ML20215L132
| ML20215L132 | |
| Person / Time | |
|---|---|
| Site: | Pilgrim |
| Issue date: | 04/27/1987 |
| From: | Harris R, Kerch H, Strosnider J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML20215L109 | List: |
| References | |
| 50-293-87-15, NUDOCS 8705120110 | |
| Download: ML20215L132 (17) | |
See also: IR 05000293/1987015
Text
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U.S. NUCLEAR REGULATORY COMMISSION
REGION I
Report No.
50-293/87-15
Docket No.
50-293
License No.
Licensee: Boston Edison Company
800 Boylston Street
Boston, Massachusetts 02199
Facility Name:
Pilgrim Nuclear Power Station
Inspection At:
Plymouth Massachusetts
Inspection Conducted:
March 2-13, 1987
Inspectors:
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Harry W.' Kerch, Lead Reactor Engineer
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H ris, NDE Tech 11cian
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Approved by: _ s
Strosnider, Chief, M&PS, DRS, EB
date
Inspection Summary:
Inspection on March 2-13, 1987 (50-293/87-15)
Areas Inspected: A special announced NRC independent measurements inspection
was conducted at the Pilgrim Nuclear Power Station, by Regional NDE personnel
assisted by two NRC contracted NDE personnel.
The NRC Mobile Nondestructive
Examination Laboratory was utilized during the inspection.
Nondestructive
examinations were performed on a sample of pipe weldments, pipe supports and
'
miscellaneous pipe materials which were selected from the Core Spray System,
High Pressure Coolant System, cascading drain line and Recirculation system.
Inspections were performed to applicable codes, standards and procedures.
Results:
Two violations were observed concerning an inadequate magnetic par--
ticle examination and an inadequate procedure for visual inspection personnel
qualification.
8705120110 870505
ADOCK 05000293
G
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DETAILS
1.
Persons Contacted
Boston Edison Company (BECO)
K. Roberts
Nuclear Operations Manager
F. Famulari
QC/ISI Group Leader
R. Grazio
Field Engineering Manager
J. Mattia
QA Surveillance Leader
B. Perkins
Sr. QC Engineer
N. Desmond
Sr. QC Engineer
C. Hamilton
Sr. Compliance Engineer
t_
NRC
J. J. Lyash
Resident Inspector
2.
Independent Measurements-Nondestructive Examination and Records Review
of Safety Related Systems
During the period of March 2 through March 13, 1987 an onsite inspection
was conducted at the Pilgrim Nuclear Power Station utilizing the NRC
Mobile Nondestructive Examination (NDE) Laboratory. This inspection was
conducted by-region based personnel in conjunction with NRC contracted
Nondestructive Examination (NDE) personnel.
The purpose of this inspection was to verify the adequacy of the
licensee's inservice inspection plan and quality control program. This
was accomplished by duplicating those examinations required of the
licensee by NRC Regulations, applicable industry codes and FSAR commit-
ments. The NRC Inspector made a random selection of pipe hangers, pipe
weldments and pipe systems. These were intended to provide a represen-
tative sample of components, pipe size, material and weldments examined in
accordance with specific site requirements. The items selected were ASME
Class 1 and 2 weldments from'the Core Spray, Recirculation, High Pressure
Coolant Injection (HPCI) and Residual Heat Removal Systems. Also, exam-
inations for erosion / corrosion of material were made on the cascading
,
drain line and the drywell liner plate. The visual and thickness exam-
i
inations of-the feedwater cascading drain lines and drywell liner plate
l
are not an NRC or ASME Code requirement; however, these inspections were
conducted in light of the December,1986, feedwater line rupture at Surry
Unit No. 2 and the thinning of the Drywell discovered at Oyster Creek in
the Fall of 1986.
2.1 Nondestructive Examinations:
Examinations were performed using NRC procedures in conjunction with
!
the licensee's procedures, specifications and applicable drawings.
l
The following examinations were performed.
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Magnetic Particle Examination
Five (5) weldments in safety related piping and adjacent base
material (1/2 inch on either side of the weld) were examined using
I
the dry magnetic particle technique per NRC procedure, NDE-6, rev. O.
Included in this examination were ASME Class 2, carbon steel piping
weldments selected from the High Pressure Coolant Injection (HPCI)
and the Residual Heat Removal (RHR) systems.
