Scoce (73753)

The inspector reviewed licensee submittals, NRC responses, and implementing documents for the inservice inspection progra Observations and Findinas Callaway Plant started commercial operation on December 19,1984. The first 10-year inspection interval was extended from December 18,1994, to July 31,1995, as allowed by ASME Section XI, paragraph IWA-2430. Union Electric Company submitted Revisions 0 and 1 of the Callaway Plant Second Interval inservice inspection Plan and associated relief requests, to the NRC by means of Letters ULNRC-3086 and ULNRC-3255 dated October 12,1994, and August 18,1995. The NRC, by means of a letter dated December 20,1995, acknowledged receipt of the plan and dispositioned the nine relief requests that were submitte The NRC, by means of a letter dated October 11,1996, approved Union Electric Company's request to use ASME Code Case N-533 at the Callaway Plant for VT-2 visual examination of Class 1 insulated pressure-retaining bolted connections for the second 10-year inservice inspection interva The Callaway Plant Second interval inservice inspection Plan, Revision 2, specified the requirements applicable to the inservice inspection program for the second 10-year interval. The plan included an inspection schedule that was divided into three periods so that approximately one third of the inspections would be completed every period. The first period included Cycle Nine and Refueling Outage Nine for the plant. Approximately 200 inspections were scheduled and completed during the perio '

Engineering Department Procedure EDP-ZZ-01003, "Non-destructive Examination Inservice Inspection Program," Revision 13, provided the administrative requirements for the implementation of the inservice inspection program. The procedure assigned responsibilities for the implementation of the inservice inspection plan. The primary l )

. _ _ _ . . . . .

.

.

'

-4-responsibility for coordinating activities necessary to implement the plan was assigned to an inservice inspection engineer. The procedure provided good detail for implementation of the inservice inspection pla Conclusions The inservice inspection program implementing procedure provided good detail for implementation of the inservice inspection pla M2 Maintenance and Material Condition of Facilities and Equipment M2.1 Visual Observation of Comoleted Code Replacement Activity

!

l insoection Scone (73753)

The inspector visually observed Essential Service Water Valve EFHV0041 and adjacent piping. Work Document W176779 required the existing Jamesbury valve to be replaced with a stainless steel Anchor Darling valv Observations and Findinas The inspector observed that Essential Service Water Valve EFHV0041 had been i installed in accordance with Work Document W176779. The inspector observed that the  !

valve label plate had not yet been reinstalled. The system engineer who accompanied the inspector noted the condition and indicated that reinstallation of the label plate was to

! be performe ,

l  !

!

The inspector also observed that housekeeping in the general pipe chase area of Control Building Room 3101, Elevation 1974, was good, with the exception of the following three observed area ;

l . Material and equipment that had been used for the replacement activity had been '

staged for removal, but had not been removed from the area.

l

. An approximately 24-inch square polyethylene bag of trash was left on the floor in '

i the are )

. Two spray cans of solvent degreaser, a spray bottle of liquid cleaner, a can of ,

l WD-40, rags and cotton gloves, and an open polyethylene bag, marked for l radioactive material and containing used cotton gloves, were observed in the area. (The essential service water pipe chase was inside the radiologically controlled area.) The inspector discussed the observed condition with the on duty health physics supervisor. Health physics personnel surveyed the contents of the bag and determined that the material was not radiologically contaminate As such, the health physics supervisor informed the inspector that the observed condition did not violate plant procedures, but the use of a bag marked

,

_ . _ _ _ _ _ _ _ _ _ _ _ _ . _ _ _ _ _ _ _ _ _ _ _ _ _ _

. _ _ _ _ _ _ - _ _ _ _

_ - _ _ _ _ _ _ _ - _ - - _ _ _ _ _ _ - _ _ _ _ _ _

'

i

!

l 5-

! radioactively contaminated material for uncontrolled trash was considered to be

poor work practic A quality assurance engineer that accompanied the inspector initiated Suggestion / Occurrence / Solution 98-2162 to document and correct the observed !

condition Conclusions Visual inspection of the replaced Essential Service Water Valve EFHV0041 indicated that the valve had been appropriately replaced in accordance with the work document.

l Housekeeping in the essential service water pipe chase, in general, was good, but three i

distinct areas were observed that needed further cleanu M3 Maintenance Procedures and Documentation M3.1 Review of inservice insoection Records Insoection Scoos (73753)

