IR 05000338/1989018: Difference between revisions

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{{Adams
{{Adams
| number = ML20244E561
| number = ML20247A252
| issue date = 06/06/1989
| issue date = 09/01/1989
| title = Insp Repts 50-338/89-18 & 50-339/89-18 on 890515-19. Violations Noted.Major Areas Inspected:Areas of Inservice Insp - Observation of Work & Work Activities
| title = Ack Receipt of 890710 Ltr Informing NRC of Steps Taken to Correct Violations Noted in Insp Repts 50-338/89-18 & 50-339/89-18.Implementation of Corrective Actions Will Be Examined During Future Insps
| author name = Blake J, Coley J, Glasman M
| author name = Julian C
| author affiliation = NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
| author affiliation = NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
| addressee name =  
| addressee name = Stewart W
| addressee affiliation =  
| addressee affiliation = VIRGINIA POWER (VIRGINIA ELECTRIC & POWER CO.)
| docket = 05000338, 05000339
| docket = 05000338, 05000339
| license number =  
| license number =  
| contact person =  
| contact person =  
| document report number = 50-338-89-18, 50-339-89-18, NUDOCS 8906200391
| document report number = NUDOCS 8909120075
| package number = ML20244E538
| document type = CORRESPONDENCE-LETTERS, NRC TO UTILITY, OUTGOING CORRESPONDENCE
| document type = INSPECTION REPORT, NRC-GENERATED, INSPECTION REPORT, UTILITY, TEXT-INSPECTION & AUDIT & I&E CIRCULARS
| page count = 1
| page count = 10
}}
}}


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September 1, 1989 Virginia Electric and Power Company ATTN: Mr. W. L. Stewart Senior Vice President - Power 5000 Dominion Boulevard Glen Allen, VA 23060 Gentlemen:
SUBJECT: NPC INSPECTION REPORT NOS. 50-338/89-18 AND 50-339/89-18 Thank you for your response of July 10, 1989, to our Notice of Violation issued on June 9,1989, concerning activities conducted at your North Anna facilit We have evaluated your response and found that it meets the requirements of l 10 CFR 2.201. We will examine the implementation of your corrective actions during future inspections.


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We appreciate your cooperation in this matte
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Sincerely, original signed by Caudie A. Julian Caudie A. Julian, Cnief Engineering Branch Division of Reactor Safety cc: W. R. Cartwright Vice President - Nuclear Operations J. P. O'Hanlon Vice President - Nuclear Services R. F. Saunders
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UNITED STATES
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o  : NUCLEAR REGULATORY COMMisslON  .
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  ,@[ ' E / E  REGION 11  f j  101 MARIETTA STREET, )
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Report Nos.: 50-338/89-18 and'50-339/89-18 s
Manager - Nuclear Licensing G. E. Kane, Station Manager l Commonwealth of Virginia bec: NRC Resident Inspector Document Control Desk J. Coley, DRS J. Blake, DRS P. Fredrickson, DRP IfDRS   , [RS RI r P7
  ' Licensee: Virginia. Electric and Power Compan .
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f    Glen Allen,.VA 23060:
cley:td   ake P edricks)on%k 9/01/89   9/01/89 09/01/89 8909120075 890901    !
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PDR ADOCK 05000338   I h
Docket Nos.: -50-338 and 50-339  License Nos.: NPF-4 and NPF-7 o
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  . Facility Name: North Anna 1 and 2 Inspection Conducted: .May 15-19, 1989 Inspectors: k . rix  d -d-8I J. LT W 1ey Q  Date Signed-k . 7 :. a // b  $~[*84 M. G ~7/ .
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    /4.1 J #Bgk5, Sect ief T"L Materia'Is & Pr sses Section Engineering anch Division of Reactor Safety SUMMARY Scope:
This routin~e, unannounced inspection was- in the areas of inservice inspection
  .(ISI) - Observation of Work and Work Activitie ' ' ' ~ ~~
Results:
Management was observed performing surveillance of vendor. activities and effectively resolving technical and human factors issues relating to radiography, ultrasonic examination, and fire watch attentiveness. A corporate level III examiner was also observed auditing vendor activities and resolving technical issues in a very effective manner. However, personnel problems were identified' by the inspectors and documented in this report pertaining to
,  failure of radiographer  to . reject radiographs of an unacceptable weld, radiographs with incorrect permanent identification and a fire watch asleep on
  . duty. Two violations were identified in the areas inspected. (para-graphs 2.a. and 2.e.)
 
