IR 05000266/1983024

IE Insp Rept 50-266/83-24 on 831108-10.No Noncompliance Noted.Major Areas Inspected:Steam Generator Replacement Project & NDE Program

ML20082U705
Person / Time
Site:	Point Beach
Issue date:	11/28/1983
From:	Kleinsorge W, Blake J NRC Office of Inspection & Enforcement (IE Region II)
To:
Shared Package
ML20082U702	List: IR 05000266/1983024
References
NRC-2020-000157 50-266-83-24, NUDOCS 8312190138
Download: ML20082U705 (12)

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o UNITE 3 STATES

1. gn ass 'o,, NUCLEAR RE;ULATO RY COMMISSION

[ o REGION il-O g 101 MARIETTA STREET * * ATLANTA, GEORGIA 30303

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Report No.: 50-266/83-24 Licensee: Wisconsin Electric Power Company 231 West Michigan Milwaukee, WI 53201 Docket No.: 50-266 License No.: DPR-24 Facility Name: Point each Inspection a e te near Two Rivers, Wisconsin Inspector: -h e W,b, kh so Date Signed Approved b N t6 3 J BlaIe, Section Chief Da'te Signed n neering Program Branch Di ision of Engineering and Operational Programs

. SUMMARY Inspectio'n on November 8-10, 1983 Areas Inspected This . routine, unannounced inspection involved 23 inspector-hours on site in the areas of steam generator replacement project-(Unit 1) and nondestructive examination program (Unit 1).

Results No violations or deviations were identifie DOcko!$Mjj6 PDR

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REPORT DETAILS Persons Contacted Licensee Employees

• C. W. Fay, Vice President

• A. L Reimer, Site Supervisor

• R. E. Link, Superintendent EQRS

• F. A. Hentje, Supervisor - Staff Services Other Organizations

• B. W. Garrow, Westinghouse (W) Lead Site QA Engineer T. Vetter, W Site QA Engineer _

A. Walcutt,~Morrison-Knudsen (M-X), Project QC Manager J.~S. Stone, M-K, NDE Level III B. Jacobs, M-K, Welding Engineer Other M-K employees contacted included technicians, mechanics and office personne NRC Resident Inspectors R. Hague, SRI

• B. E. Fitzpatrick, RI

• Attended exit interview 2.- Exit Interview The inspection scope and findings were summarized on November 10, 1983, with those persons indicated in paragraph 1 above. The inspector described the areas inspected and discussed in detail the inspection findings listed below. No dissenting comments were receited from the license (0 pen)- Inspector Followup Item 266/83-24-01: " Unaddressed Nonessential Variables" - paragraph 6.b.(1)

(0 pen) Inspector Followup Item 266/83-24-02: " Discrepancies In FQP 2.1 and FQP 2.2" - paragraph 7a (0 pen) Inspector Followup Item 266/83-24-03: " Discrepancies in FQP 9.3" -

paragraph 7.b.(3)

(0 pen) Inspector Followup Item 266/83-24-04: " Discrepancy In FQP 9.6" -

paragraph 7.b (4)

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(0 pen) Inspector Followup Item 266/83-24-05: " Radiographic Examination Program Discrepancies" - paragraph 7.b.(5) .icensee Action on Previous Enforcement Matters Not inspecte . Unresolved Items Unresolved items were not identified during this inspectio . Independent Inspection Effort Construction Progress The inspector conducted a general inspection of the preparations for the steam generator replacement project, including the weld test shop, ware-house, steam generator -tomb 'and weld rod issue station to observo replace-ment project progress and activities such as material handling and control, housekeeping and storag Within the areas examined no violations or deviations were identifie . ' Steam Generator Replacement' Project (SGRP) (Unit 1)

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The Pcint Beach Nuclear Plant Unit 1, owned by V: .,consin Electric Power Company (WEPC0), is replacing the lower steam generator assemblies. The work is being accomplished by Westinghouse (_W) the customer / client of

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Morrison-Knudsen(M-K). The hierarchy of project documents is: WEPC0-Point Beach Quality Program, W -NSID QA Program, W NSID Steam Generator Repair Supplement and QA Program Plan Supplement, 7 SGRP Quality Procedures, and M-K Quality Procedures. The applicable codes for the SGRP are listed belo ASME Section III 77S79

