IR 05000382/1986031: Difference between revisions

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{{Adams
{{Adams
| number = ML20210A382
| number = ML20212L127
| issue date = 04/29/1987
| issue date = 03/04/1987
| title = Ack Receipt of Informing NRC of Steps Taken to Correct Violations Noted in Insp Rept 50-382/86-31
| title = Insp Rept 50-382/86-31 on 861201-11.Violation Noted:Failure to Follow Instructions Re Station Mod SM-107 Concerning Backup Spent Fuel Pool Cooling Sys & to Control Nonconforming Components
| author name = Gagliardo J
| author name = Harris R, Kerch H, Strosnider J
| author affiliation = NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
| author affiliation = NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I)
| addressee name = Dewease J
| addressee name =  
| addressee affiliation = LOUISIANA POWER & LIGHT CO.
| addressee affiliation =  
| docket = 05000382
| docket = 05000382
| license number =  
| license number =  
| contact person =  
| contact person =  
| document report number = NUDOCS 8705050076
| document report number = 50-382-86-31, NUDOCS 8703100227
| title reference date = 04-03-1987
| package number = ML20212L120
| 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 = 2
| page count = 15
}}
}}


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=Text=
=Text=
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APR 2 91987 In Reply Refer To:
APPENDIX B U.S. NUCLEAR REGULATORY COMMISSION
Docket: 50-382/86-31
 
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==REGION I==
Louisiana Power & Light Company ATTN: J. G. Dewease, Senior Vice President Nuclear Operations N-80-317 Baronne Street New Orleans, Louisiana 70160
NRC Inspection Report:      50-382/86-31 License: NPF-38 Docket: 50-382 Licensee: Louisiana Power & Light Company (LP&L)
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N-80 317 Baronne Street New Orleans, Louisiana    70160 Facility Name: Waterford 3 Inspection At: Taft, Louisiana Inspection Conducted: December 1-11, 1986 Inspectors:        ~7_ 2 6 [
Gentlemen:     .
H. W. Kerch, Lead Reactor Engineer    Date'
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    . HarrTs,'NDE Technician
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I A/2d/f7 Date
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Approved:   _ 2-  Md'  2d5/67 R. Strosnider, Chief, M & P.S., EB, DRS    Date Inspection Summary Inspection Conducted December 1-11, 1986 (Report 50-382/86-31)
Areas Inspected: A special, announced independent verification inspection of plant modifications and inservice inspection was performed using the NRC Nondestructive Examination Mobile Van. Two Regional based inspection personnel assisted by two contractor NDE personnel were utilized during this inspectio The purpose of this inspection was to evaluate the plant modification program and ascertain the condition of plant materials through various NDE technique Results: Within the two areas inspected, two violations were identified (failure to follow instructions and failure to control nonconforming components, paragraph 3).
 
8703100227 870304 PDR ADOCK 05000382 G    PDR    _
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  ,  2 DETAILS Persons Contacted Louisiana Power & Light-(LP&L)
* Schultz, Station-Supervisor
* Forgala, Shift Supervisor
*A. S. Lockhart, Nuclear Support Manager
*K. W. Cook, Licensing
*J. D. Dewease, Senior Vice President -_ Nuclear
*R. C. Barkhurst, Vice President - Nuclear
*N. S. Carns, Plant Manager - Nuclear
*R. F. Burski, Engineering Manager
*G. W. Robin, Inservice Inspection
*T. F. Gerrets, Nuclear QA Manager
*J. G. Dickinson, NDE Level III J. R. McGaha, Assistant Plant Manager G. E. Wisler, Licensing L. L. Bass, Nuclear Operations Engineer T. H. Smith, Maintenance Superintendent U.S. Nuclear Regulatory Commission
*L. D. Gilbert, Reactor Inspector, RIV
*B. A. Breslau, Reactor Engineer, RIV
*T. R. Staker, Resident Inspector, RIV
*J. I. Tapia, Reactor Inspector, RIV
* Denotes those present at exit meetin . Purpose of Inspection-The purpose of this inspection was to evaluate the licensee's modification program and its implementation as demonstrated by the installation of a supplemental fuel pool heat exchanger performed during the plant outag The inspection included review of procedures, review of modification records, review of the ISI program, and review of quality assurance activitie The inspection activities included various independent nondestructive examinations (NDE), observations of work in progress, and
- review of record . NRC Conducted Nondestructive Examinations During the period of December 1-11, 1986, an onsite inspection was conducted at Waterford Power Plant Unit 3. The inspection included independent nondestructive examinations of safety related piping and supports to verify their acceptability and the effectiveness of the licensee NDE and QA/QC program _ . .  - ..
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A random sample of f safety related pipe weldsents and associated ' supports was selected from the plant modification package (SMP-107)Lfor installation'of a supplemental fuel pool cooling heat exchanger. I addition to the above,;other safety related' piping included in the. plant Inservice Inspection Program was selected for independent' inspection by the NR All items selected were previously inspected and accepted by the licensee, based on information_ supplied (QA/QC records) by the license Nondestructive. examinations were performed'using NRC procedure , , Isometrics and drawings supplied by-the licensee were used in conjunction
  -
with the procedure The following examinations were performed by two NRC-inspectors and two
,  contracted NDE personnel.+
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It was intended that, to'the extent practicable,.these inspections would be conducted in a similar manner, i.e., using the same. techniques and code specified procedures and acceptance criteria, as the original examination '
Liquid Penetrant Thirty-six safety-related pipe weldments and adjacent base material 4  (1/2 inch on either side of:the weld) were examined by.the visible dye method per NRC procedure NDE-9, Revision 0, and' Westinghouse procedure WTR-ISI-11, Revision 0. Samples' included in this selection were
,  ASME Code Class 1, 2, and 3 carbon and stainless steel weldment Results:  No violations were identifie Thickness Measurements:
Seventeen safety-related pipe weldments and adjacent base material (1/2. inch on either side of the weld) were examined using a NOVA-D 100 digital thickness gauge per NRC procedure NDE-11, Revision 0. The
  ' required minimum wall thickness was determined by use of an ASTM standard pipe size and nominal thickness chart.
 
