ML20209J081
| ML20209J081 | |
| Person / Time | |
|---|---|
| Site: | Rancho Seco |
| Issue date: | 03/23/1987 |
| From: | Harris R, Kerch H, Strosnider J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V) |
| To: | |
| Shared Package | |
| ML20209J070 | List: |
| References | |
| 50-312-87-03, 50-312-87-3, NUDOCS 8705040199 | |
| Download: ML20209J081 (14) | |
See also: IR 05000312/1987003
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U.S. NUCLEAR REGULATORY COMMISSION
REGION I
Report No.
87-03
Docket No. 50-312
License No. DPR-54
Licensee: Sacramento Municipal Utility District
6201 S Street P.O. Box 15830
Sacramento, California 95813
Facility Name:
Rancho Seco
Inspection At:
Sacramento, California
Inspection Conducted: January 27-February 5,1987
Inspectors:
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H
Kerch, Reactor Inspector
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- . H. Har'r s', NDE Technician
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Approved by:
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(f.R.Strosnider, Chief)B,DRS
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Materials and
/ date
Processing Section, t
Inspection Summary:
Inspection conducted January 27 through February 5, 1987
(Inspection Report No. 50-312/87-03)
Areas Inspected: A special, announced inspection was performed utilizing the
NRC Mobile NDE Van to perform nondestructive examination of selected safety
related piping components. Two regional based inspection personnel assisted by
two contracted NDE personnel performed this inspection. The purpose of this
examination was <o ascertain the condition of plant equipment utilizing
NDE methods.
Results: One violation was identified concerning the failure to provide a
unique weld identification (50-312/87-03-04).
Several other problem areas in
the ISI program were identified and resulted in three unresolved items.
8705040199 870416
ADOCK 05000312
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DETAILS
1.0 Persons Contacted
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Sacramento Municipal Ut'ility District
F. Hauck
Regulatory Compliance
S. Nicolls
Radiation Protection
J. Uhl
ISI Co-ordinator
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0., Jackierny
ISI Co-ordinator
H. Herkert
Quality
W. Koepke
Quality Control
G. Hein
Safety and Loss Prevention
W. Weaver
Safety and Loss Prevention
R. Colombo
Regulatory Compliance
D. Benedette
Safety and Loss Prevention
J. Field
Start-up Director
J. Barker
Level III
J. Ward
Deputy General Manager
J. Vinquist
Staff Assistant
A. Larver
Licensing
C. Willis
ANII/ANI
U.S. Nuclear Regulatory Commission
C. J. Myers
Resident Inspector, RV
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Independent Measurements-NRC Nondestructive Examination
and Out.ity Recceds Review:
An independent verification inspection was conducted at the Rancho Seco
Nuclear Power Statian on January 27, through February 5,1987 using the
NRC Mobile Nondestructive Examination (NDE) Laboratory. This inspection
was performed by NRC personnel in conjunction with contracted NDE
personnel.
The purpose of this inspection was to verify the adequacy of the licensee's
piping installation quality control program. This was accomplished by
performing independent nondestructive examinations in accordance with
applicable codes and standards.
The NRC performed the examinations on a randomly selected sample of pipe
systems, components and vendor shop and field weldments. These items were
fabricated to ASME Code Section III and subject to inservice inspection
per ASME Code Section XI. Confirmatory examinations of areas previously
inspected by the licensee were performed and compared to quality assurance
records.
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2.1 Nondestructive Examinations:
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Nondestructive examinations were performed using NRC procedures in
conjunction with 1icensee drawing, reports and approved NDE pro-
cedures. The specific items examined and results of the inspection
are listed in Attachment No. 1.
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Radiographic Examination:
radiographed using an Iridium 192 source. The radiography was
performed in accordance with NRC Procedure NDE-5, Rev. O and
Site Radiography Guidelines, AP.305-18, Rev. 4.
The resulting radiographs were evaluated per applicable code
requirements.
Results:
No violations were identified.
Magnetic Particle Examination:
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Magnetic particle examination was performed on feedwater line welds
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(6292M61 SUBA Westinghouse drawing 4515D38).
Four (4) weldments and
adjacent base material (h inch on either side of weld) were examined
per NRC procedure NDE-6, Rev. O.
Results: No violations were identified.
Penetrant Examination:
Eighteen (18) pipe weldments and adjacent base material (h inch
on either side of weld) were examined using liquid penetrant
techniques per NRC procedure NDE-9, Rev. O.
