ML16148A794
| ML16148A794 | |
| Person / Time | |
|---|---|
| Site: | Oconee  |
| Issue date: | 06/09/1993 |
| From: | Blake J, Economos N NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML16148A793 | List: |
| References | |
| 50-269-93-15, 50-270-93-15, 50-287-93-15, NUDOCS 9306220078 | |
| Download: ML16148A794 (11) | |
See also: IR 05000269/1993015
Text
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REG44
UNITED STATES
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NUCLEAR REGULATORY COMMISSION
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oREGION
II
101 MARIETTA STREET, N.W.
ATLANTA, GEORGIA 30323
Report Nos.:
50-269/93-15, 50-270/93-15 and 50-287/93-15
Licensee: Duke Power Company
422 South Church Street
Charlotte, NC 28242
Docket Nos.: 50-269, 50-270, and 50-287
License Nos.:
and DPR-55
Facility Name: Oconee 1, 2 and 3
Inspection Conducted:
May 10 - 14, 1993
Inspector:
N. E.
n os
Date igned
Approved by:
.4
J. J. Ake, Chief
Date Signed
M ter al and Processes Section
VngVneering Branch
Division of Reactor Safety
SUMMARY
Scope:
This routine, announced inspection was conducted onsite in the areas of
inservice inspection (ISI) activities in Unit-2, including eddy current (ET)
examination of once through steam generator (OTSG) tubes. Other ongoing
activities inspected included, station modifications involving pipe
replacement for protection against erosion corrosion and pipe replacement
associated with the upgrading of decay heat coolers.
Results:
This inspection indicated that, in general, a good ISI program was in place
with good implementation.
ISI nondestructive examinations were being
conducted by qualified personnel in accordance with applicable procedures.
The procedures and examination techniques used to conduct the examinations
were adequate and documentation of examination results was satisfactory.
Review of radiographs on safety related pipe welds associated with decay heat
cooler upgrade modification resulted in a violation:
Failure to Identify Code
Rejectable Indication on Radiographic Film paragraph 3.b. Additional concerns
identified in this area included an apparent degree of uncertainty on the part
.
of the Level II RT Examiner over precendence between code and procedural
requirements; documentation of all fabrication type indications; and
documentation of limiting technique/developing circumstances, paragraph 3.c.
9306220078 930610
ADOCK 05000269
0
REPORT DETAIL
1. Persons Contacted
Licensee Personnel
B. Abellana, Design Engineer
B. Carney, Senior Engineer
- T. Coleman, ISI Coordinator/Component Engineering
T. Dearing, Eddy Current Acquisition Supervisor
E. Few, Production Specialist
C. Freeman, NDE Supervisor
- J. Hampton, Vice President, Oconee Nuclear Station
- M. Hipps, Mechanical Maintenance Manager
- D. Hubbard, Component Engineering
H. Moore, Level II Examiner RT
- S. Perry, Regulatory Compliance
R. Pettit, ISI Outage Support
T. Tucker, Level III Examiner RT
Other licensee employees contacted during this inspection included
craftsmen, engineers, inspectors, technicians, and administrative
personnel.
NRC Resident Inspectors
B. Desai, Resident Inspector
P. Harmon, Senior Resident Inspector
K. Poertner, Resident Inspector
- 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
accordance with applicable procedures, regulatory requirements, and
licensee commitments. The applicable code for ISI is the American
Society of Mechanical Engineers Boiler and Pressure Vessel (ASME B&PV)
Code,Section XI, 1980 Edition with Addenda through Winter 1980. Oconee
Unit-2 is in the 13th refueling outage and in the third (3rd) period of
the second ten year ISI interval.
a.
Review of Nondestructive Examination (NDE), Procedures, Unit-2,
(IP-73052)
The following procedures have been reviewed for technical adequacy
and consistency with applicable code and regulatory requirements
during pervious inspections. (see Inspection Report 92-04) During
the present inspection, the inspector reviewed the procedures for
information and to ascertain whether recent revisions had made
substantive changes to the procedures.
