ML20077D859

Inservice Insp Rept Conducted During 821207-830407 by Swri. Describes NDE of Selected Components at Facility

ML20077D859
Person / Time
Site:	Fort Calhoun
Issue date:	07/11/1983
From:	Vanell J OMAHA PUBLIC POWER DISTRICT
To:
Shared Package
ML20077D851	List: ML20077D849 ML20077D859
References
NUDOCS 8307270345
Download: ML20077D859 (60)

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TABLE OF CONTENTS Page VOLUME I--FINAL REPORT WITH APPENDICES LIST OF ILLUSTRATIONS .................................. vii LIST OF ABBREVIATIONS .................................. ix I. INTRODUCTION ..................................... 1 A. Examination Areas .......................... 1 B. Summary of Examination Resul ts . . . . . . . . . . . . . 2 C. Radiation Exposure ......................... 3 D. E q ui p me n t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 II.

SUMMARY

OF THE INSERVICE EXAMINATION . . . . . . . . . . . . . 9 A. Explanation of Fiel d Data Records . . . . . . . . . . 9 B. Summary of Nondestructive Examinations .. . . . lu C. Exempted Components 10.a Table II.C.-l. 10.b/c APPENDICES (Not included with NIS-1 Report)

A. Class 1 Weld Identification Figures B. Class 2 Weld Identification Figures C. Southwest Research Institute Nuclear Projects Operating Procedures D. Southwest Research Institute Nondestructive Testing Procedures E. Ultrasonic Calibration Block Drawings / Sketch and Certifications F. Certificates of Personnel Qualifications G. Material and Equipment Certifications VOLUME II--APPENDICES (Con'd)(Not included with NIS-1 Report)

H. Customer Notification Fonn I. Mechanized Scan Plan J. Southwest Research Institute's Implementation of Regulatory Guide 1.150 Requirements K. Reactor Pressure Vessel Preservice Ultrasonic

, Examination Limitations at Fort Calhoun Station,

! Unit 1 l VOLUME III--FIELD DATA (Not included with NIS-1 Report)

Class 1 Components and Systems Reactor Pressure Vessel and Closure Head l

' Omaha Public Power _ Oistrict,1623 Harney St., Omaha, NE 68102, i

- Fort Calhoun Station - Unit 1, P.O. Box 399, Fort Calhoun, NE 68023-0399 Commercial Service Date 9/26/73 TABLE OF CONTENTS (Con'd)

VOLUME IV--FIELD DATA (Con'd)(Not included with NIS-1 Report)

Class 1 Components and Systems (Con'd)

Reactor Pressure Vessel and Closure Head (Con'd)

Piping Class 2 Components Piping 1

Calibration Records 190000 Series 570000 Series Linearity Verification Records Beam Spread Records I

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Omaha Public Power District,1623 Harney St., Omaha, NE 68102,

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• Fort Calhoun Station - Unit 1, P.O. Box 399, Fort Calhoun, NE 68023-0399 Commercial Service Date 9/26/73 O LIST OF ILLUSTRATIONS Figure fage, 1 Sonic FTS MK I and Pictorial Representation s of Crown Indication . . . . . . . . . . . . . 4 2 Sonic FTS MK I and Pictorial Representation of Root Indication . . . . . . . . . . . . . . 4 3 Reactor Vessel Examination Device in Position During an Inservice Examination . . . . . . . 6 4 Standard Data Acquisition System . . . . . . . 7 5 Explanation of Summary Table Format . . . . . 11 9

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Omaha Public Power District,1623 Harney St., Omaha, NE 68102, ,

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• Fort Calhoun Station - Unit 1, P.O. Box 399, Fort Calhoun, NE 68023-0399 '

Commercial Service Date 9/26/73 A

O LIST OF ABBREVIATIONS ASME -

American Society of Mechanical Engineers BC -

Branch Connection CCW -

Counterclockwise CNF -

Customer Notification Form CRT -

Cathode-Ray Tube CW -

Clockwise DAC -

Distance Amplitude Correction DNR -

Deviation and Nonconformance Report FSH -

Full Screen Height HAZ -

Heat-Affected Zone ISI Inservice Examination Lo -

Zero Reference Location Mech UT -

Mechanized Ultrasonic Examination mR -

Millirem NDE -

Nondestructive Examination NDT -

Nondestructive Testing OPPD -

Omaha Public Power District PT -

Liquid Penetrant Examination QA -

Quality Assurance RL -

Refracted Longitudinal RPV -

Reactor Pressure Vessel l . SDAS -

Standard Data Acquisition System SwRI -

Southwest Research Institute UT -

Manual Ultrasonic Examination VT -

Visual Examination l

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Omaha Public Power District,1623 Harney St., Omaha, NE 68102, Fort Calhoun Station - Unit 1, P.O. Box 399, Fort Calhoun, NE 68023-0399 4

