IR 05000553/1981001
| ML20003D129 | |
| Person / Time | |
|---|---|
| Site: | Phipps Bend  |
| Issue date: | 02/11/1981 |
| From: | Crowley B, Herdt A NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML20003D127 | List: |
| References | |
| 50-553-81-01, 50-553-81-1, 50-554-81-01, 50-554-81-1, NUDOCS 8103190338 | |
| Download: ML20003D129 (8) | |
Text
W ea
. '.'p vg'o UNITED STATES
'
- '
^^
NUCLEAR REGULATORY COMMISSION n
.E REGj0N ll g
[
101 MARIETTA ST., N.W., SulTE 3100 e
ATLANTA, GEORGI A 3o303 s
g *... o Report Nos. 50-553/81-01 and 50-554/81-01 Licensee: Tennessee Valley Authority 500A Chestnut Street Chattanooga, TN 37401 Facility Name: Phipps Bend Docket Nos. 50-553 and 50-554 License Nos. CPPR-162 and CPPR-163 Inspection at Phipps Bend site near Kingsport, Tennessee Inspector:
/br/
2 //
,
,
B. R.
o le
/
Date Signed Approved by:
k//
A. R. Herdt, Section Chief, RC&ES Branch Date Signed SUMMARY Inspection on January 20-23, 1981 Areas Inspected This routine unannounced inspection involved 28 inspector-hours on site in the areas of previous inspection findings (Unit 1), licensee identified (50.55(e))
items (Units 1 and 2), steel structures and supports - welding (Unit 1).
Results l
No apparent violations or deviations were identified.
l l
.
!
l I
i'
I L-8103190338.-
m
.
s=
DETAILS 1.
Persons Contacted Licensee Employees
- W. P. Kellegham, Project Manager
- G. Wadewitz, Construction Engineer
- T. V. Abbatiello, Assistant Construction Engineer, QC
- J. C. Cofield, Assistant Construction Engineer, PE
- D. E. Hitchcock, Supervisor Site QA Unit
- J. J. Ritts, NEB Licensing (Telecoa)
- W. A. Anders, OEDC-QA (Telecon)
- S. D. Love, Regulat)ry Staff (Chattanooga)
- W. T. Lindeman, Supervisor Welding QC Unit E. J. Barnett, Supervisor Mechanical Project Engineering Unit J. N. Odum, Project Engineer, Mechanical
.l. W. Self, Welding Engineer-QC J. E. Rose, Project Engineer, Welding R. Hagood, Welding Engineering Group Leader W. Bailey, _ Welding Engineer-QC L. C. Hatmaker, Examination Group Leader, Welding QC Unit Other Organizations
- A. G. Bishop, Site Manager (General Electric)
A. F. Finn, Site Manager for Special Projects (General Electric)
R. McCrossen, Field QA Supervisor (VSL)
- Attended exit interview.
-2.
Exit Interview The inspection scope and findings were summarized on January 23, 1981, with those persons indicated in Paragraph I above.
3.
Licensee Action on Previous Inspection Findings (Closed) Unresolved Item 553/80-15-03, VSL Record Storage Facilities. This item pertained to a subcontractor not storing site records for one job in a fire proof safe. The decision was made to store VSL QA records in the TVA records vault. The inspector verified that this was in fact being done.
This matter is considered resolved.
(Closed)
Unresolved Item 553/80-15-06, Pipe Storage - BOP.
This item pertained to poor pipe storage conditions in a non-safety-related (BOP) area of the plant.
The licensee stated that their intent is to store all permanent plant piping (safety-related and BOP) in accordance with Standard Operating Procedure (SOP) ES-9.
The inspector observed pipe storage conditions in the area in question (Condenser Bay) and other areas of the a
_ _ _ - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _.
_ _ _ _. _ _ _ _ _ _ __
__
.__ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ - _ _ _ _
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ - _ _ _ - _ _ _ _ _ _ _ _ _ _ _ _
.
V
plant. No cases of poor pipe storage were noted. This matter is considered
,
resolved.
(0 pen)
Unresolved Item 553/80-15-05, Storage and Handling of SAW Flux Material.