2
NDE- 12, Rev. 8,
General Radiography Procedure for Preservice and Inservice
Inspection Code: ASMW Section XI (80W80),Section V,
Article 2, (77S78).
NDE-B, Rev. 18,
Training, Qualification, and Certification of NDE Personnel.
NDE-25, Rev. 15,
Magnetic Particle Examination Procedures and Techniques.
NDE-35, Rev. 14,
Liquid Penetrant Examination.
NDE-620, Rev. 1,
Ultrasonic Examination of Welds in Wrought Ferritic Pressure
Vessel Greater Than Two Inches in Thickness.
NDE-640, Rev, 0,
Straight Beam Ultrasonic Examination of Welds and Base
Material in Pressure Vessels and Piping.
NDE-701, Rev. 2,
Multifrequency Eddy Current Examination of S/G Tubing at
McGuire, Catawba and Oconee Nuclear Stations Only.
- EOC-13, 5/3/93,
Eddy Current Analysis Guidelines Oconee Nuclear Station
Unit-2.
- This document was reviewed in its entirety.
In addition to the applicable ASME Code,Section XI identified
earlier in this report, the procedures above referenced ASME Code
Section V, 1980 Edition with Winter 1980 and Winter 1981 Addenda.
The revisions and documents reviewed appeared to be consistent
with referenced code requirements.
S
3
b.
Observation of Work and Work Activities Unit-2, (IP-73753)
The inspector observed work activities, reviewed certification
records of NDE equipment and materials; reviewed qualification
records for personnel utilized for ISI examinations observed. The
observations and reviews conducted by the inspector are documented
below.
Volumetric and Surface Examinations
Item
Weld No.
Exam
Procedure
Comments
Method
C01.010.006*
NDE-620
Girth Weld scanned
NDE-640
with 00,
150, 450,
and 60* transducers
B05.051.001
11
NDE-35
Clear
C05.011.203
72
NDE-35
Clear
C05.011.205
72(L)
NDE-35
Clear
- In regards to this item the inspector observed examinations
performed using 450and 600 transducers. Two recordable (code
acceptable), indications were identified near the root of the
weld. The indications had maximum amplitudes of 32% and 25% at
reference and appeared intermitently over the circumference of the
subject weld.
By these observations, the inspector ascertained that the
examinations were performed by personnel who were adequately
trained to perform their assigned tasks.
Indications were
thoroughly investigated and adequately documented in accordance
with procedural and code requirements.
Within the areas inspected violations or deviations were not identified.
c.
Review and Evaluation of Data (IP-73755)
(1) Examinations Records
Records of completed ISI NDE examinations fdr two UT, six MT
and five PT examinations were selected and reviewed to
ascertain whether: the method(s), technique, and extent of
the examination complied with the ISI plan and applicable
NDE procedures; findings were properly recorded and
evaluated by qualified personnel; programmatic deviations
were recorded as required; personnel, instruments,
calibration blocks, and NDE materials (penetrants,
couplants) were designated.
4
(2) Personnel Qualifications
The inspector reviewed personnel qualification documentation
as indicated below for examiners who performed the subject
examinations. These documents were reviewed in the
following areas: employers's name; person certified;
activity qualified to perform; current period of
certification; signature of employer's designated
representative; basis used for certification; and, annual
visual acuity, color vision examination, and periodic
recertification.
Method
Level
Number of Examiners
II
4
II
4
II
4
II
4
I
1
IIA
2
All personnel qualification documents reviewed indicated
that the examiners were qualified for the examinations
performed.
(3) Quality Records for Equipment used in ISI Examination
The certifications and/or quality records of equipment and
materials used to perform the aforementioned ISI
examinations were reviewed for completeness, accuracy and
compliance with applicable codes/standards.
