IR 05000553/1981002
| ML19347E840 | |
| Person / Time | |
|---|---|
| Site: | Phipps Bend  |
| Issue date: | 03/30/1981 |
| From: | Coley J, Herdt A NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML19347E839 | List: |
| References | |
| 50-553-81-02, 50-553-81-2, 50-554-81-03, 50-554-81-3, NUDOCS 8105140006 | |
| Download: ML19347E840 (8) | |
Text
W
o UNITED STATES
~,,
l'
NUCLEAR REGULATORY COMMISSION
,,
t
,e RE~lONll
q g
101 MARIETTA ST., N.W. SUITE 3100 D
ATLANTA, GEORGIA 30303 o
L;
T Report Nos. 50-553/81-02 and 50-554/81-03 Licensee:
Tennessee Valley Authority 500A Chestnut Street Chattanooga, TN 37401 Facility Name:
Phipps Bend Nuclear Plant Docket Nos. 50-553 and 50-554 License Nos. CPFR-162 and CPPR-163 Inspection at Phipps Bend Nuclear Plant near Kingsport, TN Inspector:
N_a 3 3-30'8]
J. L. Cole Q
Date Signed Approved by:
'D J-3o 4/
A. R. Herdt, Section Chief Date Signed Engineering Inspection Branch Engineering and Technical Inspection Division SUMMARY Inspected on March 11-13, 1981 Areas Inspected This routine, unannounced inspection involved 22 inspector-hours onsite in the areas of structural steel welding, review of containment radiographs, licensee identified (50.55(e)) items, previous inspection findings, and nondestructive examination (NDE) examiner performance.
Results Of the five areas inspected, no violations or deviations were identified.
810514 0 COh
.
.
,
h'
i
'
REPORT DETAILS 1.
Persons Contacted Licensee Employees
.
.
- W. P. Kelleghan, Project Manager
- G. Wadewitz, Construction Engineer T. V. Abbatieila, Assistant Construction Engineer, QC
- W. T. Lindemamn, Supervisor Welding, QC Unit
- L. H. Clark, Assistant Construction Engineer, E.S J. W. Self, Welding Engineer - QC R. Hagood, Welding Engineering Group Leader
- J. C. Cofield, Assistant Construction Engineer, PE
- M. Alva, Phipps Bend Quality Assurance,
- S. D. Love, Nuclear Engineer, Regulatory Staff
- S. R. Stout, Nuclear Engineer, ENDES (Telecon)
- Attended exit interview 2.
Exit Interview The inspection scope and findings were summarized on March 13,1981 with those persons indicated in paragraph 1 above.
3.
Licensee Action on Previous Inspection Findings (Closed) Unresolved Item 50-553/80-17-01, Acceptance criteria for carbon steel and stainless steel cladding on AWS D1.1 plate for the drywell vent structure. This unresolved item addressed the need for further clarifi-cation from the designer as to the sequence and methods of NDE for the
,
drywell vent structure weld and clad. The inspector reviewed the response from the designer and is satisfied with the disposition provided. This item is considered closed.
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. One new unresolved item identified during this inspection is discus-sed in paragraph 5.b.
1
- _ -.
- - -
,
.
. _. -
l
.
.
.
5.
Independent inspection Effort
,
a.
Corstruction Activities- (Unit 1)
The inspector conducted a general inspection of the auxiliary building, containment building, pipe shop, boilermakers shop, iron workers shop
,
and the NDE laboratory to observe construction progress and construc-tion activities such as welding, nondestructive examination, material
'
handling and control, housekeeping and material storage.
b.
The inspector witnessed a liquid penetrant examiner performing a penetrant examination on the stainless steel transitional clad weld located over the shell weld of the drywell vent structure (Weld No.
PI-DWVS-0005AR2). The applicable code for the transitional clad weld is the AWS Structural Welding Code D1.1 Revision 2-74.
The areas inspected involved two weld repairs which totaled 4 feet of weld.
