IR 05000280/1970001

Nonproprietary Version of NRC Memo Forwarding Excerpts from Nonproprietary Versions of Insp Repts 50-280/70-01, 50-281/70-01,50-280/70-03,50-281/70-03,50-280/70-04, 50-281/70-04,50-280/70-06 & 50-281/70-05 Re Defective Welds

ML19322D333
Person / Time
Site:	Surry
Issue date:	01/05/1977
From:	Moseley N NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
To:	Volgenau E NRC OFFICE OF INSPECTION & ENFORCEMENT (IE)
Shared Package
ML19322D327	List: IR 05000280/1970001 IR 05000321/1970002 ML19322D326 ML19322D330 ML19322D331 ML19322D332 ML19322D335 ML19322D337 ML19322D338 ML19322D339 ML19322D340 ML19322D342 ML19322D345 ML19322D346 ML19322D350
References
FOIA-79-416 NUDOCS 8002110484
Download: ML19322D333 (12)

Text

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January 5,1977 i c . . ~ . S E. Volgenau, Director, Inspection and Enforcement , ~ SURRY UllIT 2 flEUTR0fi SHIELD TAflX g In a recent telephone conversation you requested that I look into the facts concerning a question which was raised about possibic weld deficien-cies in the Surry Unit 2 tieutron Sheild Tank.

I reviewed the Surry inspec-tion report file and discussed t,he matter personally with; and W. Swan and by telephone with At the time the fabrication of the neutron shield tank for Unit 2 was being inspected' was the responsible Senior Inspector (equivalent to Branch Chief in today's organization).I was the assigned Principal Inspector, and Swan was the inspector who made the final inspection finding that the shield tank was satisfactory for service.

The conclusion of my review of the available facts is that Region II inspectors (Swan and! ) and the responsible supervisor.

were satisfied that the Unit 2 shield tank was adequately constructed for the service for which it was intended.

flone of the three individuals had any recollection of any pressure put on any fiRC (then AEC) employee to minimize the problems or to accept any. resolution short of a techni- ' - cally adequate one.

The Surry inspection reports contain a history of the problem and its resolution.

- Excerpts from the appropriate inspection reports are attached.

The chronology is as follows: - 1.

Attachment 1 - Pages 4 and 5 Appendix III, Section B of C0 Report 50-280/70-1-~ 50-281/70-1 This attachment is an excerpt from the report of a team site inspec-l tion performed February 4-6, 1970.

The inspector who prepared this section was J. M. Varela.

In the excerpted section Varela describes the deficiencies he noted during his inspection.

The deficiencies were principally related to the surface roughness of some of the welds and to some discontinuities in one weld seam.

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. . . - - - ( ( ( . . -2-January 5, 1977 . .. . E. Volgenau 2.

Attachment 2_ - Pages 4 and 5 of Summary Section of C0 ' eport ~R 50-280/70-3, 50-281/70-3

' This attachment is an excerpt from a report of a team site inspection - performed April ~ ~ ~ ~ ~21-23, 1970. The inspector who prepared this section describes information he received during wasl the exit interview from licensee personnel about actions the licensee had taken in resolving the deficiencies described in Attachment 1.

Areworkprogramwasdescribedbythelicenseepersonnelandj informed them that the repair work would be observed during a subsequent inspection.

. . 3.

Attachment 3_ - Page 17 of Details, Section X and Pages 3, 4 and 5, Appendix III of C0 Report 50-280/70-4,50-281/70-4.

This attachment is composed of excerpts from a report of a team site inspection perfonned July 22-24 and August 10-14, 1970.

The page 17 - - ~ ~ as a summary of Swan's more excerpt was p,repared either by: detailed discussion of the Section K excerpts or was directly prepared by Swan as a " cut and paste" insert to a jointly prepared section.

Both excerpts describe continuing dissatisfaction with the condition of the tank.

4.

Attachment 4_ - Pages 2 and 14 of Appendix III of C0 Report '50-280/70-6, 50-281/70-5.

- . This attachment contains information from a team site inspection perfonned October 1-2 and 6-9,1970. The inspector who prepared these was W. Swan.