Equipment
Identification
Eddy Current
MIZ-18
RDAU ET System
S/N -
59
MIZ-18
RDAU ET System
S/N -
71
MIZ-18
RDAU ET System
S/N -
74
MIZ-18
RDAU ET System
S/N - 200
MIZ-18
RDAU ET System
S/N - 271
Calibration Standard
S/N - 49155
Calibration Standard
S/N - 49156
Calibration Standard
S/N - 49158
Cleaner
Batch #92D001
Penetrant
Batch #87KO43
Developer
Batch #91C17P
5
Ultrasonic
Couplant: Ultragel II
S/N - 93001
Calibration Block
S/N - 40339
S/N -
782748
- IIW-type 1 Calibration Block
S/N - 1076-83
Transducers:
KBA - Gamma
2.25 Mhz, 150
110
S/N - 013239
KBA - Aerotech
2.25 Mhz, 0*
110
S/N - K05217
KBA - Gamma
2.25 Mhz, 450
110
S/N - M18425
KBA - Gamma
2.25 Mhz, 600
113
S/N - E30936
Instruments:
USK - 7D
S/N - 32810-775
USD -
10
S/N - 31501-921
Pyrometer
S/N - MCQUA/32848
- In discussions with the licensee's Level III corporate examiners,
on the subject of certification records for this and other IIW
blocks in the system, the inspector ascertained that, in recent
years, Duke has been purchasing these blocks as off-the-shelf
items, and as such there are no certificates available for these
items. Duke maintains traceability, through a serial numbering
system. This appears to be adequate for this type block since its
primary function is to monitor transducer angle accuracy.
Through observations, interviews and document/records review, the
inspector determined that the licensee is implementing the ISI
program for Unit 2 in a satisfactory manner. Personnel are
adequately trained to perform their assigned tasks which they
perform with interest for plant safety.
In the areas inspected violations or deviations were not
identified.
(4) Eddy Current Examination of S/G(s) Tubes, Unit 2 (IP-73753)
As stated earlier, ISI activities during this outage included eddy
current examination of tubes in "A" and "B" steam generators.
Data acquisition and analysis were being performed in accordance
with procedures identified earlier in this report. Controlling
documents/code by reference, included ASME Code Section XI
(80W80), Regulatory Guide 1.83 July 1975 and Code Case N-401,
Digitized Data Collection for Eddy Current Examination. Data
acquisition was being performed by licensee personnel.
Data
analysis was conducted at the McGuire Nuclear Station.
Examinations were being performed with a multifrequency bobbin
coil technique, utilizing the computerized MIZ-18 system.
6
The following summarizes the licensee's steam generator ET
inspection program and status for the current outage:
"BOBBIN" probe - The planned inspection included full length
examination of approximately 60%* (9537 for S/G "A" and
10074, or S/G "B") of the tubes in each generator. At the
close of the inspection, 6617 S/G "A" tubes and 5344 S/G "B"
tubes had been examined and analyzed. No confirmed pluggers
had been identified. Tubes with bobbin calls/indications Z:
40% through wall degradation included 44 for S/G "A" and 24
S/G "B".
"SLEEVE/CROSSWOUND" - The planned inspection included 124
tubes in each S/G. Inspection had been completed and all
inspection results analyzed and resolved for the sleeve
inspections.
"MRPC LANE & WEDGE" - For "Lane and Wedge" area tubes, the
planned inspection included 219 tubes in S/G "A" and 196
tubes in S/G "B".
At the close of the inspection, all tubes
scheduled for this type examination had been
inspected/analyzed; no further problems were identified.
"RE-EXPANDED TUBES" - Two tubes in each S/G were in the
inspection program. Examination in both S/Gs had been
completed; no further problems identified.
"ROLLED PLUGS" - Inconel-690: inspection plans called for
examination of 100% of the inconel-690 plugs installed
during the previous outage to establish baseline data. In
addition, 20% of the plugs which have been in service more
than one fuel cycle were scheduled for inspection. Inconel
600: inspection plans called for examination of 100% of the
plugs that could be inspected. A summary of plugs inspected
during this outage is as follows:
S/G "A"
S/G "B"
C/L
H/L
C/L
H/L
1-600
10
0
20
0
1-690
18
19
70
75
At the close of this inspection all plugs had been inspected
and analyzed. The inspector witnessed system calibration
performed on S/G "A" cold leg (lower channel-head) with ASME
standard S/N 49151. The calibration was documented on disc
No. 09ABOB. The inspector observed data acquisition and
shift turnover which was performed in a satisfactory manner.