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REPORT DETAILS Persons Contacted Licensee Employees
*G. H. Flowers, Supervisor, Site Engineering Programs
*L. N. Hartz, Manager, ISI/NDE Services
*G. E. Kane, Station Manager
  *J. H. Leberstien, Licensing Engineer
*P. J. Naughton, ISI Engineer
*H. L. Travis, NDE Supervisor S. Hamill, ISI Engineer N. Gage, L-IIA Radiographic Examiner Other licensee 1 employees contacted during this inspection included craftsmen, engineers, technicians, and administrative personne Other Organizations Westinghouse Inspection Services:
L. Markle, Site Coordinator D. Kurek, Level III Examiner NRC Resident Inspectors J. Caldwell, Senior Resident Inspector
*L. King, Resident Inspector
* Attended exit interview Inservice Inspection - Observation of Work and Work Activities, Unit 1 (73753)
L The inspectors observed ISI work activities, including steam generator
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plug repair activities, to determine whether this inservice work was being conducted in accordance with approved procedures, regulatory requirements and licensee commitment The applicable code of record for both Units 1 and 2 is the American l' Society of Mechanical Engineers Boiler and Pressure Vessel (ASME B&PV)
Code, Section XI,1974 Edition with addenda through Summer 1975.
 
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Subparagraphs delineated below describe the work activities examined by the inspectors, the inspection findings, requirements and observation Review of Radiographs for Augmented ISI of the Feedwater and Main Steam System Welds at Postulated Break Locations in the Service Building      1 I      - _ - _ - - _-
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Appendix 3C of the North Anna UFSAR for Unit 1 addresses the effects of piping system breaks outside containment. . To provide assurance that . safety-related equipment in the service building is protected against postulated pipe breaks, an augmented. inservice inspection program, coupled with a leak detection system, was included in the  '
  -UFSA The basis for the inspection program is to ensure line integrity because of the close proximity of the main steam and  u feedwater lines to safety-related equipment. -The licensee made a commitment to conduct the examinations. required in the augmented ISI E  program to the extent practical, within the limitations of design, geometry, and materials of construction of the components, to the requirements in the edition of Section XI of the ASME, B&PV Code and addenda required for the reactor coolant system (74S75). A baseline examination, providing 100% coverage, was performed prior to commercial operation to establish system integrity and baseline dat Thereafter,100% volumetric inspection of all welds was performed each period for the first 10-year interva Fct successive inspection intervals, the program required volumetric inspection of one-third of the welds at the expiration of each one-third of the inspection interval with a cumulative 100% coverage of all welds each interval. Unit 1 is presently in the last outage of the third period for the first interva Examinations performed in the baseline inspection and in previous periods were conducted using the ultrasonic method of volumetric examinatio However, the licensee has elected to perfonn the examinations required for the last inspection period of the first interval using the radiographic method of volumetric examinatio Eighteen welds had been examined by the licensee and reviewed for acceptance when the inspectors arrived at the North Anna Facilit The inspectors reviewed the film packages of the welds at break points listed below to determine if the radiographic technique and film evaluation was conducted in accordance with the licensee's approved procedure (NDE-RT-101 Rev. 0).
 
