ML16341E349
| ML16341E349 | |
| Person / Time | |
|---|---|
| Site: | Diablo Canyon |
| Issue date: | 06/24/1987 |
| From: | Harris R, Kerch H, Strosnider J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML16341E350 | List: |
| References | |
| 50-275-87-16, 50-323-87-15, NUDOCS 8707250180 | |
| Download: ML16341E349 (40) | |
See also: IR 05000275/1987016
Text
U.S.
NUCLEAR REGULATORY COMMISSION
'EGION I
50-275/87-16
Report
No.
50-323/87-15
50-275
Docket No.
50-323
OPR-80
License
No.
OPR-81
Licensee:
Pacific Gas
and Electric
77 Beale Street
San Francisco
California 94106
F i1<<:
~0i
b1
C
Inspection At:
San
Luis Obis
o
'I
Inspection
Conducted:
Ma
18 throu
h
Ma
28
1987
Inspectors:
Approved by:
a ry W. Kerch,
Lead Reactor
Engineer
ichard
. Harris,
NDE Technician
ack R. Strosnider,
Chief, Materials
and
Processes
Section,
EB,
date
date
6 z~/z7
date
Ins ection
Summar
A special
announced
NRC Independent
measurements
inspection
was conducted
using the
NRC Mobile Nondestructive
(NDE)
Laboratory.
Nondestructive
examinations
were performed
on selected
safety
related piping systems
and associated
support structures
fabricated to
ANSI B31.1, B31.7,
ASME Code Section I and Engineering
Design
Memo m-9.
In addition to a sampling of code required inspections
a verification inspection
was performed
on balance of plant (BOP) material for erosion/corrosion.
Two
region-based
inspectors
assisted
by two contracted
NDE personnel
were utilized
during this inspection.
Results:
One unresolved
item (section 7) regarding the location of Vendor
records
was identified.
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1.0
Persons
Contacted
Pacific Gas
and Electric
Com an
I
Paul
Provence,
Document Control
Otis Franks,
Supervisor Inservice Inspection
M. E. Leppke, Project Engineer
S.
G. Banton,
Engineer
Manager
R. Taylor, guality Assurance
T. Nelson,
Regulatory
Compliance
J. Gisclon, Assistant Plant Manager
Westin house
James Taylor, Site Office
Nuclear
Re ulator
Commission
Mark Padovan,
Resident
Inspector,
RV
2.0
Inde endent
Measurement
Nondestructive
Examination
and
Records
Review
of Safet
Related'
stems:
During the period of May 18 through
May 28,
1987
an onsite inspection
was
conducted at the Diablo Canyon Nuclear
Power Station utilizing the
NRC
Mobile Nondestructive
Examination
(NDE) Laboratory.
This inspection
was
conducted
by region based
NRC personnel
in conjunction with NRC
contracted
Nondestructive
Examination
(NDE) personnel.
The purpose of this inspection
was to verify the adequacy
of the licensee's
welding inservice inspection
and quality control
programs.
This was
accomplished
by independently
performing those examinations
required of
the licensee
by
NRC Regulations,
applicable industry codes
and
commitments.
The
NRC inspector
selected, pipe hangers,
pipe weldments
and
pipe systems
intended to provide
a representative
sample of components,
pipe size
and material
examined in accordance
with specific site require-
ments.
Those items selected
were Class
from the Recirculation,
Residual
Heat
Removal
(RHR) and Safety Injection (SI) Systems
and the
Pressurizer.
Also, selected for examination
were structural
components
from the Auxiliary Feedwater,
Spent
Fuel
Pump Discharge,
Salt Water
Pump
Discharge,
Component
Cooling Water, Safety Injection and Residual
Heat
Removal
Systems.
2.1
Nondestructive
Examination
Examinations
were performed using
NRC procedures
in conjunction with
the licensee's
specifications,
standards,
sketches
arid applicable
drawings.
Ma netic Particle
Examina'tion:
Four (4) safety related piping weldments
and adjacent
base material
(1/2 inch on either side of the weld) were examined
using the dry
magnetic particle method technique
per
NRC procedure,
NOE-6,
Rev.
0.
Included in this examination
were Class
1 carbon steel
piping
selected
from the
system.
Results:
No violations were identified.