Commercial Service Date 9/26/73 O I. INTRODUCTION During the January-February 1983 refueling outage, Southwest Research

, Institute (SwRI) personnel performed nondestructive examinations (NDE) of selected components at Omaha Public Power District's (OPPD) Fort Calhoun Station, Unit 1. The examinations constituted the seventh such inservice examination (ISI) performed at Fort Calhoun, and the second ISI of the third 40-month period of commercial operation.

A. Examination Areas The ISI was performed in accordance with the following documents:

Section XI of the American Society of Mechanical Engineers (ASME)

Boiler and Pressure Vessel Code, " Rules for Inservice Inspection of Nuclear Power Plant Components," 1974 Edition, with Addenda through Summer 1975.

SwRI " Project Plan for the 1983 Inservice Examination of Fort Calhoun Station, Unit 1", Document No. 83-OPP-FCS-1-1-0.

Fort Calhoun Station, Unit 1, "10-year Inservice Examination Plan for Class 1, 2, and 3 Components," revised September,1982.

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Supplement 11A, dated September 2, 1982, to Purchase Order No. 16525.

OPPD Technical Specifications SwRI Nuclear Quality Assurance Program Manual, Revision 2, with all applicable changes.

SwRI's implementation of Regulatory Guide 1.150, Revision 1, requirements (See Appendix J for implementation information).

Representative samples of the following components and areas were examined with NDE techniques.

Class 1 Reactor Pressure Vessel and Closure Head i

Longitudinal Welds l

Circumferential Welds

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• Vessel-to-Flange Weld Nozzle-to-Shell Welds Nozzle Inside Radius Sections Nozzle-to-Safe End Welds Vessel Cladding s

• l Vessel Interior g Core Support Structure 1

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Omaha Public Power District,1623 Harney St., Omaha, NE 68102 0

. Fort Calhoun Station - Unit 1, P.O. Box 399, Fort Calhoun, NE 68023-0399 Commercial Service Date 9/26/73 Piping O

4-Inch Pressurizer Spray System Class 2 s Piping 16-Inch Feedwater Piping 14-Inch Low Pressure Safety Injection System Piping 12-Inch Lok Pressure Safety Injection System Piping 8-Inch Low Pressure Safety Injection System Piping 8-Inch High Pressure Safety Injection System Piping 12-Inch Shutdown Coolant System Piping 12-Inch Containment Spray System Piping 8-Inch Containment Spray System Piping 6-Inch Containment Spray System Piping 6-Inch Safety Injection System Piping B. Summary of Examination Results The nondestructive examinations were performed using visual (VT),

liquid penetrant (PT), manual ultrasonic (UT), and mechanized ultrasonic (Mech UT) techniques. The various examinations were conducted in accor-dance with standard SwRI nondestructive testing (NDT) procedures which were written to conform to the requirements of the applicable sections of the ASME Boiler and Pressure Vessel Code and the SwRI Nuclear Quality Assurance Program Manual. A copy of each applicable SwRI NDT procedure is included in Appendix D.

SwRI operating procedures for veld joint identification marking en nuclear power plant piping, recording data during VT and PT examinations, and measuring and recording search unit location and maximum signal ampli-tude during UT examination are included in Appendix C.

One indication was observed during the VT examination of Pipe Restraint 10-PR-2(SIH-262) and reported on Customer Notification Form (CNF) 0109. Af ter evaluation, the indication was repaired by OPPD per-sonnel. Reexamination by OPPD personnel after repair revealed no record-able indications.

No reportable indications were observed during the PT, UT, and Mech UT examinations. No other reportable indications were observed.

A copy of the CNF generated during this ISI is located in Appendix H.

The SwRI Quality Assurance (QA) Section was reprasented on site by the SwRI (QA) Representative who was present for approximatelf 50 percent of the examination period. The QA Representative performed the appropriate duties outlined in Section 3.3.l(4), "Onsite SwRI Quality Assurance Activ-ities," of the Project Plan.