Drawing Number on Film Pipe Diameter and Break Point Location & Inspector Comments Wall Thickness BPL-271  6WFPD-11-601 6" x .562" (ID Incorrect on Film Shouldbe10-901)
BPL-569  6WFPD-19-601  6" x .562" BPL-873  6WFPD-11-601  6" x .719" (ID Incorrect on Film Should be 6WFPD-14-901)
BPL-251  6WFPD-11-601  6" x .562"
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Drawing Number on Film Pipe Dianeter and Break Point Location & Inspector Comments Wall Thickness (cont'd)
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BPL-281  6WFPD-10-601 6" x .719" (ID Incorrect on Film -  ;
Should be 6WFPD-10-901)  i
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BPL-582  6WFPD-19-601 6" x .719" BPL-581  6WFPD-19-601 6" x. 719" l
BPL-551  6WFPD-19-601 6" x .562" I BPL-875  6WFPD-14-601 6" x .719" (ID Incorrect on Film Should be 6WFPD-14-901)
BPL-870  6WFPD-15-601 6" x .562" BPL-571  6WFPD-19-601 6" x .562"-
BPL-874  6WFPD-14-901 6" x .719" BPL-282  6WFPD-10-601 6" x .719" (ID on Film Incorrect  '
Should be 6WFPD-10-901)
BPL-882  6WFPD-14-601 6" x .719" (ID on Film Incorrect Should be 6WFPD-14-901)
BPL-851  6WFPD-15-601 6" x .562" BPL-269  6WFPD-11-601 6" x .562" (ID on Film Incorrect Should be 6WFPD-10-901)
BPL-787  16WFPD-13-601 12 " x 1" BPL-788  16WFPD-13-601 16" x 1" In addition to the seven film packages with incorrect permanent ID, the inspectors also questioned the examination results at the following breakpoints:
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BPL-269 Film Station 0-4 was rejected by the licensee because of lack of penetration in the roo This was a significant defect in the critical area of the wel The licensee was questioned by the inspectors as to how this indication could have passed ultrasonic
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examination three times. The licensee subsequently
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re-examined this weld using the ultrasonic method and discovered that, although this was a significant radiographic indication, it did not produce a signal-that reached the ultrasonic recording leve BPL-851 The inspectors' review revealed an area of incomplete fusion between film stations 17 and 19. This area had
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not been rejected or noted by the Vendor's . Level III or the licensee's Level IIA during their review. The licensee performed parallax radiography to determine
    .the location and depth of the indication and notified the inspectors that the indication was near the outside surface and was now listed for repai BPL-882 The inspectors' review of this weld revealed a linear indication at the weld root between film stations 18 and 20. The licensec had not noted this crea on the evaluation repor Subsequent radiography revealed this condition to be a high-low area on the pipe wall inside diameter and was acceptabl Virginia Power Radiographic Procedure No. NDE-RT-101, paragraph 2.1.3, states, that "a system shall be used to produce permanent identifica-tion on the radiograph traceable to the contract, component, weld or weld seam or part numbers, as appropriate." In addition, Addendum A of procedure, NDE-RT-101, states that " incomplete fusion is unaccep-table." Therefore, the incorrect film identification noted above on radiographs for seven welds and the incomplete fusion observed by the inspectors between film stations 17 and 19 at breakpoint 851, and not ,
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previously identified by the licensee, arc examples of film interpreters failing to follow the examination procedure for etaluating radiographs for acceptanc This item was identified to the licensee as violation 50-338/89-18-01, Failure to Follow Procedure for the Evaluation of Radiograph year ISI of Unit 1 Reactor Vessel Welds  l The inspectors observed Westinghouse performing the 10-year reactor vessel ultrasonic examinations of welds located in the core region of the vessel. Data acquired during the ultrasonic examinations of welds VRA-1-1100-02 and VRA-1-1100-03 were also reviewed by the inspectors. The examinations were conducted in accordance with Westinghouse's Nondestructive Examination Procedure Number VPC-ISI-254, Rev. O. A remotely operated inspection tool with an array of transducers scanned the welds from inside the reactor. vessel utilizing the immersion method of examination. A Krautkramer Branson KB 6000,16 channel ultrasonic data acquisition system acquired the data and Dynacon's ultrasonic data recording and processing system (UDRPS) processed and recorded the data on laser disks for subsequent
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  ; analysis.- Data analyzed by the Westinghouse Level III Examiner and
  --the inspector consisted of the following scans:
Weld,N Transducer Angle   Scan Direction VRA-1-1100-02 45'  Axial UP
  .VRA-1-1100-02  45"  Axial DN-
 
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VRA-1-1100-02-  45  Clockwise  .
 