Li uid Penetrant
Examination
Nine (9) safety related pipe weldments
and adjacent
base material
(1/2 inch on either side of the weld) were examined
using the
visible dye penetrant
technique
per
NRC procedure
NDE-9,
Rev. 0.
Included in this examination
were Class
1, stainless
steel
nozzle
to pipe, pipe to elbow and pipe to pipe weldments
from the Residual
Heat
Removal
(RHR), Safety Injection (SI) and Pressurizer
Inlet.
Results:
No violations were identified.
Radio ra hic Examination:
The licensee
radiographed
the feedwater
nozzles during this outage
due to the cracking problem identified by I.E. Bulletin No. 79-13,
Rev. 2, that required re-radiographing
the feedwater
nozzle at the
first outage.
The
NRC inspector
independently
radiographed
these
four (4) safety related pipe weldments
using
an Iridium 192 source.
The technique
and procedures
used were in accordance
with NRC procedure
NDE-5,
Rev. 0.
The nozzle joints are Class
1 carbon steel
The resulting radiographs
were evaluated
per applicable
code requirements
and compared
to the licensee's
corresponding
radiographs.
The licensee's
and NRC's radiographs
indicated acceptable
conditions.
Results:
No violations were identified.
Visual Examination:
Seventeen
(17) safety related pipe weldments
were examined in
accordance
with NRC Procedures
NDE-10,
Rev. 0, Appendix A, NDE-14,
Rev. 0,
and the licensee's
associated
drawings.
The examinations
were made specifically to identify any cracks or linear indications,
gouges,
arc str'ikes with craters
or corrosion which may infringe
upon the pipe minimum wall thickness.
Aides,
such
as mirrors,
were
used in the inspection
and evaluation of
the weldments.
Included in this sample
were
ASIDE Class
selected
from the
Recirculation,
Residual
Heat
Removal
(RH), Safety Injection (SI),
Pressurizer
and
Systems.
Results:
No violations were identified.
Ultrasonic Examination:
The inspector selected
eight (8) safety related
pipe weldments,
from
the Safety Injection System,
Pressurizer
Inlet, Pressurizer
Spray
and Residual
Heat
Removal
System.
The ultrasonic examinations
were performed using
a Sonic Mark
1
ultrasonic flaw detector
in accordance
with NRC Procedure
NED-1,
Rev.
0; Diablo Canyon site procedure
N-UT-1 and associated
ultrasonic data reports.
Instrument calibration (linearity) was
. performed using
NRC procedure
NOE-2,
Rev. 0.
A distance
amplitude
correction curve was constructed
(DAC) using the licensee's
calibration blocks,
DCPP ¹6 and
DCPP ¹4 to ensure repeatability of
ultrasonic examinations.
Instrument settings
and search units
(transducers)
were matched
as nearly as possible to those indicated
by the licensee's
ultrasonic data reports.
Results:
No violations were identified.
Visual Examination
Han ers/Su
orts
A visual inspection of welds,
hangers,
support
components
and
attachments
was conducted.
Included in this inspection
were
components
selected
from the Component
Cooling Mater (CCW), Residual
Heat
Removal
(RHR), Safety Injection (SI), Spent
Fuel Pit (SFP),
Auxiliary Salt Mater Discharge
systems.
Seventeen
(17) hanger/supports
were inspected
in accordance
with NRC
Procedure
NDE-10,
Rev. 0,
and the licensee's
Procedure
Rev. 2; drawings;
and visual examination data reports.
Specific
attributes
looked for were loose
or broken members;
wear or
corrosion; missing,
damaged,
or wrong parts;
clearances
and gaps;
and
improper installation.
All components
were inspected after
protective coatings
had been applied, therefore,
cracks
and fusion
type discontinuities
could not be evaluated.
The attributes
looked
for on component
weldments with protective coatings
were fillet
and flare bevel size, location,
leg and throat size,
length of weld,
gross undercut,
large porosity and overall workmanship..
Results:
No violations were identified.
Ultrasonic Thickness
Measurements
For Erosion/Corrosion:
During this inspection it was determined that the licensee
had
examined sixty-seven
(67) pipe components
to establish
a base line
for wall thickness
data in balance of plant piping systems.
The
licensee
inspection
was performed using grid maps
and ultrasonic
thickness
The results
were recorded
on
UT thickness
data
sheets
and reviewed
by the Stress
Group Lead or his designee
and the
Mechanical
Group.