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ASME Section V 77S79

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ASME Section IX 77579

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AWS DI.1 - 1982

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SNT-TC-1A-1975 Review of Quality Program The inspector reviewed the below listed documents to ascertain whether the steam generator project had been approved by the licensee and whether adequate plans and procedures had been established to assure that the replacement project would be controlled and accomplished consistent with commitments and regulatory requirement I

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i N Title SQP-4.1, Rev. 4A " Procurement" SQP-5.2, Rev. 3A " Preparation, Control and Issue of Controlled Work Packages" SQP-6.1, Rev. 4A " Document Control" SQP-7.1, Rev. 2P " Material Control and Identifi-cation" SQP-15.1, Rev. IP " Control of Nonconformances" FWP-2.1, Rev. 2A " Welder Qualification" FWP-7.1, Rev. IP " Filler Metal Control" FWP-9.1, Rev. IP " Control of Welding" FWP-9.2, Rev. IP " Pre-Heat and Post Weld Heat Treatment" FWP-9.3, Rev. IP " General Welding Requirements" FWP-9.4, Rev. lA " Control of AWS Welding" FWP-15.01, Rev. IP " Welding Procedure Specifica-tion N-8-8-A" FWP-15.03, Rev. IP " Welding Procedure Specifica-tion M-8-8-AB" FWP-15.05, Rev. IP " Welding Procedure Specifica-tion M-1-1-AB-P" FWP-15.07, Rev. 0 " Welding Procedure Specifica-tion N-3-3-C-P" FWP-15.11, Rev. IA " Welding Procedure Specifica-tion M-1-1-B (AWS)"

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FWP-15.12, Rev. O " Welding Procedure Specifica-tion N-1-1-C (AWS)"

FWP-15.13, Rev. 0 " Welding Procedure Specifica-tion M-3-1-B (AWS)"

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FQP-7.1, Rev. IP " Receipt Inspection" FQP-12.1, Rev. 2P " Control of Measuring and Test Equipment" FQP-17.1, Rev. 0 " Processing of QA Documenta-tion" b. Welding Procedure Specification (1) General Welding (550508)

The following Welding Procedure Specifications (WPS) were selected for review and comparison with the ASME Code:

FWP-N WPS PROCESS * PQR 15.01 N-8-8-A GTAW 8-105 15.03 M-8-8-AB GTAW/SMAW 8-106 15.05 M-1-1 A8 GTAW/SHAW 1-117 15.07 N-3-3-CP FCAW 3-4

• GTAW-Gas Tungsten Arc Welding SMAW-Shielded Metal Arc Welding FCAW-Flux Core Arc Welding The above WPSs and their supporting Procedure Qualification Records (PQR's) were reviewed to ascertain whether essential, supplementary and/or nonessential variables including thermal treatment were consistent with code requirements; whether the WPSs were properly qualified and their supporting PQR's were accurate and retrievable; whether all required mechanical tests had been performed and the results met the minimum requirements; whether the PQR's had been reviewed and certified by appropriate personnel and; whether any revisions and/or changes to nonessential variables were noted. WPSs are qualified in accordance with ASME Section IX, the latest edition and addenda at the time of qualifi-catio With rega.m to the above, the inspector noted the following:

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WPS-N-8-8-A does not address nonessential variable QW410.7 -

frequency and dwell time of oscillatio WPS-N-3-3-C-P does not address nonessential variable QW41 contact tube to work distanc . .

The licensee indicated that appropriate correction would be mad This matter will be identified as inspector followup item 266/83-

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24-01: " Unaddressed Nonessential Variables".

(2) Structural Welding (55100B)

The following Welding Procedure Specifications (WPS) were selected for review and comparison with AWS 0.1.1:

.FWP-N WPS Process * PQR 15.13 M-3-1-BF SMAW 14F-234 15.12 N-1-1-C FCAW Prequalified 15.11 M-1-1-B SMAW Prequalified

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• SMAW - Shielded - Metal Arc Welding

• FCAW - Flux Core Arc Welding The above WPSs and their Supporting Procedure Qualification Records (QPR's) if applicable were reviewed to ascertain whether AWS Prequalified Procedures meet all applicable requirements of AWS DI.1, orocedures other than these prequalified were qualified

