ML18033A622
| ML18033A622 | |
| Person / Time | |
|---|---|
| Site: | 05000000, Browns Ferry |
| Issue date: | 12/28/1987 |
| From: | Brown W TENNESSEE VALLEY AUTHORITY |
| To: | |
| Shared Package | |
| ML082340470 | List:
|
| References | |
| 50100, 50100-V05-R04, 50100-V5-R4, NUDOCS 8902160161 | |
| Download: ML18033A622 (62) | |
Text
EMPLOYEE CONCERNS SPECIAL PROG VOLUBLE5 WELDINGCATEGORY SUBCATEGORY REPORT 50100 BROWNS FERRY NUCLEAR PLANT UPDATED ping A(( 8/( (
TVA NUCLEAR POWER
0
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
50100 REPORT TYPE: Subcategory REVISION NUMBER:
TITLE:
BFN Site Specific Welding Subcategory Report Page 1 of 13 REASON FOR REVISION:
Editorial Revision PREPARED BY:
PREPARATION SIGNATURE I
OArE REVIEWS SIGNATURF.
lile~
TAS:
SIGNATURE Z Z38 CONCURRENCES SIGNATURE DATE CEG-I3:
SRP:
SIGNATUR
~/Q 1
g-z~S7 DATE APPROVED 8
CSP MANAGER
<SRP Secretary's signature denotes SRP concurrences are in files.
6056T
- Preface, Glossary, and List of Acronyms for ECTG Subcategory Reports HISTORY OF REVISION REV NUMBER PAGES REVISED REASON FOR CURRENT REVISION To clarify that one or more attachments will help the reader find where a particular concern is evaluated
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
50100 FRONT MATTER REV:
3 PAGE i OF viii Preface This subcategory report is one of a series of reports prepared for the Employee Concerns Special Program (ECSP) of the Tennessee Valley Authority (TVA).
The ECSP and the organization which carried out the program, the Employee Concerns Task Group (ECTG), were established by TVA's Manager of Nuclear Power to evaluate and report on those Office of Nuclear Power (ONP) employee concerns filed before February 1, 1986.
Concerns filed after that date are handled by the ongoing ONP Employee Concerns Program (ECP).
The ECSP addressed over 5800 employee concerns.
Each of the concerns was a
formal, written description of a circumstance or circumstances that an employee thought was unsafe, unjust, inefficient, or inappropriate.
The mission of the Employee Concerns Special Program was to thoroughly investigate all issues presented in the concerns and to report the results of those investigations in a form accessible to ONP employees, the
- NRC, and the general public.
The results of these investigations are communicated by four levels of ECSP reports:
- element, subcategory,
- category, and final.
Element reports, the lowest reporting level, will be published only for those concerns directly affecting the restart of Sequoyah Nuclear Plant's reactor unit 2.
An element consists of one or more closely related issues.
An issue is a potential problem identified by ECTG during the evaluation process as having been raised in one or more concerns.
For efficient handling, what appeared to be similar concerns were grouped into elements early in the program, but issue definitions emerged from the evaluation process itself.
Consequently, some elements did include only one issue, but often the ECTG evaluation found more than one issue per element.
Subcategory reports summarize the evaluation of a number of elements.
- However, the subcategory report does more than collect element level evaluations.
The subcategory level overview of element findings leads to an integration of information that cannot take place at the element level.
This integration of information reveals the eztent to which problems overlap more than one element and will therefore require corrective action for underlying causes not fully apparent at the element level.
To make the subcategory reports easier to understand, three items have been placed at the front of each report:
a preface, a glossary of the terminology unique to ECSP reports, and a list of acronyms.
Additionally, at the end of each subcategory report will be a Subcategory Summary Table that includes the concern numbers; identifies other subcategories that share a concern; designates nuclear safety-related, safety significant, or non-safety related concerns; designates generic applicability; and briefly states each concern.
Either the Subcategory Summary Table or another attachment or a combination of the two will enable the reader to find the report section or sections in which the issue raised by the concern is evaluated.
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NVMBER:
50100 FRONT MATTER REV:
2 PAGE ii OF viii The subcategories are themselves summarized in a series of eight category reports.
Each category report reviews the major findings and collective significance of the subcategory reports in one of the following areas:
management and personnel relations industrial safety construction material control operations quality assurance/quality control welding engineering A separate report on employee concerns dealing with specific contentions of intimidation, harassment, and wrongdoing will be released by the TVA Office of the Inspector General.
Just as the subcategory reports integrate the information collected at the element level, the category reports integrate the information assembled in all the subcategory reports within the category, addressing particularly the underlying causes of those problems that run across more than one subcategory.
A final report will integrate and assess the information collected by all of the lower level reports prepared for the
- ECSP, including the Inspector General's report.
For more detail on the methods by which ECTG employee concerns were evaluated and reported, consult the Tennessee Valley Authority Employee Concerns Task Group Program Manual.
The Manual spells out the program's objectives,
- scope, organization, and responsibilities.
It also specifies the procedures that were followed in the investigation, reporting, and closeout of the issues raised by employee concerns.
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
50100 FRONT MATTER REV:
2 PAGE iii OF viii ECSP GLOSSARY OF REPORT TERMS-classification of evaluated issues the evaluation of an issue leads to one of the following determinations:
Class A:
Issue cannot be verified as factual Class B:
Issue is factually accurate, but what is described is not a
problem (i.e., not a condition requiring corrective action)
Class C.
Issue is factual and identifies a problem, but corrective action for the problem was initiated before the evaluation of the issue was undertaken Class D:
Issue is factual and presents a problem for which corrective action has
- been, or is being, taken as a result of an evaluation Class E:
A problem, requiring corrective action, which was not identified by an employee
- concern, but was revealed during the ECTG
-. evaluation of an issue raised by an employee concern.
collective si nificance an analysis which determines the importance and consequences of the findings in a particular ECSP report by putting those findings in the proper perspective.
concern (see "employee concern")
corrective action steps taken to fix specific deficiencies or discrepancies revealed by a negative finding and, when necessary, to correct causes in order to prevent recurrence.
criterion
( lural:
criteria) a basis for defining a performance,
- behavior, or quality which ONP imposes on itself (see also "requirement").
element or element re ort an optional level oi ECSP report, below the subcategory level, that deals with one or more issues.
em lo ee concern a formal, written description of a circumstance or circumstances that an employee thinks unsafe, unjust, inefficient or inappropriate; usually documented on a K-form or a form equivalent to the K-form.
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
50100 FRONT MATTER REV:
2 PAGE iv OF'viii grouping of employee concerns.
~findin s includes both statements of fact and the judgments made about those facts during the evaluation process; negative findings require corrective action.
issue a potential problem, as interpreted by the ECTG during the evaluation
- process, raised in one or more concerns.
K-form (see "employee concern")
evaluation judgment or decision may be based.
root cause the underlying reason for a problem.
~Terms essential to the program but which require detailed definition have been defined in the ECTG Procedure Manual (e.gsh generic, specific, nuclear safety-related; unrevieved safety-significant question).
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
50100 FRONT MATTER REV; 2
PAGE v OF viii Acronyms AI AISC ANSI ASME ASTM AWS BFN BLN CATD CCTS CEG-H CFR CI CMTR COC
- DCR, DNC Administrative Instruction American Institute of Steel Construction hs Low hs Reasonably Achievable American Nuclear Society American National Standards Institute American Society of Mechanical Engineers American Society.for Testing and Materials American Welding Society Browns Ferry Nuclear Plant Bellefonte Nuclear Plant Condition Adverse to Quality Corrective Action Report Corrective Action Tracking, Document Corporate Commitment Tracking System Category Evaluation Group Head Code of'ederal Regulations
~
Concerned Individual Certified Material Test Report Certificate of Conformance/Compliance Design Change Request Division of Nuclear Construction.(see also NU CON)
TVA EMPL'OYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
50100 FRONT MATTER REV:
2 PAGE vi OF viii DNQA DNT DOE DPO DR ECN ECP ECP-SR ECSP
'CTG EEOC EMRT EN DES ERT FCR FSAR FY GET HCI HVAC INPO IRN Division of Nuclear Engineering Division of Nuclear Quality Assurance Division of Nuclear Training Department of Energy Division Personnel Officer Discrepancy Report or Deviation Report Engineering Change Notice Employee Concerns Program Employee Concerns Program-Site Representative Employee Concerns Special Program Employee Concerns Task Group Equal Employment Opportunity Commission Environmental Qualification Emergency Medical Response Team Engineering Design Employee
Response
Team or Emergency
Response
Team Field Change Request Final Safety Analysis Report Fiscal Year General Employee Training Hazard Contxol Instruction Heating, Ventilating Air Conditioning Installation Instruction Institute of Nuclear Power Operations Inspection Rejection Notice
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
50100 FRONT MATTER REV:'
PAGE.vii OF viii L/R MRAI MI MSPB NCR NDE NPP NPS NQAM NRC NSB NSRS Labor Relations Staff Modifications and Additions Instruction Maintenance Instruction Merit Systems Protection Board Magnetic Particle Testing Nonconforming Condition Report Nondestructive Examination Nuclear Performance Plan Non-plant Specific or Nuclear Procedures System Nuclear Quality Assurance Manual Nuclear Regulatory Commission Nuclear Services Branch Nuclear Safety Review Staff NU CON Division of Nuclear Construction (obsolete abbreviation, see DNC)
NUMARC OSHA ONP OWCP PHR PT QAP QCI Nuclear Utility Management and Resources Committee Occupational Safety and Health Administration (or Act)
Office of Nuclear Power Office of Workers Compensation Program Personal History Record Liquid Penetrant Testing Quality Assurance Quality Assurance Procedures Quality Control Quality Control Instruction
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
50100 FRONT 'MATTER REV:
2 PAGE viii OF viii QCP QTC RIF
" RT SQN SI SOP SRP SWEC TAS TEL TVA TVTLC UT Quality Control Procedure Quality Technology Company Reduction in Force Radiographic Testing Sequoyah Nuclear Plant Surveillance Instruction Standard Operating Procedure Senior Review Panel Stone and Webster Engineering Corporation Technical Assistance Staff Trades and Labor Tennessee Valley Authority Tennessee. Valley Trades and Labor Council Ultrasonic Testing Visual Testing WBECSP Watts Bar Employee Concern Special Program WBN WP Watts Bar Nuclear Plant Work Request or Work Rules Workplans
Index 1.0 CHARACTERIZATION OF ISSUES 2.0 METHODOLOGY 3.0 ISSUES s
FINDINGS AND CONCLUSION s
3.1 Control of Weldin Filler Material 3.2 Ins ection of Melds Throu h Carbo-Zinc Primer
- 3. 3 Welder ualification and Continuit
- 3. 4 Availabilit of Ins ection Tools 3.5 Ins ector Trainin and Certification
- 3. 6 Welder Trainin and Ex erience 3,7 Surface Grindin of Welds
- 3. B Ade uac of Weldin E ui ment 3.9 Structural Steel Preweld Ins ections 3.10 Welder uglification 3.11 Meld Re airs Not Neetin ASIDE Code Re uirements 3.12 Structural Su ort Welds 3.13 Weld Ins ection Procedures 4.0 COLLECTIVE SIGNIFICANCE 5.0 CAUSE
- 6. 0 CORRECTIVE ACTION
'7.0 ATTACHMENTS A.
Subcategory Summary Table 8
~
Summary of Issues 8.0 REFERENCE A.
Welding Project Evaluation Reports Page 1 of 1
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
50100 REPORT TYPE: Subcategory Report REVISION NUNBER:
4 TITLE:
BFN Site-Specific Welding Subcategory Report Page 2 of 13 1.0 CHARACTERIZATION OF ISSUES
- 1. 1 Introduction The characterization of issues For this subcategory report are derived from 63 Employee Concerns.
Of the 63 Employee Concerns, 7
were specific to BFN (49 specific to
- WBM, 3 specific to BLN, 3
specific to SQN, 1 non plant specific).
The Employee Concerns were divided into 13 similar issues and were investigated by the Weld Project, Quality Technology Company (QTC) and/or the Nuclear Safety Review Staff (NSRS).
Each of the 13 issues was addressed by a Weld Project Evaluation Report which will be provided to the USMRC ns a
portion of the Weld Project effort.
lR4 I
1.2 Descri tion of Issues 1.2.1 Control of Weldin Filler Material 1.2.2 Inspection of Welds Throu h Carbo-Zinc Primer-1.2.3
=
Welder ualification and Continuit 1.2.4 Availabilit of Ins ection Tools 1.2.5 Ins ector Trainin and Certification 1.2.6 Welder Trainin and Ex erience 1.2.7 Surface Grindin of Welds l,. 2. 8 Ade uac of Weldin E ui ment 1.2.9 Structural Steel Preweld Ins ection
- 1. 2. 10 Welder ualification 1.2.11 Weld Re air Mot Neetin ASt1E Code Re uirements 1.2.12 Structural Su ort Welds
- 1. 2. 13 Weld Ins ection Pr ocedures 2.0 METHODOLOGY The procedure and specification histories of Browns Ferry Nuclear Plant from the beginning of construction to the present were reviewed.
These procedures and specifications were compared with the construction codes that were in effect during each phase of the procedure history
~
The Browns Ferry Weld Project Phase I Report was reviewed.
The expurgated text of the concerns was compared with the requirements IR4
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
50100 REPORT TYPE: Subcategory Report REVISION NUMBER:
TITLE; BFN Site-Specific Welding Subcategory Report Page 3
o1 13 defined in the construction codes and the commitments made in the Topical Report (TVA-TR-75-1A).
A review was made of quality indicators such as USNRC Inspection Reports and TVA audit, and deficiency reporting documents issued over the life of the plant
~
As appropriate to the issues, discussions were held with cognizant TVA Construction, Engineering, Quality and Craft Supervisory personnel.
3. 0 ISSUES FINDINGS AND CONCLUSIONS 3.1 Control of Neldin Filler Material The concerns stated that weld rods are not required to be kept in rod ovens after issue; questioned the adequacy oF weld rod control; questioned the quality of E-7018 coated electrodes; and questioned the administrative practices For the return of unused and waste welding materials.
Portable rod ovens are used at Of N to protect certain high strength
<<lectrodes From moisture absorption From the atmosphere.
The most commonly used electrodes (E7018) are not required to be issued in portable ovens.
- Rather, the atmospher ic exposure time limits prescribed by the St.ructural Welding Code, ANS D1.1 are adhered to.
In the event that electrodes are exposed to the al.mosphere b<!yond the specified time limit, they are disposed of.
The investigation of this issue did not indicate a problem with control of f'i lier mat.erial.