The inspector observed the examiner removing the excessive penetrant from the first weld repair area which consisted of 3 feet of wold.
The examiner then removed the excessive penetrant from the second weld and took a 5 minute break to comply with the 5 minute minimum drying time criteria. The examiner however, was not aware that his procedure also required that liquid developer be applied within 10 minutes after removal of the excessive penetrant. The upper portion of the first weld had been drying in excess of 25 minutes before the developer was applied. The inspector noted that the sensitivity of the test had not been compromised during the extended drying period as evident by the indications that were clearly discernable, including several which required repair and reinspection. The inspector was concerned however, that the examiner did not know the parameters for the drying time. Conditions such as elevated temperatures would have an adverse effect on the test if drying times were exceeded.
The inspector also interviewed a penetrant examiner who was performing a liquid penetrant inspection on a pipe weld in the stainless steel pipe shop. The inspector found that although this examiner knew that there
.
was a maximum drying time after the removal of excessive penetrant, the time parameters he gave the inspector were not in accordance with the licensee's procedure.
Inspector followup item 53-553/80-17-02 also reported concerns which dealt with poor penetrant examiner techniques in November 1980. The inspector found no evidence in the field that the licensee had been responsive to this concern.
However, the-licensee is in the process of developing a program where examiner performance as well as other QC functions will be verified on a periodic basis.
The above concerns including those expressed in inspector followup item 553/80-17-02 were combined and reported to the licensee as unresolved item 50-553/81-02-01, Penetrant Examiner Performance. Licensee
..
.
- - - - - - - - -
-
- - - - -. -
- -
-
--
--
-
,
,
-
---m-,
p
-
.
-
progress in this area will be verified on a subsequent inspection.
Further discussion on this matter appears under paragrpah 7 of this report.
c.
The inspector observed anr examiner conducting a magnetic particle examination on a longitudinal weld for Unit 1 containment (weld number T-2301636). This inspection was conducted in accordance with the-ASME Boiler and Pressure Vessel Code, Sections NE and V,1974 edition plus addenda through summer 1974. The inspector examined the above work to determine whether:
(1) Test surface was properly prepared.
(2) The examination was conducted using the continuous method.
(3) Dry particles provided good contrast with the background 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.
,
Within the areas inspected, no violations or deviations were identified.
6.
Licensee Identified Items.
Prior to this inspection, the licensee identified the following items considered reportable under 10 CFR 50.55(e):
a.
(0 pen) Item 553,554/81-01-03, Longitudinal cracks in U.S. Steel pipe (NCR PBNP-154).
TVA-PBNP letter dated January 30, 1981 has been reviewed and determined to be acceptable by Region II.
The inspector held discussions with the cognizant unit supervisor and found that Process Specification 3.M.5.a.(d), which would incorporate the licen-see's corrective action, has been revised and is in the review cycle.
However, the inspector was informed that distribution of the revised instruction would not be completed until March 31, 1981.
This item will remain open until all corrective action proposed has been completed.
.
b.
(0 pen) Item 553,554/81-01-02, Embedded plates without heat traceability (NCR PBNP-156). On October 14e 1980, TVA notified IE:II concerning embedded plate without heat traceability.
An interim report was submitted on November 13, 1980.
The final Construction Deficiency Report was submitted on January 13, 1981. The report was reviewed and determined unacceptable by RII because corrective actions were not
i I
,
)
l
.
.
.
.
identified to prevent future identical or similar occurrences.
Dis-cussion 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 licensee (J. Ritts, NEB-Licensing)
agreed to supplement the report with additional corrective action.
The licensee supplement to the-final report was submitted on March 2,-
1981. The supplemental response was reviewed by' Region II and deter-mined to be acceptable. However, on March 12, 1981, the inspector was notified at the site that construction was not satisfied with the supplemental response submitted on March 2, 1981 and that the licensee would submit an amended supplemental response.
The licensee also
'
i notified Region II on March 12, 1981 that an amended supplemental response would be submitted. This item will remain open and licensee corrective action will be verified on a subsequent inspection.
