IR 05000553/1980017
| ML19341C371 | |
| Person / Time | |
|---|---|
| Site: | Phipps Bend  |
| Issue date: | 01/02/1981 |
| From: | Coley J, Herdt A NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML19341C369 | List: |
| References | |
| 50-553-80-17, NUDOCS 8103030186 | |
| Download: ML19341C371 (9) | |
Text
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enuc UNITED STATES
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NUCLEAR REGULATORY COMMISSION
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,.f, REGION 11
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101 MARIETTA ST., N.W., SUITE 3100 o, f '
ATLANTA, GEORGIA 30303 g,
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Report No. 50-553/80-17 Licensee: Tennessee. Valley Authority 500A Chestnut Street Chattanooga, TN 37401 Facility Name: Phipps Bend Docket No. 50-553 License No. CPPR-162 Inspection at: Phipps Bend Nuclear site near Kingsport, Tennessee
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Inspec r:
oley Date Signed
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Approved by:
A RfHerdt,SectionChief,RC&ESBranch D' ate Signed SUMMARY Inspection on November 17-20, 1980 Areas Inspected This routine, unannounced inspection involved 31 inspector-hours on site in the areas of steel structure and supports, review of containment radiographs, review of AS!!E Code piping radiographs, review of nondestructive examination (NDE) examiner performance in the areas of liquid penetrant, magnetic particles and radiographic examination, welding material controls, and review of NDE examiner qualification records and review of NDE procedures.
Resul ts Of the seven areas inspected, no items of noncompliance or deviations were identified.
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I DETAILS 1.
Persons Contacted Licensee Employees
- W. P. Kellegham, Project Manager
- G. Wadewitz, Construction Engineer
- M. Alva, Phipps Bend Quality Assurance
- W. K. Burner, Quality Control (Welding)
- H. B. McCracken, Mechanical Engineer
- T. V. Abbatiello, Assistant Construction Engineer, QC
- J. C. Cofield, Assistant Construction Engineer, PE
- J. E. Rose, Project Engineer (Welding)
- J. Ritts, NEB Licensing
- L. Hebert, OEDC - Quality Assurance Other licensee employees contacted included construction craftmen, ten technicians, operators, mechanic, security force members, and two office personnel.
Other Organizations A. G. Bishop - General Electric Company
- Attended exit interview 2.
Exit Interview The inspection scope and findings were summarized on November 20, 1980, with those persons indicated in Paragraph 1 above.
The unresolved item described in paragraph 5.f and the inspector followup item described in paragraph 5.e were discussed.
In addition, the licensee and the inspector discussed the reply (received during the exit interview) from C. F. Braun and Co., to the licensee's Design Information Request for clarification of the inspection / acceptance criteria to be used on the carbon steel plate and stainless steel clad dry wall vent structure.
It was mutuality agreed that this item will remain an unresolved item as described in paragraph 5.f since C. F. Braun's reply raised concerns that could not be resolved during this inspection.
3.
Licensee Action on Previous Inspection Findings Not inspected.
4.
Unresolved Items Unresolved items are matters about which more information is required
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to determine whether they are acceptable or may involve noncompliance or deviations.
One new unresolved item identified during this inspection is discussed in paragraph 5.f.
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5.
Independent Inspection Effort a.
Construction Activities (Unit 1)
The inspector conducted a general inspection of the auxiliary building, the containment building, fuel building, pipe shop, stainless steel shop and the NDE laboratory to observe construction progress and construction activities such as welding, nondestructive examination, material handling and control housekeeping and storage.
b.
On November 17, 1980, the inspector returned to the site on backshift to conduct surveillance of radiographic examiner's technique to verify that radiographic examination is being conducted by properly qualified personnel, in accordance with an approved procedure.
The inspector observed three separate set-ups and shots on a welder's qualification pipe joint, number F-125 for welder 6-375 which was 6 inches in diameter and.864 inch thick.
