IR 05000259/1992026
| ML18036A816 | |
| Person / Time | |
|---|---|
| Site: | Browns Ferry  |
| Issue date: | 08/05/1992 |
| From: | Blake J, Economos N, Kleinsorge W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML18036A809 | List: |
| References | |
| 50-259-92-26, 50-260-92-26, 50-296-92-26, NUDOCS 9208200168 | |
| Download: ML18036A816 (23) | |
Text
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/p 4~*~0 UNITED STATES NUCLEAR REGULATORY COMMISSION
REGION II
101 MARIETTASTREET, N.W.
ATLANTA,GEORGIA 30323 Report Nos.:
50-259/92-26, 50-260/92-26, and 50-296/92-26 Licensee:
Tennessee Valley Authority 3B Lookout Place 1101 Market Street Chattanooga, TN 37402-2801 Docket,Nos.:
50-259, 50-260 and 50-296 License Nos.:
DPR-33, DPR-52, and'DPR-68 Facility Name:
Browns Ferry 1, 2, and 3 Inspection Conducte
. Jul, ly 8-10, and July 13-16, 1992 Inspectors:
N.
ector Date ign d le'o e, P.E.
ctor In Da e Signed Approved y:
J. J.
lake, ief r
Materials and Processes Section Engineering Branch Division of Reactor Safety te Signed SUIVIMAR Ir'cope:
This routine, unannouncedinspection was conducted onsite in the areas of Unit 3 Pipe
, Replacement Project, and as a followup to that documented in Report 92-25.
Inspection activities included work observation in the area of welding and nondestructive testing; field record review and replacement material quality records.
Results:
Installation of replacement piping appears to be proceeding in an orderly manner and in accordance with requirements set forth in applicable project specifications and the ASME Code.
The primary contractor General Electric Nuclear Energy (GENE), has 9208200168 920806 PDR ADOCK 05000259
i
provided adequately trained craft, engineering and QA/QC personnel to perform the work and provide the necessary technical expertise needed to complete the project satisfactorily.
Within the areas inspected violations or deviations were not identifie Report Details 1.
Persons Contacted Licensee Employees
"M. Bajestani, Technical Support Manager
"S. Fox, Project Radiography Supervisor
"F. Froscillo, QA/ISI Lead Specialist
"K. Groom, Welding Engineer, Supervisor/Modifications
"E. Knuttel, Licensing Engineer
"J. Maddox, Engineering Manager
"T. Pitchford, Project Coordinator, Pipe Replacement
+P. Salas, Compliance Supervisor
"J. Scalice, Plant Manager
"J. Wallace, Compliance Engineer
"O. Zeringue, Vice President, Browns Ferry Operations Other licensee employees contacted during this inspection included engineers, mechanics, technicians, and administrative personnel.
Contractors General Electric, Nuclear Energy (GENE)
"R. Cameron, QC Manager, Level III Examiner, NDE L. Grycko, Welding Specialist C. Johnson, Lead Welding Supervisor J. Lancaster, Production Manager R. Pietzak, QC Supervisor J. Rodabaugh, Project Manager G. Smith, Shift Supervisor NRC Resident Inspectors
"C. Patterson, Senior Resident Inspector
"Attended exit interview Acronyms and initialsms used throughout this report are listed in the last paragrap.
Unit 3 Piping Replacement Project This inspection is a continuation of the work activity undertaken by regional inspectors to monitor the replacement of recirculation piping and inlet nozzle safe-ends at this unit.
Similar work performed in this area has been documented in Region II Reports 92-22 and 92-25.
aO Welding (55050)
The applicable Codes and Standards for the pipe replacement project are American Society of Mechanical Engineering Boiler and Pressure Vessel (ASME, B5PV) Code Sections III, V and XI 1986 Edition.
ASME, BSPV Code Section II and IX, Latest Edition.
American Welding Society (AWS) D1
~ 1-90 AWS D1.3-89 American National Standards Institute (ANSI) B31.1 1967 Edition.
American Society for Nondestructive Testing (ASNT) SNT-TC-1A 1984 (GE)
The inspectors reviewed procedures, observed work activities in progress and reviewed records of in process and completed work, as indicated below to determine whether the licensee's welding procedures, welding/installation activities and welding records were in conformance with applicable Codes, Standards and. Regulatory commitments.
Welds and/or components where work activities were observed are as follows:
Weld No.
Descri tion
~Condi ion
% RWR-3-002-G009 Safe-End to Riser llHII Loop IlBII fitup
%RWR-3-001-G001 Safe-End to Noz.
flFII Loop TlAtl Welding out
"Welds inspected between July 6, 8-10, remaining welds inspected between
July 13-16, 199 i
Weld No.