In the excerpts Swan describes corrective actions which were taken.

He describes dissatisfaction with the sequence of events which resulted in less than desirable resolution from the standaoint of good Quality Control. The report does not concisely close tie welding questions, however, Swan verbally infonned Moseley on December 27, 1976, that it was closed at that time a.nd that he then (in October,1970)-had no concern for the safety of operations using . the tank as fabricated.

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(See . .i j. j..;'. ',,.';.'.3; Exhibit E and Exhibit A, Fhoto No. 21.) The S&'i general specification 3 "!I...-. - for fabrication of the neutron chield tank is en fue at CO H The 'i . r. '...'; h: ' j. ' fabricator is the Newport News Shipb . ..

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'., '. - excluded) shan bo groundflush.' An wolds on inside of > ~, "* , , ' tank shall bo grourd cmooth, and all pits and gouces chan - .-

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"An wolds, wherover possible, ehrill bo 100% radiographod.

, , ~ All wolds that cannot be radiographed chan be.oither dye .% . .' ' ' ' '<'4 penotrant or mgnetic particle checked at the root pass, the - ..d ', . final pass and at the intemediate depths of 1/2-inch - .. The surface of all ucids shall be ground .d ' .- inercrents reb.

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> . .. ?,-:... . - ... Inspection by CO rovcaled that the Unit 2 voasel is in nonconformnce . . There is no ovidence, visual or written, , . ... with the abovo requirements.

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'..that this vossol was rejec e. The discropancies reported are the td ' , , .f ,; These were as tonows: ,.g ,.'.~. }. . findings of CO.

,, ,. .. .. . ' a.. The interior cirth wcld contained three separate discontinuities " . . L'g./ . ..or lack of fusion 3/8-inch to 1/2-inch long and 1/32-inch to . ' . . .. '. f.. -.' 1/64-inch long at the conter or videst point. The girth weld- . - i.0 '. /, ' W.

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(See Exhibit A, Photo No. 20.)

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7.

;g.;l... q. y

- E, . JThe doficiencies observod in tank 1-Ir-WT;T-10, spent resin !^ ~.,.c.

.% ' . '}.,

S.i*y[dowatering tank wore rojected en R/D Report No. 268, dated.

- .; '.':J f2 Febmary 9,1970 Tho vendor, PX Engineering Cc.,ppy, was. M.;..' ,'<' T.

. ;. N . .- - ' ?.'. ' f . i' ..-: Y.... 4.,':,' repairs vill be.perfomed by SW personnel onsito.

.. ~ .. contacted for baekcharge eatinato on Febmary 23, 1970 '[he

'f..

- .,. ' .?..

..' ' e.

Ecwork - f:Y '. 'd cfd .. -.....I!.. had not started ab.the time of the inspection.

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3

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• The inopector infc=ed Perkins that repair work w uld be observed at a

- - ~ ' . .. .-

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-. .cubsequent inspection. Arrange:acnts vero also cado at tMn timo br .d ' ?,. :. a forthecning review of the licensce's progrca for electrical and . . .lJ ' ~ ' .. - , ' 9 *3 's ~ instrumentation installation. - . ; * - @$ .-+ a LSeg ~ ' 4. *.. - *. r,= *, w - e....: & -b N - %-* w) %.: 4,. ... ' ;(. c t J el-.

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vW.# %.-K. : Neutron Shiel'd. Tank for Unit No..

,< M.Am.17t.w:r:r :;rc:-:.T.e.c.:c.n g,%::;.cr.w.5 - . : 2... _ - ,. . . p... c.>.7.Q.

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v.. M..:fi.fy; M..; ;The inspection end listing of the discrepancies f

.@,. .. .. .. . . ... .. .., cf,'. c FIT. included in CO Eeport No. '50--281/70-1; f.ppendix III,.Soction B, and further * I*'7- $h". discussed.inCOPeportNo. 50-281/70-.32. 43QCWts'4p Mh .hf.f.{M...g.hh'h5$I"Y $1/O@NIU'.,"'NMI* $Ni [YIDN4 N k IZ M'/'d c,' Fo11oving Varela's listing of discrepancien 'on this vessel in February {.:l-l:y y . h

1 7.i .,,..../sQ..1970.,. S&W had prepared a.P&D r..eport.. Thic report subsequently shoved..:'..f.%.. . w .. r.