The applicable code for the radiographic examination technique is the ASME Boiler and Pressure Vessel Code,Section V 1974 Edition plus addenda through summer 1974.
c.
The inspector reviewed the licensee's nondestructive examination (NDE) procedures to verify that the nondestructive examination procedures met the applicable code requirements.
The applicable code for NDE is the ASME Boiler and Pressure Vessel Code,Section III and V,1974 Edition,. us addenda through summer 1974 and AWS Structural Welding Code D1.1, Revision 2-74.
The following procedures were reviewed:
(1) QCI-N-201, Revision 3, " Magnetic Particle Examination of ASME Welds Prod and Yoke Dry Powder "ethod."
(2) QCI-N-101, Revision 4, " Liquid Penetrant Examination Solvent Removable Method of ASME Welds".
(3) QCI-N-102, Revision 2, " Liquid Penetrant Examination of AWS Welds Solvent Removable Method".
(4) QCI-N-301, Revision 3, " Radiographic Examination of Welds ASME".
(5) QCI-N-501, Revision 4, " Visual Inspection of ASME Welds".
d.
The inspector observed an examiner conducting a magnetic particle examination, in the pipe shop, on a 24-inch diameter ESW pump suction system pipe weld number P0-KE-00920.
This was an ASME Code Class 3 pipe weld.
The inspector examined the above work to I
determine whether:
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(1) Test surface was properly prepared
(2) The examination was conducted using the continuous method.
(3) Dry particles provided good contrast with the back ground surface.
(4) Equipment was within its calibration intervals and a lift test was performed.
(5) Yoke poles spacing was adequate.
(6)
Proper MT coverage of the weld.
(7) Particles were properly applied and removed.
(8) Evaluation was in accordance with applicable code.
(9) Test report properly documented and work package was at the job site.
e.
The inspector observed a liquid penetrant examiner performing a liquid penetrant examination on the stainless steel transitional clad weld located over the shell weld of the drywell vent structure, (weld number PL-0W-V5-00037).
The applicable code for the stainless steel cladding is the ASME Boiler and Pressure Vessel Code,Section III subsection NE 1974 Edition including the summer 1974 addenda which is invoked by C. F. Braun and Company specification 300-09 paragraph 19.4.
The examiner noted the following concerns with the examiner's liquid penetrant technique:
(1) The examiner did not have a watch to time the inspection intervals.
Reliance on personnel including the inspector for correct time could lead to improper time periods for drying after cleaning penetrant, dwell time and time limitations for evaluation of the weld.
(2) After cleaning the excess penetrant off the weld, the examiner was observed rubbing the clean weld with their hands.
This practice could contaminate the clean surface with oil from the skin.
(3) When questioned by the inspector before the application of the developer, the temperature of the metal that the PT test was being conducted on was checked by the examiner with a thermometer and found to be below the minimum 60 degrees F required to perform the (PT) examination.
The examiner stopped the examination at this point and another PT examiner performed the examination of this weld.
(The inspector also noted that the magnet on the thermometer was not strong enough to hold the thermometer on the test surface during the inspection due to the stainless steel cladding.)
The licensee should establish a method that will ensure the thermometer will adhere to the surface near the area of interest during the entire inspection, so that surface temperatures can be monitored particularly during extreme cold weather when PT test result 3 could be jeopardized.
This item was reported as an
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4 inspector followup item no. 50-553/80-17-02, " Liquid penetrant Techniques" Liquid penetrant examiner's Techniques will be reviewed on a subsequent insnection.
f.
The inspector observed during the liquid penetrant examination perfomed by both liquid penetrant examiners noted in paragraph 5.e above that the PT examinations were being conducted and evaluated in accordance with AWS D1.1 requirements in lieu of ASME Code Section III, subsection NE as required by C. F. Braun and Company Specification 300-09 for stainless steel welds.
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Acceptance standards invoked by subsection NE of the ASME Code are more restrictive for linear indications than the requirements in AWS D1.1.