(cont'd)
%RWR-3-002-G004 Descri ion Safe-End to Noz.
"G" Loop "B" Condition k
Visual Inspection of Completed Weld
'urface RWR-3-001-G023 Left "Bullhorn" to Ringheader, Loop "A" Welding Out RWR-3-001-G013 Safe-End to Noz.
~IKII Loop IIAII
. Finish Grinding of Weld Surface RWR-3-001-G024 Left Bullhorn to Riser, Loop "A" Welding Out Following is a tabulation of weldments observed during walk-through inspections but no work was in progress at the time.
RWR-3-001-G010 Safe-End to Noz.
llJ lf Loop IIAI'I Weld Complete, Rigging of Riser in Progress RWR-3-001-G001 Safe-End to Noz.
IIFII Loop IIAII Root Complete, In-process Radiogr.
Disclosed Rejectable Indication Subsequently Repaired.
RWR-30-002-G001 Safe-End to Noz.
IIAIILoop IIBII Root Complete In-process Radiogr. Disclosed Rejectable Indications Subsequently Repaired.
For welds in process, the inspectors observed weld metal deposition through TV monitors and verified welding procedure parameter settings on the automatic welding machine panels.
Parameters checked included primary current, primary voltage, travel speed, oscillation aptitudes, wire feed and shield gas flow. Production records reviewed included log entries pertaining to shift activities, welder identification, weld wire spool changes, weld starts/stops and interpass temperature checks.
Shielding gas, dew point temperature log
entries were reviewed to ascertain whether specified parameters were being monitored and whether equipment was calibrated as required.
Within these areas the inspectors noted the following:
Auto Weld Data Sheets disclosed that in certain cases welding operators were neglecting to document the location of weld starts/stops and interpass temperatures taken during welding.
In other instances the inspectors noted that an unusually high number of weld passes were started in the same geometric reference point i.e. 0', 90', 270 etc.
Because the controlling specification ¹22A590 Rev.
1 addressed both of these areas in specific terms i.e. weld start and stops shall be staggered and shall be kept to a
minimum; interpass temperatures shall be measured...... the inspectors met with and discussed in detail these observations with GENE's welding and QC supervision.
They temporarily stopped related welding activities and cautioned welders against failing to document interpass temperatures on the subject logs. Discussions with field personnel provided adequate assurance that interpass temperatures were being closely monitored during welding. They pointed out that the absence of these temperature readings from the subject records was not a failure to monitor interpass temps but rather an oversight on the part of certain welding machine operators.
In reference to the starts and stops, the same individuals provided 'adequate and satisfactory explanation for starting in the same geometric reference point. The explanations included the fact that starts/stops within the same geometric quadrant are utilized as a means of controlling axial and/or lateral movement in the component being welded.
The inspector suggested that in cases such as those described above, a brief statement should be entered into the record to explain the reason for actions taken by field personnel.
Review of Weld Fabrication Documents GENE utilizes travelers to prepare, fabricate, inspect and test each weldment as required by code and related standards.
In an effort to determine the degree of accuracy and completeness of the information entered, the inspectors selected a sample of weld travelers, at random, for review. A list of the weld travelers and a brief description of findings is provided belo RWR-3-002-G002, Safe End to Nozzle N2 A, Loop "B".
On July 3, 1992, an information radiograph of the 'nozzle weld prep showed evidence of a linear indication approximately 3/16" long in the weld butter.
The indication was removed without violating minimum weld butter thickness and was repaired during welding of the root.
A radiograph of the root, taken on July 5, 1992, found rejectable linear indications.
Following repairs, the root was reradiographed and was again rejected for the same reason.
At this point GENE cut out the joint, repreped and rewelded the root. A radiograph of the new weld root, taken on July 15, 1992, disclosed a rejectable linear indication which was repaired before completing the weld.
The completed weld was radiographed and found to be acceptable on July 16, 1992.
RWR-3-001-G001 Safe End to Nozzle N2"F", Loop A An Information radiograph detected a 3" long linear indication (lack of fusion)
near the root on the safe-end side of the weldment.
Following several attempts at removing the indication without success the suspect area was rewelded satisfactorily as evidencedby acceptable radiographs evaluated on July 14, 1992.
The entire weld was accepted by radiography on July 16, 1992.
RWR-3-001-G010 Safe-End to Nozzle N2"J", Loop "A" An Information radiograph detected a
1/8 inch long linear indication in the nozzle weld prep, butter material. The indication was removed by excavation without violating minimum weld butter thickness requirements.