. h.W)J. 5..-*;i.if'. 8&W acceptance of the tnnk on Ju.ne 17,.1970, altho mb grinding. of. velds Ic.p' r.

iq. r~' G,1n'Y --Acrcquired by, the specifications and.dravings and as r t,.:nded by. S&W Gf.a'd- - $- - - - - - 'iY!;.$y< NASTengineering.had not been' done.t't.Q4G%.M .v.

$$$Th.5,h.&lh'%{*4&??".'.W.5.h b5$k?i.0.9SW5'.~0$0. 4N'C'*'D,6* f.

ig'pfy . , ?. T..w.'The neutron shield tnnk had been; cleared by" site QC for installa

98-g@'M' aft'er only'dinor items 'hnd been: reworked and in direl:t disregard of.

' ~ "I n . r --! d h*Mf . - I..p'kv. M6PN.-i,vritten. instructions fro'm S&W ciigineerin .~.

k'.s*. h..-S..% k,p.reinspe~c..t'.'.2.L.W. W.*N Q..i.51%m%%3h*WA 'W.

N.

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% fibis in ' ot a coded tant, but:it, is Class;I and the ' restricted spa .u , e

.,..... 1.' . r.

MU. * 'n.i.%- .';.'?s-%B4r:'%::>.4':. *#~&M.

. 6 ;.,fy,gi IQTJ:6.M y'/.between.it and the reactor ve6sel vill prevent in-nez n . W,4. W.?r : D'.5 N N lochage could cause an'operat'ionni shutdovn #. NE I[id@M'?:$[6cven 'inspe ction,. s'o ' any$(9;.6 f #,""$'Y pT. W.'( @,9 2 iy 3. y. D .CEE or' tbe reactor'. ;~--W$9.: iO'

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5.J... p .. .. . .- . . . .. . . ... ;.. , ' '.. . p. 'e ": y .'. { ;.,]Q . f. CO Report Noso~5 /70-4 e. -3- "

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Discrenant Neutron Shield ~ Tank for No. 2 Uni _t (Reference CO Re ~M . .' ... ' '. . . .. '. '; 3 " No.,50-281/70-1, Appendix III, Seetion B) . :,,,.;I p p$.y., - - , ' ' E.: ' -:h,Y,...,.* * i.'~,.M . . * :, ?;,. ~~ ? -.. h * v:..~ ** T.":- ..'*"..~-t.- ' X. ~.N. : -

- . ..' i.7.,.;'; . Follouing Yarela1s listing of discrepancies on this vessel in

$ r$

" . Q, ~ .$:.$ ..f,,- Febntary 1969, SE had prepared a E'.:D report. This report showed . i 17, 1970, although grinding of

.. .'.,(.-[..I.iSW acceptance of the tank on Junewelds required by.the speci.fic ~' -- : . . g.: . . . ';.. ni 9C.j.3i z{ D,pt.,., '...J.M.gj-j .,t.".f'7,(,;. * J.~;' by S&" engineering had not been ~done.. ,,,; ri.., , . . .:.c. %:- " *- :'. ' y.;s ,,

27;.: ; -ll.". : ?. ~: >. :.. pyt. ::...= wc;;7

. :..s

'-

< . ' %* d I.-73 told that AEC considers the vessel ' . ....W:.;/.'-:., At exit interview, they were..". .'...'. ". unacceptable because there was noncompliance with design requirements,. f.

, i  ; -;;.P.

there was no certification that radiography had been done, and the s. 9;I . .. %.J.I/.O. rough surfaces of the wolds would have detracted from the offectivo- ... '... Y.'-7.'" ( ness of RT, IR and PT.' In addition, there was no reconi of the 7.:-8

'h V,.@;y,!.Q,9 required close tolerance di=cnsional check havin

" 5 5..( * '.:. inch out of roundness at any horizontal section), and the specifications 'g.

. % ..9h M <s in,. vero deficient in that no axini tolerances had been called out.

