IR 05000317/1989021

Insp Repts 50-317/89-21 & 50-318/89-21 on 890814-18. Violation & Deviation Noted.Major Areas Inspected:Activities Re Unit 2 Pressurizer Heater Penetration Leaks & Inservice Insp Activities

ML20247Q433
Person / Time
Site:	Calvert Cliffs
Issue date:	09/14/1989
From:	Harris R, Kerch H, Strosnider J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I)
To:
Shared Package
ML20247Q282	List: IR 05000317/1989021 ML20247Q278 ML20247Q302 ML20247Q343
References
50-317-89-21, 50-318-89-21, NUDOCS 8909280194
Download: ML20247Q433 (6)

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U.S. NUCLEAR REGULATORI COMMISSION

.. REGION I 50-317/89-21

' Report.Nos. 50-318/89-21~

50-317-Docket'Nos. 50-318 DPR-53- '

License Nos. DPR-69-Licensee:. Baltimore Gas'and Electric Company MD Rts 2&4, P.O. Box 1535 Lusby, Maryland 20657-Facility Name: 'Calvert Cliffs' Units 1 and ?

Inspection At: 'Lusby, Maryland Inspection-Conducted: August 14 through 18, 1989 Inspectors:

H. W. Kerch, Senior Reactor Engineer

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f T R. H. Harris, NDE Technician date Approved by: f ef 9/#/B9

. R. Strosnider, Chief, Materials and 'date rocess Section, EPB, DRS, Region I

- Inspection: A routine announced inspection conducted on August 14 through 18,1989 (Report No. 50-317/89-21 and 50-318/89-21)

Areas Inspected: This inspection focused on activities related to the Unit 2 pressurizer heater penetration leaks and inservice inspection activities including certification of nondestructive' testing personne >

Summary and Conclusion: One violation, one deviation and one unresolved item related to inservice inspection procedures were identified during this inspec-tion. The licensee's actions to correct problems identified by the NRC on certification of nondestructive personnel have been slo '

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DETAILS l

1.0 Persons Contacted (30703)

, Baltimore Gas and Electric (BG&E)

John Osborne, Licensing Engineer Sandy Zuxbaum, Unit Superviso P. B. Cond, Materials Engineer

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.B. C. Rudell, Pressurizer Project Engineer L. M. Decker, Materials Engineering Nuclear J. B. Anuje, Supervisor Quality Audit L. B. Russell, Manager D. V. Graf, Pressurizer Pro.iect Manager

2.0 Inservice (ISI) Data Review and Evaluation (73753)

b During this. inspection the inspector reviewed documentation of ultrasonic test data (plotting and recording of indications), calibration standards and quality control records related to nondestructive testing activitie The documentation consisted of quality assurance procedures, as-built drawings of ultrasonic testing (U.T.) calibration blocks and Certified Mill test reports (CMTR's) documenting material specifications required by the ASME Code. The as-built drawings of U.T. calibration blocks were reviewed to verify that the block configurations and dimensions were-appropriate to perform U.T. equipment calibration as required by the ASME

. Cod Results: As a result of.the above review and evaluation, discrepancies

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were found in.two ultrasonic data sheets submitted by the licensee's ISI contractor (South West Research Institute). Sheet #170139, a coverage plot, indicated the plot.for weld 4-405 was 1/20 scale when the actual scale was h. Sheet 170095, a resolution record plot, did not. include or reference calculations indicating the linear interpolation used to cal-culate and determine the shape and location of the indication. After this concern was raised by the NRC inspector, the calculations showing how the indications were resolved were added to the records by the individual who performed the calculations. The inspector-had no other concerns about this issu The' inspector also found that the ultrasonic data reports do not contain the signatures of persons performing examinations nor do they indicate if the ultrasonically examined weld is acceptable by the ASME Code. A reviewer's signature is the only signature on this code required examination data sheet. The inspector discussed this issue with the licensee and indicated that.this area should be reviewed by the licensee to verify that proper accountability is being obtaine . _ - _ _ _ _ - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

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i b 2.1- ISI Contrac' tor Reporting Conditions (73753)

J Site ISI contractors report t'o the licensee various conditions and findings that require resolutio These reports are made on'various types of notification forms. The licensee's procedure is to generate

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nonconformance reports (NCRs) based on the notification received from the contractors. Once identified in an NCR the item is tracked by L

the 1icensee to assure proper disposition. However, the licensee has no. formal. system for tracking and controlling the various notifica-

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tion forms submitted by the'ISI contractors. Although no specific examples were identified by the inspector, the potential exists for reported conditions not being properly placed in the NCR system and, as a result, not being properly dispositione ~

This item-is unresolved pending licensee action and NRC review (50-318/89-21-01).