The cavity was subsequently filled while making the safe-end to nozzle weld.
The entire weld was accepted during the week of July 6, 1992.
RWR-3-002-G007 Safe-End to Nozzle N2"C" Loop "B" Information root and final radiography showed the weld and adjacent weld butter material were acceptable.
Records of visual inspection and surface examinations performed to satisfy code requirements showed the weldment was satisfactory.
RWR-3-002-G010 Safe-End to Nozzle N2D, Loop "B" Information radiography detected two small linear indications in the counterbore area. The weldment was fabricated and found to
be satisfactory by radiography.
Records of visual inspection and surface examinations required by the applicable code showed the weldment was satisfactory.
Discussions were held with GENE's welding specialist in order to review the possible root cause for the aforementioned rejectable indications associated with the fabrication of the roots of these welds.
Several scenarios were discussed included the skill of welding operators, human factors and welding parameters.
The latter was of particular interest since the welding specification placed no restriction on heat input for the root and cover pass of these welds.
Subsequent to these discussions the inspectors learned that a number of actions had,been reviewed by GENE in an attempt to rectify the root weld problem.
One of these, was to revise the welding specification allowing for a minor heat input through an incremental increase in amps and volts while decreasing the travel speed.
Updates received following this inspection indicated that the aforementioned adjustment to the weld specification corrected the problem as the rate of rejections in this area diminished significantly.
Review of Replacement Materials Quality Records Requirements for material and/or components needed for replacement of recirculation piping and inlet nozzle safe-ends were specified in Design Change Notice (DCN), W1754A and other controlling documents including Calculation No. CD-A03068-92211 Rev.
2, Reconciliation Stress Analysis Report.
The latter document invokes the following specifications both of which are applicable to this project.
B50Y267 Rev. 5 23A6908 Rev.
Forgings, Grade F316 Stainless Steel Purchase Specification, Austenitic Stainless Steel Forging's - Grade F316-Nuclear Grade Material Specification In addition, the DCN discusses the improved design of the new recirculation nozzle safe-end, citing that the new design incorporates the safe-end and the thermal sleeve as one piece, rather than being welded to the safe end as in the original design.
Also, by direct comparison of welds between the old and new design, the inspectors ascertained that there are now thirty six (36) fewer welds in the recirculation piping system.
This reduction in welds provides for a significant reduction in ISI examinations and a corresponding reduction in dosag i
In reference to replacement, the subject DCN specifies that the replacement recirculation riser piping is made from seamless Type 316 NG (Nuclear Grade) material. Replacement safe-ends are made from austenitic stainless steel forgings, nuclear grade, Type 316 material
~ The Jet Pump Instrument (JPI) nozzle seal material is nuclear grade, Type 316 stainless steel material.
By record review and through discussions the inspectors acertained the replacement material was procured by TVA under contract No. 84K05-834606 for use in Unit 1 and was subsequently released to GENE for use.in Unit 3.
The list of items identified below were selected for a review of quality records including material manufacturecomponent fabrication, examination, testing, certification, receiving, storage and release to the field for installation.
Ringheader Assemblies 23" x 24" Integrated Tee, SA-403 Type - 316Ng 28" x 22" Integrated Cross Tee, SA-403 Type - 316Ng 28" x 12" Cross Reducers, SA-403 Type - 316Ng Specific spool pieces included 68-11 and -12 in Loop "A" and, 68-38 and -41 in Loop "B" Bent Integrated Tee with Reducer SA-403 Type 316NG.
Specific spools included Nos. 68-8 and -9 in Loop "A" and 68-37 and-39 in Loop "B".
Straight Pipe 24" x 1.219" x 169.00" SA-376, Type-316 NG spool piece 74-904, Ht ¹D472701 Safe-Ends 14" OD x 1.24" wall thickness, SA-182 F316Ng Ht Nos.
D191401, D191007 and D19150 Within the areas violations or deviations were not identifie c.
Nondestructive Examination (NDE) (57050 VT) (57060 PT) (50707 MT)
(57090 RT)
The inspectors reviewed procedures, observed workactivities in progress and reviewed records of completed work as indicated below to determine whether the licensee's NDE procedures, NDE work activities and NDE records were in conformance with applicable codes, standards, and regulatory commitments.
Radiography Radiographs of complete welds were reviewed to ascertain whether film, radiogrographic quality and, associated records were consistent with applicable code, ASME Section III, 1986 Edition, and procedural (NRT-1-R16), requirements.