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Omaha Public Power District,1623 Harney St., Omaha, NE 68102, i Fort Calhoun Station - Unit 1, P.O. Box 399, Fort Calhoun, NE 68023-0399 Commercial Service Date 9/26/73 O Examination personnel were certified in accordance with SwRI' Nuclear Quality Assurance Procedures 11-1 and 11-2 which incorporate the guide-lines of SNT-TC-1A of the American Society for Nondestructive Testing. A copy of each individual's certifications is included in Appendix F.

Included in Appendix G are copies of the certifications for the ultrasonic instruments, transducers, couplant, PT materials, and marking pencils used during the examinations.

Mechanized examinations were conducted in accordance with the " Plan for Mechanized Ultrasonic Examination of Selected Components at Fort Calhoun Station, Unit 1," as modified on site as required by plant con-figuration. The updated scan plan tables incorporating necessary changes made on site are contained in Appendix I.

Drawings / sketch and certifications of the basic calibration blocks used during the ultrasonic system calibration are located in Appendix E.

C. Radiation Exposure Radiation exposure encountered during the ISI was of fundamental con-cern to all SwRI personnel involved during the daily examination activi-ties. SwRI personnel took the necessary precautions in order to minimize overall exposure and consequently received the minimum dosage practicable while performing the selected examinations. The following listing details

[ 'h the approximate radiation exposure levels associated with various examina-V tion areas.

Radiation Exposure Levels Area Exposure Level par Device Laydown Area 40 mR/hr par Control Area 10 mR/hr Top of Pressurizer 20 mR/hr Auxiliary Building Areas 5 mR/hr Cavity Floor (Vessel to Flange Exam) 100 mR/hr i

D. Equipment

1. Manual Examination Equipmant

a. Sonic FTS MK I (See Figures 1 and 2)

Sonic FTS MK I ultrasonic instruments were used for the man-ual noqdestructive testing and thickness gauging of materials. They were also used as an aid in obtaining acoustic characteristics / properties through measurements of tranrmission and attenuation of ultrasound in materials.

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Omaha Public Power District,1623 Harney St., Omaha, NE 68102, Fort Calhoun Station - Unit 1, P.O. Box 399, Fort Calhoun, NE 68023-0399 Commercial Service Date 9/26/73 l

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small, light-weight, portable units, including rechargeable 12-hour battery / charger packs. These inctruments utilize transistorized circuits of printed circuit board construction and a cathode-ray tube (CRT) for a video display of the test data.

in Appendix G. Instrument calibration certifications are

b. Transducere Various brands, sizes, types, and frequencies of ultrasonic transducers (search units) were used to perform the examinations. In most cases, a transducer frequency of either 2.25,1.0 or 1.5 MHz was used.

The 2.25 MHz transducers were used on carbon steels and 1.0, 1.5 MHz or 2.25 MHz on stainless steels as specified in the procedure. For inforna-tion on the actual transducer used for any specific examination, consult .

the data sheets and referenced calibration sheets in the field data volumes.

2. Mechanized Examination Equipment

a. :PiR Examination Device (See Figure 3)

The par Examination Device, fabricated by Programmed and Remote Systems, Inc. , with technical input from SwRI, was adapted to the n#

\- Fort Calhoun Reactor Pressure Vessel by the use of tripod legs specifi-cally designed for it. The system examined selected portions of the interior of the vessel, including nozzle welds. The examination posi-tioning apparatus was mounted on the top flange of the vessel by use of the three legs which clamped to guide studs for accurate, reproducible positioning. Attached to the boom assembly were various SwRI accessories which enabled examination of the vessel-to-flange veld, nozzle-to-shell welds, nozzle inside radius sections, nozzle-to-safe end welds, safe end-to pipe welds, vessel shell welds, and bottom head we.1ds.

b. Standard Data Acquisition System (See Figure 4) tions. Sonic MK II UT instruments were used for mechanized examina-Recording of the mechanized data was accomplished by using the SwRI Standard Data Acquisition System (SDAS), which simultaneously recorded test data from three separate ultrasonic search units. Gating and post- ,

tioning circuits were incorporated into the system to provide reflector location and amplitude information. The SwRI SDAS is a portable, compact, modular system designed for rapid and accurate recording and/or processing of ultrasonic test information obtained during mechanized examinations.

Information obtained from UT examinations was processed by the SwRI SDAS in the following manner. Signal information from each of ,

the UT instruments was displayed on the appropriate CRT for each instru-ment.