The licensee is still evaluating this problem.
During the inspection, the decision was made to revise the applicable procedures to be more specific in this area.
(0 pen) Unresolved Item 553/80-17-01, Acceptance Criteria for carbon steel and stainless steel cladding on AWS D1.1 plate for drywell vent structure.
This unresolved item addressed three separate problems relative to the drywell vent structure overlay clad - (1) the use of stainless steel for welding 1/8" in thickness of the strength member, (2) use of the Design Information Request (DIR) for resolving the questions relative to the clad, and (3) the required sequence of NDE for the weld and clad. The inspector reviewed the problems and considers items (1) and (2) to be acceptable.
However, item (3), the sequence and methods of NDE, needs further clarifi-cation from the designer. The licensee agreed to obtain this clarification.
4.
Unresolved Items Unresolved items were not identified during this inspection.
5.
Independent Inspection Effort A general plant tour was made and the following areas of interest examined by the inspector:
a.
General construction activities and conditions such as housekeeping were observed in the reactor building, auxiliary, fuel, radwaste, and turbine buildings for Unit 1.
b.
The inspector observed in process welding and inspection activities for the Unit I drywell vent structure (OVS). The applicable code for this welding is the AWS Structural Welding Code 01.1, Revision 2-74.
The following activities were observed:
(1) Weld PIDWVS00014R3 was observed during liquid penetrant (PT) of repair excavations. Inspector technique was observed.
(2) Welds P1DWVS00018R2, P1DWVS00034R5 and P1DWVS00038R2 were observed during repair welding. Use of correct procedure, correct preheat, correct welding material and welder qualification were examined.
Within the areas inspected, no violations or deviations were identified.
.
.
.
p
6.
Licensee Identified Items (LII)
Prior to this inspection, the licensee identified the following items considered reportable under 10 CFR 50.55(e):
a.
(Closed) Item 553/79-18-02, 554/79-17-02 - Improper heat treatment of reactor pressure vessel pedestal studs (NCR S-10). The studs for t5e Phipps Bend units and the Hartsville units are all part of the same order. Therefore, the certification package at Hartsville also applies to Phipps Bend.
See IE:RII Repart 50-518, 519, 520, 521/81-01 for details of the inspecter's review of this item.
b.
(0 pen) Item 553/80-06-01, 554/80-05-01 - Incorrect root face on skewed cadweld sleeves (NCR CEB 20-11).
On March 14, 1980, TVA notified IE:RII of a 50.55(e) item concerning cadweld sleeve root faces of 3/32" to 1/2" in lieu of the required 1/16". An interim report was submitted on April 14, 1980.
The final Construction Deficiency Report was submitted on June 19, 1980.
The report has been reviewed and determined to be unacceptable by RII because corrective actions are not identified to prevent future identical or similar occur rences.
It should be noted that to prevent future occurrences, the causes of the deficiency must be fully explored and identifieG.
The licensee (J. Ritts, NEB -Licensing) agreed to supplement the report with addi-tional corrective action. This item remains open pending receipt and review of supplemental information.
c.
(0 pen) Item 553/80-10-09 - RPV shroud head and moisture separator (MS)
fire (NCR PBNP 106). On June 13, 1980 TVA notified IE:II of a 50.55(e)
item concerning a fire during shipment of RPV shrodd head and MS assembly. Interim recorts were issued July 14 and September 23, 1980.
The final Construction Deficiency Report was submitted on December 19, 1980.
The report has been reviewed and determined to be unacceptable by RII because corrective actions are not identified to prevent future identical or similar occurrences. It should be ncted that to prevent future occurrences, the causes of the deficiency must be fully explored and identified.
Also, RII has requested that TVA notify RII of the results from the cleaning cperation.
The licensee (J. Ritts, NEB -
Licensing) agreed to supplement the report with additional corrective action and results from the cleaning operation.
In addition to review of the resort, the inspector visually observed the candition of the MS assembly.
Except for initial attempts to remove the melted polyethylene by hydroblasting, the cleaning operation has not started. GE has been contracted for the cleaning operation and is on site making preparations to start cleanup.