,
Results:  No violations were identified.
 
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Ferrite Measurements:
. Ten' safety-related pipe weldments were examined for delta ferrite content using a type II ferrite indicator (Severn Gauge). This test is intended to ' verify that the welding filler metal composition had achieved an as-deposited delta ferrite content sufficiently high to eliminate hot
<  crackin Results: No violations were identified.
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Thank you for your letter of' April 3,1987, in response to our letter and l Notice of Violation dated March 4,1987. We have reviewed your reply and find it responsive to the concerns raised in our Notice of Violation. We will review the implementation of your corrective actions during a future inspection to
Hardness Test:
Seven safety related pipe weldments and adjacent base material were tested using the'Equo-Tip, hardness tester per NRC procedure NDE-12, Revision ~
Measurements taken;from the impact. device are processed into "L" values as a digital readout; the "L" valuesf are then converted to Brinell hardness
; values and approximate tensile strengths by means of a conversion tabl 'Results: .No violations were identifie' . Ultrasonic Examination: ,
Ten safety-related pipe weldments were ultrasonically examined using a Sonic Mark'1 ultrasonic flaw detector per NRC-procedure NDE-1, Revision 0, Westinghouse procedure WTR-ISI-206, Revision 0, and associated ultrasonic data reports. LInstrument calibration (linearity-verification) was performed using NRC procedure NDE-2, Revision 0, and the distance amplitude correction (DAC) function was constructed using the licensee's calibration blocks,.UT-115, UT-105, UT-119 and UT-141 for this examination. Instrument settings and search unit (transducer) were matched as nearly as possible to those indicated by the licensee's ultrasonic data reports in order to attempt to duplicate the original ultrasonic examination Results: Welds 61-073 and 61-080 on drawing WTR-2-4107, welds 56-040 and 56-042 on drawing WTR-2-4211 and weld 52-019-900 on drawing WTR-2-4205 could not be examined ultrasonically with complete coverage due to physical restrictions. These restrictions were noted in the' licensee's ultrasonic data reports and verified during the NRC inspectio No violations were identifie Visual Examination:
l Forty-six safety-related pipe weldments and adjacent base material were examined for cracks, gouges, linear indications, reinforcement and surface condition that could interfere with the performance of inservice inspection. Visual examinations were performed using NRC procedure NDE-10, Revision 0, in conjunction with site documents. Samples in this examination include ASME Code Class 1, 2, and 3 carbon and stainless steel pipin A sample of 14 supports that were part of the supplemental Fuel Pool Heat Exchanger modification were selected for detailed review (see attachment 2). The supports had been installed and quality control (QC)
accepted. The supports selected were ASME III Class 3, Seismic
'
'
determine that full compliance has been achieved and will be maintaine
Category I. The Supports were examined for member size; configuration and dimensions; installation of pins and locknuts; weld appearance and clearances.
 