A review of UT thickness
data
revealed that
a High Pressure
Turbine
exhaust
pipe in unit 2 had experienced
some erosion/corrosion
and
would be repaired prior to startup.
No other lines, in the Unit 2
Turbine building were found to have
an e'rosion/corrosion
problem.
The visual
and thickness
examination of the
Steam
System,
Drain,
Steam
Dump and
Blowdown Systems,
are not an
NRC or ASME code
requirement;
however,
in light of the
December
1986 feedwater line
rupture at the Surry Nuclear Station Unit 2, independent
ultrasonic
inspections
were performed in these
systems.
Six (6) pipe components
from the Steam,
Drain,
Dump and Blowdown Systems
were selected
by the
inspector
from the licensee's
original examination.
The purpose of
these
examinations
was to determine if wall thinning had'occurred
due
to erosion/corrosion
and to verify the examination
performed
by the
licensee.
This was accompl,ished
by duplicating those examinations
performed
by the licensee for the six selected
components
and comparing
the results.
The examination
was performed in accordance
with NRC
Procedure
NDE-ll, Rev.
0, in conjunction with the licensee's
procedure
UT-11,
Rev.
1, Instruction I-66 and associated
isometrics, grid maps
and
UT data reports.
Attachment
No.
3 is
a tabulation of inspection points'ttachment
No.
3A is
a report of UT thickness
measurements
and grid map.
Results:
No violations were identified.
'
6
Conclusions
I
No deficient conditions were identified as
a result of the NRC's
independently
performed magnetic particle, .liquid penetrant,
radio-
graphic, visual,
and ultrasonic inspections.
The quality of the
piping and components
inspected
was generally
good and the
NRC
conducted
inspection verified that the licensee
conducted
inspections
satisfied applicable
NDE Codes
and Standards.
The balance of plant wall thickness
examination
performed
by the
licensee
should provide an acceptable
baseline for future monitoring
of erosion-corrosion
induced wall thinning.
The licensee's
future
plans in this area include
a review of the ultrasonic data
and
incorporating the engineering
surveillance
requirements
in Diablo
Canyon's inservice inspection
program.
3.0
Safet
Injection Accumulator Nozzles
In 1986 Diablo Canyon Unit 2 identified cracking problems with 3
tank lines, that resulted
in a leak.
The licensee
performed
a
technical
review and
has
made several
changes
to the design
such'as
material
type, larger size nozzles
and weld joint geometry in order to prevent
reoccurrence.
The inspector
reviewed the design
changes
in document
DC2-SP-38343
and found this document to be very complete
and the licensee
responsive
to the problem.
4.0
Inservice Ins ection ISI Data
Review
The inspector
reviewed ISI Data in order to verify that the examinations
were done in compliance with governing procedures
and that applicable
regulatory
and
ASME Section
XI requirements
were met.
A review also
was
performed to verify that the'licensee
had properly recorded
the evaluations.
A licensee
employee with a level III NDE certification reviewed all
ISI data
and his signature
on each of the
NDE data reports
was required
for the acceptance
of those reports.
Overall, the inspector
found that
the Inservice Inspection
Program at Diablo Canyon
was being performed
professionally
and the objectives of the ISI program are being met.
Results:
No violations were identified.
5.0
Review of the Inservice
In's ection ISI Pro
ram
The inspector
reviewed the following to ascertain
compliance with
applicable
ASME Code requirements,
licensee
commitments
and regulatory
requirements.
Faci 1 ity Techni cal Speci fication
PG&
E Letter
No. DCL-87-095 reference relief requests
APC-80,
Rev.
2, ISI program procedure
APE-4S7,
Rev. 4, control of ISI program plan
Unit 2 First ISI outage
schedule
Diablo Canyon
2 is in the process
of completing its first outage within
.the first ten year ISI plan.
The ISI plan
was prepared
and
implemented
by
the licensee.
The plan meets the requirements
of the. ASME Section XI,
1977 edition including the
summer
1978 addenda.
A review of the first
outage listing of items to be inspected
indicated that the
primary loop elbows were not examined during this outage
as scheduled.
It
was disclosed that the licensee
does not have the correct ultrasonic
calibration block nor a qualified procedure for this inspection.
These
items are being deferred to the next outage.