The inspector reviewed the inservice examinations records for eight ultrasonic tests, seven liquid penetrant examinations, and three magnetic particle examinations performed during the first inspection period of the second 10-year inservice inspection interval. The inspector reviewed the qualification records for nondestructive examiners, l the inservice inspection engineer's detailed plans for the examinations that were performed during the first inspection period, and the records for completed ASME Code l Class 2 and 3 repair and replacement activities, Observations and Findinas The inspector discussed the Callaway Plant Second Interval inservice inspection Plan and Nondestructive Examination Inservice Inspection Program Implementing Procedure EDP-ZZ-01003, Revision 13, with licensee inservice inspection personnel to determine the scope and method of performance of the plan during the first inspection L period. The licensee's inservice inspection engineer informed the inspector that l Callaway Plant utilized the services of a contractor, Nuclear Energy Services, Inc. (NES),

for performance of most of the inspections during the refueling outage. The inservice inspection engineer also informed the inspector that a small part of the inspections were also performed by Callaway Level 11 and til nondestructive examiner During the review of the plans for the examinations that were performed during the first inspection period, the inspector noted that the plan, albeit relatively informal, was comprehensive and detailed. The plan included the component identification, the location, applicable examination, interferences, and necessary preparations, such as insulation removal and scaffolding installation. The plan also included a layout drawing i

-__-__--______- __ _ -_ - --_-____ -- ____

.

-6-for the location of the component and, in most cases, a computer-generated picture of the immediate area that the component was located in.

l The inspector determined that NES utilized their own procedures for certifying nondestructive examination personnel and performing liquid penetrant, magnetic particle, and ultrasonic examinations. The inspector reviewed the NES examiner certification and nondestructive examination procedures, listed in the attachment to this report, and determined that appropriate requirements were included to perform the required inservice examinations. The inspector also confirmed that NES's examination procedures had been reviewed and accepted by the licensee's inservice inspection and quality assurance personnel prior to use at the Callaway Plan The inspector determined that the licensee's nondestructive examiners performed some of the liquid penetrant examinations during the first inspection period. The inspector also r was informed by the inservice inspection engineer that ASME VT-2 visual examinations were scheduled to be performed when the plant entered Mode 3 and normal operating pressures and temperatures had been established for the systems. The inspector reviewed the licensee's liquid penetrant examination and ASME VT-2 visual examination procedures listed in the attachment to this report. The inspector determined that appropriate requirements were included in the procedures to perform the required inservice examination From the review of the test and examination records, the inspector found that the inservice inspection program was appropriately implemented for the examinations that were reviewed. The inspector noted the following conditions during review of the examination record . Ultrasonic Examination Data Sheets 6226-98-07 and 6226-98-22 and Liquid Penetrant Examination Data Sheet 6106-98-09 recorded limited examinations due to obstructions or the configuration of the examination area. The data sheet appropriately recorded the extent of the examination area that was inspecte The inspector was informed by the inservice inspection engineer that the records for the inservice inspections performed during the first inspection period of the second 10-year inspection interval were being reviewed and relief requests, where necessary, were being prepared for areas that could not be examine . Three linear indications, approximately 0.8 to 1.5-inches long in the base material adjacent to the weld, were identified by NES on magnetic particle examination Data Sheet 6116-98-2. Licensee inservice inspection personnel issued Nonconforming Material Report 98-1431 and Work Document W618893 to remove the indications. NES subsequently reperformed the magnetic particle examination of the area and confirmed removal of the identified indication _ _ _ - - _ _ _ _ _ _ _ _ _ _ _ _ _ - _ _ _ _ _ - _ _ _ _ _ _ _ - _ _ _ _ - _ _ _ _ _ _ _ _ _ _ _ _ _ _ - _ _ - _ .

.

.

-7-

. A licensee Level ill examiner documented performance of an examination on

' liquid penetrant Data Sheet 5000-97-2596. A licensee Level ll examiner reviewed the examination results and the data sheet. The data sheet recorded no rejectable indications. The NRC inspector observed that Level ll examiners were allowed to review examinations. However, the inspector also noted that l

'

review of a Level ll1 examiner's work by a Level 11 examiner was not a common industry practice. The experience, qualifications, and stature of Level lli

examiners were generally more than that of Level 11 examiners. This could

! influence the decisions of Level 11 examiners that review the work of Level ill i

examiners. As such, the inspector considered the review of a Level ill examiner's l wort: by a Level ll examiner to be poor practice.

! The inspector reviewed the certification records for a licensee Level ill liquid penetrant l examiner and two licensee Level 11 liquid penetrant examiners. The inspector reviewed the certification records for one NES Level lli and six NES Level 11 liquid penetrant, ultrasonic, and magnetic particle examiners. The records provided data to confirm that the licensee and NES examiners were appropriately certified to perform the applicable i examinations. The records also included a review and confirmation of NES examiner l qualifications by licensee inservice inspection personnel and the Callaway Plant's l l

authorized nuclear inspecto The inspector reviewed three work packages, listed in the attachment to this report, for

'

ASME Code repair and replacement activities that were performed during the outag The inspector determined that appropriate requirements were provided to allow accomplishment of the repair and replacement activities in accordance with applicable requirements. Appropriate inspections and tests were also specified, and in most cases, performed. Some ASME VT-2 visual examinations were still scheduled to be complete c. Conclusions The procedures and records for inservice inspections, examiner qualifications, and repair and replacement of ASME Code Class 1,2, and 3 components that the inspector reviewed were good, and indicated that the inservice inspection prugram was being appropriately implemented. The practice of allowing a Level 11 examiner to review the work of a Level lil examiner was a poor practic V. Management Meetings X1 Exit Meeting Summary

. The inspector presented the inspection results to members of licensee management at

! the conclusion of the inspection on April 30,1998. The licensee personnel acknowledged the results of the inspectio The inspector asked licensee management and staff whether any material examined during the inspection contained proprietary information. No proprietary information was identified. No proprietary information is included in this report.

f

i

.