A plug list had not been generated by the close of this
inspection. Tubes plugged in this Unit during pervious
outages totaled 58 in S/G "A" and 147 in S/G "B".
Following
7
the close of this inspection, the inspector ascertained that
tubes plugged during the present outage totaled 35 in S/G
"A" and 79 in S/G "B".
Within the areas inspected violation or deviations were not
identified.
3.
Facility Modifications Unit 2 (IP-37700)
a.
The licensee is continuing with plans to replace balance of plant
carbon steel piping subject to erosion corrosion damage with pipe
made from stainless steel SS-304 material.
The inspector selected
two replacement packages for review of welding activities,
including weld inspection and material traceability. The
applicable code was identified as USAS, Power Piping Code B31.1,
1967 Edition. The pipe was identified as non-QA, Duke Class "G".
One of these packages involved "C" bleed high pressure extraction
pipe, from the moisture separator to the "C" heaters. The other
package involved replacement of six inch piping between heater
drains 2HD59 and 2HD53 and the flange connections downstream from
2HD60. Work was being performed on work order numbers WO-62485D,
-62483D and -93006885-01. Spools were being fabricated on-site in
the fabrication shop to facilitate field installation. Because
this piping was non QA (not safety related), weld acceptability
was based on visual examination by the welding foreman or his
designee. The inspector checked weld appearance and workmanship
on several welds including elbows and straight pipe. In addition
the inspector checked for material identification on the assembled
spool sections and for welder identification next to their work as
required by procedure, i.e., Maintenance Welding Program Section
VI.
Within these areas, the inspector observed that welders were
neglecting to place their identification number next to their work
as required by the subject Duke Welding Manual.
Instead, the
inspector noted that in one or two cases, a black ink marker was
used to write the welder ID number next to the weld joint. The
DPC representative acknowledge that this practice was contrary to
paragraph 5.1, Marking and Stamping of Welds, of the subject
manual which requires the use of vibro-etch for this purpose.
Following this finding, management issued problem investigation
program reports 2-093-0399 and -0400, to document the
observation. A training session was scheduled for all parties
involved along with appropriate corrective action to bring the
work into compliance with the aforementioned manual.
A review of replacement material purchase orders, chemical
analysis reports and mechanical test results indicated the
material met applicable material standards requirements. Welder
qualifications were reviewed and found to be'satisfactory.
8
b.
Upgrading of Decay Heat Coolers -
Review of Radiographs
Replacement piping associated with the upgrading of decay heat
coolers was being welded and examined, on site, in preparation for
installation during this outage. The applicable code(s) for this
work were ANSI B31.7, 1969 Edition and ASME Section XI 1980
Edition with 1980 Winter Addenda. The piping was identified as
Code Class 2, Duke Class B. The applicable radiographic procedure
was NDE-10 Revision 18, General Radiography Procedure. This
procedure referenced ASME Code Section V, (80W80 and W81), as
applicable to the method(s) used to produce the radiographs.
The radiographs and associated records were reviewed to ascertain
whether radiographic and film quality were satisfactory and
whether evaluation and disposition of rejectable indications were
consistent with Code requirements. Selection of radiographs for
this review was at random:
Weld#
Dwg#
Size
Weld description
- 2-LP-96-15
2-LP-96
10" x .250"
Pipe to 900 ELL
2-LP-98-03
2-LP-98
10" x .250"
Pipe to 90* ELL
2-LP-97-01
2-LP-97
10" x .250"
Pipe to 90* ELL
- 2-LP-100-09
2-LP-100
10" x .250"
10" Reducer T
to 10" x 8"
Reducer
Other welds fabricated and radiographed during this outage
selected for review were as follows:
Weld No.
Size
System
Work
Request No.
