IR 05000259/1982004
| ML20054D926 | |
| Person / Time | |
|---|---|
| Site: | Browns Ferry  |
| Issue date: | 02/19/1982 |
| From: | Herdt A, Kleinsorge W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML20054D903 | List: |
| References | |
| 50-259-82-04, 50-259-82-4, 50-260-82-04, 50-260-82-4, 50-296-82-04, 50-296-82-4, NUDOCS 8204230511 | |
| Download: ML20054D926 (7) | |
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UNITED STATES
NUCLEAR REGULATORY COMMISSION o
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,c REGION il
~8 101 MARIETTA ST., N.W., SUITE 3100 o,%
ATLANTA, GEORGIA 30303 s
Report Nos. 50-259/82-04, 50-260/82-04, 50-296/82-04 Licensee: Tennessee Valley Authority 500A Chestnut Street Tower II Chattanooga, Tennessee 37401 Facility Name: Browns Ferry Docket Nos. 50-259, 50-260, 50-29.
License Nos. DPR-33, DPR-52, DPR-68
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Inspection at Browns Ferry Site near Decatur, Alabama and TVA Power Service Shop near Muscle Shoals, Alabama Inspector:
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,p1 W. P irisorge Date Signed
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Approved y.
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In. IJ/. herdt, Section Chief Date Signed yineering Inspection Branch Engineering and Technical Inspection Division
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SUMMARY Inspection on January 26-29, 1982 Areas Inspected This routine, unannounced inspection involved 30 inspector-hours on site in the areas of licensee action on previous inspection findings, review of quality records, welding (Unit 3) and nondestructive examination (Unit 3).
Results
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Of the four areas inspected, no violations were identified in two areas; one violation was found in two areas (Violation
" Failure to Follow Welding and NDE Procedures" paragraph Nos. Sb and 6b). No deviations were found.
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REPORT DETAILS 1.
Persons Contacted Licensee Employees
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- G. T. Jones, Power Plant Superintendent
- M. Hellums, Office of Power
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- R. T. Smith, QA Staff
- C. J. Rozear, Compliance Staff H. Hodges, Torus Modification Staff Other licensee employees contacted included construction craftsmen, technicians, security force members, and office personnel.
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NRC Resident Inspector
- J. W. Chase i
- Attended exit interview 2.
Exit Interview The inspection scope and findings were summarized on January 29, 1982 with those persons indicated in paragraph 1 above. The inspector described the areas inspected and discussed the inspection findings listed below:
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(0 pen) Violation - 259, 296/82-04-01:
" Failure to Follow Welding and NDE i
Procedures" paragraph Nos. Sb and 6b.
l (0 pen) Unresolved Item 259, 260, 296/82-04-02: " Valve Storage Conditions"
paragraph 5.
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3.
Licensee Action on Previous Inspection Findings
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a.
(0 pen) Violation 259, 260, 296/81-13-02:
" Document Control."
This item concerned, in part, failure to assure proper revisions of nondestructive examination (NDE) procedures were distributed and used i
at work locations. The licensee stated in their letter dated April 17, 1981 that full compliance would be achieved on January 1,1982. The inspector noted a considerable number of NDE reports dated after January 1,1982, that referenced NDE procedure revisions other than the latest.
At the time of the inspection it could not be determined whether the incorrect procedure revisions were actually used for inspection or the incorrect revision numbers on the NDE reports were
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just errors in documentation. The licensee indicated that they would look into the matter further. This item remains open.
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b.
(Closed) Violation 259/81-16-04:
" Failure to Follow Welding and Inspection Procedures." TVA letter of response dated September 4,1981 has been reviewed and determined to be acceptable by Region II. The inspector held discussion with Power Plant Superintendent and examined the corrective actions as stated in the letter of response.
The inspector concluded that TVA had determined the full extent of the subject violation performed the necessary survey and follow-up actions to correct the present conditions and developed the necessary corrective actions to preclude recurrence of similar circumstances.
The corrective actions identified in the letter of response have been implemented.
4.
Unresolved Items Unresolved items are matters about which more information is required to determine whether they are acceptable or may involve violations or devia-tions. New unresolved items identified during this inspection are discussed in paragraph Sa.
5.
Independent Inspection Effort (Units 1,2 & 3)
a.
Torus Modification Progress The inspector conducted a general inspection of the Unit 3 torus, reaction building warehouse area, and the turbine building to observe torus modification progress and modification activities such as welding, material handling and control, housekeeping and storage.
With regard to the inspection above the inspector noted eight ASME Class 2 and 3 valves stored out doors in the warehouse area.
This is contrary to the requirements of ANSI N45.2.2-72, paragraphs 2.7.3(2),
and 6.1.2(3) which require valves to be stored in doors. At the time of this inspection it could not be determined whether the existing
' storage location (outdoors) of the above valves was consistant with BFNP license commitments. The licensee indicated that they would look
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further into the matter. The inspector stated that the above would be Unresolved Item 259, 260, 296/82-04-02: " Valve Storage Conditions."
b.
Review of Quality Records The inspector reviewed randomly selected nondestructive examination (NDE) reports for the Unit 1 torus modification project. The inspector noted, on January 29, 1982, that a number NDE reports did not identify the level of certification (Level I, II or III) of the NDE personnel performing the examination reported. This is contrary to TVA N-0QAM, Part II, Section 6.3 paragraph 2.4 which requires NDE personnel to enter their level of certification on nondestructive examination reports.
Therefore NDE personnel were not following a procedure requirement.
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The above failure to follow procedure is an example of Violation 259, 296/82-04-01 discussed further in paragraph 6b.
Within the areas examined, no violations or deviations were identified, except as described in paragraph 5b.
6.