- ~ -5

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i.

i;-;)$. ::,.:...i. ::- :. D.,.. :. +. ' 1

.. .t .. . . .y.9. h a This'is not a coded' tank, bdt restrictod' spaco between it and the S 'M . :4 : Ji"

jf.,1 '-

, ' reactor vessel will prevent in-service rework or even 'nspection, .

.f,.t't;6.;[/;.no any leakage could cause an operational ohutdown of the re

, .

j9: - .,. f..:g [. Q,I R : ,..:.' n:.:.:, o_:.,. q.,.:, ;;f.;',- c.. -;.y..;W,. (. :...g,4.WJ.:r....Q., ;. 'S';f-;<..~y? Foni-items of nonconfor=ance with epecifications cited (reference' .:'k: . . .;. . .. ~ .,. . . . . .. , ' 3.d:J.:.lCOReportNo. 50.-281/70-1) were listed on a' S&W R&D report, R&D 270,

' . . ':~;..w %W;:n.Q.p~::: 2 :.h 9.,t'~%

sa.h. :...c;:.,M-;.:.i-W.r.Q::a:p;b. s..;.g: f-Q. 9m., -

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.;. : ..- .,- r. 4...,;. 4.,,y.;..:. l:. ;r, p p.s r p 4 ; g. j :g ;,.,.,,, . -.m go::.J'. - . ., , n- , - - _ _..,

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.

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1. -

. 00 Report Hon. 50-280/70-4 -.4-

,

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3 : '- . . - 50-281/70-4 .

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e . -. . ...., . ~; ,.:n. . , ........:. .., . ,.. .. .... -. ...... ..x.

.. ...

. .: .. . .< .

-

.. ... . . . .. . -- .. . . on Febrhary 9,1970, and QC reject tag T858 was attached to the ',\\.f- . . . ' . . /. i <, s

.-. . .-~.: vessel. The items listed were: . . a :.r *....,;

. p.,. ~. v.

. . .,;s ........ .- ... ..: - - - . , ,. ~ .. .,.,,. .. , . " ... ., 1. ' Interior circumferential wold acam located 14. feet frors the .~ ', '. ' J ,. Drawing 11548-FI-7B) .@ top of the shield tank (reference Det. U,S..:rr. ' ,. : e." . - - . contains various cold shunts.

.. . . ... ... :.,r.

.7., . " ' - ~ - . . .g'.. <.-: .. - ,- ,- .. = - .; .z... ..: -.. - - . . ... . ,, - , 2.

Interior ocam welds are not ground emooth in accordanc'o with Ic/h ' :

.W v.

- . Drawing 11540-FI-7A.

. .-. . . ~ ; ., - -.." : - % - : '<. : :.. *;; '. :h:.?.-; /-J.:, ~. - ... - . ..,. .' -- - . .. 4.... , ... .. . ' '

Six inserts of primary chield cooling piping not ground.

...,.. ... f;,,,' - .... . .

- smooth (referenco Drawing FI-7K).

- ,x.

.~.k.. -? f I. H . ' m.+. .m ,- .. - -, -

:.s-m..s ~ - -m, -

- .- .. .:

. Various pits, gouges and weld dopcsits on interior surface.. [ ;:. , . ..,., .. . - ., .... . ,.. . ' '...... .. ~- '. y:.. '4 ':. .J . .., .. .. .. .;.. .. - ~,: ... ..[ . 'By SW interoffice correspondence to V. Suicdelis dated March 9, .. ls. : 1 _ .. :..',. - 1970, from M. Scheitner, otates, in part, "Please review QC 1.' ". ;. l . .Rojection Report No. 270. The repair shall bo done as follows: y

. ' '.

.- ' l..% /- ' '; . Condition Detail No.1: Chip out defect areas and perfom c Mr ~. .. ; '. 3; carter excavation. Preheat tank area to 200 F and weld using an

' -," ~ S ASTM E7016 or E7018 electrodo. After completion of the. weld repair ,7 Condition Detail No. 2: Weld acams shall ~f .. - perfom a hT inspection.

. ,,N I.

be ground flush to facilitate future testing (during shutdown).