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    .In general, the modifications met the requirements for design drawing ~"
    .However, discrepancies were identifiedLon the following hardware:
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  .q  1S upport number FSRR-4001: - Drawing required lock nut missing      ,
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    . Support number FSRR-4004:  Locknuts not engaged-per specification.and
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    ~ Cotter, Keys'not installed properl *
."  -' Support number FSRR-4010:  _ Required weep hole not drille :
    *~
Support number.CCRR-4521: . Locknuts not engaged per specification and
..,. Cotter keys.not installe These-items are considered a violation of 10 CFR,. Appendix'B, Criterion'V'
    -(382/8631-01).-
"  Also, the following discrepancies in documentation were identified:
    *
    . Welds FSRR-4002-FW1 and FSRR-4002-FW2 were rejected by QC, however,
  .  -the' weld records indicated that the completed welds were acceptable without having been reinspected by-QC for the rejectable attribut *
Welds FS-SM-107-M3-FW6'and FS-SM-107-M4-SW8 were rejected due to'
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excessive _ fit up gap (greater than 5/32 of an inch). Proper disposition was not documented for these nonconforming conditions in
  ,    accordance.with. site administrative' procedure QP-015-001, Revision 3, Nonconformances and Corrective Action Results:
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These items'are considered a violation.of 10 CFR, Appendix B, Criterion XV (382/8631-02).


Sincerely,
' Review of Procedures  >
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The procedures listed in Attachment Number 3 were reviewed to verify their technical adequacy and conformance to regulation and code requirement ,
S r.cd M GAG @
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J. E. Gagliardo, Chief j     Reactor Projects Branch cc:
Results:
Louisiana Power & Light Company ATTN: G. E. Wuller, Onsite Licensing Coordinator P. O. Box B Killona, Louisiana 70066 f
Review of Procedure QA.2.4, Revision 0, Qualification and Certification of
Louisiana Power & Light Company ATTN: N. S. Carns, Plant Manager P. O. Box B Killona, Louisiana 70066
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Middle South Services ATTN: Mr. R. T. Lally
Visual Examination Personnel for Preservice and Inservice Inspections,
; P. O. Box 61000
    -indicated the procedure does.not meet the industry standard nor are there
,
    . precedents within the referenced ASNT and ANSI documents for the liberties taken. The following are examples:
New Orleans, Louisiana 70161 '
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The procedure allows reduction of experience by 33-1/3 percent in
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accordance with ANSI 45.2.6 (1978). However, the procedure permits further reduction of the required experience by an additional
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m L50 percent :if the individual 'is certified to Level II for'at 'least three NDE method There is no apparent basis why an-individual who is certified Level II in PT, MT, and UT should have the require experience' level for VT3 and VT4 reduced by 50 percen *
iFurthermore, the p'rocedure eliminates the requirement for an
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individual to take a practical-exam if he has a specified amount of
  ' training. . There is no basis presented for this relaxation in
  , requirement This-issue is considered unresolved pending the licensee's evaluation and justification and subsequent NRC review (382/8631-03).
 
5. -Review of Modification SM-107 Inspection was concentrated on the installation of a Backup Spent Fuel Fool Cooling heat exchange Cooling water lines and related accessories on the 35-foot elevation in the Fuel Handling Building were inspecte The heat exchanger and its interconnecting piping are safety-related equipment and were designed to ASME Section III, Class-3 requirement The backup spent fuel pool cooling system is a Seismic Category I installatio .
The following documents were reviewed in order to-determine if the licensee's program for control of design changes and modifications-had been adequately implemente Ebasco's independent design verification for modification SM-10 *
Ebasco's Quality Assurance review of the independent design verification for modification SM-10 *
Ebasco's procedure control for design changes and modifications E6 The NRC inspectors examined the as-built configuration of the system and compared this configuration to the piping and hanger isometric drawings and specifications. Several discrepancies were noted as discussed in
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Section 3. The type of discrepancies found indicate that site installation procedures were not properly implemented to ensure that quality requirements were me . Review of the Inservice Inspection (ISI) Program The Waterford 3 ISI program was prepared and is implemented by the licensee. The plan meets the requirements of ASME Section XI 1980 edition including addenda through Winter 1981. This outage was the first in the first 10 year interval of the ISI progra ,. . _ - - _ - . - - .  .- -
 
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Organization and Staffing of ISI Program The Waterford 3 Plant Manager - Nuclear has the prime responsibility for coordinating and conducting the ISI Program. The inspector concluded that Waterford 3 has adequate staff comprised of site personnel, augmented by contract personnel, to properly execute the ISI progra Quality Assurance Audits of ISI The inspector reviewed the documents. listed below to. ascertain that ISI vendors are audited by the QA department prior to their being considered as a-qualified supplier of ISI service LP&L Audit report on Westinghouse for ISI Contract (dated January 8-10, 1985).
 
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LP&L Audit report on Westinghouse for ISI Contract (dated August 29, 1986).