Controls are in place to ensure Chat.
only qualified welders are issued welding materials and that welders use weld filler materials specified for the work being per fvreied.
Unused and waste filler material is controlled by a procedure more stringent than the applicable code requirement The quality of coated electrodes has not been a problem at BFN.
- However, one lot of coated electrodes was returned to the vendor From Watts Bar for a concentricity problem.
Welding electrodes from this lot were not issued at Browns Ferry.
Welding filler material used for permanent plant installations at BFM is purchased and tested in accordance with the requirements of the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel
- Code, Sections II and III. Additionally, TVA performs operability tests beyond the code requirements For all electrodes not already having a satisfactory performance history with TVA.
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
50100 REPORT TYPE: Subcategory Report REVXSZON NUMBER:
4 TITLE:
BFN Site-Specific Welding Subcategory Report Page 4 of 13 The administrative practices for return of unused and waste filler material are not technically significant.
This part of the filler material control issue is generically evaluated in Management Practices Subcategory
- 70200, and is not addressed further by this report.
I IR4 I
I Complete details of the evaluation of this issue are discussed in IR4 Weld Project Evaluation Report WP-01-BFN.
I 3.2 Ins ection of Welds Throu h Carbo-Zinc Primer Evaluation showed that this issue is not applicable to Browns Ferry.
Xn early 1982 General Construction Specification G-29C, Process Specification 3.C.5.4 was revised to permit certain reinspections of structural welds which had been primed.
This process specification is site unique to Watts Bar, and was never implemented at BFN.
Complete details of the evaluation of this issue are discussed in Weld Project Evaluation Report WP-02-BFN IR4 I
3.3 Welder ualification and Continuit The concerns stated the po~~ibi) ity that one wr~lder's test plate could be completed by another welder; the possibility of welding being performed by an unqualified individual; questioned I:he adequacy of the basis for welder qualification continuity updates; and questioned maintenance of welder qualifications for personnel whose, duties do not regularly require welding.
No one except the Weld Test Supervisor is allowed to enter the test booth while a test is in process.
If the Supervisor leaves the test shop for any reason, he collects all weld rod, making it impossible for one welder to work on another's test coupon.
There have been isolated occurrences of welders performing work outside their limits of qualification, i ~ e., diameter and thickness, or when their qualification continuity for the work could not be verified.
These isolated instances were identified and corrected through the ongoing quality assurance activities.
They do not represent a
breakdown in the welder qualification program at BFN.
Browns Ferry uses manually prepared documents to verify and suspense welder qualification and continuity.
The repeated manual preparation of listings to control continuity inevitably leads to error and
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
50100 REPORT TYPE: Subcategory Report REVISION NUMBER:
4 TITLE:
BFN Site-Specific Welding Subcategory Report Page 5 of.
13 omission.
CATQ 50103-BFN-01 recommends that all TVA nuclear activities adopt a uniform computerized system comparable to that used at BLN and WBN in order to minimize the likelihood of a welder working outside of his parameters or allowing a qualification to expire
~
Corrective Action Plan Effective July 1,
- 1987, BFN implemented Site Director 's Standard Practice (SDSP) 13.9, "Welding/
azing/Soldering Filler Material Issue and Welder/Brazer/Solder r ification Computer Program."
The computer program is seen s a prog enhancement and is similar to the ones at BLN and WBN.
The program is used in con'on wi xisting Site Procedures SDSP 13.2, "Welding, Brae' l
r ng Filler Mater ial Control at Browns Ferry Nuclear "hogan 13.4, "Welder, Brazer and Solderer Qualification ng t'
y at Browns Furry Nuclear Plant."
Welder qualification o
'l9ifitI'sed on the welder's utilizing the welding process(
s wh c ey were previously qualified within the specific "li TVA uses the issue of weld filler material as eviden e
rope sage.
This is a widely used practice througho t r construction industry, and is not in violation of cod
~commi ieelder qualiti a c 'y for personnel whose duties normally do not requir
'n t a violation of code or commitment.
Many welders P~rq seyeisiy P remen or hiqher, and continue to weld occasionall i
roficiency.
This may be done on production w
d'or a 'eld test shop.
In maintenance of these qualific i+y, the re ired code and procedural controls apply.
Complete detai ~f We ld Pr ojec t Eva lua IR4 I
3
~ 4 Availabilit of Ins ection Tools These concerns state either that inspection tools were never
- issued, or that inspection tools were not issued prior to 1979.
Inspection tools, locally manufactured and commercially procured, were available to the inspectors throughout construction and operation.
While not all inspectors had a full set of tools at all
- times, any tool necessary for a given task was available upon request.
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
50100 REPORT TYPE: Subcategory Report REVISION NUMBER:
4 TITLE; BFN Site-Specific Welding Subcategory Report Page 6 of 13 Complete details of the evaluation of this issue are discussed in Weld Project Evaluation Report WP-04-BFN.
I R4 I
3.5 Ins ector Trainin and Certification The concerns questioned the adequacy of inspector training; qualification of inspectors for the tasks assigned; and exceptions to ANSI N45.2.6 as specified in the Topical Report.
Additionally, one concern states that welding inspectors should also be welders.
The question of the adequacy of inspector training evolved from concerns which state that personnel with no prior experience are permitted to inspect welds after training periods of two weeks to two months.
TVA did issue limited weld inspection certifications based in part on two weeks on the job training.
These certifications were limited to verification of weld size, length and location only
~
Training and testing were appropriate to the limits of this certification.
Such limited certifications are in accordance with the Nuclear Quality Assurance Program.
The BFN ISI Group was requested to assist in the USNRC Bulletin 79-14 pipe support walkdown.
The inspectors received special training for the visual weld examination portion of the walkdown.
When the program actually began, it was learned Lhat the inspectors were expected to perform tasks for which they were not 1.rained or certified.
These inspectors were removed from the assignment, and did not actually perform any work for which they were not qualified.
It is true that the TVA program for certification of welding inspectors would not meet the requirements of ANSI N45.2.6.
TVA welding inspectors have historically been treated as nondestructive examination (NOE) personnel under the guidelines of the American Society for Nondestructive Testing Recommended Practice SNT-TC-lA, rather than under the rules of ANSI N45.2
~ 6.
SNT-TC-1A does not mandate specific experience requirements, and does not specifically deal with visual inspection.
It is intended to be used as a guide for employers in establishing their.,own written practices for qualification and certification of NOE personnel.
The TVA practice of using SNT-TC-1A satisfies TVA's commitments as stated in the Topical Report (TVA-TR-75-1A) ~
There is no code or regulatory requirement for a welding inspector to also be a welder.
Complete details of the evaluation of this issue are discussed in Weld Project Evaluation Report WP-06-BFN IR4 I
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
50100 REPORT TYPE: Subcategory Report REVISION NUMBER:
TITLE:
BFN Site-Specific Welding Subcategory Report Page 7 of 13 3.6 Welder Trainin and Ex erience The concerns questioned the qualification of subjourneymen for the work to which they are assigned and the adequacy of the TVA welder IR4 training progr am.
The primary purpose of the subjourneyman is to free the journeyman from trade related tasks which do not effectively utilize his skills. It is possible, however, for the subjourneyman to progress beyond the menial tasks to those requiring a higher degree of skill.
This includes becoming a qualified welder.
With appropriate training and experience, the subjourneyman may become a qualified welder through satisfactory performance testing under the rules of AWS Dl.1 and/or ASME Section IX.
These rules establish the ability of the welder to deposit sound weld metal within the parameters of the
'same performance qualification tests taken by journeyman we lders.
The TVA Welder Training Program, a voluntary off-duty course, was offered at BFN approximately during the years 1974 through 1976.
The length of training was dependent on the progress of t,he individual trainee.
When sufficient competence was demonsLrated, the trainee was given a performance qualification test in accordance with the rules of the governing code.
This test was the same test as that given to journeyman welders, with acceptance standards governed by AWS 01. 1 and ASME Section IX.
The governing
- codes, industry standards or regulatory requirements do not quantify the experience required of a welder.
The code specified performance qualification test is the measure of a welder's capability to deposit sound weld metal.
Complete details of the evaluation of this issue are discussed in Weld Project Evaluation Report WP-07-BFN.
IR4 3.7 Sur face Grindin of Welds The concerns questioned the surface grinding of welds and raised the issue of excessive circumferential shrinkage in stainless steel welded joints.
The concerns state that surface grinding of pipe welds may mask surface defects and stainless steel butt welds seem to have excessive metal removed.
Grinding of welds is not a violation of
- codes, standards or UFN procedures.
- Rather, in many cases these standards require grinding to obtain suitable surfaces for the proper interpretation of the specified NDE and to eliminate or reduce surface defects.
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
50100 REPORT TYPE: Subcategory Report REVISION NUMBER:
4 TITLE:
BFN Site-Specific Welding Subcategory Report Page 8 of 13 The construction
- codes, specifications and procedures do not quantify an acceptance cr iteria for circumferential shrinkage in welded butt joints.
Distortation, including shrinkage is inherent in stainless steel weldments.
This distortation is controlled through application of sound engineering practices in development of the detailed weld procedure specifications and design detail.
Factors considered are material type and thickness, filler material
- size, heat input {amperage),
and maximum interpass temperature.
TVA has implemented detailed welding procedures to minimize distortion and warping when welding stainless steels.
Complete details of the evaluation of this issue are discussed in Weld Project Evaluation Report WP-11-BFN.
I R4 I
3.8 Ade uac of Weldin E ui ment These concerns stated that the welding machines did not have remote switches and suitable amperage settings.
Browns Ferry has, since beginning'onstruction, used the Lincoln Idealarc TIG 300, K1312 welding machines.
These machines are equipped with remote adjustment controls, and operate at a current output range of two to 375 amps.
The TIG 300 is suitable for welding wi th either the shielded metal arc or the gas tungsten arc processes.
This concern was made generically applicable to BFN from WBN where some of the Lincoln Idealarc welding machines were removed from the power block and replaced with multigrid welding machines which generally do not have remote switches and amperage control gradients as fine as the Lincoln Idealarc welding machines.
IR4 Complete details of the evaluation of this issue are discussed in Weld Project Evaluation Report WP-13-BFN.
1R4 I
3 '
Structural Steel Preweld Ins ections This issue centers around the fact that TVA does not require
- 100K, mandatory fitup inspection by certified welding inspectors on all structural joints.
The foreman is responsible to ensure that the preweld requirements, including correct fitup are met prior to weld out.
Certified inspectors monitor each foreman at least bi weekly to ensure that the foremen are properly performing the required activities.
This issue has been evaluated by NSRS, and determined not to be in violation of the Structural Welding Code or ANSI N45.2
~ 5. It was also evaluated for all TVA nuclear sites after being reported {in a Bellefonte Quality Assurance Audit) to the USNRC under the provisions of 10 CFR 50.55(e),
and again found to be an acceptable practice.
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
50100 REPORT TYPE: Subcategory Repor t REVISION NUMBER:
TITLE:
OFN Site-Specific Welding Subcategory Report Paqe 9 of-13 Complete details of the evaluation of this issue are discussed in Weld Project Evaluation Report WP-16-BFN.
IR4 I
- 3. 10 Welder uglification This issue evolved from a misinterpretat;ion of ASME Section IX, due to the omission oF Article QW-302.3 from the 1974 edition.
The concern stated that welders qualified at Muscle Shoals may not have had t:he required number of bend tests.
The same misinterpretation occurred at OFN, resulting in only t:wo guided bend tests being performed for certain qualifications where Four bend tests were required.
The problem wa idenLified through t:he ongoing Quality Assurance
- program, and corrected by retest:ing all of the affected welders.
All of the retest.ed welders were requalified.
The production welds made by t:hese welder.s were evaluated and found to be acceptable.
Complete details of the evaluation of Lhis issue are discussed in Meld Project Fvaluation R~!por t WP-24-BFN.
I IR4 3.11 Meld Re airs not. MeeLir!<.
ASME Code Re uirerner!Ls This issue involves t:he practice of making temporary repairs by overlay welding and pat,ching.
The concern also ment:ioned t.he use of Iurmanite, a viscous sealing compound.
The use of Furnnanite is addressed by Operation'ubcat.egory Report.
- 30800, and is not cor!sidered I'ur L'her by L'his repor t.
TVA does use mechanical and welded patches t.o temporarily contain leakage.
At Browns Ferry, L'his has occurred pr incipally in the I'ire protection system.
These patches are not intended or used Lo subst.it.ute for proper repairs in accordance with the code and regulatory requirements.
The af'fected piping i" replaced as soon as practicable.
TVA also makes repair's to ASME piping by using welded overlays.
Stainless steel pipir!g in boiling wat:er reactors is susceptible to intergranular st:ress corrosion cracking (IGSCC).
Overlay welding is the most commonly used practice to correct for IGSCC.
With regard to overlay welding, the USNRC has issued Safety Evaluat:ion Reports to allow Units 1 and 3 to be returned to power in their repaired condition.
Complete details of the evaluatior!
of. this issue are discussed in Weld Project: Evaluation Report: WP-25-BFN.
IR4 I
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
50100 REPORT TYPE: Subcategory Report REVISION NUMBER:
4 TITLE:
BFN Site-Specific Welding Subcategory Report Page 10 of 13 3.12 Structural Su ort Welds The concern questions the adequacy of the structural support welds.
The concerned individual stated that the process followed today with regard to welding and weld inspection is more detailed and that the original welds would not meet today's requirements.
The concern is factual, in that some of the support welds do not meet the visual acceptance criteria required by the original installation specification (AMS D1.0-1966).
Mhether or not this is a problem requires engineering evaluation.
Also, relative to supports, the process (program) is now clearly defined, where prior to mid-1983 some support welds were not subject to the controls of the Quality Inspection Program.
Field construction at BFN began in September, 1966. It should be noted that construction of BFN was largely completed prior to the TVA commitment to 10 CFR 50, Appendix B in July, 1972.
Discussion with cognizant DNE (Meld Project) personnel revealed that the Welding Project Phase II reinspection of structural supports was an engineering biased sample representative of welding performed over the life of the plant.
These inspections included groups of large bore, small bore, instrument pipe and tubing supports, conduit and cable tray supports, HVAC duct
- supports, and electrical equipment and instrument supports.
Preliminary results of the weld reinspection indicate that the discrepancies identified were largely configurational, i.e.,
- size, length and location. It was noted,
- however, that some of the supports also had rejectable discontinuities in one or more welds.
'Engineering analysis of these results has thus far shown that, with the exception of instrumentation piping supports, the identified discrepancies are not design significant, i.e.,
the support welds are suitable for service.
The suitability for service of the instrumentation piping support welds is being evaluated, and has not been established to date.
