ML20024C212
| ML20024C212 | |
| Person / Time | |
|---|---|
| Site: | Cooper  |
| Issue date: | 06/16/1983 |
| From: | Hunnicutt D, Tomlinson D, Westerman T NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20024C203 | List: |
| References | |
| 50-298-83-10, IEB-83-02, IEB-83-2, NUDOCS 8307120414 | |
| Download: ML20024C212 (7) | |
See also: IR 05000298/1983010
Text
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APPENDIX
U. S. NUCLEAR REGULATORY COMMISSION
REGION IV
Report: 50-298/83-10
License: DPR-46
Docket: 50-298
Licensee: Nebraska Public Power District (NPPD)
.P. O. Box 499
Columbus, Nebraska 68601
Facility Name: Cooper Nuclear Station
Inspection At: Cooper Nuclear Station, Nemaha County, Nebraska
Inspection Conducted: April 27-29, May 4-13, and May 23-27, 1983
Inspectors
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D. P. Tomlinson, Reactor Inspector
Ddte /
Engineering Section
Approved:
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D. M. Hunnicutt, Chief
Date'
Engineering Section
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-T.lestermati, Chief / ' A
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Reactor Project Section
Inspection Summary
Inspection Conducted April 27-29, May 4-13, and May 23-27, 1983 (Report 50-298/83-10)
Areas Inspected: Routine, unannounced inspection of activities related to
inservice inspection, actions taken as a result of IE Bulletin 83-02, and a
review of the evaluation and repair of Mark I modifications. The inspection
involved 129 inspector-hours ensite by one NRC inspector.
Results : Within the three areas inspected, no violations or deviations were
Tdintified.
8307120414 830617
PDR ADOCK 05000298
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DETAILS
1.
Persons Contacted
Principal Licensee Employees
- P. Thomason, Station Superintendent
- V. L. Wolstenholm, Quality Assurance Supervisor
W. Rushton, Engineering Supervisor
D. Torczon, Quality Assurance Specialist
M. Henry, Quality Assurance Engineer
R. Hooper, Field Engineer
M. Williams, Field Engineer
G. Craigo, Field Engineer
M. Heath, Inspector Level III
J. Briggs, Inspector Level III
E. Secko, Inspector Level III
Others
M. Basford, Nuclear Power Consultants, Inc.
E. Hartnett, EDS Nuclear, Site Project Manager
- D. DuBois, Region IV Resident Reactor Inspector
- Indicates those attending the exit interview on May 13 and May 27,-1983.
2.
Inservice Inspection
The NRC inspector reviewed six of the ten inspection procedures being
used by GE in the performance of -Inservice Inspection (ISI) during the
current refueling outage. These procedures, covering visual, magnetic
particle, and ultrasonic examinations, contained all of the elements
required by Section XI of the ASME B&PV Code including personnel
qualifications requirements, equipment to be used, acceptable consumable
supplies, examination directions and angles, manual scanning speed,
and reportability requirements. The NRC inspector reviewed the
documentation for three calibration standards used for the inspection
of 10" Schedule 140 stainless steel piping, 12" Schedule 140 carbon steel
,
piping, and 16" Schedule 80 carbon steel piping.
Records indicate
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that each standard was fabricated of the proper material, each was
certified to the proper material grade or heat treat condition, and
the heat number of each was traceable to an acceptable certified
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material test report (CMTR). The personnel qualification records
for ten of the GE inspectors were reviewed to assure that the
minimum experience, time, and educational requirements of ASNT TC-1 A
for each inspector level had been met.
The NRC inspector accompanied one inspection team and observed the
visual and ultrasonic inspection of six welded joints on three
supports. All six welds were acceptable visually in that each was of
the proper size, configuration, and contour.
Anomolies such as
undercut, porosity, and lack of penetration were not noted on any
of the welds. The ultrasonic inspection revealed that minor slag
inclusions were present in two welds but were not of sufficient size
or number to be a cause for rejection. These slag inclusions were
reported to NPPD.
The NRC inspector randomly selected and reviewed the records for
the ultrasonic examination of ten welded joints.
Each record package
noted the names and certification levels of those performing the
inspections. The instrument used, the transducer size and frequency,
inspection angles, and the location of recordable indications
were recorded on each inspection sheet. The records of the total
inservice inspection could not be reviewed, as this activity was still
in progress at the end of this inspection period. These records will
be reviewed during a subsequent inspection.
No violations or deviations were identified during this portion of
the inspection.
3.
Actions Taken as a Result of IE Bulletin (IEB) 83-02
As a result of IEB 83-02, an inspection has begun on the stainless steel
recirculation and residual heat removal piping to determine the
existence and extent of intergranular stress corrosion cracking (IGSCC).
Two GE inspection teams and an NPPD observer attended a qualification
and certification session at the EPRI NDE Center in Charlotte, North
Carolina. The purpose of this session was to demonstrate for NPPD and
NRC that the GE procedure, equipment, and personnel are capable, as a
unit, of locating and dimensioning IGSCC. Six GE inspectors and two
ultrasonic instruments were certified at this time, utilizing selected
samples of piping from Nine Mile Point containing known cracks.
Criteria for certification included crack identification and
dimensioning with strict adherence to the parameters.of GE Procedure
MIGSCC-S752, Revision 5.