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signals which exceeded these levels, calibrated voltages were generated relative to the gate positions and lengths for each instrument. The time analog and amplitude analog voltages corresponded to the first triggering signal encountered along the sound beam and the signal with the largest amplitude, respectively. These data were combined with location infor-mation and sent to a six-channel strip-chart recorder.

This system produced the following types of examination records:

(1) Videotape (2) Strip chart As a requirement of every examination, the television video-tape recording provided a continuous record of all information displayed on the CRT units as well as time, amplitude, and positional information displays. Thus, it furnished an exact record of the information which can be used as a more interpretative tool for the other record forms, and it also provides a redundant backup examination record and is reviewed inde-pendently by a certified examiner in its entirety.

The six-channeled strip-chart recording provided a "hard copy" of test data for the gated regions of each of the three UT instru-ments. Transducer module position was also recorded, providing exact correlation with other data records.

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Omaha Public Power District,1623 Harney St., Omaha, NE 68102, Fort Calhoun Station - Unit 1, P.O. Box 399, Fort Calhoun, NE 68023-0399 Commercial Service Date 9/26/73 O

b II.

SUMMARY

OF THE INSERVICE EXAMINATION This section of the report provides a discussion of the field data records and a summary of the nondestructive examinations performed.

A. Explanation of Field Data Records The results of the NDE examinations and calibrations performed by SwRI personnel were recorded on standard SwRI forms. These completed docu-ments constitute a portion of the Inservice Examination Report. The orig-inal records are retained in the SwRI Data Storage Facility, and copies are provided herein for completeness.

The field data records for each veld or area are assembled into a package preceded by a summary sheet. The examination areas and summary sheet numbers correspond to those listed in the Summary Table. A general I explanation of the individual field data forms follows.

The instruments used in performing UT examinations were cali- l brated prior to use, then verified again at specified intervals during the examinations and upon completion of the examinations.

The calibration parameters were recorded on the appropriate cali-bration record sheet as specified in the applicable NDT proce-dure. The documented calibration and calibration verification

-g provide immediate assurance that the examinations were performed g ) using properly calibrated instruments.

The results of UT and Mech UT examinations were recorded on the applicable data record sheets as specified in the appropriate NDT procedure. The information documented on these forms describes the parameters associated with those indications which were greater than the recording levels specified in the applicable NDT procedures.

When required, the size, location, and nature of reflectors were determined by analyzing the indication parameters recorded on the forms described above. The analysis is documented on SwRI Indica-tion Resolution Record Sheets, which are included as a part of each affected data package.

Visual Examination and Liquid Penetrant Examination Record Sheets were used to record the results of those examinations. Both remote and direct visual examination techniques utilize the.same basic format for documenting indications. The equipment and/or materials used in VT and PT examinations are also identified on the record sheets.

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Omaha Public Power District,1623 Harney St., Omaha, NE 68102, Fort Calhoun Station - Unit 1, P.O. Box 399, Fort Calhoun, NE 68023-0399 Commercial Service Date 9/26/73 B. Su=marv of Nondestructive Examinations 8

The following section of this report is the Summary of Nondestructive Examinations Table (Summary Table). The Summary Table provides informa-tion and results for the NDE examinatione performed during this ISI.

Figure 5 provides an explanation of the Summary Table format. A descrip-tion of the weld identification system used to assign unique identifiers to each examination area and weld identification figures for Class 1 and Class 2 systems are located in Appendices A and B, respectively.

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Omaha Public Powsr District,1623 Harney St., Omaha, NE 68102, Fort Calhoun Station - Unit 1, P.O. Box 399, Fort Calhoun, NE 68023-0399 Commerical Service Date 9/26/73 II. (Continued)

C. Exempted Components Pages 10b and 10c are a listing of the component areas tested by hydrotest because of ISI exemption.

OPPD perfonned two Hydro-tests during the 1983 Inservice Inspection. They are:

1. ST-ISI-RCS-4, " Inservice Inspection Reactor Coolant System Hydrostatic and Leak Test".

2. ST-ISI-MS-4, " Inservice Inspection Main Steam Pressure Test".

By successfully perfonning these tests to the requirenents of IWA and IWB 5000, OPPD has fulfilled the exemption commitments on the Inservice Inspection of the components listed on pages 10b and 10c.