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The audit reports indicated that various aspects of the ISI Program were examined, audit findings were properly closed out, and that the licensee's ISI vendor was properly qualified as a supplier of ISI service ISI Personnel Record Review The inspector reviewed 24 nondestructive examination ~(NDE) personnel qualification and certification records.- One individual was identified for which additional information was required to justify marginal experience at the' time of his certification. The individual had received adequate experience since his certificatio The inspector had no further concerns on this ite Inservice Inspection (ISI) Data Review During this inspection the inspector reviewed all the ISI data that had been taken as of December 9, 1986. The total count was:
24 ultrasonic examinations
:  117 visual examinations l
19 liquid penetrant examinations
*
i  2 magnetic particle examinations The inspector verified that the examinations were done in compliance with governing procedures and that applicable ASME code and Regulatory requirements were met. The review also was undertaken 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 report __  _ _ , _ - . - - - .


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l Louisiana Power & Light Company 2
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.      l 8  l Overall, the. inspector found that the Inservice Inspection Pro' gram at
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Waterford 3 including its documentation,is being performed adequately and that the_ objectives of the ISI program are being met. No violations were identifie . Attachments:
Attachment No.'1 is a tabulation of piping weldments inspected and the results. Attachment Nc. 2 is a tabulation of_ specific pipe supports inspected during this inspection and the inspection results. Attachment
  .No.' 3 is a list of procedures reviewed during this inspectio . Unresolved Items Unresolved' items are those for which more information is necessary for the
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NRC to determine whether the item or items are acceptable, a violation or a deviation. An unresolved item is contained in Section . Exit On December 11,-1986, the NDE Van personnel attended an exit meeting with the. licensee: staf . The findings of this' inspection were described' at
  'this meetin No written material was~provided;to-the licensee during this inspectio .
 
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valv WTR-2-4211          Limited exam.
  : P. O. Box 60340 New Orleans, Louisiana 70160 s
 
Louisiana Radiation Control Program Director
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ORLEANS, LOUISlANASTREET P. O. BOX 60340 70160 +
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April 3, 1987 W3P87-1002 A4.05 QA U.S. Nuclear Regulatory Commission   }@ j g g'AI 2,
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ATTN: Document Control Desk   '


Washington, D.C. 20555
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Subject: Waterford 3 SES
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License No. NPF-38 NRC Inspection Report 86-31 Attached is the Louisiana Power and Light Company (LP&L) response to Violation Nos. 8631-01 and 8631-02 identified in Inspection Report N .
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If you have any questions on the response, please contact G.E. Wuller, operational Licensing, at (504) 464-349 Very truly yours, lA1 ywm
SD      n do  i eS  P w
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K.W. Cook Nuclear Safety and Regulatory Affairs Manager KWC:KLB:ssf cc: R.D. Martin, NRC Region IV '
s fo  sC S  lP T s  a  to N i hr  on E
I G.W. Knighton, NRC-NRR J.H. Wilson, NRC-NRR NRC Resident Inspectors Office E.L. Blake W.M. Stevenson W/
  "AN EQUAL OPPORTUNITY EMPLOYER"