' .d ., . " ' if Condition Detail No. 3: Let them rework the six inserts. Condition < . - .. _. Detail No. 4: Any weld deposit or veld splatter chall be removed."

,, . .u..c.'t;.. -. . - to D. H.' Amstrong, Scheibner states: [ ' :.:.' Ol ...,: .- . - . . . . . -.. :. .. . .. ..a ?- ".. f I' e ~ By'I.C. dated April 23, 1970, ~ +'9 . "Please refer to the above entter and to I.C. between our Vito - '... e --....

_.

• T.,:.,.,. '... Suziedelis and cyscir dated March 9,1970. Condition Detail No. 2

' of the neutron @ ..O 2 r., '.,; should reads 'All velds on the outside vertical walla ... shield tank (skirt excluded) shall be ground flush. All welds on .

n.

, ., , f.:.. '.r.. +.. -

." l,,

the inside of the sh ei ld tank shall be ground smooth, but need not .

... . l ..J(..., ;. be ground flush.

For reference see NUS-96, revised September 20, .f . ..

:,,.:...

. ~.

.' f. 2.5,:%

'.y .p ~: d.;

.;:.. ;.--- t. '

'. ".) 1968, page 4, thint paragraph."

., ,. a ...., g- .. .. ... .. '. '.... r .,...... ~ Despite these clear instructions from the mechanical equipent .. ..

~ ~

.. design supervisor, a QC MD disposition was signed off on June 11, .j . 1970, dir-etly under.a typed notation that " Repairs will be perfomed .. , ., i ,. - in acconiance with attached I.C. from H. Scheibner to V. Suziodolis ' ~ - - ., ,I.

v; - . r. ;v :?'

• '

. -dated March 9,1970."

....<< .. - . . "- . .. . -. .. .. .... . - - - .. . . e . .1 .. . . , - .... . .... l*; 97W. ' " ;;. f;[;::.... C.:.; . . . . . ' . . ', .',.," 9,'.. * # The" aeceptanee notations are ' - ., ,. - , ,^.: ::.4.; .g..;,.

f

,.l.;;-

. - ' .- . - . :s - . ...... -* .. . ..y . i/ ~.,. - 2 '?. '.i: - I.:. " .'.!.:.! _ ' ~ "Ite=s 1 and 4 completed and accepted.

_

;.. * M..%<,)...*",

s., : :..: '...# - . . , ......~.... '.

• .

'. 3,y. Item 3 acceptable as is.

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. , ' .' .- ' ~ Item 2 acceptablo as is 4 sec attached test records certifying - c . ~j$ ,!',- ' - .. , '. - , sound welda."

- ;2 - ,. .., , .. f.,. . . ,. ' ' ?.. .l.' '.. .. ....g ~ - - ,- . . . - .- Q : f.....*:.yr . ..- The inspector found that ite=s 1 and 4 had been completed acceptably.

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. . . .. .. .- , .. . . . . 'No grinding had been done of the velds on the six'lnsorts under .,.M -..,... ... ~! ~'? t'. J.. % .; ; , 6. '., *.. 'ite:n No. 3 and the wold surfaces woro very rough.

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. .. :: ?. - 4., . '. . The test records used as basis to accept item 2 consisted of Ierox . . , . .. f. *.J 1-S J' reproductions of IE report cada and a statement by I-18 Weldors . lil

. .vthat an IE and/or PT inspection had been accomplished and that , ;?.M - (Radiographic Rop ir Data) vore on file at

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. 1 '. 50 N.N. Forms 1211 . I-18 Weldors' office. It appears that radiographs were cade of ' f,:} [ .- - ~ ' ' 7. f. e, :_, ,;,. . . .[ 3. p.g.. repairs found necessary by ET.. . ' ' . ,,- , ., ... ... . '~' }?.',2 . . - '.., The ' rough surface of the welds could mask additional flaws.

- . - .% i . c . -. - .. u c.. .. . . .,, SGI brought Schoibncr to the site to talk to the inspector concerning.

.