Procedures for the cleaning are in the process of being reviewed and approved. This item remains open pending completion of the cleanup and receipt and review of supplemental information.
_
_ _. _
_
..
>
.
4 d.
(0 pen)
Item 553, 554/81-01-01, Specification of fillet welds in lieu of beveled groove welds.
(PBRD-50-553, -554/81-01).
On December 8, 1980, TVA notified IE:II of a 50.55(e) item concerning specification of fillet welds in lieu of groove welds. An interim report was submitted on January 7,1981.
TVA anticipates transmitting a final report on this matter by April 6,1981.
e.
(0 pen)
Item 553, 554/81-01-02, Embedded plates without heat trace-ability (NCR PBNP 156). On October 14, 1980, TVA notified IE:II of a 50.55(e) item concerning embedded plates without heat traceability. An interim report was sabmitted on November 13, 1980.
The final Construction Deficiency Report was submitted on January 13, 1981. The report has been reviewed and dete-mined to be unacceptable by RII because corrective actions are not identified to prevent future identical or similar occurrences. It should be noted that to prevent future occurrences, the causes of the deficiency must be fully explored and identified.
Discussions with site personnel revealed that the cause of the problem had been identified as mis-identification of plates during transfer of heat numbers when plates were cut. The site had started the use of a heat number log to correct this problem. The licensee (J. Ritts, NES - Licensing) agreed to supplement the report with additional corrective action.
This item remains open pending receipt and review of supplemental informaticn.
f.
(0 pen) Item 553, 554/81-01-03, Longitudinal cracks in U. S. Steel pipe (NCR PBNP 154). On October 3,1980, TVA notified IE:II of a 50.55(e)
item concerning cracks in U. S. Steel pipe. An interim report was submitted on November 3,1980. TVA anticipates transmitting a final report on this matter by February 2, 1981.
Discussions with site personnel reveal that inve:tigations to date indicate the defects identified were normal manufacturing laps and seams rather than cracks.
g.
(0 pen)
Item 553, 554/80-01-04, Inadequate welds on embedded pipe sleeves to plates (NCR PBNP 160). On October 24, 1980, TVA notified IE:II of a 50.55(e) item concerning the use of a fillet weld in lieu of full penetration welds on sleeve to flange welds for embedded sleeves.
An interim report was submittea on November 24, 1980. TVA anticipates transmitting a final report on this matter by February 23, 1981. At
'
the time of this inspection, the licensee was in the process of correcting this protstem by reworking all sleeve to flange welds to effect a full penettstion weld. The inspector examined the following Unit 1 in process work:
(1) Observed final welds for. sleeves RW-330, RW-335, RW-336, RW-337,
' RW-339, RW-340 and RW-344.
(2) Observed grinding for full penetration weld preps on sleeves RW-482 and RW-483.
a
.-
.
_ _.
e^
(3) Observed welding, reviewed operation checklist, verified welder qualification, and verified use of correct welding procedure on sleeve RW-830.
h.
(0 pen)
Item 553, 554/81-01-05, Deficient welds on weir wall liner plates (NCR PBNP 135). On August 20, 1980, TVA notified IE:II of a 50.55(e) item concerning deficient welds on weir wall liner plates.
Interim reports were submitted on September 19 and November 24, 1980.
The final Construction Deficiency Report was submitted on December 22, 1980.
The report has been reviewed and determined to be unacceptable by RII becausa corrective actions are not identified to prevent future identical or similar occurrences. It should be noted that to prevent future occurrences, the causes of the deficiency must be fully explored and idcntified.
The licensee (J. Ritts, NEB - Licensing) agreed to supplement the report with additional corrective action. The inspector observed Unit 1 panels WW-6, WW-7, WW-8, WW-9, and WW-10 in the shop being assembled.
Many areas of poor workmanship such as unfused welding wire fused to welds, arc strikes and weld spatter were noted.
The inspector questioned the licensee relative to these welds since the final Construction Deficiency Report indicated that all welds had been corrected. The licensee stated that the welds had been corrected to meet the vendor's obligation, but TVA still intended to clean up the welds from a workmanship standpoint during assembly. This item remains open pending receipt and review of supplemental corrective action and completion of weld cleanup.
