IR 05000566/1981002
| ML19347E323 | |
| Person / Time | |
|---|---|
| Site: | Yellow Creek  |
| Issue date: | 03/04/1981 |
| From: | Herdt A, Kleinsorge W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML19347E206 | List: |
| References | |
| 50-566-81-02, 50-566-81-2, 50-567-81-02, 50-567-81-2, NUDOCS 8104240574 | |
| Download: ML19347E323 (9) | |
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UNITED STATES
""j, NUCLEAR REGULATORY COMMISSION
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OU REGION 11
101 MARIETTA ST., N.W., SUITE 3100 ATLANTA. GEORGIA 30303
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Report Nos. 50-566/81-02. and 50-567/81-02 Licensee: Tennessee Valley Authority 500A Chestnut Street Chattanooga, TN 37401
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Facility Name: Yellow Creek Docket Nos. 50-566 and 50-567 License Nos. CPPR-172 and CPPR-173 Inspection at Yellow Creek Site near Iuka, MS h
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Inspector
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./- W. P. Kleinsorge Date Signed Approved by 2/5'M A. R. Herdt, Section Chief, M&P Section, Date Signed EI Branch, ETI Division SUMMARY Inspection on February 17-20, 1981 Areas; Inspected This routine, unannounced inspection involved 26 inspector-hours on site in the areas of reinforcing steel (Unit 1), safety-related piping (Units 1 and 2) and steel structures and supports (Unit 1).
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Results
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Of the three areas inspected, no violations or deviation were identified in one area; two violations were found in each of two areas (Violation
" Failure to Follow Concrete Inspection Procedure" paragraph 5.b.; Violation
" Failure to Establish Adequate Measures to Control Welding and NDE" paragraphs 6.b(1) (a)1 and 6.b(2)(c)1).
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s DETAILS 1.
Persons Contacted Licensee Employees
- M. M. Price, Project Manager
- L. S. Cox, Construction Engineer
- C. G. Wages, Assistant Construction Engineer - QC
- R. G. Delay, QC - M&C
- S. Blount, PMS - TS, Construction
- J. C. Barron, PMS - TS Construction
- L. B. Parker, QC - MSU Construction
- L. Wyatt, Welding QC
- D. Norsworthy, Welding QC j
- L. C. Marshall, PE, Mechanical Other licensee employees contacted included several construction craftsmen, technicians, and office personnel.
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- Attended exit interview 2.
Exit Interview The inspection. scope.and findings were summarized on February 20, 1981 with
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those persons indicated in paragraph 1~above. ~The inspector identified the areas inspected, and discussed the two violations and two unresolved. items in detail. th) dissenting. comments were received from the licensee.
3.
Licensee Action.on Pr.ev. iou Inspection F.indings Not inspected.
4.
Unresolved Items Unresolved items are matters about which more information is required to determine whether they they are acceptable or may involve noncompliance or l
deviations.
New unresolved items identified during this inspection are discussed in paragraph nos. 6b(1)(b)1 and 6b(3)(a).
5.
Independent Inspection Effort (Units 1 and 2)
a.
Construction Progress (Units 1 and 2)
The inspector conducted a general inspection of the unit 1 and 2 containment construction sites, control building, turbine building, pipe fabrication shop, all TVA welding material issue stations and
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storage areas to obsecve construction progress and construction acti-vities such as welding, nondestructive examination, material handling and control, housekeepinp and storage, b.
Reinforcing Steel (Unit 1)
With regard to the above inspection, on February 17., 1981, the inspector, accompanied by a representative of the licensee, noted two examples of improper reinforcing bar lap spacing. In each case four bars were spliced together without the one inch minimum splice separa-tion required by TVA QC Instruction C-207, Revision 4, " Reinforcing Steel Inspection", paragraphs 3E1 and 3E3.
After the inspector identified the above condition the licensee documented the condition in QCIR 34125. The above discrepar.t condition is present in a ccmpleted QA controlled concrete pour. Failure to follow procedure, for activi-ties affecting quality, is in violation of 10 CFR 50 Appendix B, Criterion V.
This violation will be identified as 566/81-02-02:
" Failure to Follow Concrete Inspection Procedure".
Within the areas examined no violations or deviations except as noted in paragraph 5b were identified.
6.
Safety-Related Piping (Units 1 & 2)
The inspector observed non-welding and welding work activities for safety-related piping as described below.to determine whether applicable code and procedure requirements were being met.
The applicable code for safety-related piping is the ASME B and PV Code,Section III,1974 edition with addenda through summer 1976.
a.
Observation of Non Welding Activites Observition of' specific word act'ivities' we'reconcuctdd to determine
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conformance, where applicable, with the following; inspection and/or work p'ocedures, record Feeping, installation specifications or plans, r
specified materials, specified NDE, calibration and use of proper test equipment and qualified inspection and NDE personnel.