VRA-1-1100-02  45  Counter. Clockwise VRA-1-1100-02  60  Axial UP VRA-1-1100-02  60"  ' Axial DN VRA-1-1100-02  60  Clockwise-
  .VRA-1-1100-02-  60  Counter. Clockwise-VRA-1-1100-0 O  Clockwise:
C  VRA-1-1100-03  45  Axial UP VRA-1-1100-03  45  Axial D VRA-1-1100-03  45  Clockwise
  ~V RA-1-1100-03  45  Counter Clockwise VRA-1-1100-03  60  ' Axial UP g  " VRA-l-1100-03--  60  Axial D VRA-1-1100-03  60  Clockwise VRA-1-1100-03  60  Counter Clockwise VRA-1-1100-03  0  Clockwise The . inspectors reviewed the above examinations . to -detemine if approved procedures were being followed, specified nondestructive examination equipment was used, examination personnel were knowledgeable of examination method and test equipment, and examination results were properly analyze The UDRPS aystem processed, recorded, and displayed the ultrasonic data in a very effective manne The forged rings of the reactor vessel and the joining welds examined by the inspectors were extremely sound' material with only- a few low amplitude spot indications recorde Ultrasonic Examination of Pressurizer Surge Line Welds for Thermal Stress Cracking (NRC Bulletin No. 88-08)
The inspectors observed work activities, reviewed certification records of NDE equipment and materials, and reviewed NDE personnel qualifications for personnel that had been utilized during the required ISI examinations this outag The observations and reviews conducted by the inspectors are documented belo (1) The inspectors observed calibration activities and the in-process ultrasonic examinations being conducted on the welds indicated belo The observations were compared with the applicable procedures and the ASME B&PV Code in the following areas: availability of and compliance with approved NDE procedures; use of knowledgeable NDC personnel; use of NDE    l I
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personnel qualified to the proper level; type of apparatus usad; calibration requirements; search units; beam angles; DAC curves; reference level for monitoring discontinuities; method _ of demonstrating penetration; extent of weld / component examination coverage; limits of evaluating and recording indications; recording significant indications; and acceptance limit Drawing N Weld ID Component VRA-1-4501  11 Pressurizer Surge Line VRA-1-4501  7 Pressurizer Surge Line The inspectors conducted an independent ultrasonic verification examination, using Virginia Power equipment, on portions of weld 7. This examination was performed in order to evaluate the'
technical adequacy of the ultrasonic examination procedure being used by the licensee's contractor to perform ultrasonic examinations and to assess the validity of the information being reported by the ultrasonic examiner The verification ultrasonic examinations conducted by the inspectors indicated that the procedure being used to conduct the examinations was adequate and the verification examination results compared favorably with the information being reported by the ultrasonic examiner (2) The following listed ultrasonic equipment and materials certifi-cation records were reviews:
Ultrasonic Instruments Manufacturer /Model  Serial N Sonic /MK1  01496E Sonic /MK1  10159E The inspectors reviewed spectrum analysis data for the ultrasonic transducers listed below:
Serial N Size Frequency 4274 .5" 2.25 MHz M02103  .5" 2.25 MHz 17254  .375" 2.25 MHz Ultrasonic Calibration Block: VRA-02, SCH 160 The inspectors reviewed certification documentation of the following NDE personnel listed below:
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    ' Initials Method  Employer JO  EPRI, IGSCC, LII VCR UT, LII MT, LII n    PT, LII VT(1,2,3,4)LII RS  EPRI (GSCC, LII VCR UT, LII MT, LII PT, LII VT(1,2,3,4) LII d. Observation of Steam Generator Plug-in-Plug Repair Activities The. inspectors observed Westinghouse (W) personnel perform Plug-in -
Plug- (PIP) repairs of steam generator (S/G) tube plugs known, or suspected to be susceptible to intergranular stress corrosion cracking (IGSCC). The plugs involved are W mechanical tube plugs fabricated from Alloy 600. A hot leg mechanical tube plug of the same type catastrophically failed in February 1989 when the plug tip became separated from the body of the plug and, with primary pressure as the driving force, the plug tip was accelerated up the iength of the S/G tube. The result was a ruptured S/G tube, and significant primary-to-secondary leakage. The purpose of the PIP is'to limit the amount of primary-to-secondary leakage in case a mechanical type plug fails, and to limit primary pressure behind a plug tip should it become separated. The PIP used to effect repairs, at the time of the inspection, resembled a socket head cap screw with threads that mate with the threads in the internal expander of the installed plug. The PIP is then threaded into the S/G plug, ' torqued a predetermined amount, and tack welded where the shoulder of the PIP contacts the bottom of the S/G plug. The PIPS were machined from Alloy 600 bar stock, and then thermally treated to attain a microstruc-ture resistant to IGSCC. If at all possible, all installation operations were done with a remote-controlled robot arm in the S/G bowl with video observation by the equipment operators. Listed below is a summary of the Unit 1 PIP work:
Number of Steam Generator Plug-in-Plugs Installed, Unit 1 Steam Generator A Steam Generator B Steam Generator C 114  97 188 The inspectors witnessed various work associated with the PIP installation work, including location of S/G plugs requiring PIP repair, calibration of the robot-arm, and tack welding of installed PIP The welding process employed the tungsten inert gas process
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using W " Weld Qualification Record" #178. The PIP repair work was covered by W procedure STD-FP-1989-4450 ' revision 0, "SM-10W Installation for the Plug in Plug for 7/8 mech plugs)." In addition, the inspectors observed the work activities to determine if applicable drawings of the S/G tubesheet were available, if independent verification of tubesheet locations was performed, if required remote video equipment was adequate, and if standards of tack weld quality were established and adhered to. The inspectors observed the tack welding of the following' PIPS:
Unit 1, Steam Generator C, Hot Leg Tube Location Row Column 7  84 6  84 7  79 2  76 Firewatch Asleep While on Duty During ongoing inspection activity in the Unit I containment, the inspectors encountered a contractor employee sleeping while on firewatch duty. The firewatch was required due to welding activity taking place on work order DCP 88-11, which was taking place in the
  #inity of column 11, at the 262' elevation, and under Radiation Work iW mit 1885. The inspectors informed the employee's supervisors, and he was then awakened. North Anna's fire protection procedure, " Fire Protection Program," Section 3.5.7 requires posting a firewatch during welding activity, and 30 minutes after completion of the jo The inspectors also held discussions with North Anna's Site Services Superintendent related to this item, who indicated that the employee was terminated from the sit This matter was identified as Violation 338/89-18-02, "Firewatch Asleep on Duty."
 