1.
(0 pen) Item 553/81-01-06, Base metal crack in drywell vent structure.
On January 14, 1981, TVA notified IE:II of a potential 50.55(e) item concerning cracks in the drywell vent structure (DVS).
TVA confirmed the matter to be reportable on January 23, 1981. A written report is due February 14, 1981. During the inspection, the inspector examined four cracks as follows:
(1) A through wall crack was observed in the top ring of the outer shell of the DVS starting at the corner of a square cutout at the top of the plate and running diagonal down the plate to the first horizontal weld approximately three feet below.
(2) A crack partially in the fusion line and partially in the base metal was observed at one of the vertical welds in the outer shell of the OVS. The crack was approximately 20" long.
(3) A third crack war observed in the fusion line of another vertical weld of the DVS. The length of this crack was not determined.
(4) The inspector also observed one crack in a radiograph of another vertical weld of the outer shell.
.
--
-
..
.
e-
The licensee had removed samples from the first crack noted above and was in the process of performing metallurgical examinations of the samples.
Within the areas inspected, no violations or deviations were identified.
7.
Inspector Followup Items (IFI)
(0 pen) Item 553, 554/78-08-01, Inspection of weir wall and fusi pool liners (SMC). The vendor has corrected the weld problems identified on the initial-inspection of the weir wall liners.
However, additional poor welding has been identified and is still in process of being corrected (see paragraph 6.g. of this report). TVA has corrected the welds on the Unit I fuel pool itners. Unit 2 fuel pool liners have not all been shipped to the site.
Upon receipt, TVA will inspect and correct accordingly.
The inspector visually observed the following Unit 1 panels on the Fuel Transfer Pool to verify that welds had been corrected:
FTP-WU3 FTP-WU4 FTP-WUS.
Within the areas inspected, no violations or deviations were identified.
8.
Steel Structures and Supports (Unit 1)
The inspector examined welding activities for steel structures outside the containment as described belcw to determine whether applicable code and procedure requirements were being met. The applicable code for the welding examined is the ASME Boiler and Pressure Vessel Code,Section III, Sub-section NE,1974 Edition including Addenda through S74.
a.
Observation of Welding Activitie; The inspector observed in process fuel pool liner welds PINM00207, PINM00197, and PINM00199 at various stages of completion. The work was observed to determine whether:
(1) Work is conducted in accordance with a document which coordinates and sequences operations, references procedure, establishes hold points, and provides for production and inspection approval.
(2) Weld identification and location are as specified.
(3) Procedures, drawings, and other-instruc;!ons are at the work station and readily available.
(4) WPS assignment is in accordance with applicable code requirements.
-(5) Welding technique and sequence are specified and adhered to.
a
.
..
e
(6) Welding filler materials are the specified type and traceab'<e to certifications.
(7) Weld joint geometry is in accordance with applicable procedure and inspected.
(8) Alignment of parts is as specified.
'
(9) Preheat and interpass temperatures are in accordance with procedures.
(10) Electrodes are used in positions and with electrical character-istics specified.
(11) Welding equipment is in good condition, (.12)
Interpass cleaning is in accordance with applicable procedures.
(13) Temporary attachments are removed in accordance with applicaole procedures.
(14) Process control system has provision for weld repairs.
(15) Welding and inspection personnel are qualified.
-
(16) Weld history records are adequate.
b.
Visual Examination of Welds The inspector visually examined completed fuel transfer pool welds P1HM00528, PINM00529, P1NM00531, PINM00533, PINM00558, PINM00559, PINM00594 and PINM00595 to determine whether the folicwing character-istics conformed to applicable codes and specification (1) location, length, size and shape (2) Weld surface finish and appearance (3) Weld reinforcement - height and appearance (4) Removal of temporary attachments, arc strikes and weld spatter (5) Finish grinding or machining of weld surface - surface finish and absence of wall thinning (6) Surface defects - cracks, laps, lack of penetration, lack of fusion, porosity, slag, oxide film and under cut exceeding prescribed limits.
Within the areas inspected, no violations or deviations were identified.
f
___
_
_;