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Omaha Public Power District,1623 Harney St., Omaha, NE 68102, Fcrt Calhoun Station - Unit 1, P.O. Box 399, Fort Calhoun, NE 68023-0399 Commerical Service Date 9/26/73 ASME SEC. XI ASME SEC. XI EXNi AREA EXAM -

ITEM NO. CATECORY IDENTIFICATION METHOD REMARKS Reactor Vessel:

Bl.2 B-B Dome Weld, VT Inaccessible to Closure Head volumetric Exam.

Examined per IWA 5000.

B1.5 B-E Vessel Pene- VT Performed by trations OPPD per IWA '

5000 '

Bl.19 B-P Exempted VT Performed by Components OPPD per IWA 5000 Pressurizer:

B2.3 B-E Heater Pene- YT Performed by trations OPPD per IWA 5000 B2.11 B-C-2 Pressure Retaining VT Performed by 0 PPD per IWA 5000 Bl.10 B-P Exempted Compo- VT Performed by nents (Pressurizer) OPPD per IWA 5000 Steam Generator #1:

B3.9 B-P Exempted Compo- VT Performed hy nents 0 PPD per IWA 5000 Steam Generator #2:

B3.9 B-P Exempted Compo- VT Performed by nents OPPD per IWA 5000 Regenerative Heat Exchanger:

j B3.9 B-P Exempted Compo- VT Performed hy nents OPPD per IWA 5000 l

\

l 10b

Omaha Pubite Power District,1623 Harney St., Omaha, NE 68102, Fort Calhoun Station - Unit 1, P.O. Box 399, Fort Calhoun, NE 68023-0399 Commerical Service Date 9/26/73 ASME SEC. XI ASME SEC. XI EXAM AREA EXAM ITEM NO. CATEGORY IDENTIFICATION METHOD REMARKS Reactor Coolant Piping:

B4.11 B-P Exempted Compo- VT Performed by nents OPPD per IWA

, 5000 Reactor Coolant Pumps:

i B5.8 B-P Exempted Compo- VT Performed by nents 0 PPD per IWA 5000

, Valves Body Welds (Line 12" SDC-20):

B6.8 B-P Exempted Compo- VT Performed by nents OPPD per IWA 5000 t

t 100

Omaha Public Power District,1623 Harnsy St. , Omaha, NE 68102,

. Fort Calhoun Station - Unit 1, P.O. Box 399, Fort Calhoun, NE 68023-0399 Commercial Service Date 9/26/73 i .

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= = = { g ,C B C O L 8 7 7

-4 .--

4 '1 J, 8 C C

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2=. e e e e

=J O2 9 N 'u

=>C Cw I  % N T === Z 4 f. 1  :'" 4

• == == 6; N I 3 4

== W 1 *E O

• I O ':t

1 r= 220 0 C e.2 4%1 412 8 7 7 n==

M *S N I L.a 9 OO4 C 8 O Z 67 *C e O 4 fI I 7J 4- 8 J J x- 8 - e=

4* 2. 4 > *>

d2 7 a O 5

- = = 2 I e 1 O I 8 0 .J l I wO I I I I I

> 9 2" 8 e I T O 8  : I

• 8 4 wa == 3 =a e C == 0 == 8 8 8 I F. 0 4 0 4 8 O = 1 y 8 8 67 .J l >= t e 9 8 . 8 O I W: 0 J == 0 Z l

.a I O- 3 I a

• ! l N Z 0 m I I O 8 O =. O Z t O w* 9 ZC 9 8 *= *

= 8 w- 5 J l == 1 6 8 8 == 0 0 0 4 2 at 8 m I 3

=. B = I l 5 E B e 1 4 4

1. .- O E 4 9 s 0 ft L*I w f O 4 e9 4 == 4-

1. 20 0 =* 6 -2 == 2

'J l O 9 0 e == I -

Z 9 C == 0% 8 e et

= 0 =J ~ t I e .n.e 41 == ?.

1 8 4 0 f( l e == ;r, ==

- 6 1 8 m.J2 0 - t =a M wW

- 0 C 6 A 8 C 3

• 3 # . g  ; ;

1 e g I l, 6 g a

== 1 4 8 == 0 ,,s 2J

• 8 == 0 '/. t *T 1 11

-* 3 8 I I e e ==

8,* 4 9 4 5 %1 N1 e

t == g 2 0 4 i O 8 > 0  % N

8

• f a e

e  ; ,, . a A .

= 3 .* 4 I g e

• 8 *C .~.W8 y '.J ,

== I .= ; g I > <t 0 m a g "I *= E G *

• 1 I.

= 1 &*. . = =-g a

=(.

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.) f i#" O , W