Results:
One of the five weldments examined (weld DB-23-2-IC) was found to
have an indication approximately 3/4 inch in length starting at the
toe of weld and propagating at an angle into the base material. This
component was previously inspected and accepted by the licensee as
indicated by Magnetic Particle Data Sheet #1351. This data sheet
reads, in part, " accept no relevant recordable indications ... com-
ponent meets ASME Section XI acceptance criteria." Contrary to this,
NRC independent inspection found that the Class 2 component did have
a recordable indication and did not meet the acceptance criteria of
The licensee issued nonconformance report NCR 87-99
describing the unacceptable condition of weld DB-23-2-IC as identi-
fied by the NRC magnetic particle examination.
This item is considered
a violation (50-293/87-15-01) in that the licensee failed to effectively
complete an ASME Code required examination and did not identify or
disposition a rejectable linear surface indication.
Liquid Penetrant Examination
Four weldments in safety related piping and the 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. O.
ASME Class 1, stainless steel to Inconel weldments from the Reactor
Water Level Instrumentation System were included in this sample.
Results:
No violations were identified.
Visual Examination
Eleven (11) safety related pipe weldments were visually examined in
accordance with NRC procedure NDE-10, Rev. O, Appendix A.
The exam-
j
inations were completed specifically to identify any cracks or linear
'
indications, gouges, leakage, or arc strikes with craters or corrosion,
all of which may infringe upon the piping minimum wall thickness
Mirror, lights and weld gauges were used to assist in the inspection
and evaluation of the weldments. See attachment No. I for a list of
the weldments examined and the results of these inspections.
____
_ _ _ _ _ _ _ _ _ _
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4
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Results:
Visually, one (1) weldment was found visually to have a linear indi-
cation.
This deficiency was also found during the magnetic particle
examination noted in section 2.1.
This weld is identified as
DB-23-2-1C and does not meet the visual acceptance criteria.
No other violations were identified.
Ultrasonic Examination ISI
The inspector selected six (6) pipe weldments for independent ultra-
sonic inspection. Those weldments selected were from the Recircu-
lation System, Core Spray and High Pressure Coolant Injection (HPCI)
Systems.
The ultrasonic examinations were performed using a Sonic Mark 1 flaw
detector and in accordance with NRC procedure NDE-1, Rev. 0; Boston-
Edison Company procedures QCI No. 50.70, QCI-No. 50.71, TP 86-130;
and associated ultrasonic data reports.
Instrument calibration
_
(linearity verification) was performed using NRC procedure NDE-2,
Rev. O.
A distance amplitude correction curve was constructed (DAC)
using the licensee's calibration blocks, PIL-68 and PIL-84, 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.
ASME Class I stainless steel and Class 2 carbon steel piping samples
were included in this examination.
The stainless steel pipe weld-
ments were also ultrasonically examined for intergranular stress
cerrosion cracking (IGSCC) in accordance with NRC Generic Letter 84-11, Augmented Inspection Program.
Those carbon steel pipe weld-
.
ments selected were included in the licensee's inservice inspection
program.
Results:
Geometric reflectors and root conditions which were noted in
licensee's ultrasonic inspection reports were verified by this
inspection. No violations were identified.
3.0 Review of Reactor Water Level Instrumentation Lines
Modification / Installation PDC #85-07)
During this inspection a walk down of a Reactor Water Level Instrumen-
tation Line was performed. The walkdown consisted of a visual inspection
of pipe hanger supports and repair and installation of the 2" hot tap
drain nozzles.
In addition to the visual examination, a dye penetrant
inspection was performed on the 2" hot tap drain nozzle welds. A review
of the radiographs for these 4 welds was also performed.
.
_
_
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5
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The following hanger components were examined per NRC procedure #NDE-10,
Rev. 0., Appendix B, and the associated Isometric drawings M1002 124
Rev. H:
Hanger No.
Detail Dwg./Rev.
Comments
H-2-1-7
H-2-1-7
B
ACCEPTABLE
H-2-1-8
H-2-1-8
C
ACCEPTABLE
H-2-1-9-
H-2-1-9
C
ACCEPTABLE
H-2-1-10
H-2-1-10
ACCEPTABLE
H-2-1-11
H-2-1-11
ACCEPTABLE
H-2-1-12
H-2-1-12
ACCEPTABLE
H-2-1-24
H-2-1-24
ACCEPTABLE
H-2-1-25
H-2-1-25 B
ACCEPTABLE
H-2-1-26*
- Hanger was not installed.