Results: No violations were identified.
Visual Examinations:
Forty (40) pipe weldments and adjacent base material were
visually examined per NRC procedure NDE-10, Rev. O, Appendix A.
The
examination was performed using visual aids such as lights, mirrors
and welding gauges.
These examinations were performed to determine
the general condition of the pipe weldments and adjacent base material,
specifically checking for cracks, misalignment or other visual
discontinuities.
Results:
No violations were identified,
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Inservice Inspection / Ultrasonic Examination:
Duri.ng this examination, portions of five (5) ASME Class,2 stainless
steel pipe weldmen,ts were examined per NRC procedure NDE-1, Rev. O
and the licensee's procedure ISI-120, Rev. 12.
The examinations
utilized a manual contact ultrasonic scan in the shear mode, using a'
2.25 MHZ, .25 inch, 45 DEG. angle beam search unit. A Sonic Mark 1
flaw detector, calibrated in accordance with NRC procedure NDE 1,
Rev. O was used. A Distance Amplitude Correction (DAC) Curve was
' established using the licensee's calibration block (41129) for
8" stainless steel piping. All instrument settings were as near as
practical to those used during the original examination by licensee's
site personnel.
Results: No recordable indications were observed during this exami-
nation; however, it was determined that due to weld surface conditions
(as welded) a meaningful examination could not be performed using a
zero degree (straight beam) transducer.
Scanning requirements described
in Babcock and Wilcox Inservice inspection procedure, ISI-120, Rev.
12, para. 9.1.2 require that this area be examined by straight beam
and angle beam and that the beams pass through all of the weld material
on each of the scans.
It was found by the NRC inspector that two of
the three scanning directions identified by Babcock and Wilcox inservice
inspection procedure, ISI-120, Rev. 12 and associated ultrasonic reports,
could not be performed due to weld conditions (as welded). The two
inspections that could not be performed were a zero degree (straight
beam) en top of the weld and a 45 degree (angle beam) circumferential
atop the weld. This was the case for all weldments examined by the
NRC inspectors. Grinding of welds for UT examination was not a
requirement for class 2 weldments of the 74-75S Edition of Section XI.
Thickness Measurements (Erosion / Corrosion)
Two pipe fittings were inspected for erosion / corrosion using a
Nova-D100 ultrasonic digital thickness gauge, to determine wall
thinning in areas. A two inch grid was laid out on the outside
radius of the fittings and the minimum thickness was measured in
these areas and recorded. Attachment No. lA is a sketch of the
fittings and a table of the recorded thicknesses.
No violations were identified.
3.0 Inservice Inspection ISI
The inspector reviewed the following documents to ascertain compliance
with applicable sections of the ASME code, regulatory requirements and
licensee commitments:
Current 10 year ISI plan
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14 month extension to the current 10 year plan
-(approved by NRC May 30,1973)
Relief Request (January 28,1983)
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Inservice Inspection procedure ISI 120 Rev. 12
Surveillance reports
Ultrasonic Data
At the beginning of the current ten year interval, the licensee's ISI
program incorporated the requirements of ASME Boiler and Pressure Vessel
Code,Section XI, 1974 Edition through the Summer of 1975 addenda.
Rancho Seco's ISI program is in its first ten year interval and this is
the plaat's seventh outage. The ISI program was prepared and implemented
by Babcock and Wilcox, the licensee's ISI contractor for the site.
There
are several inspection items on the reactor pressure vessel that are not
scheduled for completion during this 10 year program. The licensee is
preparing to request NRC approval to defer these items to the second ten
year interval.
The inspector made the following observations based on his review of the
ISI program and discussions with cognizant personnel.
A.
Quality Assurance Surveillance reports were reviewed for the
contracted ISI activities. These surveillances were dated August 25,
1986 and October 14, 1986. The purpose of these QA surveillances was
to ascertain the effectiveness of the ISI program.
The surveillance
reports did not include an assessment of personnel performance,
ultrasonic examination data reporting or fracture mechanics analyses.
Personnel performing the surveillances were qualified auditors to
ANSI N45.2.6 and used a programmatic type check list. However, they
were not qualified in ultrasonic testing techniques nor did they have
appropriate skills to pprform a technical surveillance of the ISI
contractor performance. Rancho Seco's Quality A'ssurance Surveillance
Program for the ISI contractor / program, as it is implemented, has not
been effective in verifying the contractor's technical performance.
This is an unresolved item pending licensee's action and NRC review
(50-312/87-03-01).