The inspector initiated
a conference call
on June
27,
1987 to discuss
relief requests
made in PG&E's letter No. DCL-87-095.
Representatives
from NRR,
EG&G and
PG&E participated
in the call.
Below is
a list of the
felief requests
discussed.
NDE 005
Minor Radius
NDE 015 Pressurizer
minor radius
NDE 007 Physical accessibility to regenerative
heat exchanger
centrifugally cast stainless
steel
NDE 13 Product
form of regenerative
heat
exchanger
NDE 4 Reactor
Vessel
Nozzle Melds.
NDE-9 Class I and
2 pipe welds.
NRR requested
additional information from PG&E in order to complete
NRC's
review of the relief requests.
6.0
Or anizati'on
and Staffin
of the ISI Pro
ram
The inspector determined that the Diablo Canyon ISI Group has the prime
responsibility for coordinating
and conducting the ISI program,
including
schedules,
procedures
and providing qualified inspection personnel.
Based
on this review, the inspector concluded that, the Diablo Canyon Unit 2
nuclear facility staff, comprised of site personnel
augmented
by contract
personnel,
was adequate
to properly execute
the ISI program.
The inspector
also reviewed the qualification and certification records for ISI personnel
for compliance to
SN7-TC-lA, ASME Section
XI and ANSI N45-2-9 ctiteria.
Results:
No violations were identified.
7.0
Vendor
ualit
Records
Based
on previous inspections
at Beaver Valley 2 Nuclear Powei'lant,
the
regenerative
heat
exchangers
'construction
radiographs
contained
unacceptable
weld indications
and inconsistencies
in their quality records
documentation
(See
Region I Inspection
Report 50-412/87-13).
The regenerative
heat exchangers
at Diablo Canyon Unit 2 were supplied
by the
same
vendor (Joseph
A. Oates,
Inc.) as those at Beaver Valley 2.
Based
on the above information the inspector
requested all the radio-
graphic film for the regenerative
heat exchangers
for both Diablo Canyon
Units
1 and
2 in order for the
NRC to assess
the adequacy of the
radiographic
and welding quality control
program.
The licensee did not possess
the vendor's
radiographic film on site nor
did their system identify the location.
Eventually the radiographic film
was located within the Mestinghouse
system;
however,
the film was not
retrieved in time for NRC review during this inspection.
These films still
need to be reviewed
by the
NRC.
This situation pointed out a weakness
with Diablo Canyon guality Assurance
records retrievability for vendor guality record, storage
locations.
This
item was discussed
in detail with the licensee.
This item is unresolved
pending
NRC review of regenerative
heat exchanger
radiographic film and
licensee's
action
on identification of vendor quality record identified
storage. locations.
Unresolved
Item 50-233/87-15-01.
8.0
Review of Procedures
The following procedures
were reviewed for compliance to the licensee's
FSAR commitments
and applicable
codes,
standards
and specifications.
APC-80,
Rev. 2, ISI Program
and First ISI schedule
APR-4S7,
Rev.
4, Control of ISI Plan Control
2. 1, Rev. 3, gualification of Personnel
4.6,
Rev. 0, Ultrasonic Transducer
Evaluation
APC-1"1S2,
Rev.
4, Plant Design
Changes
APC-lS4,
Rev.
0, Alara Reviews for Design
Changes
,
NPAPC-NOPG-4.2,
Rev. 6, Modification Program
I-66, Rev. 0, Instruction Conducting Erosion/Corrosion
Inspection
N-UT-1, Rev.
1, Ultrasonic Procedure
for Pipe
-
~
N-MT-1, Rev.
2,
Magnet ic Parti cl e ( Yoke)
~
N-PT,
Rev. 2, Liquid Penetrant
~
QAP-17.A, Quality Assurance
Records
Results
No violations were identified.
9.0
Review of Licensee's
Radio ra hs
A sample of the licensee's
site safety related
radiographs
was reviewed
to verify the adequacy
of the radiographic
program.
Radiographs
were
reviewed for technique,
film quality and weld integrity.
Also four welds
were re-radiographed
by the
NRC and the radiographs
were compared to site
.
films in order to independently verify the correct radiographic file film
was
on hand.
(See Section
2. 1)
See Attachment
No.
4 for specific
licensee
radiographs
reviewed.
Results:
No violations were identified.