,.y . .'.1: NN SB&DD disregani of specification requirements and sito QC over- ' ~...,-: ~ riding his written additional instructions. He had no explanation - g ;.f .,. :. ','./.. S..of the QC action. He did cay that ho thought Newport, News Ship- - ).4 . . . Mb " ' ,.j' ;., ' ;. building and Drydock Compny and I-18 Weldors have adequate NDT - . - @ ,. ' Ho agreed that better test interpretations could have - ~ . reconis.

.- ' " ~ been obtained if the welds had been grourri snooth.

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. . . . ~ .: .' 'P..... Scheibn >r then pointed out a weakening a:61guity izi the Specification ~.y . - c.. f.,.;.6.;NUS-96,revisedScptc=ber 20, 19,60: . .,. - >, .n.,. . .,, ,. .. . L.;..- - ,* s. w

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..- ..' ion' page 4, thini paragraph, the second sentence says "All wolds l , 1.y , '*. - * , -C' 'I " -f "., l. - - 7 on the inside of the tank shall be ground smooth, but need not . ,0 -

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be ground flush.". - c...:- . .: ... .. . ... u. te' . *. . . - .;. . ... .: ...

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??5 , .: :...... ~, '. ;. ; . On page 5, fourth paragraph, the next to last sentence says, .M 4G?..-

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• "The surface of all welds shall be ground to a surface

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'. condition suitable for the checking procedurti used."

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.,.- -.... ; , . . He was told, as were those at the exit ini,orview, that the fabricator ih . ,, , - . . '. ' .;- had i nored, and the inspection agents at the shop and at the site had

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condonod the ignoring, measures (grinding) which could have been imposed _..

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' . . '. 2,' Discrcrent Ucutron Shield Tank for M3 ..~[,... Roport No. 50-200/70-1,_ Annendix III. Section B) . . ....;...... '-?..'.'. . .,. . , ' ;... W. y.. -.. J,.. Tank has been rolcased for instelint. ion by SW QC through engineering .... .. .. - . .. v.

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- ., ,. . . . '.9 - .. , ,' i.*l " dispositions after minor grinding and sandblasting of inner wall surface.

. ,' ,. ;. ~ ;,This incident highlights a failuro of chop inspection followed by a .; . ', -,',.', substitution of field QC judg=ent for apoeification requirements,

'...foU.oued by stubborn refusal to trio correctivo action, culm% ting ...: 1 in forcing enginocring to writo an acceptance disposition contrary to [9 - ' 'e prior engineering written corrective instructions.

(See discussion on -

' , Ve pages 3-6 of 1,ppendix III to CO Report No. 50-280/70-4.).: *:i:.. h LCh" .'- .

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• Appendix III, cares 3 to 6 r;

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2,M,.....The neutrcn chield tank uns inspected in the storage yard in company 'y . .

. , ; T. %. ~.. .e...vd.e ~ ith Woot. It was found that the tank had been candblasted and.

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clean ~od.

' Ens sandbinsting improved visual inspection of the major . ',...J.;W .'.b.'- . . . ', '. uelds..Houover, the unground nelds cited in the refornneed report .j..c - . -] A ' ' - . '"' g...c..,. f.W . j ' ' otill hcd such a rough curfa.co that effective PI was unlikely.

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- ..... ._ . . . . .. .., _ . '- . .a ....".. d...Q . . . .. J '.# .'. '.i'.- The document was revicued. It' abowed that the tank had been .. ~ . c. 3 2,c. rolcased on August 27,11970, by CC for instnllation after the roccipt , l3 :p .. . :.e.

.. of engincoring disposition fro

s M. Scheibner otating that inspection

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• y, recordaccdsthe eldadhow they are acceptable and that radiographic

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Spence was . - - r ., . .. - l.,.cf ".. doronsivo and asked the inspector if AIC considors the tank Ji ;t.'g M . .,.

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. unacceptable. He was told that Complianco does not accept or reject

/ -:: -..' hardware. We observe and report.

VEPCO and its agents are. 'l.. '.R '. responsible for hardware acceptaneo and safe operatien.

. Inadiscussion-o

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' with Perkins at end of the exit interview, the inspector stated that ' - .16 si ' i. ; if... tho handling of the prob 1c:a on this tnnk indicated a covere lack of - c,,

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. prudence concerning possible future operating difficulties.

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