B.
Review of ultrasonic inspection results for the pressurizer support
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lugs (report numbers85-006, 85-007,85-010 and 85-0014) revealed
that additional indications have been detected since the 1983 outage.
The inspection results show that some of the new indications are
close to previously reported indications suggesting possible dimensional
changes.
Fracture mechanics analyses have been performed by the site
ISI contractor and the licensee has filed the reports. However, the
reports do not addres, the following concerns:
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Are-these indications growing as reported and if they are, what
is the rate of growth?
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2.
If these new indications are fabrication welding indications "not
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detected before, do they require further evaluation to determine why
these indications were not detected before?
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This is an unresolved item pending licensee's action relating to the
above concerns and NRC review (50-312/87-03-02).
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C.
ISI figure C2.1.136 for weld 26121-33-BW revealed that a 0 , 45*
axial and 45 circumferential examination was performed. Section 2.1
of this report discussed limitations for the 0 , 45 and 60 ultrasonic
inspections (note:
no 60 report was available for this weld).
It
is not possible to determine from the report what volume of the weld
was or was not examined and, therefore, it could not be determined if
applicable code requirements had been satisfied.
The foregoing is an
example of similar deficiencies identified in other weld package
reviews. Thus, this is a generic problem with the ISI ultrasonic
data at Rancho Seco. This is an unresolved item pending licensee's
action and NRC review (50-312/87-03-03).
D.
During this inspection, it was revealed that there was no formal
system for notifying ISI personnel of changes to drawings or modifi-
cations that could effect the ISI program. A new procedure, AP.44,
Rev. 10, Plant Mod - ECN Implementation, Enclosure 7.13(7), with an
effective date 02-05-87 was presented after the inspection exit. The
procedure was reviewed and found to contain a formal method of
notifying the ISI group of changes that could affect the ISI program.
The inspector had no further questions concerning this item.
E.
As part of the inspection, the NRC selected welds for re-examination.
One drawing utilized as part of this re-examination, Drawing No.
20529-10" EA, main steam piping system, contained two sets of welds
which had common weld identifiers "M" and "N".
Welds must be uniquely
identified to assure positive location. This is required generally
by 10 CFR 50, Appendix B, Criterion VIII, and specifically by the
licensee's Welding Manual paragraph 6.12.
The licensee's Quality
Assurance Manual, Section 2, invokes ANSI N45.2 which prescribes
further that items must relatable to specific drawings or specifications.
The failure to positively identify the foregoing welds is a violation.
(50-312/87-03-04)
4.0 Wall Thinning IE Notice No.86-106 Feedwater Line Break
As of 2/5/87, the licensee had not implemented an inspection program for
wall thinning as discussed in IE Notice 86-106, feedwater line break. The
licensee wanted to wait until Virginia Power Company made its presentation
on this subject on February 10, 1987, in order to include any new information
in the program development.
During this inspection the NRC performed wall
thickness examinations and did not find any wall thinning in its very limited
sample.
See paragraph 2, page 4 for details and attachment No. lA for a
sketch of the components inspected and recorded thicknesses.
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5.0 Decay Heat Drain Line
The Decay Heat Drain lines had leaked due to pipe wall thinning.
Because
of this, the lines were reengineered and replaced. During this inspection,
the NRC reviewed the problem and re-examined portions of the Decay Heat
Drain Line piping. A listing of the associated inspection activities is
described below.
Reradiographed similar piping.
(see attachment No. I for listing)
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Reviewed 13'radiog'raphs.
(see attachment No. 2 for listing)
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Visually examined the cross-section of the problem piping.
Reviewed the Failure Analysis repo~ t from Vallecitos Nuclear Center,
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dated 1/27/87.
From these observations and reviews the inspector had no further questions
concerning the licensee's findings.
6.0 Unresolved Items
Unresolved items are matters about which more information is_ required in
order to ascertain whether they are acceptable items, violations or
deviations. Three unresolved items are discussed in paragraph 3.0 of this
report.
7.0 Attachments:
Attachment No. 1 is a tabulation of specific items examined and the re-
sults achieved. Attachment No. IA is a sketch thickness readings of
pipe component fittings examined for wall thinning (erosion / corrosion).
Attachment No. 2 is a list of specific licensee radiographs reviewed.
8.0 Exit Interview:
An exit interview was held on February 5, 1987 with members of the
licensee's staff. The inspector summarized the scope and findings of this
inspection. No written material was provided to the licensee during this
inspection.
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