IR 05000259/1973007
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UNITED STATES o#
- q ATOMIC ENERGY COMMISSION
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Q; DIRECTORATE OF REGUIATORY OPERATIONS I
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REGloN 16 - Suit E 818
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AT L. A NT A, GEoRG A 30303 RO Inspection Report No. 50-259/73-7 Licensee: Tennessee Valley Authority 818 Power Building Chattanooga, Tennessee 37401 Facility Name: Browns Ferry Unit 1 Docket No. : 50-259 License No.: CPPR-29 Category: A3/B1
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Location: Decatur, Alabama Type of License: BWR 1098 Mwe (GE)
Type of Inspection: Routine, unannounced Dates of Inspection: May 15-18, 29, 1973,
Dates of Previous Inspection: April 28-May 4, 1973 Inspector-in-Charge:
W. D. Kelley, Reactor Inspector, Engineering Section F -ilities Construction Branch Other Accompanying Personnel: None,
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Principal Inspector:
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3 W. S/LTefle, Reactor Inspector
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FaciptisTestandStartupBranch Reviewed By: //
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C. E. Yu(phy, Ac(ing Chief
'Date Facilities Test and Startup Branch
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8604300430 860317 PDR FOIA MORROW 85-782 PDR
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l RO Rpt. No. 50-259/73-7-2-
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SUMMARY OF FINDINGS I.
Enforcement Action A.
Violations None B.
Safety Items None II.
Licensee Action on Previously Identified Enforcement Matters Violations Not inspected.
III. New Unresolved Items
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73-7/1 TVA Designed Hangers Steamfitters had modified TVA-DED designed hangers on
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Class I RHR piping for Unit 2 without documentation and design approval.
During the inspection of May 29, 1973 at TVA-DED Knoxville office the inspector was informed
that the same condition existed for Class I hangers for Unit 1 and they were being reinspected and reworked where necessary, by DEC.
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IV.
Status of Previously Reported Unresolved Items Valve Wall Thickness (AEC letter to TVA dated June 30, 1972)
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The wall thickness of valves in Class I systems has been measured and the data have been ovaluated.
The report has not
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(Details I, paragraph 2)
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Design Changes None
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R0 Rpt. No. 50-259/73-7-3-VI.
Unusual Occurrences None VII. Other Significant Findings None VIII. Management Interview A management interview was held at the Browns Ferry Nuclear Plant Unit 1 site on May 18, 1973 and was attended by the following:
Tennessee Valley Authority (TVA)
R. T. Hathcote - Project Manager - DEC M. M. Price - Construction Engineer - DEC A. L. Mazzetti - QA Section - DED L. D. Weber - QA Coordinator - DED J. T. Lence - Nuclear Engineer - DPRP
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The inspector discussed his inspection of the valve thickness measurement program and stated that he had no further questions at this time.
Final evaluation awaits the issuance of the TVA report.
(Details I, paragraph 2)
2.
The new unresolved item, 73-7/1, identified above was discussed in detail.
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R0 Rpt. No. 50-259/73-7 I-1
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df 8' 7:7 DETAILS I Prepared by:
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W'. D. Kelley, Lleactor spector Date Engineering Section Facilities Construction Branch Dates of Inspection: May 15-18, 1973 May 29, 1973
~ /M m 6 /p/- f3 Reviewed by:
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[,.' C. Brjagff Senior' Inspector
~Date v' Engineering Section Facilities Construction Branch 1.
Individuals contacted Tennessee Valley Authority (TVA)
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R. T. Hathcote - Project Manager (DEC)
J. A. Morgan - Mechanical Engineer (Welding and NDT) (DEC)
K. A. Hasting - Associate Engineer (Construction - NDT)(DEC)
- M. N. Bressler - Principal Nuclear Engineer (DED)
- J. I. Given - Head Mechanical Engineer (DED)
- J. Wilkens - Principal Mechanical Engineer (DEC)
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Valve Wall Thickness (AEC Letter to TVA Dated June 30, 1972)
TVA has measured the wall thickness of all valves in Class I safety systems 1-1/2-inch nominal pipe size and over in accordance with their process specification 5.M.1.1(a), " Specification for Thickness Measurements", dated September 6,1972, with the exception of the valves manufactured by Darling Valve Manufacturing Company. These valve wall thicknesses had been previously measured by the vendor and valves with wall thicknesses less than specified on the design drawing were repaired.
- Contacted in DED Knoxville, Tennessee, Office on May 29, 1973
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R0 Rpt. No. 50-259/73-7 I-2 TVA did not invoke their stated exception in their letters of September 29, 1972, and December 1,1972, to messure the wall thick-ness of cast steel valves larger than two-inch nominal pipe size in water lines and four-inch nominal pipe size in steam lines. The valve list attached to their letter of September 29, 1972, was extended to meet the requirements of the RO:II letter of June 30, 1972, and included forged steel valves.
Instead of invoking the statement it. their letter of December 1, 1972, that measurements of all Class I safety system valves in Units 2 and 3 would provide the level of confidence required to guarantee that all Unit 1 valves met the standards and specifications under which they were purchased, all valves in Unit 1 were measured in accordance with the requirements of RO:II's letter of June 30, 1972.
The valve wall thickness measurements of Class I safety system valves has also met the requirements of RO:II's letter of February 15, 1973, enclosure, item 1, "Va'1ve Size."