The NRC inspector reviewed the inspection procedure, the results of
the certification examinations, and the personnel qualification records
for each inspection team member. Due to the limited number of certified
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inspectors and the high radiation levels encountered, the number of
certifications was increased to preclude " burn-out" of available
personnel prior to the completion of this inspection. A verbal
,
agreement was reached between the NRC inspector, NPPD management,
and NRR representatives that onsite certification of additional
,
personnel and equipment could be accomplished, if proficiency in crack
,
detennination and dimensioning was clearly demonstrated to the satis-
faction of the NRC inspector and NPPD management. Utilizing this
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criterion, six additional inspectors and three additional ultrasonic
instruments were certified. These certifications were based upon
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the identification of defects during examinations of an onsite sample
of Nine Mile Point piping containing defects known to the NRC inspector
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and NPPD.
Four. of these inspectors were tested using a remote CRT
instrument commonly known as a " slave scope." Using this technique, a
Level I inspector and the small slave scope are in close proximity with
the weld being inspected, while the Level II or III inspector performs
the actual indication recording and evaluation at a remote location. Both
instruments are calibrated simultaneously to ensure that responses
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to signals are identical and head-set communications ~are maintained
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throughout the inspections. The most important reason for the slave
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scope is to limit the exposure to persons performing the examinations.
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Witnessing of half of the inspection is possible by observing either the
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slave or evaluation instrument.
The NRC inspector observed calibration operations or equipment
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calibration verifications on approximately 15 different occasions by
the various teams. The NRC inspector also observed portions of the
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ultrasonic examination of eleven welded joints in the recirculation
and the residual heat removal (RHR) piping systems. All activities
observed were performed in accordance with procedural requirements.
All plotting and evaluation was accomplished by a certified
Level II or III-inspector. The inspection results, including
indication lengths and depths, were forwarded to GE, San Jose,
,
California, for final evaluation utilizing fracture mechanics and
calculations.
Recommendations are then made as to specific actions
for individual weld joints. At the end of this inspection period,
approximately 90 weld joints had been inspected, with approximately
17 exhibiting IGSCC to varying lengths and depths. GE calculations,
which were incomplete at the time, indicated that four of the areas
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- exhibiting the worst cracking should be temporarily repaired by
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weld overlay cladding to restore the pressure boundary. material thickness.
This area will be reviewed during a subsequent inspection.
NPPD has voluntarily committed to inspect 100%.of the recirculation,
RHR, and bypass piping weld joints. This inspection,-along with
a review of inspection records and repairs. performed will be
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monitored during a future NRC inspection.
. No violations or deviations were identified during this portion of
the inspection.
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4.
Repair of Mark 1 Modifications
On October 11, 1982, NPPD notified Region IV, via correspondence number
LQA8200192, of a potential problem involving steel plate supplied by
Paxton and Vierling Steel Company (PVS). While fabricating parts
for the modification and addition of piping supports, it was noted
that a " thick steel plate contained laminations. Work was immediately
stopped and samples of all PVS steel plating were sent to an independent
testing laboratory (lab) to determine the chemical and physical properties
of each plate. The lab reports stated that four of the samples did
not meet the requirements established for A-36 steel physical properties.
All material supplied by PVS was subsequently quarantined. A
quality assurance audit was performed by NPPD of the PVS facility
which revealed that PVS had no system for positive material traceability.
PVS was immediately removed from the qualified vendors list. NPPD
determined that the nonconforming physical properties test results
would not have any adverse effects on the use of the steel due to
the nature of the nonconformances. NPPD further decided that all
parts fabricated from the laminated steel plate would be removed and
replaced with sound material. The only exceptions to this will be
parts, such as shims, upon which the stress loading is of a
conpressional nature. A total of 85 piping supports were affected
by the addition of one or more pieces of laminated steel. Seventy-five
of these have been or will be modified during the current outage to
remove the laminated plate. The ten remaining supports are considered
suitable for use "as-is" due to the compression-only loading of the
nonconforming material.
Following completion of the original Mark l modifications, an audit
performed by NPPD disclosed that welding by Dravo Utilities Constructors,
Inc. (DUCI) had been performed by welders not qualified in accordance
with the requirements of Section IX of the ASME B&PV Code.
Full pene-
tration groove welds had, in some cases, been perfonned by welders qualified
only for fillet welds. A total of 214 welds on 51 piping supports
fabricated or modified by DUCI were identified as having welds
produced by improperly qualified welders. These numbers represent
welds inside and outside the torus.
Additionally, 12 bracket welds
on 3 torus penetrations, designated as full penetration welds, were
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installed by DUCI with no bevel penetrations and. welded as partial
penetration fillet welds.
One of the 12 welds was removed, the
proper configuration achieved, and a full penetration . weld redeposited.
Problems were encountered during this rework and it was decided to
replace rather than repair the 11 "emaining brackets.
NPPD has
documented these DUCI errors on NCN-2311 and NCR-2623.
This work
was in progress at the end of this report period. The final fabrication,
installation, and inspection records will be reviewed by the NRC
inspector during a subsequent inspection.
No violations or deviations were identified during this portion af
the inspection.
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5.
Exit Interview
The NRC inspector met with licensee representatives (denoted in
paragraph 1) on May 13 and May 27, 1983, to discuss the scope and
findings of this inspection. The NRC resident participated in these
meetings.
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