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Attachment to W3P87-1002 Sheet 1 of 2 LP&L Response To Violation Nos. 8631-01 and 8631-02 VIOLATION NO. 8631-01 10 CFR 50, Appendix B, Criterion V; and Ebasco Specification - General Power Piping Requirements, LOU 1564-100, require that quality affecting activities be prescribed by documented instructions, procedures, or drawings of a type appropriate to the circumstance and that they be accomplished in accordance with these instructions, procedures, or drawing Contrary to the above, Station Modification SM-107, Backup Spent Fuel Pool Cooling System was not accomplished in accordance with instructions, procedures, and drawings. Listed below are examples of discrepancies between Ebasco Specification LOU-1564-100 and as-built conditions:
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o Pipe Supports FSRR-4004 and CCRR-4521: Lock nuts not engaged per specifications and Cotter keys not installed properl o Pipe Support FSRR-4001: Drawing required lock nut missin o Pipe Support FSRR-4010: Drawing required weep hole not drille This is a Severity Level IV violatio RESPONSE (1) Reason for the Violation The support sketches included in the Station Modification Package (SMP) may have lacked adequate details to assure that supports were installed in accordance with design requirement l (2) Corrective Action That Has Been Taken Supports ins.alled under Station Modification 107 including the four identified in the inspection report were reinspected and the deficiencies noted in the reinspection were corrected (refer to CIWA-030338 & CIWA-032292). The design group has been directed to provide more detail and clearer directions in future design drawings for those design packages that relate to installation of support I (3) Corrective Action To Be Taken No further action is deemed necessar (4) Date When Full Compliance Will Be Achieved The directive was approved on March 27, 198 ]?'
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cr. . '-    Attachssnt to W3P87-1002
. Sheet 2 of 2 VIOLATION NO. 8631-02 10 CFR 50, Appendix B, Criterion XV and site procedure QP-015-001 Nonconformances and Corrective Actions, require that measures be established to control materials, parts, or components which do not conform-to requirements in order to prevent their inadvertent use or installatio Contrary to the above, the following-two examples of failure to control the use of nonconforming components were identifie o Documentation on two butt welds, FS-SM-107-M3-FW6 and FS-SM-107-M4-SW8 indicates the welds were rejected by QC'due to fit up problem Specifically, the gap opening was. greater than 5/32 of an inc Proper disposition was not documented for these nonconforming
_
_
conditions in that a required nonconformance report was not prepare o Welds FSRR-4002-FW-2 and FSRR-4002-FW-1 were rejected by QC, however, the weld records indicated that the completed welds were acceptable without having been reinspected by QC for the rejectable attribut This is a Severity Level IV violatio RESPONSE (1) Reason for the Violation The documentation to accept the welds identified was in the packages, however, the QC acceptance after the QC rejection was difficult to deciphe (2) Corrective Action That Has Been Taken The weld packages were reviewed by a welding engineer and QC inspectors and dispositioned acceptable as foun (3) Corrective Action To Be Taken LP&L procedure MM-1-054 is being revised to incorporate Weld Specification Documentation Sheets that will allow for better dispositioning of items in questio (4) Date When Full Compliance Will Be Achieved t
    '
. The procedure is expected to be approved by April 15, 1987.
.:.- . i
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Attachment No. 3: List of Procedures Reviewed
    '
    .
Title (We'stinghouse Procedures)
Preservice and Inservice Examination  Documentation WTR-0PS-101, Revision 0 Qualification of Ultrasonic Manual  WTR-ISI-10, Revision 0
" Equipment
. Manual Ultrasonic Examination of Welds  WTR-ISI-206, Revision 0 Manual Ultrasonic Examination of Welds  WTR-ISI-47, Revision 0 in Vessels Manual Ultrasonic Examination of Vessel  WTR-ISI-247, Revision'0 Nozzle Inside Radius (Training) Qualification and  WTR-QA-2.2, Revision 1 Certification of NDE Personnel Visual Examination  WTR-ISI-8, Revision 0 Magnetic Particle Examination  WTR-ISI-70, Revision 0 Liquid Penetrant Examination  WTR-ISI-11, Revision 0 Qualification and Certification of Combustion Engineering Procedures Visual Examination Personnel for PSI  QA.2.4, Revision 0 Certification of NDE Personnel  NQA 1 (Louisiana Power and Light Company Procedures)
Section IV Repairs and Replacement  PE-1-001 Modification    MP-107, Revision 0, 1, 2 Control of Inservice Inspection  PE-1-003 l Modification    SM-107, Revision 0, 1, 2 l
Penetrant Examination  PT QI-009-011, Revision 3 Administration Control of ISI  PE-003, Revision 2-(Louisiana Power and Light Company Procedures)
Administration Plant Engineering  PE-2-006, Revision 8 Station Modification
'
(EBASCO Procedures)
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PC-I General Power Piping    hCR-MP-2050
        '
  (GE0 Proce'dures)
  - Penetrant Examination    PT-23, A. 58, Revision 23
  .
m_ _ _ _ _ . - _ _ _ _ _ - - - - - _ - - - - - -_ - - - -
}}
}}

Latest revision as of 20:59, 18 December 2021

Insp Rept 50-382/86-31 on 861201-11.Violation Noted:Failure to Follow Instructions Re Station Mod SM-107 Concerning Backup Spent Fuel Pool Cooling Sys & to Control Nonconforming Components
ML20212L127
Person / Time
Site: Waterford Entergy icon.png
Issue date: 03/04/1987
From: Harris R, Kerch H, Strosnider J
NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I)
To:
Shared Package
ML20212L120 List:
References
50-382-86-31, NUDOCS 8703100227
Download: ML20212L127 (15)
v • d • e


Text

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APPENDIX B U.S. NUCLEAR REGULATORY COMMISSION

REGION I

NRC Inspection Report: 50-382/86-31 License: NPF-38 Docket: 50-382 Licensee: Louisiana Power & Light Company (LP&L)

N-80 317 Baronne Street New Orleans, Louisiana 70160 Facility Name: Waterford 3 Inspection At: Taft, Louisiana Inspection Conducted: December 1-11, 1986 Inspectors: ~7_ 2 6 [

H. W. Kerch, Lead Reactor Engineer Date'

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. HarrTs,'NDE Technician

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I A/2d/f7 Date

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Approved: _ 2- Md' 2d5/67 R. Strosnider, Chief, M & P.S., EB, DRS Date Inspection Summary Inspection Conducted December 1-11, 1986 (Report 50-382/86-31)

Areas Inspected: A special, announced independent verification inspection of plant modifications and inservice inspection was performed using the NRC Nondestructive Examination Mobile Van. Two Regional based inspection personnel assisted by two contractor NDE personnel were utilized during this inspectio The purpose of this inspection was to evaluate the plant modification program and ascertain the condition of plant materials through various NDE technique Results: Within the two areas inspected, two violations were identified (failure to follow instructions and failure to control nonconforming components, paragraph 3).