Corrective Action will be tracked on CATD 50132-BFN-01.
IR4 IR4 Corrective Action Plan Evaluation of the results of the Melding Project reinspection show that the attributes of presence,
- size, length, and location are the significant attributes affecting welding serviceability.
The other attributes (undercut, lack of fusion, etc.)
were sometimes present but did not contribute significantly to any overstresses in welds.
Thus the action outlined in this Corrective Action Program is needed to provide sufficient confidence in any future engineering stress evaluation of structures at BFN.
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
50100 REPORT TYPE: Subcategory Report REVISION NUMBER:
4 TITLE:
BFN Site-Specific Welding Subcategory Report Page 11 of 13 The, actions specified are required based on the results of the Welding Project basis sample reinspections and a review of welding-'related employee concerns.
In order to incorporate this at BFN, the following should be included in an engineering procedure and/or in each program/
activity that considers structural adequacy:
1.
Identify that the purpose of the engineering data collection is for use in evaluation of structures.
2
~
Define the training and qualification requir
~ vients of the personnel performing the engineering data col'lection.
The training should be similar to that used for Mechanical Maintenance Instruction 99 (MMI), Instruction for the Implementation of Phase I,
NRC IE Bulletins 79-14 Units I, II, and.lII, which appear s to have the basic requirements included.
3.
Specify that the engini~ering data collection will consist of the weld presence, type, size, length and location.
The data collectors should also be aware of such indications as burn
- through, missing welds, excessive
- slag, etc.
and document their presence for consideration in the structural evaluation.
IR4 4.
The data collection criteria should be the same tolerance as Ipl?cified in G29C Process Specification 3.C.5. 4 for s ice,
- length, and location.
Oocumentation shall consist of:
1.
A means to identify the item from which the data has been taken.
2.
A structural sketch indicating presence or lack thereof along with type, size,
- length, location, and those indications deemed necessary by the engineer of all welds For the identified item.
IR4 3.
A date and sign off by the data collector.
4.
The engineering data collected should be included in a calculation package and a statement made concerning its acceptability.
5.
The calculation should be documented in accordance with BFN procedure.
6.
Document and retain training records.
TVA EMPLOYEE CONCERNS SPECIAL P ROG RAM REPORT NUMBER:
50100 REPORT TYPE: Subcategory Report REVISION NUMBER:
4 TITLE:
BFN Site-Specific Welding Subcategory Report Page 12 of 13 Furthermore, it is felt that this need not be backfitted to the cable tray and conduit supports already completed because the United Engineers and Constructors'valuation should be the basis for Unit 2 restart and the unresolved safety issue A-46, Seismic Qualification of Equipment in Operating Plants, the basis for long-term qualification (both programs address welding) of cable tray and conduit supports.
Action to prevent recurrence is not required, in that Standard Practice 6.2; and later Site Director Standard Practice
- 13. 1 place all safety related welding at BFN under an inspection program.
This program has been 'in effect since mid-1983.
lR4 Complete details of the evaluation of this issue are discussed in Weld Project Fvaluation Report WP-32-BFN.
IR4 I
- 3. 13 Weld Ins ection Procedures The concerns questioned the adequacy of weld inspection p'rocedures and the adequacy of the inspection criteria; inspection of welding and brazing on HVAC ductwork; and the reporting of defects.
Adequate inspection criter ia has been available at OFN since the beginning of construction.
Initially, inspection was performed by direct application of the governing" codes.
A syst: em of procedures evolved and at the time TVA committed to compliance with 10 CFR 50 Appendix B, these procedures contained or made reference to all of the detail and criteria necessary to facilitate weld inspections.
The HVAC ductwork at BFN was fabricated and erected by mechanical means.
In mid 1986, welded modifications to the sheet metal ductwork were specificed
~
At that time, TVA emp'laced a procedure which included all of the necessary inspection requirements.
The concerns relating to reporting of defects state that the NDE Inspectors can only use a Notice of Indication for inservice defects, and a Maintenance Request for preservice defects
~
The Notice of Indication is the specified form for reporting of all defects identified within the scope of a defined examination.
'The Maintenance Request is used to report all observations by any plant personnel, outside the scope of a defined examination.
This practice is in accordance with the Nuclear Quality Assurance Manual.
Complete details of the evaluation of this issue are discussed in Weld Project Evaluation Report WP-35-BFN.
IR4 I
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
50100 REPORT TYPE: Subcategory Repor t REVISION NUNBER:
4 TITLE:
BFN Site-Specific Welding Subcategory Report Page 13 of 13
- 4. 0 COLLECTIVE SIGNIFICANCE Through the subcategory overview of the evaluation report findings and the IR4 subsequent integration of information, no new significant items were identified.
The evaluation report investigations and the subcategory overview indicated IR4 that the welding procedures and the practices used at BFN were consistent with good industry practices used throughout the country even though a few quality problems appeared.
TVA's welding control practices at BFN were adequate and reflected common industry practices.
Some problems were identified, as one would expect with the size of the operation and the time frame, and were addressed by the ongoing QA program and the Weld Project Evaluation Report Investigations.
IR4 5.0 CAUSE The cause of a perceived problem'or the cause of a problem which initiated a
CATO is limited to the cause identified in the evaluation report.
IR4 6.0 CORRECTIVE ACTION No corrective action is specified as a result of this subcategory report.
Corrective actions for problems or perceived problems are limited to the issued CATDs as a portion of the Weld Project Evaluation Reports.
Oiscussion of enhancements to the existing TVA syst: em, other than CATD 50103-8FN-01, will be deferred to the category report.
CATO 50103-BFM-01 was issued as a program enhancement.
This enhancement recommends that BFN (and all TVA Nuclear Sites) adopt a uniform computerized system comparable to the system used at WBN and BLN in order to minimize the likelihood of a welder working outside his parameters or allowing a qualification to expire.
IR4 7.0 ATTACHMENTS A.
Subcategory Summary Table 8.
Summary of Issues 8.0 REFERENCE A,
Welding Project Evaluation Reports IR4
REFERENCE
" ECPS120J-ECPS121C FREQUENCY REQUEST OWP - ISSS - RIIII CATEGORY<
NE tlON QA/QC flELDItlG TEWIIESSEE VALLEY AUTHORITY OFFICE OF tlUCI.EAR PONER ENPLOYEE COIICERW PROGRAN SYSTEN (ECPS)
EPIPLOYEE COWCERII IWFORNATIOtl BY CATEGORY/SUBCATEGORY SUBCATEGORY'0101 TRACEABILITYp ACCOUIITABILITY> AWD COIIDITIOIIItlG PAGE 1
RUtl TINE - llsl5i02 RUtl DATE 12/17/87 CONCERN HUNBER CAT SUB CA1' H
R PLT D LOC REPORT APPL SAF RELA1ED BF BL SQ IIB HISTORICAL CONCERN REPORT ORIGIN CONCERN DESCRIPTIOW EX 039-00101 T50ICI6 IIE 50301 S
NBII 02 NE 50101 S
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HA WA SR WA 1Y H
tl W
2 SR HA WA WA III-85-053-OOCI QTC IIBIIPi TtIERE ARE HO PORTABLE OVENS FOR STORING IIEL D
ROD AFTER IT HAS BEEN ISSUED TO THE IIELDER AWD THE IIELD ROD IS tlOT ADEQUATELY ACCOUNTED FOR NHEW IT IS RETURNED, I.E.
ROD STUDS AHD UNUSED ROD.
CO IIST.
DEPT.
COHCERII.
CI HAS tlO FURTHER ItlFORNATIOW IIO FOLLOIIUP REQUIRED.
(SQtl ISSUES ADDRESSED Itl RPT IIP-01-SQII R3)
IH 23CI-00101 T50027 IIE 50301 S
IIBH IN 2CI7-00101 T50022 flE 50312 S IIBtl 02 IIE 50101 S
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WA SR WA HA EX-85-021-001 QTC III-85-284-001 QTC IIELD RODS ARE HOT REQUIRED TO BE KEPT IH ROD OVENS AFTER ISSURAWCE TO STEAIIFITTER IIELDERS.
THE ROD CAH BE KEPT UNHEATED FOR 8
HOURS AT A TINE IH A LE ATWER POUCH.
(SQtl ISSUES ADDRESSED Itl RPT IIP-01 "SQ' R3) 7018 RODS (PURCHASED)
ARE OF POOR QUALITY. THIS CO IITRIBUTES TO POROSITY AWD PIWHOLES.
(SQII ISSUES AD DRESSED III RPT IIP-12-SQH R2)
I
REFERENCE
- ECPS120J-ECPS121C FREQUEIICY REQUEST OWP ISSS - RIIII CATEGORY>
IIE IIOtl QA/QC PIELDIIIG TENNESSEE VALLEY AUTHORITY OFFICE OF IIUCLEAR POllER EI1PI.OYEE CONCERN PROGRAII SYSTEH (ECPS)
El'1PLOYEE COIICERW itlFORIIATION BY CATEGORY/SUBCATEGORY SUBCATEGORY> 50101 TRACEABILITYp ACCOUIITABILITY, AIID COWDIT10tlING PAGE
2 RUtl TIIIE -
11 c 45 s 02 RUW DATE " 12/17/87 CONCERt) IIUIIBER CAT SUB CAT S
N R PLT D
LOC 1
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HELD ROD CAH BE KEPT OUT OF OVEN FOR AH EWTTRE SNTFT AWD R ETURIIED TO OVEII FOR LATER USE.- (SQtl ISSUES ADDRESS ED IW RPT IIP-01-SQW R3) iH -&5-426"00101 T50061 02 HE 50301 S
IIBW IIE 50101 S IIBII 1 tl tl 2 IIA HA 1Y II 2
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THE ROD OFTEN COLI.ECTS NOISTURE AHD SIIOULD WOT BE USE D.
(SQW iSSUES ADDRESSED IW IIP"01"SQW R3) 03 HE 50201 S IIBH 06 IIE 50601 S IIBtl 1W Y
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~ QTC QA TRAilliNG CLASS, 6-5-85, IIIFORtlED CRAFT THAT STE Al'IFITTERS COULD IliTNDRAII AIID CONTROL IIELD ROD IF T HEY HAD A IIELDER SIGIIED IIELD SLIP AtlD THE IIEDERS C
ARD.
(SQW ISSUES ADDRESSED III RPT III'-01-SQW R3)
5'EFERENCE ECPS120J "ECPS121C FREQUENCY
- REQUEST OWP - ISSS - RIIM CATEGORY'IE NON QA/QC HELDTWG TENNESSEE VALLEY AUTHORTTY OFFICE OF NUCLEAR PONER EMPLOYEE CQIICERII PROGRAM SYSTEM (ECPS)
EMPLOYEE COtlCERII 1IIFORIIATIOII BY CATEGORY/SUBCATEGORY SUBCATEGORY'0101 TRACEABTLITY, ACCOUIITABILITY, AWD CONDITIOHIIIG PAGE 3
RUtl TIME "
1 1 i 65 i 02 RUW DATE 12/17/87 CONCERN NUMBER S
H SUB R
CAT CAT D
PLT LOC 1
REPORT APPL 2 SAF RELATED BF BL SQ IIB HISTORICAL CONCERN REPORT ORIG1H CONCERN DESCRIPTIOH I
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04 klE 50601 S
02 IIE 50101 S
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IN 426-00701 T50102 5IE 50301 S
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ROD ROOtl FOR NORE.
SITE POLICY ALLOIIS LEAVING R OD IIITII OTHER IIELDORS>
OR LETTIHG SUB-JOURIIEYML'tl C HECK"OUT ROD AWD RETURN ROD.
(CAW ALSO LEAVE ROD III TOOL BOXES).
THE ROD ROOM DOES WOT COUNT ROD N HLtl IT IS ISSUED, AtlD DOES IIOT REQUIRE ACCOUNTIWG FOR ROD STUBS.
OCCASSIONALLY> IIELDORS ARE REPRIMA tlDED FOR NOT TURtt?IIG Itt ROD IIITHDRAIIALSLIPS>
EVEII THOUGH (SQH ISSUES ADDRESSED Itl RPT HP-01-SQN R3)
IH "85"426-00101 T50065 02 IIE 50301 S
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EX-85-021 "001 WA W
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'PORTABLE OVENS ARE HOT REQU?RED.
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WO FOLLOH"UP- (
SQW ISSUES ADDRESSED IH RPT IIP-01-SQH R3)
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REFERENCE
- ECPS120J-ECPS121C FREQUENCY REQUEST OWP - ISSS - RIIM CATEGORYs IIE HOtl QA/QC NELDItlG TENNESSEE VALLEY AUTHORITY OFFICE OF tlUCLEAR POWER EMPLOYEE CONCERN PROGRAM SYSTEM (ECPS)
EMPLOYEE COWCERtl INFORMATION BY CATEGORY/SUBCATEGORY SUBCATEGORY< 50101 TRACEABILITYe ACCOUNTABILITY>> AWD COIIDITIOttIWG PAGE RUII TIME lls45a02 RUH DATE " 12/17/87 CONCERN NUMBER CAT S
N SUB R PLT CAT LOC 1
REPORT APPL 2 SAF RELATED BF BL SQ flB HISTORICAL REPORT COIICERW ORIGIN CONCERN DESCRIPT ION IH 441-00301 T50040 llE 50301 S
IIBW 02 IIE 50101
.S NBW 03 NE 50201 S IIBH 04 flE 50401 S llBtl 1 tl H
Y H
2 HA WA SR WA 1
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SR WA WA WA 1H Y
tl H
2 HA SR WA WA 1 tl tl tl Y
2 HA WA HA SR EX-85-021-001 QTC WO PORTABLE OVEtlS Otl WATTS BAR.
THE ROD SOMETIMES COL!.ECTS IIOISTURE BY THE EHD OF TWE SHTFT AHD CAW HOT BE USED.
(SQII ISSUES ADDRESSED IN RPT MP"01-SQ tl R3)
IH 453-00901 T50030 02 03 04 flE 50301 5 IIBII tlE 50101 S
IIBW IIE 50201 S
IIBW IIE 50401 S
IIBW 1 tl tl 2
HA WA 1
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2 SR WA 1
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tl SR WA tl tl WA IIA tl H
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Y WA SR EX-85-021-001 QTC IIELDERS FREQUENTLY GIVE IIELD ROD TO OTHER IIELDERS.