'in accordance with AWS D1.1, changes or revisions to WPS essential variables are supported by requalification of the original WPS or a new WPS, and that changes to nonessential variables are properly identified or documented, c. Welding Filler Material Control (55050B and 55100B)

The inspector reviewed the M-K program for control of welding materials to determine whether materials are being purchased, accepted, stored, and handled in accordance with QA procedures and applicable code requirements. The following specific area were examined:

- Purchasing, receiving, storing, distributing and handling procedures, material identification, and inspection or welding material issuing station d. Welder Qualifications (55050B and 55100B)

The inspector reviewe the M-K program for qualification of welders and welding operators for compliance with QA procedures and applicable code requirement (1) The inspector observed the following Welder Qualification tests in progress. The inspector confirmed by positive identification that the person welding the test assembly was the person being quali-fie ,. - -. .- - - . - - . - -

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Welder Qualification Test N PF-101 PF-98 (2) The inspector reviewed the below listed Welder Qualification Test Records, including radiographs, to verify that qualification testing and documentation was consistent with the applicable code requirement Welder Qualification Test N PF-69 PF-62 PF-54 BM-72 BM-13 IW-7 Within the areas examined, no violations or deviations were identified. Nondestructive Examination Program (Unit 1)

The inspector reviewed procedures for nondestructive examination program

. applicable to the steam generator replacement project to determine whether applicable code and procedure requirements had been met. For applicable code see paragraph 6.- Review of Quality Program The inspector reviewed the below listed documents to ascertain whether the nondestructive examination program had been approved by the licensee and whether adequate plans and procedures had been established to assure that the replacement project would be controlled and accom-plished consistent with commitments and regulatory requirement N Title FQP-2.1, Rev. IP " Qualification and Certifica-tion of Inspection Personnel ANSI N45.2.6" FQP-2.2, Rev. 2A " Qualification and Certifica-tion of Inspection Personnel SNT-TC-1A" FQP-9.1, Rev. IP " Visual Weld Examination" FQP-9.2, Rev. 2A

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-" Liquid Penetrant Examination Procedure"

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N Title FQP-9.3, Rev. 2A " Magnetic Particle Examination" FQP-9.4, Rev. 2P " Radiographic Examination Procedure" FQP-9.5, Rev. IP "Ultransonic Examination" FQP-9.6, Rev. 2A " Ultrasonic Thickness Procedure" FQP-10.1, Rev. 1A " General Instructions for the Conduct of Inspections" FQP-10.2, Rev. 1A " Coordination of Periodic Inspection Activities"

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With . regard to the inspection above, the inspector noted the following discrepancies:

- FQP-2.2, Rev. 2A does not specify the correct edition of SNT-TC-1 FQP-2.1, Rev. IP does not define the duties, responsibilities and limitations of Level I, II, III inspector FQP-2.1, Rev. IP does not clearly define the relationship between experience required for Level I, II, and III inspectors and college credit less than that necessary for a baccalaureate degre The licensee indicated that appropriate corrections would be mad This matter will be identified as inspector followup item 266/83-24-02:

" Discrepancies in FQP-2.1 and FQP-2.2". Procedure Review (1) Visual Examination (57050B)

The inspector reviewed M-K Procedure FQP-9.1 to ascertain whether it had . been reviewed and approved in accordance with the licensee's established QA procedures. The above procedure was reviewed for technical adequacy and conformance with ASME, Section V, Article 9 and other licensee commitments / requirements in'the below listed areas:

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Method

- Application

- How visual examination is to be performed

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Surface condition

- Method for surface preparation

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Direct /remoteviewin Special illumination

- Sequence of performing examination

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Data.to be tabulated

- Acceptance criteria

- Report fonn (2) Liquid Penetrant (570608)

The inspector reviewed M-K Procedure FQP-9.2 to ascertain whether it has been reviewed and approved in accordance with the i

licensee's established QA procedure The above procedure was reviewed for technical adequacy and conformance with ASME,Section V, Article 6 and other licensee commitments / requirements in the below listed areas:

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Specified method

- Penetrant c,aterials identified

- Penetrant materials analyzed for sulfur

- Penetrant meteriais analyzed for total halogens

- Acceptable pre-examination surface

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Drying time

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Method of penetrant application

- Surface temperature

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~ Solvent removal / Water washable

