ML20215L132

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Independent Measurements Insp Rept 50-293/87-15 on 870302- 13.Violations Noted:Inadequate Magnetic Particle Exam & Procedure for Visual Insp Personnel Qualification
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.

DPR-35

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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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

PDR

ADOCK 05000293

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PDR

,

.

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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_ - _ _ - _ _ _ _______ - ____ ___-_____ ___

_ _ _

_ _ _ _ _ _ _ _ _

_

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3

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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

ASME Section XI.

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.

____

_ _ _ _ _ _ _ _ _ _

.

4

.

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.

.

_

_

_

.

5

.

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

i

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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

Procedure

  • General' Electric No. 87-59 Ultrasonic 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

.

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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