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The requirements of the enclosure, item 2, " Acceptable Measurement l
Techniques and Accuracy," to attempt to meet a 2% maximum error in repeatability and accuracy has been met. This has been demonstrated by comparing physical measurements with ultrasonic measurements of calibration test blocks and comparing these valves against physical and ultrasonic measurements of uninstalled valves.
TVA did not invoke the enclosure, item 3, " Conditional Acceptance,"
or item 4, " Valve Verification Alternatives." All valve wall thick-ness measurement data sheets were transmitted by DEC Browns Ferry to DED Knoxville for evaluation. It was not known by the site construction forces during the inspection of May 15-18, 1973, if any valve would require the condition imposed by enclosure item 5, " Valve Acceptance Through Evaluation or Special Testing."
The valve wall thickness measurement data sheets were audited by the inspector in the TVA DED Knoxville office on May 29, 1973. The inspector was informed that only one valve (MPL-2-71) out of eleven identical safety valves supplied by G-E had an area that was questioned. The standard required wall thickness given TVA by G-E for these valves was 1.875 inches. TVA (to assure the valves met the minimum wall thickness requirement) added the 2.0% instrument error tolerance permitted in R0:II's letter of February 15, 1973, enclosure, item 2, to the 1.875
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RO Rpt. No. 50-259/73-7 I-3 inches giving a required wall thickness of 1.91 inches. On the valve in question, one area measured 1.891 inches which was less than the established acceptance standard thickness. TVA checked and used the actual instrument error of 0.63% which gives an acceptance standard thickness of 1.887 inches for this one valve. TVA stated that the valve is acceptable and will so indicate in their report.
3.
TVA Designed Hangers Hangers for Unit 1, Class I, RHR piping were fabricated and erected by steamfitters using design drawings that were not checked and approved.
They made field changes without prior approval and the mechanical engineer was not aware of many of the modifications. The inspector will audit the records on Unit 1 on a subsequent inspection to deter-mine that hangers designed by TVA for Class I piping have been fabri-cated and erected in accordance with approved design drawings and all field changes are recorded and approved by DED.
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REGION II
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FEEDER INSPECTION REPORT IDENTIFICATION SHEET REPORT NO. 50-259/73-7 TO:
J. C. Bryant, Sr. Reactor Inspector, Engineering Section
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Facilities Construction Branch Licensee: Tennessee Vallev Authority Inspection Dates May 15-18. 1973 May 29, 1973 Browns Ferry Nuclear Station - Unit 1
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Other Inspectors F. U. Bower
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f Feeder Report Prepared By:
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e W. D. Kelley / Reactor [nspector Date Inspector's Evaluation (continue on attached sheet, if necessary)
No items of direct safety concern were identified.
No item other than the new unresolved item in the sununary is to be included in the letter to the licensee.
TVA-DEC has measured the wall thicknesses of all valves in Class I safety syatem 11/2 inch nominal pipe size over as required by RO:II's letter of June 30, 1972. The procedure, instrument and calibration blocks were reviewed with the technicians who performed the measurements and in the opinion of the inspector the measurements were made within the accuracy required in RO:II's letter of February 15, 1973, enclosure item 2.
TVA has stated that all of the valv'es. meet the minimum wall requirements;-
however, the inspector questions their blind acceptance of wall thickness
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requirements given them by GE on their: supplied valves.
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The attached Feeder Inspection Documentation is transmitted in reviewed and approved form.
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Comments:
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JUL 16 B73 i
In Reply Ra
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50-259/73-7 i
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Tennessee Yalley Authority
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Atta Mr. J. E. Watson Manager of Power j
~818 Peuer Building Chattanoese, Tennessee 37401
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Gentlemen:
@l f./jk This refers to the inspection conducted by Mr. Kelley of this offiefer $:gdf
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at the Browns Ferry site and at your Kaezvilge'f'-f w y T May 15-18 and 29, 1973, office of activities authorised by AEC Construction Permit No. CFF $ %, % P
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and to the discussion of our findings with Mr. Hathcote and other members
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i of the TVA staff at the conclusion of the inspection.
Areas examined during this inspection included the thin walled valve meas-
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urement program and pipe hanger installation. Within these areas, the inspection consisted of selective examinations of procedures and represen-
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tative records, interviews with plant personnel, and observations by the inspeeter.
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Within the scope of this inspection, no violations or safety iteres were
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disclosed.
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A copy of the report of this inspection is enclosed. In accordance with Section 2.790 of the AEC's " Rules of Practice," Part 2 Title 10, Code of
Federal Regulations, a copy of this letter and the enclosed inspection r
p8 aged in the AEC's Public Document Room. If this report
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emaammamion that you believe to be proprietary, it is asses-asha a written application within 20 days to this offies to
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- =ammmation from public disclosure. Any such application
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'a full statement of the reasons on the basis of which it is
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claimed that the information is proprietary, and should be prepared se that proprietary information identified in the application is sentained q
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in a separate part of the document. If the repeirt contains no informa-I tion which you believe to be proprietary, please inform us in writing
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JUL 16 573
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t wit 51 20 days to this effect. In such case, the report, as anclosed with this letter, will be placed in the Public Document Room.
Should you have any questions concerning this letter, we will be glad to discuss them with you.
Very truly yours, o,;g.nai s...
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tt c, Mo.elet Norman C. Moseley Director Enclosure:
Inspection Report No.
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50-259/73-7
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