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(SQW ISSUES ADDRESSE D IW RPT IIP-01-SQW R3) 03 04 IIE 50201 S IIBH IIE 50401 S
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REFERENCE
- ECPSI20J-ECPSI21C FREQUENCY REQUEST OHP ISSS - RIHI CATEGORY'IE tlotl QA/QC IIELDItlG TEHtlESSEE VALLEY AUTHORITY OFFICE OF NUCLEAR POHER EHPLOYEE CONCERN PROGRAtl SYSTEM
( ECPS)
EHPI OYEE COWCERtl IHFORtlATIOH BY CATEGORY~SUBCATEGORY SUBCATEGORY s 50101 TRACEABILITY, ACCOUHTABILITYp AHD CotlDITIOtlIHG PAGE
5 RUH TIIIE 11il5i02 RUH DATE - 12/l7/87 COHCERtl HUIIBER IW 501-00101 T50031 S
H SUB R PLT CAT CAT D LOC IIE 50319 S IIBtl 04 IIE 50601 S IIBH IH "&5-672-00301 T50207 HP 70202 S
I.IBH 02 IIE 50301 5 flBH 03 IIE 50101 S IIBH 06 IIE 50201 S IIBH 05 IIE 50601 S IIBH 02 IIE 50101 S
IIBW 03 IIE 50201 S IIBH 1
REPORT APPL 2
SAF RELATED BF BL SQ IIB 1
H H
Y H
2 HA HA SR HA 1
Y N
tl tl 2
SR HA HA HA 1H Y
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HA SR WA HA I
H H
tl Y
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HA SR HA HA 1
H H
H Y
2 HA HA HA SR HISTORICAL CONCERN REPORT ORIGIN CONCERN DESCRIPTIOH QTC AT SHIFT ENDS flELD ROD SLIPS ARE TURtlED Itl.
THE S
I.IPS ARE CHECKED THEW THROWN AIIAY.
IF THE ISSUE R
Doll DETERtlIHES AT A LATER DATE THAT A IIELDER DID tl OT COHFORtl To "TURN IH" PROCEDURES, IT IS HIS IIORD-AGAIHST TIIEIRS AWD HE GETS THE IIARHIHG LETTER.
T NESE LCITERS HAVE BEEtl ISSUED IIITHOUT PROOF OF IIRO WGDOIHG.
CONSTRUCTION DEPT.
CONCERN.
(SQH ISSUES ADDRESSCD IH RPT IIP-Ol-SQH R3)
IH-85-501-001 QTC UNUSED BUtIDLES OF HELD ROD FREQUENTLY FOUND IH TRA SW CANS I.E.
TURBINE BLDG.i 708'i 729'i AHD 755' LEVATIOHSp UNIT N2 (15-20 RODS FOIIIID 6-7-85)
(SQH ISSUES ADDRESSED IH RPT HP-19-SQH R1)
IH 067-00101 T50110 02 IIE 50316 S IIBH IIE 50101 S 1lBtl 03 HE 50201 5 IIBH OCI IIE 50CI01 S IIBH 1 tl tl Y
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HA HA SR HA 1
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tl tl 2
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HA HA HA SR QTC A SYSTEtl IS HEEDED THAT VERIFYS TtIAT THE IIELDER DI D RETURN THE UNUSED IIFLD ROD AHD STUBS AHD HILL PR OVIDE THE IIELDER A RECEIPT SO THAT THE IIELDER CAH PROVE HE DID RETURN THE tlATERIAL Itl CASE AH ERROR IIAS tlADC.
CI IIAS HO ADDITIONAL ItlFORIIATIOH.
COWS TRUCTIOH DEPARTIIEHT. (SQH ISSUES ADDRL'SSED Itl RPT IIP-lk-SQII R1)
REFEREHCE ECPS120 J-ECPS121C FREQUEHCY
- REQUEST OHP " ISSS RIM CATEGORY IIE HOH QA/QC IIELDIHG TEHHESSEE VALLEY AUTHORITY OFFICE DF IIUCLEAR POIIER EMPLOYEE COHCERH PROGRAM SYSTEH (ECPS)
EHPLOYEE COHCERH IHFORIIATIOH BY CATEGORY/SUBCATEGORY SUBCATEGORY'0101 TRACEABILITYp ACCOUHTABILITYp AtlD COtIDITIOHItlG PAGE
6 RUtl TINE IIc15~02 RUH DATE - 12/17/B7 S
H 1
REPORT APPL SUB R PLT 2 SAF RELATED COHCERH tIUHBER CAT CAT D LOC BF BL SQ IIB HISTORICAL COHCERH REPORT ORIGIH COHCERH DESCRIPTIOH 02 IIE 50101 S
03 IIE 50201 S
IIBH 1
Y H
H H
2 SS HA HA HA IIBH 1 tl Y
tl H
2 HA SS HA HA OCI IIE 50001 S IIBH 1
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H Y
2 HA HA HA SS III 053-Ooc401.
IIE 50301 S
IIBH 1
H H
Y H
T50135 2
HA HA SS HA III-85-053"OOA QTC IIELD ROD COHTROL DOES NOT SATISFY CODE REQUIRBIEHT S.
TVA ATTITUDE IS "ALL ttATERIAL IS CODE tlATERIAL COHSTRUCTIOtl DEPT COtlCERH.
CI HAS HO FURTHER IHFORIIATIOH. (SQII ISSUES ADDRESSED IH RPT IIP-01-SQ tl R3) 16 COHCERHS FOR CATEGORY IIE SUBCATEGORY 50101
REFERENCE
- ECPS120J-ECPS121C FREQUEltCY REQUEST OHP I5 SS RIIH CATEGORYc HE HOH QA/QC HELDIHG TENNESSEE VALLEY AUTHORITY OFFICE OF NUCLEAR POWER EHPLOYEE CONCERN PROGRAH SYSTEH (ECPS)
EHPLOYEE CONCERN IHFORHATIOW BY CATEGORY/SUBCATEGORY SUBCATEGORY i 50102 INSPECTION OF IIELDS THROUGII PAINT PAGE
7 RUtl TII'IE llcct5c 02 RUH DATE " 12/17/87 CONCERN tIUHBER CAT SUB CAT S
H R PLT D LOC 1
REPORT APPL 2 SAF RELATED BF BL SQ IIB HISTORICAL REPORT CONCERN ORIGIN CONCERN DESCRIPTION Itl cc58-00101 T50105 IIE 50102 S IIBH 02 IIE 50202 S IIBtl 03 HE 50302 S
HBH Oct flE 50402 S IIBN IN 019-00101 T50219 flE 50102 S IIBtl 02 IIE 50202 S IIBH 03 HE 50302 S
HBH Occ IIE 50cc02 S IIBtl 1
Y W
2 SS WA 1 tl Y
2 HA SS H
N WA tlA H
tl HA HA 1
N N
Y H
2 HA HA SS WA 1 tl tl H
Y 2
HA HA HA SS 1
Y W
H H
2 SR HA HA HA 1
H Y
H H
2 HA SR HA WA 1
W H
Y H
2 HA HA SR HA 1
H H
H Y
2 WA WA HA SR IH-85-ct58-001 QTC QTC TVA USED IHPROPER INSPECTION CRITERIA FOR AHS HELD S
HEIIO FROH'KNOXVILLE (POSSIBLY EHDESp 1980 OR 1
981)
ALLOIIED INSPECTION THROUGH PAINT.
INDIVIDUAL FROH KNOXVILLE (KHOHH) INVESTIGATED THIS, BUT RES ULTS ARE UWKtlOIIH.
CI HAS tlO NORE ItlFORHATIOH. (SQ W ISSULS ADDRESSED IN RPT HP"02-SQW R2)
CI IS COtlCERHED THAT HELDS HERE ACCEPTED THROUGH C ARBO-ZINC.
INSPECTORS HERE DIRECTED VIA HEHO TO A
CCEPT IIELDS TIIROUGH PAINT.
CI COULD WOT PROVIDE A HY ADDITIONAL IWFORHATIOH.
UNIT 1.
CONSTRUCTION DEPT.
CONCERN.
(SQH ISSUES ADDRESSED IH RPT I'IP-02 SQH R2)
HS -85"001-00101 T50022 02 03 Oct IIE 50102 S IIBH IIE 50202 S
IIBW HE 50302 S
HBH IIE 50cc02 S
1lBH 1
Y H
2 SR WA 1
tl Y
2 HA SR 1
H H
2 HA WA 1 tl tl 2
WA tlA W
H HS-85-001-001 WA HA H
H WA WA Y
H SR WA tl Y
WA SR QTC IIELDS (AIIS) ItlSPECTED SUBSEQUEtlT TO PROTECTIVE COA TING (CARBOZIHC PRIHER)
APPLICATIOHJ FItIAL VISUAL IIELD EXAHIHATIOW OF STRUCTURAL IIELDS IW CATEGORY I STRUCTURES'tlCLUDIttG PIPE HAHGERSr CABLE TRAY SU PPORTS AWD DUCT SUPPORTS; UNIT 1
& 2 (SQH ISSUES A
REFERENCE ECPS120J-ECPS121C FREQUENCY
" REQUEST OHP ISSS - RIIM CATEGORYS IIE WOtl QA/QC tlELDIHG TEWIIESSEE VALLEY AUTHORITY OFFICE Of NUCLEAR POWER EMPLOYEE COHCERII PROGRAM SYSTEM (ECPS)
EMPLOYEE COtlCERII ItlFORIIATIOH BY CATEGORY/SUBCATEGORY SUBCATEGORY'0102 ItlSI'ECTIOW OF IIELDS THROUGH PAINT PAGE 8
RUW TIME lli45c02 RUW DATE " 12/17/87 SUB CAT S
H R PLT D LOC 50102 S
tIBW 02 IIE 50202 S tIBII 03 HE 50302 S IIBH 06 IIE 50602 S
WBII CONCERN NUMBER CAT PH 060"00101 llE T50203 1
REPORT APPL 2
SAF RELATED BF BL SQ HB 1
Y tl H
tl 2
SR HA HA WA 1 tl Y
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2 HA SR HA HA 1
H W
Y H
2 HA HA SR HA 1 tl tl tl Y
2 HA WA HA SR I
HISTORICAL CONCERN REPORT ORIGIN CONCERN DESCRIPTION I
Itt-85-458"001 QTC'.
QA NAtlGERS IIERE FREQUEtlTLY PAINTED BEFORE THE llELD S IIERE IIISPECTED.
AUX. BUILDIIIG, REACTOR BUILDING Oli ELEV. 762'-0"i
& 765'-0".
1983.
COIISTRUCTIO H DEPT.
COtlCERtl.
CI HAS tlO FURTHER DETAILS.
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HA HA tl tl HA WA H
tI HA IIA tl tl IIA WA Y
H SS HA tl Y
HA SS III-85-013-003 QTC G29C (CONSTRUCTION SPECIFICATIOHS)ALLOIIED IIELDS TO BE ItlSPECTED AFTER PAINTTHG FROM 1981 THROUGH TttE EWD OF THE HELDIIIG SAMPLIHG PROGRAM.
THIS IS IW VIOLATIOW OF AMS D1.1.
CI NAS HO MORE IHFORWAT10H' (HOTEI THIS ITEN IS CURREH'TLY UNDER IWVESTIGATI Otl BY ERT.
THE REVISIOtt IIAS I'IADE TO SEPARATE THE ORIGjHAL 003 CONCERN INTO TIIO DISTINCT CONCERNS.)
(SQW ISSUES ADDRESSED III RPT NP-02-SQII R2) tlI 030-00701 T50185.
IIE 50116 S
HBH 02 IIE 50102 S
MBH 03 IIE 50216 S
iIBW 1Y tl W
H 2
SR tIA HA WA 1
Y tl tl H
2 SR HA WA HA 1WYH tl 2
WA SR WA WA 06 IIE 50316 S
I.IBW 1
H W
Y H
2 HA WA SR WA
CONTRARY TO THESE REQUIREIIEIITSi THE G-29C PROCESS SPECIFICATIOII IIAS llODIFIED TO REFLECT LESS STRItlGEtlT ItlSPECTIOW REQ UIREMEWTS (E.G.
VISUAL IIISPECTIOH OF IIELDS THROUGH PAINT (CARBO ZINC PRIMER)
AHD IIO DOCUtlEtlTED IHSPE CTIOW BY CERTIFIED VISUAL INSPECTORS (FIT-UPp IW-P ROCESS)
PRIOR TO FINAL INSPECTION.) CI HAS HO ADDI TIOHAL IIIFOPNATIOH.
IIUC.
POWER DEPT.
CONCERN.
(SQ tl ISSUES ADDRESSED IH RPT IIP-16-SQII R2) 05 IIE 50c416 S
IIBW 06 IIE 50202 S
HBW 08 IIE 50602 S IIBtl W
W tlA tlA tl Y
WA SR H
Y WA SR W
tl HA HA 1 tl W
tl Y
2 HA HA WA SR
all REFERENCE
- ECPS120J-ECPS121C FREQUENCY
- REQUEST OWP '- ISSS - Rtttt CATEGORY s IIE HON QA/QC IIELDING TENNESSEE VALLEY AUTHORITY OFFICE OF NUCLEAR POIIER EIIPLOYEE COtlCERH PROGRAII SYSTEtt (ECPS)
EHPLOYEE COIICERtl IHFORIIATIOW BY CATEGORY/SUBCATEGORY SUBCATEGORY'0102 INSPECTION OF IIELDS THROUGH PAINT PAGE 9
RUtl "T1HE llc65s02 RUH DATE 12/17/87 CONCERN WUNBER CAT SUB CAT S
H R PLT D LOC REPORT APPL SAF RELATED BF BL SQ IIB HISTORICAL REPORT CONCERN ORIGIN CONCERN DESCRIPTIOW HI 030-00801 T50185 IIE 50319 S IIBtl I
TVA REPORTS IH DICATE THAT OWLY 100"150 IIELDS HERE INSPECTED IH T HIS HAWHER EVEN THOUGH THERE IS NO DOCUIIEWTATIOW I DEWTIFYIWG IIHICH NELDS IIERE INSPECTED THROUGH CARS 0-ZItlC PRIHER.
HUC.
POIIER CONCERN.
CI HAS IIO ADDI TIOHAL IWFORIIATIOH. (SQW ISSUES ADDRESSED IW RPT ll P-19-SQW R1) lll 061-00801 T 50193 HE 50102 S IIBH 02 IIE 50202 S
ItbW 03 IIE 50302 S IIBtl 04 IIE 50602 S
I<BII 1
Y W
H H
2 SS HA WA HA 1H Y
H tl 2
HA SS WA WA 1
H H
Y H
2 tIA HA SS WA 1 tl tt tl Y
2 WA WA HA SS IH-85-658-001 QTC PROCESS SPECIFICATIOW W3.C.5.CI OF G-29C PERNTTTED INSPECTION OF AIIS IIELDS THROUGH COATING (CARBO-ZIW C PRIIIER)
FOR ELEVEN HOHTIIS AFTER EHGTHEERIWG EVAL UATTOW/TEST SHOI'IED TIIAT I'IELD QUALITY (POROSITY'R
- ACKS, ETC)
COULD tlOT BE ltISPECTED THROUGH PAINT.