' Welding (Unit 3)
The inspector observed welding work activities for torus modifications as described below to determine whether applicable code and procedure requirements were being met.
AWS D1.1 is the applicable code for the welding activities observed.
a.
Welding The below listed welds were examined in process to determine work conducted in accordance with traveler; welder identification and location; welding procedure assignment; welding technique and sequence; materials identity; weld geometry; fit-up temporary attachments; gas purging; preheat; electrical characteristics; shielding gas; welding equipment condition; interpass temperature; interpass cleaning; process control systems; identity of welders; qualification of inspection personnel; and weld history records.
E-Weld - Bay 13 Pair 2 and 3 Ring Header Support Welds - Various b.
Welding Filler Material Control The inspector reviewed the TVA program for control of welding materials to determine whether materials are being purchased, accepted, stored, and handled in accordance with QA procedures and applicable code requirements. The following specific areas were examined:
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Purchasing, receiving, storing, distributing and handling procedures, material identification.
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Welding material purchasing and receiving records for the following materials were reviewed for conformance with applicable procedures and code requirements:
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HEAT, LOT, BATCH TYPE SIZE OR CONTROL NO.
E-7018 3/32" 9334 E-309-15 1/8" 58175 E-309-15 3/32" 50017-1 E-7018 1/8" B222 E-7018 1/8" B221 E-7018 1/8"
'B202 E-7018 5/32" 0031C122145 With regard to the inspection above the inspector, on January 27, 1982 noted type E-309-15 welding electrodes frem two different batches /
lots / heats, mixed together in one compartment of an electrode oven in the Unit 3 torus welding electrode issue station.
The above is contrary to MAI-21, " Control of Torus Modification Activities" dated April 15, 1981, Appendix B, paragraph 3.3, which requires that welding electrodes be maintained in electrode ovens separated by heat numbers.
Therefore the issue station attendent did not follow the welding material control procedure requirements. The above failure to follow procedure and that discussed in paragraph Sb are in violation of 10 CFR 50 Appendix B Criterion V.
This violation will be identified as 259, 296/82-04-01: " Failure to Follow Welding and NDE Procedures."
c.
Welder Qualification The inspector reviewed the TVA program for qualifications of welders and welding operators for compliance with QA procedures and ASME Code requirements. The applicable code for welder qualification is ASME B&PV Code Section IX.
The following welder qualification s.tatus records and " Records of Performance Qualification Test" were reviewed relative to the welds listed in paragraph 6a and 6d.
WELDER SYMBOL ORGANIZAT10_N 003 Service Shop MS 158 Service Shop MS 002 Service Shop MS PACH BFNP l
BFO-230 BFNP
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d.
Visual Inspection of Welds The inspector visually examined completed welds as described below to determine whether applicable code and procedure requirements were being met.
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(1) The below listed welds were examined relative to the following:
location, length, size and shape; weld surface finish and j
appearance, transitions between different wall thickness; weld reinforcement--height and appearance; joint configurations on
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permanent attachments and structural supports; removal of temporary attachment, arc strikes and weld spatter; finish grinding or machining of weld surface, surface fininsh and
absence of wall thinning; surface defects, cracks, laps, lack of penetration, lack of fusion, porosity, slag, oxide film and
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undercut exceeding prescribed limits:
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WELD ID i
E-11-1-N E-11-2-N E-11-3-N B11-N (2) Quality records for the above welds were examined relative to the following:
records covering visual and dimensional inspections
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I indicate that the specified inspections were completed; the i
records reflect adequate weld quality; history records are adequate.
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Within the areas examined, no violations or deviations were identified j
except as described in paragraph 6b.
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7.
Nondestructive Examination (Unit 3)
i The inspector reviewed procedures, reviewed records and observed
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nondestructive examination work activities for torus modifications as
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described below to determine whether applicable code and procedure
requirements were being met.
a.
Procedure Review (1) Liquid Penetrant
The inspector reviewed TVA procedure NPT-1, Revision 4, " Liquid l
Penetrant Examination using the Color Contrast Solvent Removal Method," to ascertain whether it have been reviewed and approved consistent with TVA established procedures.
NPT-1 was reviewed
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j-for technical adequacy consistent with ASME,Section V, Article 6 and other licensee commitments / requirements, in the below listed
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areas.
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Specified method Penetrant materials identified
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Penetrant materials analyzed for sulfur
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Penetrant materials analyzed for total halogens
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Acceptable pre-examination surface Drying time
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Method of penetrant application
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Surface temperature Solvent removal
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Dry surface prior to developing
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Type of developing
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Examination technique
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Evaluation technique
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Reporting results
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Requalification conducted when required (2) Magnetic Particle Examination The inspector reviewed TVA Procedure N-MT-1, Revision 2, " Magnetic Examination of Nuclear Power Plant Components," to ascertain whether it have been reviewed and approved consistent with TVA's established procedures.
N-MT-1 was reviewed for technical adequacy consistent with ASME,Section V, Article 7 and other licensee commitments / requirements, in the below listed areas.
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Type and color of ferromagnetic particles Material surface preparation / cleanliness
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Material surface temperature
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Examination technique / coverage Prod condition / usage
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Magnetizing current Prod or pole spacing
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Yoke lifting power Demagnetization
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b.
Work Observation In process magnetic partical examination was observed on weld
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Nos. 15-2-C and 15-2-D.
The above examination was compaired with NMT-1 Revision 2 in the areas listed in paragraph 7a(2).
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c.
Examiner Qualification The inspector reviewed the qualification records for the below listed i
examiners, to determine whether examiner qualification was consistent l
with TVA procedures and regulatory requirements.
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EXAMINER LEVEL & METHOD ATL I
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PRS II PT JMR II PT MRH II MT Within the areas examined no violations or deviations were identified.
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