ML16341E349

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Insp Repts 50-275/87-16 & 50-323/87-15 on 870518-28.No Violations Noted.Major Areas Inspected:Nde on Selected safety-related Piping Sys & Associated Support Structures & Balance of Plant Matl for Erosion/Corrosion
ML16341E349
Person / Time
Site: Diablo Canyon  Pacific Gas & Electric icon.png
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

California

'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,

DRS

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

FSAR

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

1 weldments

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

weldments

selected

from the

steam generator

feedwater

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

weldments.

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,

lights and weld gauges

were

used in the inspection

and evaluation of

the weldments.

Included in this sample

were

ASIDE Class

1 weldments

selected

from the

Recirculation,

Residual

Heat

Removal

(RH), Safety Injection (SI),

Pressurizer

and

Steam Generator

Feedwater

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

and Auxiliary Feedwater

systems.

Seventeen

(17) hanger/supports

were inspected

in accordance

with NRC

Procedure

NDE-10,

Rev. 0,

and the licensee's

Procedure

ISI VT 34-1,

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

gauges.

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

accumulator

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

NDE

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

steam generator

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

ISI

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

Steam Generator

Minor Radius

NDE 015 Pressurizer

minor radius

NDE 007 Physical accessibility to regenerative

heat exchanger

centrifugally cast stainless

steel

welds.

NDE 13 Product

form of regenerative

heat

exchanger

welds.

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

2K16-554-16

MICG-102-2

2K16"555-16

MICG"102-3

2K16-557-16

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

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Stm.

Gen.

2-1

Feedwater

System

Nozzle to 16" pipe

Stm.

Gen.

2-2

Feedwater

System

Nozzle to '16" pipe

Stm.

Gen.

2-3

Feedwater

System

Nozzle to 16" pipe

Stm.

Gen.

2-4

Feedwater

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

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ISO

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WIB-394

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SITE:

DIablo Canyon

U T

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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

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N/A

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N/A,

N/A

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WE NUMBB~+~/

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NOMSAL WALL THICKNESS~RZa.

UT TIICKNESS CACE NO.

DAIOOIAONI DOE OAIB

BY:

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0

~

ATTACHMENT ¹4

List of Specific Licensee

Radiographs

Reviewed

SYSTEM/LINE

e

Safe 4nd

II

II

II

II

II

II

II

2K16-554-16"

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

~

~