System or Activity Component Unit Procedure Storage Pipe & Fittings 1&2 RIS&PN 415 R5 &
(Various)
RIS&PN 413 R9 b.
Observation of Welding Activities The inspector observed in process welding activities of safety-related piping field welds outside the reactor ccolant pressure boundary as described below to determine whether applicable code and procedure requirements were being met.
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l (1) Visual Inspection of Welds The inspector visually examined completed and accepted safety-related welds as described below to determine whether applicable code and procedure requirements were being met.
(a) The following welds were examined relative to the following:
location, length, size and shape; weld surface finish and appearance, including inside diameter of pipe welds when accessible; transitions between different wall thickness; weld reinforcement--height and appearance; joint configura-tions of permanent attachments and structural supports; removal of temporary attachments; arc strikes and weld spatter; finish grinding or machining of weld surface--
surface finish and absence of wall ' thinning; surface defects--cracks, laps, lack of penetration, lack of fusion, porosity, slag, oxide film and under cut exceeding prescribed limits.
Weld No.
Assembly No.
System 8006 INM-MPIP-8001 Fuel Pool Cooling 8007 1NM-MP1P-8001 Fuel Pool Cooling 8008 1NM-MP1P-8001 Fuel Pool Cooling 8009 1NM-MPIP-8001 Fuel Pool Cooling 8010 1NM-MPIP-8001 Fuel Pool Cooling 8011 INM-MPIP-8001 Fuel Pool Cooling.
8012 INM-MP1P-8001 Fuel Pool Coolina 8013 1NM-MP1P-8001
' Fuel Pool Cooling 8015 INM-MP1P-8002 Fuel Pool Cooling 8016 1NM-MP1P-8002 Fuel Pool Cooling 8017 1NM-MPIP-8002 Fuel Pool Cooling i
8018 1NH-MPIP,8002_
Fuel _ Pool Cooling
With regard to the above inspection, on February 18, 1981 the inspector noted the following conditions. The single bead cover pass on weld No. 8016 deposited with l
1/8" diameter type 308L-16 electrode was 3/4 -inch wide.
l TVA General Constructiosn Specification G-29M, Process i
Specification 1.M.1.2(b) paragraph 14.9.1(b) requires l
bead width for 1/8" diameter type 308L-16 electrodes not
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to exeed 1/2-inch maximum. Therefore the welder failed to follow procedure and the welding inspector accepted
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an unacceptable weld surface condition.
In addition the (
inspector of record for weld No. 8012 incorrectly entered the heat number for the 12-inch elbow on the weld fit-up card as 54495 vice 54494.
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The above conditions indicate inadequate measures for the control of special processes and are examples of
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violation 566, 567/81-02-01. This matter is discussed further in paragraph 6b(2)(c)1.
(b) Quality records for the following welds were ' examined relative to the following:
records covering e isual and v
dimensional inspections indicate that the specified,inspec-tions were completed; the records reflect adequate weld l
quality; history records are adequate.
Weld No.
Assembly No.
System 8009 INM-MP1P-8001 Fuel Pool Cooling
.O 8011 INM-MP1P-8001 Fuel Pool Cooling
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8012 INM-MP1P-8001 Fuel Pool Cooling i
8013 INM-MP1P-8001 Fuel Pool Cooling 8016 1NM-MPIP-8002 Fuel Pool Cooling 1_
With regard to the above inspections the inspector noted that the final weld records only reflect the actual welding procedure specification and the welding filler material type, size, and heat number for the f.it-up tack -
o welds not the remainder of the weld. This information is only annotated at the time of fit-up, on the fit-up inspection card.
At the time of this inspection it could not be determined whether the above was consistent
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with the licensee's commitments. The licensee indicated
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that they. would..look further into the. matter.
The
inspector stated that the above will be identified as un' resolved item 566, 567/81-02-03: " Weld Records Do Not Reflect All WPS and Weld Filler Materials".
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(2) Welder Qualification
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' iThe' inspec' tor re' viewed 'the TVA program' for qualification ~of '
welders and welding operators for compliance with QA procedur,es
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and code requirements. The applicable code for welder qualifica-tion is ASME B&PV Code Section IX, for safety related piping and AWS D1.1 for control building structures.
(a) The following welder qualification status records and
" Records of Performance Qualification Test" were reviewed
relative to the weld joints listed in paragraph 6b(1) and 7a.