8703100227 870304 PDR ADOCK 05000382 G PDR _

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, 2 DETAILS Persons Contacted Louisiana Power & Light-(LP&L)

  • Schultz, Station-Supervisor
  • Forgala, Shift Supervisor
  • A. S. Lockhart, Nuclear Support Manager
  • K. W. Cook, Licensing
  • J. D. Dewease, Senior Vice President -_ Nuclear
  • R. C. Barkhurst, Vice President - Nuclear
  • N. S. Carns, Plant Manager - Nuclear
  • R. F. Burski, Engineering Manager
  • G. W. Robin, Inservice Inspection
  • T. F. Gerrets, Nuclear QA Manager
  • J. G. Dickinson, NDE Level III J. R. McGaha, Assistant Plant Manager G. E. Wisler, Licensing L. L. Bass, Nuclear Operations Engineer T. H. Smith, Maintenance Superintendent U.S. Nuclear Regulatory Commission
  • L. D. Gilbert, Reactor Inspector, RIV
  • B. A. Breslau, Reactor Engineer, RIV
  • T. R. Staker, Resident Inspector, RIV
  • J. I. Tapia, Reactor Inspector, RIV
  • Denotes those present at exit meetin . Purpose of Inspection-The purpose of this inspection was to evaluate the licensee's modification program and its implementation as demonstrated by the installation of a supplemental fuel pool heat exchanger performed during the plant outag The inspection included review of procedures, review of modification records, review of the ISI program, and review of quality assurance activitie The inspection activities included various independent nondestructive examinations (NDE), observations of work in progress, and

- review of record . NRC Conducted Nondestructive Examinations During the period of December 1-11, 1986, an onsite inspection was conducted at Waterford Power Plant Unit 3. The inspection included independent nondestructive examinations of safety related piping and supports to verify their acceptability and the effectiveness of the licensee NDE and QA/QC program _ . . - ..

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A random sample of f safety related pipe weldsents and associated ' supports was selected from the plant modification package (SMP-107)Lfor installation'of a supplemental fuel pool cooling heat exchanger. I addition to the above,;other safety related' piping included in the. plant Inservice Inspection Program was selected for independent' inspection by the NR All items selected were previously inspected and accepted by the licensee, based on information_ supplied (QA/QC records) by the license Nondestructive. examinations were performed'using NRC procedure , , Isometrics and drawings supplied by-the licensee were used in conjunction

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with the procedure The following examinations were performed by two NRC-inspectors and two

, contracted NDE personnel.+

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It was intended that, to'the extent practicable,.these inspections would be conducted in a similar manner, i.e., using the same. techniques and code specified procedures and acceptance criteria, as the original examination '

Liquid Penetrant Thirty-six safety-related pipe weldments and adjacent base material 4 (1/2 inch on either side of:the weld) were examined by.the visible dye method per NRC procedure NDE-9, Revision 0, and' Westinghouse procedure WTR-ISI-11, Revision 0. Samples' included in this selection were

, ASME Code Class 1, 2, and 3 carbon and stainless steel weldment Results: No violations were identifie Thickness Measurements:

Seventeen safety-related pipe weldments and adjacent base material (1/2. inch on either side of the weld) were examined using a NOVA-D 100 digital thickness gauge per NRC procedure NDE-11, Revision 0. The

' required minimum wall thickness was determined by use of an ASTM standard pipe size and nominal thickness chart.

,

Results: No violations were identified.

.

Ferrite Measurements:

. Ten' safety-related pipe weldments were examined for delta ferrite content using a type II ferrite indicator (Severn Gauge). This test is intended to ' verify that the welding filler metal composition had achieved an as-deposited delta ferrite content sufficiently high to eliminate hot

< crackin Results: No violations were identified.