WUC POHER DEPT.
CONCERN.
CI HAS HO ADDITIONAL IWF ORtIATIOH. (SQtl ISSUES ADDRESSED IH RPT I<P-02-SQII R
2) 9 CONCERNS FOR CATEGORY IIE SUBCATEGORY 50102
~
~
- gi s
~
REF EREWCE ECPS120 J-ECPS121C FREQUEHCY
- REQUEST OWP -
TSSS - RIIH CATEGORY) IIE tlOW QA/QC IIELDIWG TEHWESSEE VALLEY AUTHORITY OFFICE OF IIUCLEAR POIIER EHPLOYEE COHCERII PROGRAH SYSTEH (ECPS)
EHPLOYEE COIICERW IHFORHATIOH BY CATEGORY/SUBCATEGORY SUBCATEGORY~ 50103 IIELDER PERFORHAIICE QUALIFICATIOH COIITIHUITY PAGE 10 RUII TINE " lls65c02 RUW DATE 12/17/87 COWCERW WUHBER CAT SUB CAT S
H R PLT D LOC 1
REPORT APPL 2 SAF RELATL'D HISTORICAL BF BL SQ IIB REPORT
~ COWCERW ORI01W COHCERH DESCRIPTIOH EX 021"00201 T50069 IIE 50103 S
HBW 02 IIE 50203 S
IIBW 03 IIE 50303 S
IIBW 06 IIE 50403 S I)BII Itti-85-306-00301 T50026 IIE 50103 S
HBH 02 IIE 50303 S
IIBW HI 077-H1701 IIE 50103 W
BFW 1
Y H
H H
Itl-85-352-001 2
SR WA HA HA 1 tl Y
H tl 2
WA SR WA HA 1
W H
Y W
2 WA WA SR WA 1 tl H
tl Y
2 WA HA WA SR 1YHW'H 2
SR WA WA WA 1
Y H
tl W
IW-85-352-001 2
SR HA WA WA 1H tl Y
W 2
WA WA SR WA HRC QTC IIRC iDEWTIFIED THE FDLLOIITIIG COWCERH FROW REVIEW 0 F THE QTC FILE>
'%lELDIHG BY UIICERTIFIED WELDER AT BROIIHS FERRY."
tIELDER CERTIFICATIOWS ARE UPDATED OII EVIDEHCE OF R
OD IIITHDRAIIALSLIPS.
TIIE PROCESS tlAY tloT IIAVE BEE tl USED IW TIIE APPLICABLE TItlE PERIODS 90 DAY OR/80 DAY. DEPEtlDIIIG Otl AStIE OR AIIS. (SQtl ISSUES ADDRES SED IH.RPT IIP-03-SQW R3)
QTC THERE IS tlo HETHOD/OBJECTIVE EVIDEIICE To VERIFY TH AT A IIELDER HAS USED A SPECIFIC PROCESS HHEtl THEIR IIELD CARDS ARE STAIIPED/UP-DATED BY QC.
tlo FOLLOII
-UP REQUIRED IIO ADDITIOWAL IIIFORHATIOH AVAILABLE (SQH ISSUES ADDRESSED Itl RPT IIP-03-SQH R3) 03 IIE 50CI03 S
HBW tl tl WA WA tl Y
HA SR IW c426-00201 T50065 IIE 50103 S IIBH 02 Ilf 50203 S IIBtl 03 IIE 50303 S IIBH 06 I<E 50403 S
IPBII 1
Y W
H H
IH-85-352-001 2
SR WA WA WA 1W Y
tl H
2 WA SR WA HA 1H tl Y
W 2
WA HA SR HA 1
H H
H Y
2 HA WA HA SR QTC UPDATItlG OF IIELDER CERTIFICATIOIIS IS 1WADEQUATE IH THAT A IIEI.DER IS OIILY REQUIRED TO PRESEtlT THEIR C ARD FOR UPDATIWG AHD SOIIETIHES Is ASKED To RUW A B
EAD-tlEVER A CotIPLETE IIELD.
tlo FOLLOH-UP. (SQtl IS SUES ADDRESSED IW RPT HP-03"SQH R3)
REFERENCE
- ECPS120J-ECPS121C FREQUENCY
- REQUEST OWP " Isss - RIIII CATEGORY)
IIE WOII QA/QC WELDItlG TEWtIESSEE VALLEY.AUTHORITY OFFICE OF NUCLEAR POWER EHPLOYEE COtlCERW PROGRAII SYSTEH (ECPS)
EIIPLOYEE COHCERtl IHFORI)ATIOII BY CATEGORY/SUBCATEGORY SUBCATEGORY'0103 WELDER PERFORIIAWCE QUALIFICATIOtlCOtITItlUITY PAGE
ll RUH TINE ll'a65s02 RUH DATE - 12/17/87 CONCERN HUIIBER CAT S
H SUB R PLT CAT D LOC 1
REPORT APPL 2 SAF RELATED BF BL SQ IIB HISTORICAL REPORT CONCERN ORIGIN CONCERN DESCRIPTIOH IN 480-00601 T50031 IIE 50103 S
WBH IH 725-XI%01 T50167 WE 50319 S
IIBW 02 IIE 50103 S IIBH 03 IIE 50603 S flBH IH 725-X1501 T50167 WE 50319 S IIBtl 02 IIE 50103 S
WBH 03 HE 50203 S
WBH 04 IIE 50603 S IIBtl 02 WE 50203 S
WBH 03 WE 50303 S flBtl 04 IIE 50603 S IIBH 1
Y tl tt tl 2
SR WA HA HA 1 tl Y
H tl 2
WA SR HA HA 1 tl tl Y
tl 2
WA HA SR HA 1
H tl tl Y
2 HA WA HA SR 1
W tl Y
tl 2
WA WA SR HA 1Y W
H tl 2
SR HA WA WA 1 tl H
H Y
2 HA WA WA SR 1
tt tl Y
tl 2
WA WA SR HA 1 Y H
H H
2 SR WA WA WA 1N Y
H tl 2
HA SR HA WA 1tl WHY 2
WA WA WA SR IN-85-770-002 QTC IH-85-725-Xl0 QTC IH-85-725-X15 QTC WELDER CERTIFICATION UPDATE IS INADEQUATE.
PERSON WEL HAY IIORK IH A POSITION THAT DOES WOT REQUIRE A WY llfLDIHG FOR 5-6 YEARS BUT CERTIFICATIONS ARE CO HTIWUALLY UPDATED.
WHEW THESE PERSONS RETURN TO W
ELDIWG HO TESTS ARE CONDUCTED.
THEY JUST RUH STRI HGERS TO UPDATE CERTIFICATIOHS.
(SQH ISSUES ADDRES SED IW RPT IIP-03-SQW R3)
WELDER RECERTIFICATIOtl PROGRAt'I HAD ItlADEQUATE SUPE RVISORY OVERSIGHTI IT COULD HAVE BEEN POSSIBLE FO R
A GOOD IIELDER TO WELD THE TES1 PLATES FOR AH IWC APABLE WELDER.
DETAILS KtlOWtl TO QTCi WITHELD TO H AIWTAIW CONFIDENTIALITY. (SQH ISSUES ADDRESSED IW RPT WP-19-SQH Rl)
THE CONTROL OF WELDER RECERTIFICATIOH TEST PLATES WAS IIIADEQUATEs TEST PLATES BEGUN BY OtlE WELDER C OULD HAVE BEEN COI1PLETED BY ANOTHER WELDER.
DETAI L
KtlOIIW TO QTC-WITHELD TO NAItlTAItlCOIIFIDEtlTIALITY (SQW ISSUES ADDRESSED IH RPT WP-19-SQII Rl) 7 CONCERNS FOR CATEGORY IIE SUBCATEGORY 50103
P 1
P I'I REFERENCE
- ECPS120J-ECPS121C FREQUENCY REQUEST OtlP - ISSS - RIIN CATEGORY$ IIE tlOW QA/QC flELDIIIG TENNESSEE VALLEY AUTHORITY OFFICE OF tlUCLEAR PONER EI'IPLOYEE CONCERN PROGRAH SYSTEN (ECPS)
EtIPLOYEE COHCERII IWFORtlATIOtl BY CATEGORYiSUBCATEGORY SUBCATEGORY$ 50104 1HSPECTIOH TOOLS AT BFHP PAGE 12 RUH TINE 11$ 45$ 02 RUH DATE - 12/17/87 CONCERN tIUNBER CAT SUB CAT S
N R PLT D LOC 1
REPORT(APPL 2 SAF RELATED BF BL SQ IIB HISTORICAL COHCERII REPORT ORIGIN CONCERN DESCRIPTIOH IN 007-00101 T50001 IIE 50104 S
I.IBW 02 IIE 50204 S
I.IBH 03 IIE 50304 5 IIBII 04 IIE 50404 S IIBtl r
1 Y
tl tl tl 2
SR IIA HA HA 1
W Y
H W
2 HA SR HA HA 1 WHY tl 2
WA HA SR HA 1H tl H
Y 2
HA WA HA SR QTC INSPECTION TOOLS FOR IIELDING INSPECTORS HERE NEVER ISSUED.
I.E. FILLET IIELD SIZE GAGES'IT"UP GUAG ES ETC.
(SQW ISSUES. ADDRESSED Itt RPT PIP"04"SQH R2
)
IW 134$ -00201 T50050 02 03 04 IIE 50104 S
HBII IIE 50204 S IIBH IIE 50304 S IIBtl IIE 50404 S 'l3H 1
Y tl tl H
2 SS HA HA WA 1
H Y
tl tl 2
HA SS tIA HA 1 tl tl Y
tl 2
WA HA SS WA 1 tl tl tl Y
2 HA HA HA SS QTC UNTIL RECEtlTLY (PAST 2 YEARS),
TVA DTD tlOT PROVIDE QC INSPECTORS NITN IIEI.DING IIISPECTIOW TOOLS.
SON E INSPECTORS PROVIDED THEIR OIIH TOOLS BUT OTHERS D
ID HOT.
CI NAS PASSED AIIAYi IIO FURTHER DETATLS AV AILABLE. (SQH ISSUES ADDRESSED Itl RPT IIP-04-SQtl R2
)
Ttl 406-00301 T50013 02 03 04 IIE 50104$
S IIBW IIE 50204 S
$ IBH IIE 50304 S IIBtl IIE 50404 S I'BH 1
Y H
H H
2 SS WA HA HA 1
H Y
H H
2 HA SS HA HA 1 tl tl Y
tl 2
HA HA SS HA 1H tl H
Y 2
HA HA WA SS QTC PRIOR TO 1979'lO IIELD IIISPECTIOH TOOLS IIERE ISSUE D
TO INSPECTORS.
(SQH 1SSUES ADDRESSED IH RPT HP-0 4-SQtl R2) 3 CONCERNS FOR CATEGORY t - SUBCATEGORY 50104
Is REFERENCE ECPS120 J-ECPS121C FREQUENCY
- REQUEST OWP - ISSS - Rlllt CATEGORYs IIE WOtf QAzQC IPELDIWG TENNESSEE VALLEY AUTHORITY OFFICE OF NUCLEAR POHER EMPLOYEE COtlCERH PROGRAI) SYSTEII (ECPS)
EMPLOYEE COWCERII INFORMATION BY CATEGORY/SUBCATEGORY SUBCATEGORYs 50106 TRAIIIIIIG8 CERTIFICATIOII Of COIIST flELD INSPECTORS PAGE
13 RUII TIME 11sss5s02 RUtl DATE - 12/17/87 CONCERN NUMBER CAT SUB CAT S
H R PLT D LOC 1
REPORT APPL 2 SAF RELATED BF BL SQ IIB HISTORICAL REPORT CONCERN ORIGIN COHCERN DESCRIPTIOH Itl si76-00ss02 T50037 HE 50206 S
HBW 03 IIE 50106 S IIBII Oss I.IE 50306 S IIBtl 05 IIE 50ss06 S flBtl IW 981-00102 T50111 WE 50206 S IIBtl 03 IIE 50106 S
IIBW Oss 1lE 50306 S flBII 05 IIE 50ss06 S IIBtt 1
H Y
N H
2 IIA SR WA WA 1
Y W
N W
2 SR IIA WA WA 1 tl tl Y
H 2
HA WA SR WA 1 tl tl H
Y 2
WA WA WA SR 1
N Y
W H
2 WA SR IIA WA 1Y II W
H 2
SR HA WA WA 1 tl tl Y
H 2
WA WA SR WA 1 ti tl W
Y 2
WA WA WA SR EX-85-052-005 EX-85-052-005 QTC IIELDIIIG ItlSPECTORS IIERE IIIADEQUATELYTRAItlED PIROR TO 1981
~ I E s
PERSOtltlEL IIITH tlO EXPERIENCE IIIVOL VIWG IIELDIWG HERE SEIIT TO A TIIO HEEK TRAIHTHG CLAS S AIID THEW FUIICTIOWED AS A IIELD1WG IIISPECTOR.
CI HAS WO MORE IWFORMATIOH.
HO FOLLOII UP REQUIRED.
(
SQW ISSUES ADDRESSED IW RPT IIP-06-SQII RO)
QTC APPROX. 1980'VA IMPLEMENTED A IIELDIHG INSPECTORS
'IRAIIIIHG PROGRAII AWD PEOPLE WITH A GROCERY CLERK BACKGROUND IIERE INSPECTING IIELDS WITHItt TIIO HEEKS.,
(SQII ISSUES ADDRESSED ltl RPT IIP-06-SQtl RO),
SQW-86-035-00101 IIE 50106 W
BFW 1 Y W
H W
2 SS WA WA WA SQII-86-035-00201 IIE 50106 W
BFW 1
Y W
tl H
2 SS WA WA WA HSRS WSRS DUR1IIG THE IWTERVjEW CONTACT THE CI STATED AND LAT ER DOCUMEtlTED THAT THE CI AtlD FELLOH ISI INSPECTOR S
IIERE ASKED TO PERFORM IIELD IWSPECTjOIIS IIITHOUT B EItlG QUALIFIED.
DURING Atl IHTERVIEII CONTACT THE C1 STATED AHD LATE R
DOCUIIEWI'ED THAT THE CI AWD FELLOII ISI INSPECTORS IIERE REMOVED FROID PERFORtlIWG IIELD ItlSPECTTOIIS BEC AUSE TIIFY IIERE WOT QUALlF1ED.