Further investigation revealed this hanger was
being re-designed and would be installed at a later date.
.All hangers were inspected for evidence of wear, corrosion, cracks,
extraordinary movement, correct dimensions and proper installation.
Results: No violations'were identified.
4.0 Ultrasonic Thickness Measurements of the Drywell Wall
The licensee examined twelve 6 inch by 6 inch areas on the Drywell liner
plate in response to NRC Information Notice 86-99, and General Electric
Company Rapid Information Communication Services Information Letter
(RICSIL) No. 09. These documents alerted utilities of possible corrosion
of the drywell wall based on experience at the Oyster Creek Nuclear Power
Plant.
The NRC Inspectors performed independent measurements of the drywell wall
thickness. No degradation of the drywell wall material was detected.
Thickness measurements were performed using a Nova D100 digital thickness
gage in conjunction with NRC, Nondestructive Examination procedure, NDE II
Rev. O.
Attachment No. 2 is a comparison of the licensee and the NRC
Inspection results (high and low thickness measurements).
Results: No violations were identified.
4.1 Ultrasonic's Thickness Measurements of Feedwater Cascading Drain Lines
Three hundred sixteen (316) thickness measurements were taken on
three (3) carbon steel 90 degree elbow to pipe components. The
'
thickness measurements were performed to determine if wall thinning
had occurred due to erosion / corrosion. This was accomplished by
laying out a 1 or 2 inch grid (determined by pipe size) on the com-
ponent and recording the measurements obtained by use of a NOVA D-100
'
thickness-gauge.
...--
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6
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Measurements were taken in areas where erosion / corrosion might' occur. The
areas selected consisted of two (2) elbows to the feedwater heater and one
(1) elbow to the heater drain cooler. Attachment 4 presents a tabulation
of the NRC wall thickness measurements.
Result: No violations were' identified.
5.0 Review of Procedures
The procedures listed in attachment number three were reviewed to verify
their technical adequacy and conformance to regulatory and code requirements.
Results:
The inspector reviewed the ISI contractor's procedure QC-7 revision 3,
titled " Qualification and Certification of ASME Section XI Visual Exam-
ination Personnel". The inspector noted the contractor's procedure no.
QC-7, revision 3, section 8.0 requires only four months experience for
VT2, VT3 and VT4 level II qualification. ANSI N45.2 and licensee proce-
dure QC 10.6 require 4 years experience for visual inspector certifica-
tion. The' contractor's four month time period for experience is inappro-
priate and does not conform with NRC or Code requirements and is
considered a violation 50-293/87-15-02.
The licensee took several actions with regard to this subject during the
inspection.
Procedure QC-7 was revised to include the ANSI experience
requirements. The licensee audited the personnel visual qualification
records of all personnel who performed visual examinations at this
facility and indicated by letter dated March 9, 1987 that examination
personnel had exceeded the experience requirements of ANSI 45.2.6.
The
inspector also reviewed the visual personnel training records and did not
identify any personnel that did not meet ANSI N45.2.6 experience
requirements.
6.0 Review of the Inservice Inspection-ISI Program
The Ptigrim ISI Program was prepared and is implemented by the licensee.
The plan for this outage meets the requirements of ASME Section XI 1980
edition including addenda through Winter, 1980. This outage was the 2nd
in the second 10 year interval of the ISI program.
(1) Staffing of ISI Program
Based on this review, the inspector concluded that the Pilgrim
nuclear facility staff, comprised of site personnel augmented by
contract personnel, was adequate to properly execute the ISI program.
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7
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(2) ISI Personnel Record Review
The inspector reviewed the qualifications and certification records
for 15 examination personnel. No violations were identified.
(3) Quality Assurance Audits and Surveillances
The inspector reviewed the documents listed below to ascertain that
ISI and modification contractors are audited by the QA department
prior to their being considered a qualified supplier of services.
Also, the on site QC surveillance of contractor performance to assure
procedure compliance was reviewed.
- Boston Edison Audit Report #86-73 conducted at King of Prussia,
Pennsylvania, General Electric Nuclear Field Services Division. This
audit covered modifications, maintenance, repair and replacement
capabilities.
Boston Edision Audit Report #87-1 Preaward of ISI Contractor (GE)
for ISI/IST.