Within the areas inspected, no violations or deviations were noted.
7.
Inspector Followup (Closed) Inspector Followup Item 50-553/8C-17-02, Liquid Penetrant Tech-niques. This item pertains to poor liquid penetrant examiner techniques observed during an examination of the transition layer of clad on the drywell vent structure. The inspector performed additional surveillance of liquid penetrant examiners this inspection and found that the licensee's liquid penetrant examiner's techniques have not improved. Examples of poor examiner techniques noted this inspection are as follows:
a.
Examiners performing liquid penetrant examination on more weld than they can complete in the times qualified by their procedures.
b.
Examiners do not know all the qualified parameters of their test procedure.
c.
Examiners are not using test procedures that are on the job, wh~en they are not sure of a requirement.
d.
One examiner did not bring a test procedure to the job and did not know all the qualified parameters of the procedure when interviewed.
e.
Examiners (2) using calibrated thermometers on the job that had broken gage glass or no gage glass in them.
f.
Examiners that when questioned were not assured as to what steps they would take to disposition a non-relevant indication.
This item was closed as an inspector followup item and has been open as
+
unresolved item 50-553/81-02-01. Further discussion on this matter appears under paragraph 5.b of this report.
.
__
..-
_ -.. _ _ _
-
.-.
. - -.
!
.
- 8.
Steel Structures and Supports a.
Observation of welding activities on the drywell vent structure. The applicable code for welding on the drywell vent structure is the AWS l
structural welding code D1.1, revision 2-74. The following welding was observed:
Weld Number Item Welded l
PIDWVS00038AR3 Vertical seam (2) weld repairs P1DWVS0001:R4 Vertical seam weld repair on cladding P1DWVS00015AR2-Vertical seam weld repair on cladding IT000020025 Vertical seam T.I.P Room Plate Assy.
IT000020027 Vertical seam T.I.P Room Plate Assy.
The inspector examined the above work to determine whether:
(1) Work is conducted in accordance with a document which coordinates and sequences operations, references procedures, and provides for hold points.
"
(2) 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.
(6)
Electrodes are used in positions and with electrical character-istics 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 weld material storage / segregation, oven temperatures and issue records.
Within the areas inspected, no violations or deviations were identified.
.
.
___ _- _.
_. _
.--
.
_. _
.
.,
-
5.
Steel Structures and Supports a.
Observation of Welding Activities on Unit 1 Containment The inspector observed field welding of the unit 1 containment. The-applicable code for welding on the containment is the ASME Boiler and Pressure-Vessel Code,Section III Subsection NE,1974 Edition including the 1974 summer addenda. The following welds were observed.
Weld Number Weld Status T2301632 Intermediate layers
- T2301636 Root back gouge T2301771 Completed weld T2301769 Completed weld
'
The inspector examined the above work to determine whether:
(1) Work is conducted in accordance with a document which coordinates and sequences operations, references procedures and provides for hold points.
(2) 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 4 in accordance with applicable procedure and inspected.
(5) Alignment of parts are-in accordance with applicable requirements (6) Electrodes are used in positions and with electrical character-istics specified.
(7) Welding equipment is in good working condition.
b.
~ Review of Radiographic Film for Unit 1 Containment The inspector reviewed radiographs for the containment shell plate t
welding. The applicable code for this welding is the ASME Boiler and l
Pressure Vessel Code,Section III, Subsection NE 1974 Edition plus
)
addenda through summer 1974. Radiographs of the following welds were I
reviewed.
I Weld Number Thickness & Length of Weld Ring #
T2301738 1.5" X 120"
T2301699 1.5" X 120"
,
l T2301701 1.5" X 120"
.
d
.
e-
,-
-
- - - - -,,. - -
-
--
. - - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
.o
..
i T2301742 1.5" X 120"
T2301740 1.5" X 120"
Within the areas inspected, no violations or deviations were identified.
.
l
.
-
-
.
- - - - -