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Hardness Test:

Seven safety related pipe weldments and adjacent base material were tested using the'Equo-Tip, hardness tester per NRC procedure NDE-12, Revision ~

Measurements taken;from the impact. device are processed into "L" values as a digital readout; the "L" valuesf are then converted to Brinell hardness

values and approximate tensile strengths by means of a conversion tabl 'Results
.No violations were identifie' . Ultrasonic Examination: ,

Ten safety-related pipe weldments were ultrasonically examined using a Sonic Mark'1 ultrasonic flaw detector per NRC-procedure NDE-1, Revision 0, Westinghouse procedure WTR-ISI-206, Revision 0, and associated ultrasonic data reports. LInstrument calibration (linearity-verification) was performed using NRC procedure NDE-2, Revision 0, and the distance amplitude correction (DAC) function was constructed using the licensee's calibration blocks,.UT-115, UT-105, UT-119 and UT-141 for this examination. Instrument settings and search unit (transducer) were matched as nearly as possible to those indicated by the licensee's ultrasonic data reports in order to attempt to duplicate the original ultrasonic examination Results: Welds61-073 and 61-080 on drawing WTR-2-4107, welds56-040 and 56-042 on drawing WTR-2-4211 and weld 52-019-900 on drawing WTR-2-4205 could not be examined ultrasonically with complete coverage due to physical restrictions. These restrictions were noted in the' licensee's ultrasonic data reports and verified during the NRC inspectio No violations were identifie Visual Examination:

l Forty-six safety-related pipe weldments and adjacent base material were examined for cracks, gouges, linear indications, reinforcement and surface condition that could interfere with the performance of inservice inspection. Visual examinations were performed using NRC procedure NDE-10, Revision 0, in conjunction with site documents. Samples in this examination include ASME Code Class 1, 2, and 3 carbon and stainless steel pipin A sample of 14 supports that were part of the supplemental Fuel Pool Heat Exchanger modification were selected for detailed review (see attachment 2). The supports had been installed and quality control (QC)

accepted. The supports selected were ASME III Class 3, Seismic

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Category I. The Supports were examined for member size; configuration and dimensions; installation of pins and locknuts; weld appearance and clearances.

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.In general, the modifications met the requirements for design drawing ~"

.However, discrepancies were identifiedLon the following hardware:

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.q 1S upport number FSRR-4001: - Drawing required lock nut missing ,

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. Support number FSRR-4004: Locknuts not engaged-per specification.and

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~ Cotter, Keys'not installed properl *

." -' Support number FSRR-4010: _ Required weep hole not drille :

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Support number.CCRR-4521: . Locknuts not engaged per specification and

..,. Cotter keys.not installe These-items are considered a violation of 10 CFR,. Appendix'B, Criterion'V'

-(382/8631-01).-

" Also, the following discrepancies in documentation were identified:

. Welds FSRR-4002-FW1 and FSRR-4002-FW2 were rejected by QC, however,

. -the' weld records indicated that the completed welds were acceptable without having been reinspected by-QC for the rejectable attribut *

Welds FS-SM-107-M3-FW6'and FS-SM-107-M4-SW8 were rejected due to'

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excessive _ fit up gap (greater than 5/32 of an inch). Proper disposition was not documented for these nonconforming conditions in

, accordance.with. site administrative' procedure QP-015-001, Revision 3, Nonconformances and Corrective Action Results:

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These items'are considered a violation.of 10 CFR, Appendix B, Criterion XV (382/8631-02).

' Review of Procedures >

The procedures listed in Attachment Number 3 were reviewed to verify their technical adequacy and conformance to regulation and code requirement ,

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Results:

Review of Procedure QA.2.4, Revision 0, Qualification and Certification of

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Visual Examination Personnel for Preservice and Inservice Inspections,

-indicated the procedure does.not meet the industry standard nor are there

. precedents within the referenced ASNT and ANSI documents for the liberties taken. The following are examples:

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The procedure allows reduction of experience by 33-1/3 percent in

-

accordance with ANSI 45.2.6 (1978). However, the procedure permits further reduction of the required experience by an additional

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m L50 percent :if the individual 'is certified to Level II for'at 'least three NDE method There is no apparent basis why an-individual who is certified Level II in PT, MT, and UT should have the require experience' level for VT3 and VT4 reduced by 50 percen *

iFurthermore, the p'rocedure eliminates the requirement for an

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individual to take a practical-exam if he has a specified amount of

' training. . There is no basis presented for this relaxation in

, requirement This-issue is considered unresolved pending the licensee's evaluation and justification and subsequent NRC review (382/8631-03).

5. -Review of Modification SM-107 Inspection was concentrated on the installation of a Backup Spent Fuel Fool Cooling heat exchange Cooling water lines and related accessories on the 35-foot elevation in the Fuel Handling Building were inspecte The heat exchanger and its interconnecting piping are safety-related equipment and were designed to ASME Section III, Class-3 requirement The backup spent fuel pool cooling system is a Seismic Category I installatio .