- Bechtel No.87-136 radiographs procedure
- General Electric No.87-124, 86-264, 87-59 Magnetic Particle
Procedure
- General' Electric No. 87-59 Ultrasonic Procedure
- General Electric No.86-239, 86-206 Liquid Penetrant Procedure
The audit and surveillance reports indicated that various aspects of
the ISI Program were examined, audit findings were properly closed
out,-and the licensee's ISI vendor was properly qualified as a sup-
plier of ISI services. This inspection identified a weakness in that
the deficiency discussed in Section 5.0 in the ISI contractor's
procedure for Qualification and Certification of ASME Section XI
Visual Examination Personnel (QC-7 Revision 3) was not identified
during the above audits.
(4)
Inservice Inspection (ISI) Data Review
During this inspection the inspector reviewed the ultrasonic data
'
listed below.
System 16.2 Recirculation Volume
- System 16.3 Recirculation Drywell
- System 7.1 BV.111.1 Volume
System 10.2 RHR Volume
1
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8
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The inspector verified that the examinations were done in compliance
with governing procedures and that applicable regulatory and ASME
code 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
acceptance of those reports. Overall, the inspector found that the
Inservice Inspection Program at Pilgrim was being performed ade-
quately and the objectives of the ISI program are being met.
How-
ever, a weakness in the ultrasonic examination documentation was
identified in that cross references for the automatic ultrasonic
examination and the supplemental manual ultrasonic examination did
not exist on the ultrasonic examination data report. Also, their
were several -cases of incomplete ultrasonic examination data record-
ing on the examination data records.
The inspector determined that
the data was available elsewhere, although not documented on the
official ultrasonic examination record.
During this inspection the
licensee revised and corrected all the documentation deficiencies on
the ultrasonic examination data reports for this outage. To prevent
reoccurrence the licensee has issued instruction No. 01 Rev. 0
" Review of Data" to ensure all the required data is recorded on the
ultrasonic examination record. The inspector has no further concerns
with this item and considers this issue closed.
. 7.0 Attachments:
f
'
Attachment No. 1 is a tabulation of specific piping weldments inspected
and results. Attachment No. 2 is a sketch of specific areas of the pri-
mary containment drywell liner plate tested for wall degradation and
comparisons to licensee measurements. Attachment No. 3 is a list of
specific procedures reviewed during this inspection. Attachment No. 4 is
a sketch indicating thickness measurements and areas inspected for
erosion / corrosion.
8.0 Exit
On March 13, 1987, the NDE Van personnel had an exit meeting with the
licensee's staff. The findings of this inspection were described at.that
meeting.
No written material was provided to the licensee during this inspection.
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Attachment No. 3
List of Procedures & Manuals Reviewed
-Boston Edison Company (BECO) Procedures:
Ultrasonic Examination-General Requirements No. 50.70
Ultrasonic Examination of Class 1, 2 and 3 Pressure Retaining Welds No. 50.71
Manual Ultrasonic Examination of Austenetic Metal Welds for IGSCC. No.
TP86-130, P86-130, UTM-002. Rev.0
Quality Assurance Dept. No. 4.06
- -
. Procurement of items and services
Quality Assurance Dept. No. 4.01
Review of Preliminary Procurement Documents
Quality Assurance Manual, Section 2 and 15
Quality Control Instruction QCI 10.06 Rev. 4
Training and Certification of QAD Personnel for
Inspection and testing activities
General Electric (GE) Procedures:
Procedure No. QC-7 Rev. 3
Qualification and Certification of-ASME Se: tion XI
Visual Inspection: Personnel
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Attachment No. 3
List of Procedures & Manuals Reviewed
Boston Edison Company (BECO) Procedures:
_ Ultrasonic Examination-General Requirements No. 50.70
-Ultrasonic Examinationlof Class 1, 2 and 3 Pressure Retaining Welds No. 50.71
Manual Ultrasonic Examination of Austenetic Metal Welds for IGSCC. No.
TP86-130, P86-130, UTM-002. Rev.0
Quality Assurance Dept. No. 4.06
Procurement of items and services
. Quality Assurance Dept. No. 4.01
Review of Preliminary Procurement Documents
Quality Assurance Manual, Section 2 and 15
Quality Control Instruction QCI 10.06 Rev. 4
Training and. Certification of QAD Personnel for
-Inspection and testing activities
General Electric (GE) Procedures:
Procedure No. QC-7 Rev. 3
Qualification and Certification of ASME Section XI
Visual Inspection Personnel
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