10.0 Unresolved
Items
Unresolved
items are matters
about which more information is required in
order to ascertain
whether they are acceptable
items, violations or
deviations.
One unresolved
items is discussed
in paragraph
7.0 of
this report.
11.0 Attachments
Attachment
No.
1 is a tabulation of specific pipe weldments
examined
and
the examination results.
Attachment
No.
2 is
a tabulation of specific
hanger/support
components
examined
and examination results.
Attachment'os.
3 and
3A are
a tabulation of specific pipe components
examined for
erosion/corrosion
and the examination results.
Attachment
No.
4 is
a
list of specific radiogpaphs
reviewed
and compared to the licensee's
radiographs.
12.
Exit Interview
An exit interview was held
on May 28,
1987 with members of the licensee's
staff.
The inspector
summarized the
scope
and results of this inspection.
No written ma'terial
was provided to the licensee
during this inspection.
TABULATION OF
ITEMS EXAMINED AND
Attachment
g1
Day:
May 18-2S,
19S7 - Page
1 of 2
TS OF
INDEPENDENT MEASUREMENT PROGRAM
SITE:
Diablo Canyon
MELD NUMBER
~EiRR is
~DASH
~FERRiT
~THIS
H T
~RT
~UT
HARDNESS
~ISUAL
REHARKS
MICG-102
1
MICG-102-2
2K16"555-16
MICG"102-3
MI CG-102-4
2K16-554" 16
MI8-387
2"56"730-6
MIB-393
2"56-4081-4
MIB"369
2"56-729"6
MIB-423
2-56-728-6
MIB-424
2-56-728-6
MIB-422
2-56-728-6
MI8-392
2-56-4081-4
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
ACC
ACC
ACC
ACC
N/A
N/A
N/A
N/A
N/A
N/A
N/A
ACC
ACC
ACC
ACC
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
ACC
ACC
ACC
ACC
N/A
N/A
N/A
N/A
N/A
N/A
N/A
ACC
ACC
ACC
ACC
ACC
ACC
ACC
N/A
ACC
N/A
ACC
N/A
ACC
N/A
ACC
N/A
ACC
N/A
ACC
N/A
ACC
N/A
ACC
N/A
ACC
N/A
ACC
N/A
ACC
Stm.
Gen.
2-1
System
Nozzle to 16" pipe
Stm.
Gen.
2-2
System
Nozzle to '16" pipe
Stm.
Gen.
2-3
System
Nozzle to 16" pipe
Stm.
Gen.
2-4
System
Nozzle to 16" pipe
TABULATION OF
ITEMS EXAMINED AHD R
TS OF
INDEPENDENT MEASUREMENT PROGRAM
Attachment
//1
Oay:
May 18'-28,
1987 - Page
2 of 2
WELO NUMBER
~lee
~CS 'IMARI
T
~HIC
~MT
WIB-394
~RT
SITE:
DIablo Canyon
U T
P T
~AROIAES j
~ISUAL
RERARKS
2-56-4081-4
WIB-6
2"56-235-6
WIB-234
2-56-237"6
WI8-201A
2-56-3846-6.
WIB-88
2-56-14-4
WlB-89
2-56-14-4
H/A
N/A
N/A
H/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
H/A
H/A
N/A
N/A
H/A
N/A
H/A
H/A
N/A
N/A
H/A
H/A
H/A
ACC
N/A
N/A
ACC
ACC
ACC
N/A
ACC
ACC
N/A,
N/A
N/A
N/A
ACC
N/A
ACC
H/A
ACC
N/A
ACC
H/A
ACC
N/A
ACC
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DIABLO CANYON NUCLEAR POWER PLANT
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~
ATTACHMENT ¹4
List of Specific Licensee
Radiographs
Reviewed
SYSTEM/LINE
e
Safe 4nd
II
II
II
II
II
II
II
2K16-555"16*
2K16"557"16"
2K16"556-16"
WELD ID
W/824-2A
W/824"18
W/82¹-2A"
W/823-18
W/822"2A
W/822-18
W/821-2A
W/821-18
WICG-102-1
WICG-102-2
WICG-102-3
WICG-102-4
ACCEPTED
REJECTED
X
X
X
X
X
X
X
X
X
X.
- Denotes
radiographs
that were compared to
NRC re-radiographs
~
~