- 226
8" x 0.250"
Building Spray
93016431
216
8" x 0.148"
Building Spray
93016431
217
8" x 0.148"
Building Spray
93016431
- 81
14" x .250"
Building Spray
92030384/
EO-4526
- Findings and comments communicated to the licensee from this
review were as follows:
Weld No. 226:
The reader sheet for this radiograph, indicated the weld section
covered by film station 2-3 had been repaired. However, the
repair, designated by the letter (R) and number had not been
marked on the film as required by the above radiographic
procedure. Also the inspector noted that the radiographic reader
sheet was incomplete in that the radiographic technique used to
shoot the radiograph had not been identified. The inspector also
noted that the film packages for stations 1-2 and 2-3 contained
9
only one of the two films loaded in the cassette used to shoot
these two stations. The licensee stated the missing film(s) were
damaged by the automatic developer and were discarded. Having
only one film to review, does not allow for verification of film
artifacts, and questionable weld fabrication indications in the
area of interest.
Weld No. 81:
The reader sheet indicated the weld sections covered by film
stations 0-1, 1-2, 2-3 and 3-4 had been repaired, but as stated
above the repairs had not been marked on the film presented for
review. In addition the inspector noted that tungsten indications
and certain acceptable fabrication type discontinuities i.e,
porosity, were not documented on the reader sheet. Failure to
note existing weld indications/conditions on the reader sheet
renders this document incomplete and inaccurate.
Weld No. 2-LP-96-15:
The radiograph for weld station 1-2 exhibited a linear OD surface
indication near station mark #2. Following the close of this
inspection, the inspector ascertained, by telephone, that the
indication was removed by grinding and the weld location reshot.
The licensee stated that the new radiograph showed the indication
had been removed. As in the previous weld, a tungsten indication
and acceptable porosity was identified on station 2-3.
Weld No. 2-LP-100-09:
The radiograph for weld station 3-0 exhibited a linear indication
in the center of the root of the weld. Following the close of
this inspection, the inspector ascertained by telephone that the
indication was removed by grinding and the area rewelded.
USA Standard B31.7, Nuclear Power Piping, 1969 Edition, requires
that radiographs be examined and interpreted to assure compliance
with code and the applicable radiographic procedure. Also the
subject code requires that welds showing unacceptable defects be
repaired. Procedure NDE-10 Rev. 18 paragraph 9.2 requires that,
where weld repairs are made the repair number (R#) appear on the
film. Also, paragraph number 19.1 of the subject procedure
requires that, interpretation of radiographs shall include
verification of compliance to all the requirements of the
procedure related to the quality of the radiograph, and the
evaluation of all discontinuities to the applicable acceptance
criteria.
As delineated in the findings above, the inspector determined that
the licensee was in violation of the requirements described in the
referenced code and applicable procedure. Failure to follow
procedural requirements for activities affecting quality is a
10
violation of 10 CFR 50 Appendix B, Criterion V. This violation
will be identified as 50-269,270,-287/93-15-01, Interpretation of
Radiographs and Documentation of Findings. Following the close of
this inspection, the inspector discussed this violation with the
licensee and ascertained through telephonic discussions with Level
III Examiner RT, that plans were underway to provide training to
on site personnel on procedural/code requirements applicable to
Oconee. Also the inspector ascertained that a re-review of
previously reviewed radiographs would be performed.
4.
Action on Previous Findings (92701)
Closed, Violation:
50-269,-270, and -287/92-29-01 Failure to follow PT
Procedure.
By work observation, see paragraph 2.b and review of the applicable NDE
procedure (NDE-25 Rev. 15) which addresses the use of detailed drawings
for proper weld location and examination of the area of interest the
inspector ascertained that the licensee has implemented corrective
actions described in his response dated February 8, 1993 to the subject
violation. Therefore this item is closed.
5.
Exit Interview
The inspection scope and results were summarized on May 13, 1993, with
those persons indicated in paragraph 1. The inspector describedthe
areas inspected and discussed in detail the findings listed below.
Although reviewed during this inspection, proprietary information is not
contained in this report. Dissenting comments were not received from
the licensee. The licensee was informed by telephone on May 17, 1993,
of the violation related to radiograph deficiencies.
Violation 50-269, 270, and 287/93-15-01, Interpretation of Radiographs
and Documentation of Findings.