The following documents were reviewed in order to-determine if the licensee's program for control of design changes and modifications-had been adequately implemente Ebasco's independent design verification for modification SM-10 *

Ebasco's Quality Assurance review of the independent design verification for modification SM-10 *

Ebasco's procedure control for design changes and modifications E6 The NRC inspectors examined the as-built configuration of the system and compared this configuration to the piping and hanger isometric drawings and specifications. Several discrepancies were noted as discussed in

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Section 3. The type of discrepancies found indicate that site installation procedures were not properly implemented to ensure that quality requirements were me . Review of the Inservice Inspection (ISI) Program The Waterford 3 ISI program was prepared and is implemented by the licensee. The plan meets the requirements of ASME Section XI 1980 edition including addenda through Winter 1981. This outage was the first in the first 10 year interval of the ISI progra ,. . _ - - _ - . - - . .- -

- - .  ;

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Organization and Staffing of ISI Program The Waterford 3 Plant Manager - Nuclear has the prime responsibility for coordinating and conducting the ISI Program. The inspector concluded that Waterford 3 has adequate staff comprised of site personnel, augmented by contract personnel, to properly execute the ISI progra Quality Assurance Audits of ISI The inspector reviewed the documents. listed below to. ascertain that ISI vendors are audited by the QA department prior to their being considered as a-qualified supplier of ISI service LP&L Audit report on Westinghouse for ISI Contract (dated January 8-10, 1985).

.

LP&L Audit report on Westinghouse for ISI Contract (dated August 29, 1986).

The audit reports indicated that various aspects of the ISI Program were examined, audit findings were properly closed out, and that the licensee's ISI vendor was properly qualified as a supplier of ISI service ISI Personnel Record Review The inspector reviewed 24 nondestructive examination ~(NDE) personnel qualification and certification records.- One individual was identified for which additional information was required to justify marginal experience at the' time of his certification. The individual had received adequate experience since his certificatio The inspector had no further concerns on this ite Inservice Inspection (ISI) Data Review During this inspection the inspector reviewed all the ISI data that had been taken as of December 9, 1986. The total count was:

24 ultrasonic examinations

117 visual examinations l

19 liquid penetrant examinations

i 2 magnetic particle examinations The inspector verified that the examinations were done in compliance with governing procedures and that applicable ASME code and Regulatory requirements were met. The review also was undertaken 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 report __ _ _ , _ - . - - - .

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. l 8 l Overall, the. inspector found that the Inservice Inspection Pro' gram at

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Waterford 3 including its documentation,is being performed adequately and that the_ objectives of the ISI program are being met. No violations were identifie . Attachments:

Attachment No.'1 is a tabulation of piping weldments inspected and the results. Attachment Nc. 2 is a tabulation of_ specific pipe supports inspected during this inspection and the inspection results. Attachment

.No.' 3 is a list of procedures reviewed during this inspectio . Unresolved Items Unresolved' items are those for which more information is necessary for the

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NRC to determine whether the item or items are acceptable, a violation or a deviation. An unresolved item is contained in Section . Exit On December 11,-1986, the NDE Van personnel attended an exit meeting with the. licensee: staf . The findings of this' inspection were described' at

'this meetin No written material was~provided;to-the licensee during this inspectio .

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Attachment No. 3: List of Procedures Reviewed

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Title (We'stinghouse Procedures)

Preservice and Inservice Examination Documentation WTR-0PS-101, Revision 0 Qualification of Ultrasonic Manual WTR-ISI-10, Revision 0

" Equipment

. Manual Ultrasonic Examination of Welds WTR-ISI-206, Revision 0 Manual Ultrasonic Examination of Welds WTR-ISI-47, Revision 0 in Vessels Manual Ultrasonic Examination of Vessel WTR-ISI-247, Revision'0 Nozzle Inside Radius (Training) Qualification and WTR-QA-2.2, Revision 1 Certification of NDE Personnel Visual Examination WTR-ISI-8, Revision 0 Magnetic Particle Examination WTR-ISI-70, Revision 0 Liquid Penetrant Examination WTR-ISI-11, Revision 0 Qualification and Certification of Combustion Engineering Procedures Visual Examination Personnel for PSI QA.2.4, Revision 0 Certification of NDE Personnel NQA 1 (Louisiana Power and Light Company Procedures)

Section IV Repairs and Replacement PE-1-001 Modification MP-107, Revision 0, 1, 2 Control of Inservice Inspection PE-1-003 l Modification SM-107, Revision 0, 1, 2 l

Penetrant Examination PT QI-009-011, Revision 3 Administration Control of ISI PE-003, Revision 2-(Louisiana Power and Light Company Procedures)

Administration Plant Engineering PE-2-006, Revision 8 Station Modification

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(EBASCO Procedures)

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PC-I General Power Piping hCR-MP-2050

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(GE0 Proce'dures)

- Penetrant Examination PT-23, A. 58, Revision 23

.

m_ _ _ _ _ . - _ _ _ _ _ - - - - - _ - - - - - -_ - - - -

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