Welds whose radiographs were reviewed are listed below:
Weld No.
RWR-3-002-G023 Left Bullhorn to Ringheader, Loop "B" Results Satisfactory RWR-3-002-G004 Safe-End to Nozzle N2B, Loop "B" Satisfactory RWR-3-002-G007 Safe-End to Nozzle N2C, Loop "B" Acceptable slag indication in previous weldment.
Weld satisfactory RWR-3-002-G01 3 Safe-End to Nozzle N2E, Loop "B" Satisfactory RWR-3-001-G004 Safe-End to Nozzle N2G, Loop "A" Satisfactory RWR-3-001-G013 Safe-End to Nozzle N2K, Loop "A" Excessive Penetration, ID reinforcement acceptable slag in previous weldment.
Weld satisfactory
Wel No.
(cont'd)
RWR-3-002-G01 5 Descri ion Riser to Safe-End of Nozzle N2 "E" Results Root repair to remove linear at the root.
Weld satisfactory RWR-3-001-G001 Safe-End to Nozzle N2F, Loop "A" See discussion under Traveler Review above.
Weld satisfactory Liquid Penetrant Examinations The inspectors observed the solvent removable Liquid Penetrant (PT) and visual examinations of weld No. RWR 3-002-G025, a
28-inch pipe to the butt weld in the Reactor Recirculation system.
The inspectors evaluated the examiner's findings and had the following comments.
One end of a personnel work platform (scaffold) appeared to be supported by a pipe support providing lateral support for Control Rod Drive system piping.
The licensee investigated and determined that this scaffold though in contact with the support was not supported by the support.
The licensee did find an additional scaffold that was supported by a pipe support and removed the scaffold.
One can of PT Remover used in conjunction with the examination above, on July 8, 1992, had a TVA shelf life expiration date of June 1992.
The expiration date had not been noted by the GE QC examiner performing the examination.
Investigation indicated that other cans of PT Remover with the same manufacturer's Lot number, had the TVAshelf life expiration date extended to 1996.
Therefore, there is no question as to the validity of the examination, but the above does exhibit a lack of attention to detail. As immediate corrective action, GE made a sweep of the dry well that same day, and discarded approximately five additional cans of expired PT materials.
Visual Examinations.
The inspectors performed an independent visual examination of completed and accepted weld numbers:
RWR 3-002-G025 and
RWR-3-002-G004, to confirm the GE QC examiner's findings.
The examination disclosed that the surface condition of both welds was satisfactory.
In the area inspected, violations or deviations were not identified.
Machining of Replacement Components.
The inspector observed ongoing machining operations associated with Reactor Recirculation System riser piping at Geneial Machine and Fabrication (GMSF), of Decatur, AL. GM5F is contracted by GE to provide machine shop services to support the Pipe Replacement Project, with round the clock GE engineering and QC oversight.
The inspectors noted that traveler packages were current; adequate halogen controls were observed; M 5 TE were properly calibrated; and material handling and control was acceptable.
3.
Exit Interview The inspection scope and results were summarized on July 10 and 16, 1992, with those persons indicated in paragraph 1.
The inspectors described the areas inspected and the findings listed below. Although reviewed during this inspection, proprietary information is not contained in this report.
Dissenting comments were not received from the licensee.
4.
Acronyms and lnitialisms ANSI ASME ASNT AWS B&PV BF BPC BWR CFR CVR DPR EPRI GE GL IGSCC IN American National Standard Institute American Society of Mechanical Engineers American Society for Nondestructive Testing American Welding Society Boiler and Pressure Vessel Browns Ferry Bechtel Power Corporation Boiling Water Reactor Code of Federal Regulations Construction Verification Program Demonstration Power Reactor Electric Power Research Institute General Electric Company NRC Generic Letter Integranular Stress Corrosion Cracking NRC Information Notice
'
NRC NSR P.E.
RBCCW RPV RT RWCU SSP SWEC TVA UT VT WBS WPS Measuring and Test Equipment Maintenance Management Manual Magnetic Particle Nondestructive Examination Nuclear Grade Number Nuclear Regulatory Commission Non Safety-Related Professional Engineer Procedure Qualification Record Performance Qualification Test Record Liquid Penetrant Quality Assurance Revision Reactor Building Closed Cooling Water System Reactor Pressure Vessel Radiography Reactor Water Cleanup System Site Standard Practice Stone and Webster Engineering Corporation Tennessee Valley Authority Ultrasonic Test Visual Test Welding, Brazing and Soldering Welding Procedure Specification
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