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Dry surface prior to developing

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Type of developing

- Examination technique

- Evaluation technique (3) Magnetic Particle (570708)

The inspector reviewed M-K Procedure No. FQP-9.3 to ascertain whether it had been reviewed and approved in accordance with the licer,see's established QA procedures. The above procedure was reviewed for technical adequacy arid for conformance with ASME Section V, Article 7 and other licensee commitments / requirements in the below listed areas:

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Examination method

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Surface preparation

- Contrast of dry powder particle color with background and surface temperature

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Suspension medium and surface temperature for wet particles

- Viewing conditions

- Examination overlap and directions

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Pole or prod spacing

- Current or lifting power (yoke)

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Acceptance criteria i-

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With regard to the inspection above, the inspector note that FQP-9.3, Rev. 2A does not specify the correct edition of SNT-TC-1A. The licensee indicated that appropriate corrections would be made. This matter will be identified as inspector followup item 266/83-24-03: " Discrepancy in FQP-9.3".

(4) Ultrasonic (57080B)

The inspector reviewed M-K procedures FQP-9.5 and FQP-9.6 to ascertain whether they had been reviewed and approved in accordance with the licensee's established QA procedures. The e above procedures were reviewed for technical adequacy and con-formance with ASME,Section V, Article 5 and other licensee commitments / requirements in the below listed areas:

- Type of apparatus used

- Extent of coverage of weldment

- Calibration requirements

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Search Units

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Beam Angles

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DAC Curves

- Reference level for monitoring discontinuities

- Method of demonstration of penetration

- Limits for evaluating and recording indications

- Recording significant indications

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Acceptance limits With regard to the examination above, the inspector noted that FQP 9.6, Rev. 2A, Page 16 inadvertently indicated 10% correct was a passing score vice 70% correct. The licensee indicated that appropriate corrections would be made. This matter will be identified as inspector followup item 266/83-24-04: " Discrepancy in FQP 9.6".

(5) Radiography (570908)

The inspector reviewed M-K Procedure No. FQP-9.4 to ascertain whether it had been reviewed and approved in accordance with the licensee's established QA procedures. The above procedure was reviewed for technical adequacy and for conformance with ASME Section V, Article 2 and other licensee commitments / requirements in the below listed areas:

- Material and weld surface condition requirements

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Types of material

- Material thickness range

- Type of radiation source, effective focal spot or effective source size, X-ray equipment voltage rating and equipment manufacturer, as applicable

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- Film brand or type and number of films in cassette

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Minimum source to film distance

- Blocking or masking technique, if used

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Type and thickness of intensifying screens and filters

- Exposure conditions for procedure qualification, if appli-cable

- Radiographic film processing requirements

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Quality of radiographs - limits on mechanical, chemical or other blemishes, such as fogging, process marks, scratches, finger marks, loss of detail or false indications

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Film density limits for single and composite viewing

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Use of densitometers for assuring compliance with film density requirements

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System of radiograph identification

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Use of location markers

- Records for showing filr ' source location with reference to the part being radiographed

- Use of intensifying screens

- Methods of reducing and testing for backscatter

- Description of or reference to the welding procedure

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Material type ar.d thickness restrictions for isotore radio-graphy

- Geometrical unsharpness limitations

- Selection and use of penetrameters including:

Penetrameter design Selection of essrntial hole

Penetrameter thickness including special requirements

.for single and double wall viewing

Penetrameter placement including special requirements for single and double wall viewing Number of penetrameters

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Shims under penetrameters

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Radiographic technique requirements for double wall viewing

- Qualification of radiographic procedure (radiographs taken to demonstrate procedure capability)

- Requirements for evaluation and disposition of radiographs

- Records requirements With regard to the inspection above, the inspector noted the following discrepancies:

- FQP-9.4, Rev. 2P does not specify the ASME Section V, Paragraph T-282(c) and (d) parameters, " Minimum Source-To-Film Distance" and " Maximum Source Size".

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- The M-K quality program does not make any provisions for periodic verification of Image Quality Indicator (penetra-

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meterdimensions).

The licensee indicated that appropriate corrections would be mad This matter will be identified as inspector followup item 266/83-24-05: " Radiographic Examination Program Discrepancies".

Within the areas examined, no violations or deviations were identified.