The inspector inquired concerning the licensee's use of the AWS D1.1 acceptance criteria on stainless steel welds when AWS D1.1 does not apply to stainless steel and C. F. Braun and Company specification 300-09 specifically states; "All stainless steel welds, and welds of stainless steel to carbon steel, shall be examined for 100 percent of the length by the liquid penetrant method in accordance with NE-5100 of ASME Code Section III.
In addition, all repair welds shall be examir.ed in the same manner.
Acceptance standards shall be in accordance with NE-5300 of ASME Code Section III."
The inspector was shown a Design Infomation Request, (DIR No.
W-012) which the licensee had requested from General Electric Company pemission to incorporate stainless steel (E 309-15 or 16 type electrode) to the carbon steel shell plate welds of the drywell vent structure by reducing the thickness of the carbon steel strength member by 1/8 inch and welding this reduced area with E-309 stainless steel to develop strength in the completed strength weld. The licensee had requested that welding be perfomed per an AWS D1.1 weld procedure (SM-U-6 rev.1).
General Electric's design project disposition was as follows; "Yes, type 309 or 309L may be incorporated in the strength weld of clad plates up to 1/8" max. The weld overlay shall consist of two or more layers, the layer deposited on the carbon steel shall be 309L. The final layer shall be 308L or 309L."
The licensee concluded that since he had requested the weld to be part of the strength member and has ask for permission to use a AWS welding procedure that he would also examine the final transitional stainleu steel clad weld to AWS acceptance criteria for liquid penetrant inspection.
However the inspector pointed out to the licensee that he did not request this relief to the C. F. Braun and Company specification (300-09). The licensee requested in part for and received permission to deviate from paragraph 17.8.1 of the C. F. Braun specification which for the welding of stainless steel states that; "All welding shall be done by qualified welders and only after welding procedure specifications and procedure qualification records have been submitted on foms similar to those shown in ASME Section IX and
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approved by the Engineer.
All welding procedures and qualification tests shall be in accordance with Section IX of the ASME Code.
The licensee decided to send another Design Information Request (DIR-W-023) for clarification of the acceptance criteria to be used since the licensee had not proceeded on any stainless steel cladding beyond the final transitional layers of the strength member.
The reply to DIR-W-023 was received during the exit interview.
The inspector had the following questions that could not be resolved as a result of this reply were:
(1)
Should the carbon steel have been magnetic particle inspected in accordance with paragraph 19.3 prior to stainless steel cladding (300-19) which states; " Magnetic of the C. F. Braun specification particle examination shall be performed on all carbon steel plate seams and all other welaed carbon steel joints of the drywell vent structural steel.
Personnel shall be qualified in accordance the AWS Structural Welding Code Paragraph 6.7.7.
See Section 19.4 of C. F. Braun specification 300-09 for welds between carbon and stainless steels."
(2) Would you have to PT the first layer of the stainless steel to carbon steel to the ASME acceptance criteria since paragraph 19.3 and 19.4 of the C. F. Braun specification both required this inspection.
The licensee had not performed a magnetic particle inspection of the carbon steel outside surface prior to clad welding nor had the licensee PT examined the first layer of the stainless steel clad weld but had PT examined the second layer or final layer of the transitional clad weld.
(3) The inspector questioned General Electric's (GE) reply which now considered the transitional layers of the stainless steel as part of the cladding which would only receive a final PT.
The inspector questioned the licensee if a 1/8" reduction in the strength member would violate minimum wall for the drywell vent structure?
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(4) The inspector also questioned the licensee concerning the use of a DIR for changes to design requirements.
The title de.iotes design information is requested not design criteria changea. This information is received by telephone and this verbal exchange could lead to misinterpretation, which apparently is what has
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happened in this situation where the reply to DIR (W-012) does not agree with the reply to DIR (W-023).
Due to the questions raised above, the inspector and the licensee concurred that this item could not be resolved without more information on the points raised by the inspector.