AFTER TIIEY IIERE REM OVED FROM THE JOB THEY IIERE REPLACED BY INSPECTORS ALSO WOT QUALIF1ED.
~
~
1
\\
~
~-
PAGE
14 RUW TINE 11)65)02 RUW DATE 12/17/87 REFERENCE ECPS120 J-ECPS121C FREQUENCY
- REQUEST OHP ISSS - RIIN CATEGORY> IIE tlOH QA/QC IIELDItlG S
N SUB R
CAT D
1 REPORT APPL PLT 2 SAF RELATED LOC BF BL SQ IIB CONCERN HUNBER CAT III 061-00202 WE T50103 QUALIFICATIOtl/TRAININGOF IIISPECTORS FOR STRUCTURA L (AIIS) IIELD VISUAL EXANIHATIOtl IS QUESTIOttABLE)
L EVEL II CERTIFICATION IS GRANTED HITN ONLY TIIO NOH TNS OF OJTp IINICN IS HOT DOCUIIEHTED) THE TOPICAL R
EPORT HAS "BASTARDIZED" ANSI H65.2.6, REGARDItlG QU ALIFICATIOH OF IHSPECT10H/EXANIHATION PERSONNEL.
CI NAS HO FURTtlER ItlFORIIATIOW.
tlO FOLLOII UP REQUI RED.
(SQW ISSUES ADDRESSED IH RPT NP-06-SQH RO) 50206 5
NBW 1
H Y
H H
2 HA SS HA WA EX-85-052-005 QTC 03 IIE 50106 S
I-IBW 1 Y H
H H
2 SS HA HA WA 06 IIE 50306 S
IIBW 1
H H
Y H
IIBW 1
H tl H
Y 2
HA HA WA SS TEtHIESSEE VALLEY AUTHORITY OFFICE OF tlUCLEAR POllER EIIPLOYEE COtlCERW PROGRAH SYSTEN (ECPS)
ENPLOYEE COWCERtl IWFORIIATIOW BY CATEGORY/SUBCATEGORY SUBCATEGORY 50106 TRA1WItIG 8 CERTIFICATION OF CONST HELD INSPECTORS II I
HISTORICAL CONCERN REPORT ORIGIN CONCERN DESCRIPTIOH III 081-00702
)IE 50206 S IIBtl 1
H Y
tt tl T50237 2
WA SR WA WA 03 NE 50106 S
IIBW 1
Y H
H W
2 SR WA WA WA 0%
IIE 50306 S
NDH 1
H H
Y H
2 WA WA SR WA 05 IIE 50CI06 S
IIBW 1
H H
H Y
2 HA WA HA SR 6
CONCERNS FOR CATEGORY IIE SUBCATEGORY 50106 EX-85-052-005 QTC Ci EXPRESSED THAT NELDIHG INSPECTORS ARE HOT QUAL1 FIED FOR THE JOB.
CI STATED THAT AW INSPECTOR HEE DED TO BE A flELDER SO TNE INSPECTOR IIOULD KWON IIHA T
TO LOOK FOR IN A GOOD IIELD.
CI DECLINED TO PROV IDE AWY ADDITIONAL IHFORNATIOH.
CONSTRUCTION DEPA RTtlftlT C01ICERtl
~
tlO FOLLOII UP REQUIRED.
(SQII ISSUE S ADDRESSED IW RPT IIP"06-SQH RO)
a~, ~
~ '
tl
~ s 4'
"'d l
l REFERENCE ECPS120J-ECPS121C FREQUENCY REQUEST OWP - ISSS RIIH CATEGORY'IE tlOW QA/QC flELDIIIG S'
SUB R PLT CONCERN WUHBER CAT CAT D LOC PAGE 15 RUtl TINE lls45s02 RUH DATE 12/17/87 1
REPORT APPL 2 SAF RELATED HISTORICAL COtlCERW BF BL SQ IIB
'EPORT ORIGIN CONCERN DESCRIPTIOII I
I TENNESSEE VALLEY AUTHORITY OFFICE OF NUCLEAR POIIER EHPLOYEE COtlCERtl PROGRAII SYSTEN (ECPS)
EHPLOYEE COtlCERtl IWFORtlATTOII BY CATEGORY/SUBCATEGORY SUBCATEGORY'0107 IIELUER TRAItlIWG PROGRAH FOR COtlST AWD HELDItlG IIISP EX 008-00101 T50051.
02 03 04 HE 50107 S
IIBW IIE 50207 S
IIBW IIE 50307 S HBtl IIE 50607 S flBH 1 Y W
II tl EX-85"010-002 2
SR WA WA tIA 1W Y
W tl 2
WA SR WA WA 1 tl tl Y
W 2
WA WA SR WA 1
N tl tl Y
2 WA WA WA SR QTC SUBJOURtlEYHEH USED TO DO 140RK THAT THEY'E tlOT QUA LIFIED TO DOi THEY WEEDW'T HAVE AHY SPECIFIC TRAI
- WItlG, BUT DO HORK (EG PIPE FIT-UPS AtlD l<ELDS ON 1/
L1IIES) tlORttALLY DONE BY A JOURtlEYIIAtl HTTH 5 YEA RS HIW1ttUH EXPERIENCE.
SUBJOURWEYNEW REQUIRE CLOS ER TECIIWICAL SUPERVISION THAW TVA PROVIDES.
IIHEW CRAFTS COHPLAIIIp THEY ARE "CHEIIED OUT" BEYOND ALL REASONABLE LIHITS.
WO IIORE DETAILS KNOWN.
(SQW IS SUES ADDRESSED IN RPT IIP-07-SQN R1)
IN -85"706-00101 T5006 CI 02 03 06 HE 50107 S
IIBW WE 50207 S
flBW IIE 50307 S
NBW IIE 50607 S HBII 1
Y tl N
tl 2
SR WA WA WA 1
N Y
W N
2 WA SR WA WA 1
N N
Y W
2 WA WA SR WA 1
W tl tl Y
2 WA WA WA SR QTC FIELDERS IIHO HEtlT THROUGH TVA'S PIELDER TRAIIIIHG PRO GRAII HAVE IIISUFFICIEIIT TRAIIIIHG AWD EXPER1ENCE TO HANDLE ALL VARIABLES ItlVOLVED TO PERFORII ADEQUATE IIELDS FOR A NUCLEAR 1NSTALI.ATIOH.
THIS
?NADEQUACY-HAS CREATED A LOT OF REIIORK.
CI HAS WO FIORE DETA ILS.
(SQW ISSUES ADDRESSED IW RPT IIP"07-SQW R1)
ZH 158-00601 T50180 02 03 04 kIE 50316 S IIBtl HE 50107 S IIBH IIE 50207 S
IIBW IIE 50407 S
IIBW 1W tl 2
WA WA 1
Y W
2 SR WA 1tl Y
2 WA SR 1 tl tl 2
WA WA Y
W SR WA tl ti WA WA W
W WA WA W
Y WA SR QTC UWT1L 1973 TVA DID NOT LET THEIR APPREIITICESHIP PE OPLE IIELD.
DURltIG THAT YEAR, EVEII IITTH TflO OR THR EE tlOIITHS EXPERIEIICEr AW APPREIITTCE COULD TAKE TWE
- TEST, PASSp AIID BE ABLE TO HELD Itl THE FIELD ~
TH E SYSTEH HAS WORKED THAT HAY EVEII SINCE 1973.
COW ST.
DEPT.
COIICERII.
C/I !IAS WO FURTHER IIIFORIIATIOW (SQW ISSUES ADDRESSED IW RPT IIP-1'-SQW R1) 3 COtlCERNS FOR CATEGORY IIE SUBCATEGORY 50107
REFERENCE
- ECPS120J-ECPS121C FREQUENCY
- REQUEST OWP - ISSS - RIIH CATEGORYI IIE WON QA/QC HELDING TENNESSEE VALLEY AUTHORITY OFFICE OF NUCLEAR POWER EHPLOYEE CONCERN PROGRAH SYSTEM (ECPS)
EHPLOYEE COtlCERtl IIIFORIIATIOtl BY CATEGORY/SUBCATEGORY SUBCATEGORY'0111 SURFACE GRltlDItlG OF IIELDS PAGE 16 RUW TINE - llsl5s02 RUtl DATE - 12/17/87 CONCERN NUBBER CAT IW 282-00202 HE T5001CI S
H 1
REPORT APPL SUB R PLT 2 SAF RELATED CAT D LOC BF BL SQ IIB 50111 S
HBW 1
Y W
W W
2 SR WA WA WA 03 HE 50236 '
IIBII 1 tl Y
tl tl 2
WA SR WA WA 06 IIE 50311 S IIBN 1 tl tl Y
tl 2
WA WA SR WA 05 PIE 50411 S IIBtl 1
N W
tl Y
2 IIA WA WA SR HISTORTCAL CONCERN REPORT ORIGIN TW-85"282-002 QTC COIICERW DESCRTPTIOII i
UNTIL RECEtlZLY, TVA IIELD TtlSPECTORS REQUIRED ALL P IPE HELDS TO BE SURFACE GROUND TO A SHOOTH FINISH.
TtlE COIICERW TS THAT StlOOTH GR1ttDTtlG NAY ACTUALLY HASK A SURFACE DEFECT IIHICH NOULD OTtIERIITSE BE DE TECTABLE.
WO FURTHER DETAILS HERE AVAILABLE. (SQW ISSUES ADDRESSED TW RPT IIP-11"SQN Rl)
Itt 299-00301 HE T50188 50319 S
IIBW 1
W N
Y N
2 WA WA SR IIA 02 IIE 50231 S
IIBW 1 tl Y
W tl 2
WA SR IIA WA 03 IIE 50111 S
IIBW 1
Y W
W W
2 SR WA NA WA QTC SS HELDS SEEN TO HAVE EXCESS HETAL REHOVED AT BUTT PIELD JOlWTS, AI.SO THE HELDS EXHIBIT EXCESSIVE SHR IWKAGE AT JOItlTS.
TtITS CONCERN IS GEIIERIC BUT HAV E EXAIIPLES.
THIS HAS BEEN NOTICED FOR THE PAST 6
YEARS Itl BOTH UNITS.
DETAILS KtlOlltl TO QTCi HTTIIHEL D
DUE 10 COWFIDEtITIALITY.
COWSTRUCTTOW DEPT CONGE R.
(SQW 1SSUES ADDRESSED IW RPT IIP-19"SQW R1)
<<04 IIE 50032 S
05 llE 50411 5
IIBW 1
W W
W Y
2 WA WA WA.SR HBW 1
W W
II Y
2 WA WA WA SR P
2 CONCERNS FOR CATEGORY IIE SUBCATEGORY 50111
REFERENCE ECPS120 J-ECPS121C FREQUENCY
- REQUEST OWP ISSS - RIIH CATEGORY< IIE tlOtl QA/QC IIELDING TENNESSEE VALLEY AUTHORITY OFFICE OF NUCLEAR POHER EHPLOYEE CONCERN PROGRAH SYSTEH (ECPS)
EHPLOYEE CONCERN IWFORI'IATIOW BY CATEGORY/SUBCATEGORY SUBCATEGORYI 50113 SUITABILITY OF NELDTWG. EQUIPHEIIT PAGE 17 RUW TINE - 11 )65) 02 RUW DATE - 12/17/87 CONCERN WUHBER CAT SUB CAT S
H R PLT D LOC 1
REPORT APPL 2
SAF RELATED BF BL SQ IIB HISTOR1CAL, REPORT CONCERN ORIGIN CONCERN DESCRIPTIOII III 247-00201 IIE T50022 50113 S
HBW 02 IIE 50213 S HBtl 03 HE 50313 S
IIBW 06.
IIE 50413 S
HBW 1
Y W
W W
2 SR WA WA WA 1
N Y
tl tl 2
NA SR WA WA 1
N W
Y W
2 NA WA SR WA 1N tl N
Y 2
WA WA WA SR QTC HELDTWG MACHINES (HCKAY & HOBART) USED IN FIELD BY STEAII FITTERS HAVE 2 SETTINGS 50
& 100 AHPS BOTH OF PIHICH ARE UNSUITABLE FOR IIELDIIIG IIITH 3/32" ROD THIS CONTRIBUTES TO POROSITY AWD PIWHOLES.
(SQN ISSUES ADDRESSED IN RPT HP-13-SQW RO)
IN 303-00101 tIE 50113 S
IIBW 1 Y W
W W
T50 021 2
SR WA WA WA 02 HE 50213 S
IIBW 1 tl Y
tl tl 2
WA SR WA WA 03 IIE 50313 S
HBW 1
W W
Y W
2 WA WA SR WA 06 flE 50613 S
IIBW 1 tl W
W Y
2 WA WA WA SR 2
CONCERNS FOR CATEGORY HE SUBCATEGORY 50113 QTC ALL THE I<ELDIIIG tIACHIIIES SHOULD HAVE REHOTE SNITCH ES SO THAT THE TUtlGSTEtl TIP DOESII'T HAVE TO TOUCH THE BASE tIETAL TO START THE HELD.
PRESEtlTLY THE H
Otl-HODART IIELDERS, IIWEN USED, HAY CAUSE TUtlGSTEW T 0
BE LEFT IW THE HELD.
(SQW ISSUES ADDRESSED IN RP T IIP-13-SQW RO)
REFEREWCE ECPS120 J-ECPS121C FREQUEWCY
- REQUEST OWP " TSSS - Rlltl CATEGORY~ IIE tlOW QA/QC IIELDIWG TEIIIIESSEE VALLEY AUTHORITY OFFICE OF tlUCLEAR POllER Et'IPLOYEE COWCERW PROGRAN SYSTEN (ECPS)
ENPLOYEE COWCERW IWFORNAT10W BY CATEGORY/SUBCATEGORY SUBCATEGORY<
50116 PERFORNAIICE OF PRE-IIELD IIISPECTIOW PAGE
18 RUtl TINE lls65s02 RUII DATE 12/17/87 COHCERW WUNBER S
H SUB R
CAT CAT D
PLT LOC 1
REPORT APPL 2
SAF RELATED BF BL SQ IIB HISTORICAL REPORT COWCERW ORIGI W COHCERH DESCRIPTIOW BEN-85-001 "00101 T50227 WE 50116 S
02 WE 50216 S
03 IIE 50316 S
04 IIE 50%16 S
BLII BLW BLW BLtl 1
Y W
W W
2 SR WA WA WA 1 tl Y
tl tl 2
WA SR WA WA 1
W W
Y W
2 WA WA SR WA 1 tl tl tl Y
2 WA WA WA SR QTC BELLEFDWTE - THE GENERAL CONST.
SPEC.