Within the areas examined, violations or deviations were not identified except as noted in paragraphs 2.a. and 2.e. abov . Exit Interview The inspection scope and results were summarized on May 19,1989, with those persons indicated in paragraph 1. The inspectors described the areas inspected and discussed in detail the inspection results listed belo Proprietary information is not contained in this repor Dissenting comments were not received from the license (0 pen) Severity Level IV Violation 50-338/89-18-01, Failure to Follow Procedure for the Evaluation of Radiographs at Break Point 851 on the Feedwater System, paragraph 2.a.
 
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       (0 pen) Severity Level IV Violation 50-338/89-18 02, Fire Watch Asleep on Duty. paragraph k
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Revision as of 00:41, 12 February 2021

Ack Receipt of 890710 Ltr Informing NRC of Steps Taken to Correct Violations Noted in Insp Repts 50-338/89-18 & 50-339/89-18.Implementation of Corrective Actions Will Be Examined During Future Insps
ML20247A252
Person / Time
Site: North Anna  Dominion icon.png
Issue date: 09/01/1989
From: Julian C
NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
To: Stewart W
VIRGINIA POWER (VIRGINIA ELECTRIC & POWER CO.)
References
NUDOCS 8909120075
Download: ML20247A252 (1)
v • d • e


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September 1, 1989 Virginia Electric and Power Company ATTN: Mr. W. L. Stewart Senior Vice President - Power 5000 Dominion Boulevard Glen Allen, VA 23060 Gentlemen:

SUBJECT: NPC INSPECTION REPORT NOS. 50-338/89-18 AND 50-339/89-18 Thank you for your response of July 10, 1989, to our Notice of Violation issued on June 9,1989, concerning activities conducted at your North Anna facilit We have evaluated your response and found that it meets the requirements of l 10 CFR 2.201. We will examine the implementation of your corrective actions during future inspections.

We appreciate your cooperation in this matte

Sincerely, original signed by Caudie A. Julian Caudie A. Julian, Cnief Engineering Branch Division of Reactor Safety cc: W. R. Cartwright Vice President - Nuclear Operations J. P. O'Hanlon Vice President - Nuclear Services R. F. Saunders

,

Manager - Nuclear Licensing G. E. Kane, Station Manager l Commonwealth of Virginia bec: NRC Resident Inspector Document Control Desk J. Coley, DRS J. Blake, DRS P. Fredrickson, DRP IfDRS , [RS RI r P7

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cley:td ake P edricks)on%k 9/01/89 9/01/89 09/01/89 8909120075 890901  !

PDR ADOCK 05000338 I h

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