This item was reported as an unresolved i tem no.
50-553/80-17-01, " Acceptance Criteria for Carbon Steel and Stainless Steel Cladding on AWS D1.1 Plate for the Drywell Vent Structure".
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The inspector reviewed the qualification records for six individuals who were qualified to perform visual, liquid penetrant, magnetic particle and/or radiographic examinations.
In addition certifications for the penetrant material's used were reviewed for the following material; Material Type Batch No.
Liquid Penetrant SKL-HF/S 78H008 Penetrant Cleaner SKC-NF 80E116 Developer SKD-NF 78H045 Within the areas inspected, no violations or deviations were identified.
6.
Steel Structure and Supports a.
Observation of Welding Activities on the Dry Weld Vent Structure and the Foundation Plate The inspector observed field welding of the drywell vent structure and the drywell foundation plate. The applicable code for welding on the drs 1 vent structure is the AWS structural welding code D1.1, Rev-2-74.
The applicable code for the welding of the drywell ve ucture to the foundation is the ASME Boiler and Pressure Ved Code,Section III subsection NE,1974 Edition including the
,,4 summer addenda. The following welds were observed; Weld No.
Part Code 1DWVS 00013 Interplate Longitudnal AWS Weld 22-J Transitional Clad Weld AWS 500 T-Bar Weld from Drywell ASME to foundation
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The inspector examined the above work to determine whether:
(1)
Work is conducted in accordance with a document which i
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coordinates and sequences operations, references procedures,
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establishes hold points, and provides for hold points.
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Procedures, drawings, and other instructions are at the work station and readily available.
(3) Welding technique and sequence are specified and adhered to.
(4) Weld joint geometry is in accordance with applicable procedure and inspected.
(5) Alignment of parts are in accordance with applicable requirements.
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(6) Electrodes are used in positions and with electrical characteristics specified.
(7) Welding equipment is in good working condition.
b.
Inspection of weld material issue stations The inspector observed the weld rod control issue station outside of the containment and at the pipe shop to determine adequacy of
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weld material storage / segregation, oven temperatures and issue records.
Within the areas inspected, no violations or deviations were identified.
7.
Steel Structures and Supports - Review of Radiographic Film for Unit 2 Containment The inspector reviewed radiographs for the containment shell plate welding. The applicable code for this welding is the ASME Boiler and Pressure vessel Code,Section III, Subsection NE 1974 Edition plus addenda through summer 1974.
Radiographs of the following welds were reviewed.
Joint No.
Thickness Weld Procedure 1T23-01631 1.750" GM-11-B-6R-3 1T23-01662R1 1.750" DWP-SA1181-R2 IT23-01672 1.750" DWP-SA11B1-R-2 IT23-01707 1.500" DWP-SA1181-R-2 IT23-01697 1.500" DWP-SA1181-R-2 1T23-01635 1.750" GM-11-B-6R-3 1T23-01629 1.750" GM-11-B-6R-3 IT23-01662 1.750" GM-11-B-6R-3 IT23-01666 1.750" GM-11-B-6R-3
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1T23-01742 1.500" DWP-SA1181-R-2 Within the area inspected, no violations or deviations were identified.
8.
Safety-Related Piping - Review of Radiographic Film The inspector reviewed radiographs of welds for the Water Positive Seal System. The applicable code for this welding is the ASME Boiler and Pressure Vessel Code Section III 1974 Edition with addenda through summer 1974.
Radiographs of the following welds were reviewed; Joint No.
Class Diameter Thickness 1-P6000003S1
2"
.154" 1-P60000005
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.154" I
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1-P6000007
2"
.154" 1-P6000008
2"
.154" 1-P6000008B
2"
.154" 1-P6000009
2"
.154" 1-P6000010
2"
.154" 1-P6000013
2"
.154"
1-P6000015
2"
.154" 1-P6000016
2"
.154" Withh the area inspected, no violations or deviations were identified.
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