G-29Ci PROCE SS SPEC. O.C.l.l IS Itl COtlFLTCT WITH THE TVA QUALI TY ASSURAWCE CONNITNEWTS AS STATED BY THE TVA TOPI CAL REPORTS TVA"TR75"lAi IH THAT PROCESS SPEC.
O.C
.1.1, SECTIOW 6.0 ALLOIIS UNCERTIFIED tIELDER FORENE tl.
IIHO HAVE DIRECT RESPOWS1BILITY FOR THE ItlSTALLA
- TIOW, TO PERFORN PRENELD IIISPECTIOWS.
WUCLEAR POH ER COtlCERW.
CI HAS WO FURTIIER IWFORNATIOII. (SQtl I SSUES ADDRESSED IW RPT IIP-16-SQW R2)
BEN-85"001-00201 T50227 IIE 50116 S
02 IIE 50216 S
03 IIE 50316 S
06 IIE 50616 S
BLW BLW BLW BLtl 1
Y tl tl W
2 SR WA WA WA 1 tl Y
W W
2 WA SR WA WA tl W
Y tl WA WA SR WA 1
W W
W Y
2 WA WA WA SR QTC BELLEFOWTE - UWCERTIFIED IIELDER FORENEW ARE REQUIR ED BY TVA TO PERFORN PREIIELD IWSPECTIOtlS GW ItlSTAL LATIOIIS THEY ARE DIRECTLY RESPOWSIBLE FOR HH1CH IS A VOTLATTOtl OF AWS1 REQuiREI<EIITS.
WUCLEAR rOWeR COWCERW.
CI HAS WO FURTHER IWFORIIATIOII. (SQW ISSU ES ADDRESSED IW RPT IIP-16-SQW R2) 8FN-85" 001-00101 T50221 02 IIE 50116 S
flE 50216 S
03 IIE 50316 S
06 IIE 50616 S
BLW BLW BLW BLW 1
Y tl tl tl 2
SR WA WA WA W
Y W
tl WA SR WA WA W
W Y
tl WA WA SR WA W
W W
Y WA WA WA SR QTC BELLEFOtlTE - THE GEtlERAL COtlST.
SPEC.
G-29Cp PROCE SS SPEC.O.C.1.1 1S 1W COWFLICT H1TH THE TVA QUALIT Y ASSURAWCE COtlNITNEtlTS AS STATED BY THE TVA TOPIC AL I',EPORT, TVA-TR75-1A, Itl THAT PROCESS SPEC.
O.C.
l.li SECTION 6.0 ALLOIIS UtlCERTIFIED IIELDER FORllEWp IIHO HAVE D1RECT RESPONSIBILITY FOR THE IWSTAI.LATIO ttr TO PERFORII PREIIELD ItlSPECTIOWS.
IIUCLEAR POIIER COWCERW.
CI HAS tlO FURTHER 1tlFORIIATIOtl. (SQW ISSU ES ADDRESSED IW RPT IIP"16"SQII R2)
REFERENCE
- ECPS120J-ECPS12]C FREQUENCY
- REQUEST OWP - ISSS - RIIN CATEGORY)
ICE NON QA/QC llELDIHG TENNESSEE VALLEY AUTHORITY OFFICE OF NUCLEAR POtlER ENPLOYEE CONCERN PROGRAII SYSTEN (ECPS)
EIIPLOYFE CONCERN IWFORIIATTOII BY CATEGORY/SUBCATEGORY SUB'.A IEGORYc 50116 PERFORNAtlCE OF PRE-IIELD INSPECTION PAGE 19 RUH TINE 11 s 65: 02 RUH DATE 12/1?/87 COIICERW WUNBER SUB CAT CAT S
N R PLT D LOC 1
REPORT APPL 2
SAF REI.ATED BF BL SQ IIB HISTORICAL CONCERN REPORT ORIGIN CONCERN DESCRIPTION BFN-85-001-00201 T50221 IIE 50116 S
BFW ftBI4-85-001-00102 T50227 flE 50116 S IIBH 03 IIE 50216 S IIBH 06 IIE 50316 S
PIBH 05 flE 50616 S IIBtt 02 NE 50216 5
BFH 03 IIE 50316 S
BFH 04 IIE 50916 S
BFH 1 Y H
W H
2 SR WA WA WA 1
N Y
H H
2 WA SR tIA HA 1
H W
Y H
2 WA WA SR HA 1
W W
H Y
2 HA WA WA SR 1
Y H
H H
2 SR HA HA WA 1 tl Y
II tl 2
HA SR WA HA 1tl WYH 2
HA WA SR WA 1 tl tl H
Y 2
WA WA WA SR QTC BROIIH'S FERRY - UNCERTIFIED flELDER FORENEH ARE REQ UIRED BY TVA TO PERFORN PRE-IIELD ItlSPECTIOWS Otl IH STALLATIOWS THEY ARE DIRECTLY RESPONSIBLE FOR NNIC N IS A VIOLATIOW OF ANSI REQUIREIIENTS.
IIUCLEAR PO IIER CONCERN.
CI HAS HO FURTHER IHFORtlATTOW. (SQH ISSUES ADDRESSED IH RPT IIP"16-SQtl R2)
QTC IIATTS BAR - THE GEttERAL CONST.
SPEC.
G"29C, PROCES S
SPEC.
O.C.1.1 IS IH CONFLICT NITN THE TVA QUALIT Y ASSURANCE CONNITNENTS AS STATED BY THE TVA TOPIC AL REPORTS TVA-TR75"lA. IH THAT PROCESS SPEC.
O.C.
1.1.
SECTION 6.0 ALLOIIS UtlCERTIFIED IIELDER FOREIIEH IINO HAVE DIRECT RESPONSIBILITY FOR THE IIISTALLAT ION p TU PERFORN PREIIELD ItlSPECTIOHS.
NUCLEAR POIIE R CONCERN.
CI NAS HO FURTHER INFORHATIOW. (SQW IS SUES ADDRESSED IW RPT IIP-16-SQH R2) flBth-85-001-00201 T50227 02 03 IIE 50316 S
SQII 04 IIE 50616 S
SQW 1 tl tl Y
tl 2
HA HA SR WA 1 tl tl H
Y 2
WA WA WA SR NE 50116 S
SQH 1
Y tl tl H
2 SR WA WA HA flE 50216 S
SQtl 1 tl Y
tl H
2 WA SR WA WA QTC SEQUOYAH UIICERTIFIED NELDER FORENEN ARE REQUIRED BY TVA TO PERFORN PREIIELD INSPECTIONS 0H IHSTALLA TIOIIS THEY ARE DIRECTLY RESPONSIBLE FOR IIN1CN IS A
VIOLATIOH OF ANSI REQUIREWEHTS.
tlUCLEAR POIIER CO WCEPW.
CI HAS HO FURTHER IWFORNATIOII. (TRAWSFERRE D
TO IIBII-85-001-003, CONCERN IIAS ADDRESSED BY IIELD ItlG CATLGORY BEFORE TRANSFER IIAS DOCUIIEtlTED, AWD II ILL WOI BE ItlPUZ TO Gtl CATEGORY, SQH ISSUES ADDRES SED Itt RPT IIP-16-SQW R2)
REFERENCE
- ECPS120J-ECPS121C FREQUENCY
- REQUEST OWP ISSS - RIIH CATEGORYs HE WOH QA/QC IIELDIWG TENNESSEE VALLEY AUTHORITY OFFICE OF tlUCLEAR POllER EHPLOYEE CONCERN PROGRAII SYSTEII (ECPS)
EHPLOYEE COtlCERW ItlFORI1ATIOII BY CATEGORY/SUBCATEGORY SUBCATEGORYs 50116 PERFORthAIICE OF PRE-HELD ItlSPECTIOH PAGE 20 RUII TINE " llsss5s02 RUW DATE 12/17/87 COtlCERtl NUHBER CAT III "85-030-00701 IIE T50185 S
H 1
REPORT APPL SUB R PLT 2 SAF RELATED CAT D LOC BF BL SQ IIB 50116 5
IIBW 1
Y H
W W
2 SR WA WA WA
~ s 02 IIE 50102 S IIBH 1 Y H
H W
2 SR WA WA WA 03 IIE 50216 S
IIBW 1
H Y
W.
W 2
WA SR WA WA 0 ss I IE 50 316 5
05 IIE 50si16 S
IIBW 1
H It Y
tl 2 IIA WA SR WA llBII 1 tl W
tl Y
2 HA WA WA SR 06 HE 50202 S HBII 1
N Y
W H
2 WA SR HA WA OB IIE 50sl02 S
HBH 1
H H
Il Y
2 WA WA WA SR 7
CONCERNS FOR CATEGORY IIE SUBCATEGORY 50116 HISTORICAL CONCERN REPORT ORIGIN CONCERN DESCRIPTIOH QTC THE flBH FSAR COHHITS TVA TO THE REQUIREIIEIITS OF All S D.l.l FOR STRUCTURAL IIELDIHG.
CONTRARY TO THESE REQUIREHEHTS0 THE G-29C PROCESS SPECIFICATION IIAS HODIFIED TO REFLECT LESS STRINGENT INSPECTION REQ UIRENEIITS (E.G.
VISUAL INSPECTION OF HELDS THROUGH PAINT (CARBO ZIIIC PRIHER)
AIID tlO DOCUIIEIITED IIISPE CTIOII BY CERTIFIED VISUAL ItlSPECTORS (FIT-UP, Itl-P ROCESS)
PRIOR TO FINAL INSPECTION.) CI HAS WO ADDI TIOWAL IWFORIIATION.
WUC.
POIIER DEPT.
CONCERN.
(SQ ti ISSUES ADDRESSED IH RPT IIP-16-SQW R2)
REF EREHCE ECPS120 J-ECPS121C FREQUENCY REQUEST ONP - ISSS - RIIII CATEGORY< HE tlOH QA/QC flELDIIIG TEIIHESSEE VALLEY AUTHORITY OFFICE OF IIUCLEAR POHER EMPLOYEE CONCERN PROGRAM SYSTEM (ECPS)
EMPLOYEE CONCERN IHFORIIATIOH BY CATEGORY/SUBCATEGORY SUBCATEGORY) 50129 IIELDER PERFORMANCE QUALIFICATIOtl PAGE 21 RUtl TIME 11345<02 RUtl DATE - 12/17/8?
CONCERN NUMBER CAT S
H 1
REPORT APPL SUB R PLT 2 SAF REI.ATED CAT D LOC BF BL SQ HB HISTORICAL CONCERN REPORT ORIGIN CONCERN DESCRIPTIOH JLH-85-002 01 IIE 50124 S
SQtl 1 Y tl lt N
2 SS HA HA HA 02 IIE 50203 S
SQII 1 tl Y
tl H
2 HA SS IIA HA 03 IIE 50326 S
SQH 1
H tl Y
H 2
HA IIA SS HA 04 IIE 5042%
S SQtl 1
H H
tl Y
2 IIA HA HA SS 1
CONCERNS FOR CATEGORY llE SUBCATEGORY 5012%
OECP THIS CONCERN HAS HOT DOCUMENTED PER SQA166 BUT HAS BEEt( IWCt.UDED IH THE EMPLOYEE COIICERtl LOG.
IIELDE RS FROI1 tIUSCLE SHOALS MAY HOT HAVE RECEIVED THE AP PROPRIATE IIUMBER OF BEND TESTS IIHEII TAKItlG IIELD QU ALIFICATIOH TESTS.
(SQII ISSUES ADDRESSED IN RPT HP SQII RO)
J
~
~
'>> 'f: >>
ieger.4>>' '
III REFERENCE ECPS120 J-ECPS121C FREQUENCY REQUEST OHP - ISSS -
REIN CATEGORYa IIE HOH QA/QC IIELDING TEHHESSEE VALLEY AUTHORTTY OFFICE OF NUCLEAR POllER ENPLOYEE COIICERII PROGRAI< SYSTEN (ECPS)
ENPLOYEE COtlCERII IIIFORNATIOtl BY CATEGORY/SUBCATEGORY SUBCATEGORY) 50125 EFfECTS OF IIELD REPAIRS tlOT IIEETING AStIE CODE PAGE 22 RUtl TItIE lli45i02 RUH DATE - 12/17/87 CONCERN NUI'IBER CAT S
N 1
REPORT APPL SUB R PLT 2 SAF RELATED CAT D LOC BF BL SQ IIB HISTORICAL REPORT CONCERN ORIGIII CONCERN DESCRIPTIOII 02 IIE 50125 5
03 IIE 50236 S
tIPS 1 Y H
II H
2 SS HA WA HA HPS 1
N Y
N H
2 WA SS HA HA 04 tlE 50325 5
HPS 1
H tl Y
tl 2
HA WA SS HA 05 IIE 50CI25 5
WPS 1
N tl N
Y 2
HA IIA HA SS 1
CONCERNS FOR CATEGORY NE SUBCATEGORY 50125 2850162005 01 OP 30803 S
HPS" 1
Y Y
Y Y
2 SS SS SS SS IIRC TVA HAKES REPAIRS TO THEIR NUCLEAR PLAIITS HHTCN AR E IIOT IH ACCORDAtICE NITN ASIIE CODES.
SUCH AS OVERL AYS> PATCHES'WD EVEN FURNATITE (SOPHISTICATED GL UE).
(SQtl iSSUES ADDRESSED Itl RPT IIP-25"SQtl RO)
REFERENCE
- ECPS120J-ECPS121C FREQUEIICY
~
REQUEST ONP - ISSS - RIIH CATEGORY! HE t)0)l QA/QC IIELDIIIG TEIIHESS EE VALL EY AUTHORITY OFFICE OF t)UCLEAR PONER EHPLOYEE CO))CERN PROGRAI) SYSTEN (ECPS)
EHPLOYEE CONCERtl IIIFORNATIO)I BY CATEGORY/SUBCATEGORY SUBCATEGORYI 50132 ADEQUACY OF STRUCTURAL SUPPORT IIELDS PAGE 23 RUtl TINE llc45a02 RUII DATE - 12/11/87 CONCERN IIUt)BER S
H SUB R PLT CAT CAT D LOC 1
REPORT APPL 2
SAF RELATED BF BL SQ IIB HISTORICAL REPORT CONCERN ORIGIII CONCERN DESCRIPTIOII BFN"85-019-00101 PIE 50132 N
BFN 1 Y tl H
tl 2
SS WA HA IIA HSRS DURING AH EXIT IHTERVIEH THE CI EXPRESSED HIS CONC ER)l THAT HAIIY IIELDS AND HANGERS ARE QUESTIOIIABLE N ITH RESPECT TO THEIR ADEQUACY.