- _ - _ _ _ _ _ _ _ _ _ - _ _ _ _ _ _ . - _ _ _ - _ _ _ _ _ _ - _ _ _ _

,

l

,

ATTACHMENT SUPPLEMENTAL INFORMATION PARTIAL LIST OF PERSONS CONTACTED Licensee l

l R. Affolter, Plant Manager F. Eggers, Welding Engineer, Nuclear Engineering Technical Support G. Forster, NDE Inspector, Performance and Inservice inspection 3 D. Hollabaugh, Supervisory Engineer, Performance and Inservice inspection !

G. Hughes, Acting Quality Assurance Manager i J. Laux, Quality Assurance Manager G. Randolph, Vice President and Chief Nuclear Officer M. Rice, inservice inspection Engineer T. Shaw, Quality Control Supervisor D. Stepanovic, Design Engineer, Design Engineering E. Thomton, Engineering Evaluator, Quality Assurance L. Zahara, inspector, Quality Control NflG D. Passehl, Senior Resident inspector F. Brush, Resident inspector INSPECTION PROCEDURES USED Inservice inspection

'

73753 l

DOCUMENTS AND PROCEDURES REVIEWED Procedures Engineering Department Procedure EDP-ZZ-01003, Non-destructive Examination Inservice Inspection Program, Revision 13

!

Quality Control Procedure QCP-ZZ-05000, Liquid Penetrant Examination, Revision 10 Quality Control Procedure QCP-ZZ-05041, Visual Examination to ASME VT-2, Revision 16 NES Procedure 80A9068, Procedure for Certifying Nondestructive Examination Personnel, Revision 14 NES Procedure 83A6106, Liquid Penetrant Examination Procedure, Revision 0 NES Procedure 83A6116, Procedure for Magnetic Particle Examination, Revision 3 l

___ _____ _____-______ _-_______ _ _ _ _ - _ _ _ _ _ ____ - __ _ _ _ _ _ ____ _ _ _ _ _ _

!

! -2-NES Procedure 83A6216, Ultrasonic Examination Procedure for Ferritic Piping Welds and Vessels s 2 inches Thickness, Revision 4 NES Procedure 83A6226, Ultrasonic Examination Procedure for Austenitic Piping and Vessels s 2 inches Thickness, Revision 3 Callaway Plant Second Interval inservice Inspection Plan, Revision 2 Ultrasonic Examination Data Sheets 6216-98-37 - Feedwater System, 2-AE-04-FW9 6226-98-04 - Chemical and Volume Control, 2-BG-02-SO40-E 6226-98-05 - Chemical and Volume Control, 2-BG-02-F063 6226-98-06 - Residual Heat Removal System,2-EJ-04-S010-C 6226-98-07 - Residual Heat Removal System,2-EJ-01-F045 6226-98-22 - Accumulator Safety injection System,2-EP-02-F019 6226-98-22 - Accumulator Safety injection System,2-EP-02-F007 6226-98-31 - Containment Spray System, 2-EN-01-S013-8 Maanetic Particle Examination Data Sheets 6116-98-02 - Feedwater System, 2-AE-04-F005 6116-98-03 - Feedwater System, 2-AE-05-F005

6116-94-04 - Feedwater System, 2-AE-04-F005 Post Repair l 1 Liouid Penetrant Examination Data Sheets l

5000-97-2596, Chemical and Volume Control System,2-BG-02-SO40-E ]

l 5000-97-2606, Chemical and Volume Control System, 2-BG-02-F063 l 6106-98-09, Accumulator Safety injection System,2-EP-02-F007 )

6106-98-10, Accumulator Safety injection System,2-EP-02-F019 )

6106-98-15 Residual Heat Removal System, 2-EJ-01-F045 i

_

6106-98-16, Residual Heat Removal System,2-EJ-04-S010-C j 6106-98-17, Containment Spray System,2-EN-01-S013-B l ASME Code Reoair and Replacement Work Documents W176679, Replace Essential Service Water Valve EFHV0041 )

W192765 Remove, Rod Out, and Clean Piping to Essential Service Water Valve EFV0049

- C611275, Install New Essential Service Water Isolation Valve EFV0382 L___________________ _ _ _ _ _ _ _ _ _