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l Welder
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Symbol Unit Organization Application FABB
TVA Safety Related Piping FACS
TVA Safety Related Piping FAAN
TVA Safety Related Piping
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TVA Steel Structures (
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TVA Steel Structures
& Supports IADY
TVA Steel Structures
& Supports (b) The inspector observed in process performance qualification g
testing for the.below listed welders-
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Welder Symbol Unit Qualification Test'
EABE 1&2 GMFC-6-L(3) R6 FAHP 1&2 GT-7-0-1-L(a) R0 FAAY 1&2 GT-7-0-1-L(a) R0 (c) The inspector observed the removal, preparation,'and testing I
of root and face bend specimens - from - qualification test assemblies for the below listed welders:
Welder Symbol Unit Qualification Test
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EABE 1&2 GMFC-6-L(3) R6
With regard to the above inspection on Febraury 18, 1981, the inspector noted that the above welder's face
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bend specimen had two fissures approximately 1 inch long at the weld fussion line, on both sides of the
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weld, 'on' the convex face of the bend.
The maximum acceptable fissure on the convex surface of a welder
- qualification bend _ specimen. permitted by AWS D1.1 and ASME Section IX is 1/8 inch.
est'sup'ervisor ' informed the inspector tha' 'the "'
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e e above fissures resulted from improper bend specimen preparation and not welder technique.
Therefore, the welder is considered qualified without any additional qualification testing.
The supervisor further stated that the above had occurred several times before. The inspector statad that the welder could not be considered
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qualified until such time that acceptable bend specimens could be removed from acceptable test plates he (the
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welder) had welded.
i Qualification of welders without acceptable test results combined with the example as discussed in paragraph 6b(1)(a)1 indicate that the licensee does not have adequate measures for the control of special processes.
Failure to establish adequate measures to control
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special processes, including welding and nondestructive
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testing is in violation of 10 CFR 50 Appendix B Crite-rion IX.
This violation will be identified as 566, 567/81-02-01: " Failure to Establish Adequate Measures to Control Welding and NDE".
(3) Welding Filler Material Control The inspector reviewed the TVA program for control of welding materials to determine ' whether materials are being purchased, accepted, stored, and handled in accordance with QA procedures, and applicable code requirements. The following specific areas were examined:
Purchasing, receiving, storing, distributing and handling
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procedures, material identification, and inspection of welding material issuing stations.
Welding material purchasing and receiving records for the
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following materials were reviewed for conformance with applicable procedures and code requirements:
Heat Lot or Process *
Type Size Batch No.
Application SMAW 308L-16 3/32" 0F3C Safety Related Piping
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SMAW.
308L-16 1/8" OC18/4 Safety Related Piping GTAW~
308L 3/32"
~C4611R
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Piping GTAW 308L 1/8" 04611R Safety-Related Piping
.SMAW.
7018 3/32"
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& Supports SMAW 7018 1/8" N96733 Steel Structures
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- SMAW - Shielded Metal Arc Welding
- GTAW - Gas Tungsten Arc Welding (a) With regard to the above inspection on February 20, 1981, the receiving inspection records and the certified material test report (CMTR) were not retrievable for type 308L-16 welding electrodes with heat number 0C18/4. The licensee indicated that they would look further into the matter. The inspector stated that the retrievability of these documents would be an unresolved item No. 566,567/81-02-04:
"Nonretrievable CMTR and Receiving Inspection R9 port".
Within the areas examined no violations or deviations except as noted in paragraph Nos. 6b(1)(a)1_and 6b(2)(c)1 were-identified.
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7.
Steel Structures and Supports (Unit 1)
The inspector observed welding work activities for steel structures and supports as described below to determine whether applicable ccde' and pro-cedure requirements were being met.
The applicable code for control building fabrication is AWS D.1.1-72 with addenda through 1974.
The inspector observed in process welding activities of structaral field welds outside of containment as described below to determ'ne whether applicable code and procedure requirements were being met.
a.
Welding The following welds were examined in process to determine work con-ducted in accordance with traveler; welding procedures available; welding technique and sequence; weld geometry; fi tup electrical characteristics; equipment condition:
Structure Unit Weld No.
Drawino No.
Control Building Decking
94 1C30003 R1 Control Building Decking
95 1C30003 R1 Control Building Decking
21 1C30001 R1 b.
Welder Qualification Welder Qualification is discussed in paragraph 6b(2).
Welding Filler MN.erial Control c.
Weldin'g filler material control is discussed in pragraph 6b(3).
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Stud Wel. ding,
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The incpector observed stud welding activities on the below listed structures to determine the attributes listed below. The applicable code for stud welding is AWS D1.1-72 with addenda through 1974.
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Type, length, diameter, material and finish of studs are as specified.
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Stud base qualification requirements are met.
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Suitable stud welding equipment and power source are used.
Stud welding is accomplished in accordance with adequate, and
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approved procedures.
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Location, including lateral and longitudinal spacing, is as specified.
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Testing and inspections of completed stud welds are satisfactorily
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completed.
Test to quality procedure and stud welding operator have been
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successfully completed prior to use.
Structure Control Building Framing Steel EL.490 Within the areas examined, no violations or deviations were identified.
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