THE PROCESS FOLLO)I ED TODAY WITH REGARD TO IIELDIHG AND WELD INSPECTIO II IS NORE DETAILED AND THAT ORIGINAL I'IELDS It) QUES TIOII WOULD IIOT PASS CURREIIT REQUIREHEt)TS.
1 CONCERNS FOR CATEGORY. HE SUBCATEGORY 50132
REFERENCE
- ECPS120J "ECPS121C FREQUENCY
- REQUEST DWP.-
ZSSS - RIIH CATEGORY'IE WOH QArQC IIELDIWG TEIIWESSEE VALLEY AUTHORITY OFFICE OF tlUCLEAR POHER EtIPLOYEE CONCERN PROGRAII SYSTEH (ECPS)
EHPLOYEE CONCERN IWFORIIATTOW BY CATEGORYrSUBCATEGORY SUBCATEGORY'0135 IIELD ItlSPECTIOW PROCEDURES PAGE 24 RUtl TINE - ll c 45 i 02 RUW DATE - 12rl7r87 CONCERN NUMBER CAT SUB CAT S
H R PLT D LOC 1
REPORT APPL 2 SAF RELATED BF BL SQ I.IB H1STORI GAL COHCERII REPORT ORIGIN CONCERN DFSCRIPTION Ttl %06-00201 T50013 HE 50135 S IIBtl 02 WE 50309 5 tIBII 03 HE 50243 S HBII 06 IIE 50%32 S
HBN 1 Y H
tl tl 2
SS WA WA WA 1
H H
Y H
2 HA WA SS WA 1
H Y-O' 2
WA SS WA WA 1N W
tl Y
2 WA WA WA SS QTC PRIOR TO 1979 THERE HAS HO SPECIFIC HELD INSPECTIO II CIIITCRIA FOR USE BY TtISPECTZOtl PERSOtltlEL.
IT IS BELIEVED THAT THIS PROBLEII HAS VALID TVA SYSTEtt II IDE-AI.L PLANTS.
(SQW ISSUES ADDRESSED III RPT IIP-0 9-SQW R1)
PH 012-X0301 T50077 IIE 50135 S
02 HE 50305 S
03 IIE 50235 S
-- 06 flE 50405 S
I<8W tI8W IIBH HBH 1
Y 2 SR 1 tl 2
WA 1
H 2.WA 1 tl 2
WA H
H W
PH-85-012 "X03 WA HA WA W
Y W
WA SR WA Y
tl W
SR WA HA H
W Y
WA HA SR QTC IIELDIWG AHD BRAZING INSPECTION OF SAFETY-RELATED H VAC DUCTIIORK IIAS DELETED SUBSEQUEtlT TO 1981 FROID T HE QA PROGRAN IIITf{OUT ADEQUATE JUSTIFICATIOII.
IIAT TS BAR UWlTS 1
8 2, SAFETY RELATED DUCTIIORK.
ADDI TIOHAL DETAILS ARE AVAILABLEIW FILE.
(SQH ISSUES ADDRESSED Itl RPT IIP-05-SQW Rl)
XX 102"00601 T50172 QA 80201 S
03 klE 50135 S
06 IIE 50243 S
05 LIE 50CI 32 S
06 QA 8 0252 S
BFW BFtl BFH BFW BFH tl 2
WA tl Y
tl WA SR WA 1 Y 2
SR 1 tl 2
WA 1 tl 2 IIA 1
tl 2 tlA tl tl H
HA WA WA Y
H H
SR WA WA H
W Y
WA WA SR H
Y tl WA SR WA QTC BROIIW'S FERRY)
THE VISUAL EXAHItlATIOtlPROCEDURE IIH ICH COVERS ASHE SECT10W II IS VERY HON SPECIFIC.
NUCLEAR POIIER DEPT.
CONCERN.
CI HAS WO ADDITIONAL 1WFORIIATIOH.
WO FOLLOII UP REQUIRED.
REFERENCE
- ECPS120J-ECPS121C FRFQUEWCY
- REQUEST OHP - ISSS - Rtlll CATEGORY'lE tloW QArQC llELDItlG I
TEtIWESSEE VALLEY AUTHORITY OFFICE OF NUCLEAR POWER EllPLOYEE CollCERH PROGRAH SYSTEtt (ECPS)
EttPLOYEE COllCERtl IHFORt'lATIOtl BY CATEGORY/SUBCATEGORY SUBCATEGORY'0135 HELD ItlSPECTIOW PROCEDURES PAGE
25 RUtl TINE " Iii%5:02 RUll DATE 12i17~87 COHCERtl HUHBER CAT SUB CAT S
N R PLT D LOC 1
REPORT APPL 2 SAF RELATED BF BL SQ NB HISTORICAL REPORT CONCERN ORIGIIl CONCERN DESCRIPTIOtl XX 102-00701 T50172 flE 50243 S
BFN 02 llE 50135 S
BFH 03 flE 50%26 S
BFH XX 102-01101 T50172 NE 50243 S
SQW 02 HE 50399 S
SQW 03 IIE 50135 S
SQW OA NE 50626 S
SQtl 1!l Y
H H
2 HA SR IlA HA 1 Y tl H
tl 2
SR HA IlA IIA 1 tl tl tl Y
2 tIA tIA WA SR 1H Y
tl H
2 lIA SR tIA WA 1
N tl Y
tl 2 IlA tIA SR tIA 1
Y tl tl H
2 SR WA HA IIA ltl HHY 2
HA HA tIA SR I-W5"735-SQW QTC BRONtl'S FERRYs NDE ItlSPECTORS CAH ONLY WRITE A NOT ICE OF ItISPECTIOW OH Ill-SERVICE RELATED DEFECTS.
PRESERVICE DEFECTS CAN OWLY BE IDEtlTIFIED BY A ttAI HTEWAlICE REQUEST.
NUCLEAR POllER DEPT.
CONCERN.
C I NAS WO ADDITIONAL IttFORHATIOH.
tlo FOLLOW UP REQ UIRED.
QTC SEQUOYAHi ttDE ItlSPECTORS CAN OtlLY WRITE A tlOTICE 0 F INSPECTION Otl Itl-SERVICE RELATED DEFECTS.
PRESE RVICE RELATED DEFECTS CAll OWLY BE IDENTIFIED BY A tlAItlTEtlAIICEREQUEST.
NUCLEAR POllER DEPT.
COWCERtl ~
CI WAS tlO FURTHER ItlFORNATIOfl.
tlO FOLLOll UP REQU IRED.
(SQH ISSUES ADDRESSED IH WSRS RPT I-85-735"S QH) 5 CONCERNS FOR CATEGORY NE SUBCATEGORY 50135
ATTACHMENT 0 CONCERN DESCRIPTION OF XSSUES COMMENTS EX-85-039-001 IN-85-234-001 IM-85-247-001 IN-85-352M02 IM-85-424-001 IN-85-424-004 IN-85-424-006 IN-85-424-007 IM-85-426-001 IN-85-44 1-003 IM-85-453-009 IN-85-454-004 IN-85-501-001 XM-85-672-003 IN-86-047-001 WZ-85W53M04 Lack of portable rod ovens to protect coated electrodes from moisture absorption.
Inadequate control of weld rod.
Poor quality E7018 electrodes Administrative practices for return of tiller material.
The Browns Ferry program for contr ol of welding filler material meets the requirements of ANSI/AWS 01.1 Section 4,
ASME Section III NB-4000 and ASME Section XI XWB-4000.
The quality of the electrodes purchased meets the requirements of ASME Section II-and XXI.
This issue has been address-ed by Weld Project Evalua-tion Report WP-01-BFN.
IN-85-458-001 IN-86-019-001 NS-85-001-001 PH-85-040W01 WI-85-013-003 WI-85-030-007 WI-85-030-008 WI-85-041-006 WI-85-041-008 The Process Specification permitted inspection of AWS welds through coating oF
~arbo-zinc primer.
Thousands of welds may have been inspected through primer.
There is no documentation to show which welds were involved.
Inspectors did not under-stand the coating thickness limit for inspecting primed weld s The Process Specification in question was site unique for Watts Bar, and was never implemented at Browns l-erry.
The BFN specifications and procedures meet the requirements oF ANSI/AWS 01.1.
This issue has been address-ed by Weld Project Evalua-tion Report WP-02-BFN.
EX-85-021-002 HI-85-077-N 17 IN-85-346-003 IM-85-426M02 IN-85-480-004 IN-85-725-X14 IM-85-725-X15 The possibility exists that one welder could weld or complete a test plate for another welder.
Welding by an uncertified welder.
Mo one except the Weld Test Supervisor is allowed to enter the test booth while a welder is being tested.
There have been isolated instances of welders operating outside their Page 1 of 6
ATTACHMENT B CONCERN DESCRIPTION OF ISSUES COMMENTS I
I Inadequate basis for s!elders qualification continuity I
updates.
I I
Personnel whose duties do notl require welding continue to I
have their qualification I
continuity updated.
I I
I I
I I
I I
I limits of qualification.
These instances were identified and corrected by the ongoing Quality Assurance activities.
The basis for qualification continuity updates satisfies requirements and parallels industry practice.
Continuation of supervisory personnel qualifications is an acceptable practice.
This issue has been address-ed by Weld Project Evalua-tion Report WP-03-BFN.
IM-85-007-001 IN-85-13 4-002 IN-85-406-003 Availability of inspection tools.
Inspection tools were available throughout construction and operation.
This issue has been addressed by Weld Project Evaluation Report WP-04-BFM.
IM-85-476-004 IN-85-981-001 SQN-86W35-001 SQM-86-035-002 WI 041W02 WI-85-081-007 I.
I Qualification of'-li lding Inspectors.
Topical Report not in compliance with ANSI M45.2.6.'elding Inspectors are qualified in accordance with the Nuclear Quality Assurance Manual.
Welding Inspectors are qualified and certified using SNT-TC-lA as a guide, rather than ANSI N45.2.6.
Appropriate exceptions to Regulatory Guide
- 1. 58 are made in the Topical Report.
This issue has been address-ed by Weld Project Eval-uation Report WP-06-BFN.
Page 2 of 6'
ATTACHMENT B CONCERN DESCRlPTXON OF ISSUES COMMENTS EX-85-008-001 IN-85-706-001 ZN-86-158M06 Qualification and experience of Subjourneymen.
Adequacy of TVA Welder Training Program.
Subjourneymen are utilized in accordance with the applicable labor agreement and good i:....gument practices.
Welders are tested and qualified in accordance with AWS Dl. 1 and ASME Section IX.
This issue has been address-ed by Weld Project Evalua-tion Repor t WP-07-BFN.
IN-85-282-002 IN-85-299W03 Surface grinding of welds.
Shrinkage of stainless steel I butt joints.
I' Surface grinding and shrinkage Surface grinding of welds is provided for by the
- ASME, ANSZ and AWS codes.
Some shrinkage is inherent in girth butt welded joints in stainless steels.
Heat input during welding is controlled by adherence to approved welding procedures.
This issue has been address-ed by Weld Project Evalua-tion Report WP-11-BFN.
IN-85-247-002 IN-85-303M01 I
I I
I I
I I
I I
I I
I I
I Suitability of welding equipment.
The Lincoln IDEALARC TXG 300 welding machine was used at Browns Ferry.
This machine features remote current adjustment, soft
- start, and current output range of two through
.375 I amperes.
I This issue has been address-ed by Weld Project Evalua-tion Report WP-13-BFN
~
Page 3 of 6
ATTACHMENT 0 CONCERN Ul.'SCRIPTION OF ISSUES COMMENTS BEN-85M01-001 BEN-85W01-002 BFN-85M01W01 BFN-85M01W02 WBN-85-001-001 WBN-85-001-002 WI-85-030-007 JILL-85-002 Foremen perform preweld inspections, which is not in accordance with the Topical Report, ANSI N45. 2. 5 and AWS 01.1.
Welders from Muscle Shoals may not have had the appropriate number of bend tests.
AWS Dl.l allows preweld activity examinations to be on a sampling basis.
Browns Ferry procedures and specifications mandated surveillance programs of all welding activities.
Practice aL ".r owns Ferry does not violate the TVA Topical Report or ANSI N45.2.5.
This issue has been address-ed by Weld Project Evalua-tion Report WP-16-BFN.
All affected welders at OFN were requalified to the requir i!menL's uf AQME Section IX.
This issue has been addressed by Meld Project Evaluation Report WP-24-BFN.
2850162005 Weld repairs such as I overlays, patches and I Furmani te (v iscous fluid I sealant) not in accordance with the ASME Code.
I I
I I.
I I
I I
I I
I Overlay welding is an acceptable method of making temporary repairs to correct for intergranular stress corrosion cracking.
TVA' plan for use of Over lays was approved by the USNRC.
Temporary mechanical and
~,."'
d patches are used to contain leakage.
They do not substitute for permanent repairs in accordance with applicable codes.
Page 4 of 6
ATTACHMENT B CONCERN DESCRIPTIOM OF ISSUES COMMENTS This issue has been address-ed by Weld Project Evalua-tion Report WP-25-BFN.
Use of viscous fluid sealant is outside the scope of the Weld
- Project, and has been addressed by Subcategory 30800 BFN-85-019-001 Many welds and hangers are questionable with respect to adequacy.
Original welds would not meet today' requirements.
This issue is factual in that some of the support welds do not meet the visual inspection criteria.
This issue has been addressed by We ld Project Evaluation Re ort WP-32-BFM.
IN-85-406-002 P H-85-01 2-X03 XX-85-102-006 XX-85-102-007 XX-85-102-011 Mo specific inspection criteria pr ior to 1979.
Welding and brazing inspection of safety related
)<<Lwork was deleted I'rom thel QA program.
MDE Inspectors can only wr i to a Notice of T<<ipse
~<.Lion for inservice related defects.
Preservice defects can only be identified by a Maintenance Request.
Ouring initial construction, direct application of the codes provided all of the necessary inspection criteria.
At the time of conuni Lv>ent to 10CFR50 Appendix B,
a procedure system was in place and provided all of the necessary inspection criteria.
HVAC at BFN was fabricated and erected using mechanical means.
When welding vuwiifications were specified, an appropriate procedure for inspection was emplaced.
Page 5 of 6
ATTACHMENT B CONCERN I
DESCRIPTION OF ISSUES I
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COMMENTS I
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I The Notice of Indication is I used to report defects I identiFied within the I defined scope of an, I inspection, inservice or I preservice.
The Maintenance I Request is used to report I obser vations identified I outside the defined scope I of an inspection.
I I This system is in I compliance with the Nuclear I Quality Assurance Manual.
I I This issue has been address-I ed by Weld Project Evalua-I tion Repor t WP-35-UFN.
I Page 6 of 6