2.2- Qualification and Certification of ISI Personnel NRC Inspection Report 88-14-01 issued'an unresolved item dealing with ISI personnel not having proper certifications. This' unresolved item was upgraded to a violation during NRC inspection 89-15-01 when it was found that the problem with certification of ISI personnel still existed. The licensee stated in response to the violation that corrective actions would be completed by the end of September 198 During this inspection the qualification and certification records for nondestructive testing and visual inspection personnel were reviewed. It was determined that one individual's eddy current exami-

' nation certification had expired and he had performed eddy current examinations after the certification expiration date. The inspector determined that site procedure NDE-CP5.002, section 6.8.3, permitted a 60 day grace period for decertification of examination personne Allowance of a grace period is not permitted by Section XI of the ASME Code. In response to the inspector's finding, the licensee issued a letter dated August 16,1989 (during this inspection) delet-ing section 6.8.3 of procedure NDE-CP5.002 which eliminated the 60 day grace period. This same letter stated that a review of the work performed by the subject eddy current examiner determined that no ASME code work had been performed by the individual during the extended grace period. This subject was discussed with the licensee and the inspector indicated that further reviews by the licensee are I required in order to determine if other examination personnel per-formed ASME examinations during the 60 day grace period in which they 3 were not certifie Failure of procedure NDE-CP5.002 to effectively implement Code require-ments is a violation of NRC requirements (50-317/318/89-21-02). This item is considered separate from the unresolved item and violation identified in inspection reports 88-19 and 89-15; although, this procedural deficiencey may have been a contributor to those problem _ - - - _ _ _ _ - - - _ - _ - - _ _ _ - . - _

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During the review of qualification and certification of testing personnel, procedure CC1613D was reviewed. This procedure deviated from licensee commitments in that ANSI 18.1, 1971 was being used to

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establish the training and qualification program for visual personnel; whereas. ANSI N45.2.6, 1978 should be the controlling documen *

Procedure CCI613D invokes ANSI N18.1-1971 as the primary document for the training and qualifying visual examination personne *

.The. site 2nd 10 year program dated November 6, 1986 invokes ASME Section XI, 1983 Summer 83 addenda, paragraph IWA.2300 (c) which states . visual examination personnel "shall be . qualified in accordance-with N45.2.6-1973."

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ASME Code Case N424 authorizes the use of ANSI N45.2.6 1978 in lieu of N45.2.6 197 *

The Calvert Cliffs FSAR endorses ANSI 45.2.6 197 Failure of licensee procedure CC1613D to reference the appropriate version of ANSI 45.2.6 is a deviation from the licensee's commitment as . stated in the Calvert Cliffs FSAR (50-317/318-89-21-03).

3.0. Pressuriz,er

.The inspectors reviewed nondestructive testing report ISI 89-866 and a proposal (BGE 89-014) for the repair of the pressurizer heater sleeves. A

" core bore" sample including a heater sleeve and surro nding vessel material had been removed and sent off site for metallurgical analysis. At the time of this inspection the licensee had not decided on what repair method to use nor had the cause of the leaking heater sleeves been determine Videotapes of the liquid penetrant examination performed by the licensee were reviewed. The purpose of reviewing the tapes of liquid penetrant examinations was to evaluate the types of indications detected and the quality of the remote liquid penetrant examinatio Results: Liquid penetrant examination provided meaningful informatio .0bserved were several areas of heavy penetrant bleed outs and at least one area revealed a linear indication. All indications appeared to be above or below the "J" grove weld area, none were observed in the weld itsel It should be noted that some of the leaking sleeves did not show liquid penetrant indications, and some sleeves that showed indications with eddy current testing did not show indications with liquid penetrant; therefore, it is concluded that liquid penetrant testing cannot be relied upon to identify every defect in the sleeve _ _ _ _ _ _ _ - _ _ _ _ _ _ _ _ _ _ _ _ _ - _ _ _ _ _ _ _ _ _ _ _ _ - _ _ _ _ _ _ _ _ - _ _ _ - ___- -

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' Review of Procedures (73753)

The following procedures were reviewed during this inspection for compliance with the licensee's commitments, applicable codes, standards and specification Baltimore Gas & Electric

CCI-135D: Administration of ISI NDE CP5.002 Rev. 13: -Qualification and Certification of Nondestructive Examination Personne ME&A IPS.03 Rev 0: Materials Engineering and Analysis Implementing ME&A~IPS.07 Rev 0: ' Calibration Standards and Records CCI613D: Qualification of Test and Inspection Personnel SWRI-600-49 Rev. 2: Manual' Ultrasonic Examination Straight Beam 600-15 Rev. 71: Manual Ultrasonic Examination Pressure Vessel 600-31 Rev. 24: Manual Ultrasonic Examination Piping 800-53 Rev. 7: Manual Ultrasonic Examination Nozzle Radius-IX-FE-132- Rev. 0: Ultrasonic Indication Resolution

Results: Procedure NDE CP5.002 was not in compliance with ASME Code requirements, as discussed in Section 2.2, and Procedure CCI613D, ISI Qualification and Certification of personnel, deviated from the licensee's

! FSAR. commitment as discussed in Section .0 Unresolved Items Unresolved items are matters about which more information is required in order to_ ascertain whether they are acceptable items or violations. An o unresolved item is discussed in paragraph .0 Management Meetings (30703)

Licensee management was informed of the scope and purpose of the inspection at the entrance interview on July 5,1989. The findings of the inspection were discussed with the licensee representatives during the course of the inspection and presented to licensee management at the exit interview (see paragraph 1.0 for attendees).

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At no time during the inspection was written material provided to the licensee by the inspector. The licensee did not indicate that proprietary information was involved within the scope of this inspection.

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