ML18033A623
| ML18033A623 | |
| Person / Time | |
|---|---|
| Site: | Browns Ferry, Bellefonte, 05000000 |
| Issue date: | 12/28/1987 |
| From: | Brown W TENNESSEE VALLEY AUTHORITY |
| To: | |
| Shared Package | |
| ML082340470 | List:
|
| References | |
| 50200, 50200-V05-R04, 50200-V5-R4, NUDOCS 8902160166 | |
| Download: ML18033A623 (71) | |
Text
EMPLOYEE CONCERNS SPECIAL PROG VOLUBLE5 WELDINGCATEGORY SUBCATEGORY REPORT 50200 BELLEFON'ZE NUCLEAR PLANT UPDATED rec~~j'.~i~4 TVA NUCLEAR POWER
J l
TVA ENPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
SO2PP REPORT TYPE:
Subcategory REVISION NUNBER:
4 TITLE:
BLN Site Specitic Welding Subcategory Report PAGE 1
OF 19 REASON FOR REVISION:
Editor ial Revision PREPARED BY:
PREPARATION SIGNATURE DATE PEER: viQ~
SIGNATURE REVIEWS Iz/~>i<1 DATE TAS:
SIGNATURE z zz
$ 7 0
I'E CONCURRENCES SIGNATURE DATE CEG-H:
~IGNATU
~g, -2~57 DAl'E APPROVED BY:
ECSP NA AGER 0
E
<SRP Secretary's signature denotes SRP concurrences are in files.
6446T
- Preface, Glossary, and List of Acronyms for ECTG Subcategory Reports HISTORY OF REVISION REV NUMBER PAGES REVISED REASON FOR CURRENT REVISION 3
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:
50200 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 extent 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 NUMBER:
50200 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:
50200 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 h:
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.
I 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 of 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.
TVd EMPLOYEE CONCERNS SPECXAL PROGRAM REPORT NUMBER; 502PP FRONT KLTTER REV:
2 PAGE iv OF viii evaluator(s) the individual(s) assigned the responsibility to assess a specific 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")
s 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.gse
- generic, specific, nuclear safety-related, unreviewed safety-significant question).
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
50200 FRONT MATTER REV:
2 PAGE v OF viii hcronyms AI Administrative Instruction AISC American Institute of Steel Construction ANSI ASME ASTM AWS BFN BLN CCTS CEG-H CFR CI CMTR COC DCR DNC 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 Federal Regulations Concerned Individual Certified Material Test Report Certificate of Conformance/Compliance Design Change Request Division of Nuclear Construction (see also NU CON)
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
50200 FRONT MATTER REV:
2 PAGE vi OF viii DNE DNQA DNT DOE DPO DR ECN ECP ECP-SR ECSP ECTG EEOC EQ EMRT EN DES ERT FCR FSAR 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'ontrol Instruction Heating, Ventilating, Air Conditioning Installation Instruction Institute of Nuclear Power Operations Inspection Rejection Notice
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT NUMBER:
50200 FRONT MATTER REV:
2 PAGE vii OF viii L/R MLAI Labor Relations Staff Modifications and Additions Instruction MSPB NCR NPP Maintenance Instruction Merit Systems Protection Board Magnetic Particle Testing Nonco'nforming Condition Report Nondestructive Ezamination Nuclear Performance Plan NPS NQAM NRC NSB NSRS 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 QA QAP QC QCI Nuclear Utility Management and Resources Committee Occupational Safety and Health Administration (or Act) 6ffice of Nuclear Power Office of Morkers 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:
50200 FRONT MATTER REV:
2 PAGE viii OF viii QCP QTC RIF RT SQN SI SOP SRP SWEC TAS TSL 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 TVA TVTLC UT WBECSP WBN WR Tennessee Valley Authority Tennessee Valley Trades and Labor Council Ultrasonic Testing Visual Testing Watts Bar Employee Concern Special Program Watts Bar Nuclear Plant Work Request or Work Rules
-Workplans
Index 1.0 CHARACTERIZATION OF ISSUES 2 '
METHODOLOGY 3. 0 ISSUES FINDINGS AND CONCLUSION-3.1 Control of Meldin Filler Material 3.2 Ins ecLion of Welds Throu h Carbo-Zinc Primer 3.3 Welder uglification Continuit 3
~ 4 Ins ecLion Tools
- 3. 5 Ins ection ual ification 3.6 Welder Trainin IEx erience 3.7 Im lementation of ualit Assurance Evaluation AE-2
- 3. 8 Meldin E ui ment and Bottled Gases 3.9 Structural Steel Preweld Ins ections 3.10 M~ld'ltual~it 3.11 Meld Ins ection Procedures 3.12
~Meld Re <<irs
- 3. 13 Ade uac of Procedures 4.0 COLLECTIVE SIGNIFICANCE 5.0 CAUSE 6.0 CORRECTIVE ACTION 7 '
ATTACHf'lENTS t
A.
Subcategory Summary Table B.
Summary of Issues 8.0 REFERENCE A.
Welding Project Evaluation Reports Page 1 of 1
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT TYPE:
Subcategory REPORT NUMBER:
50200 REVISION NUMBER:
4 TITLE:
BLN Site Specific Welding Subcategory Report PAGE 2
OF 19 1.0 CHARACTERIZATION OF ISSUES
- 1. 1 Introduction The characterization of'ssues for this subcategory report are derived From 79 Eoiployee Concerns.
OF the 79 Employee Concerns, 19 were specific to BLN (53 specific to WBM, 3 speciFic to BFM, 3 specific L'o SQN, 1 non plant specific).
The Employee Concerns were divided into 13 similar issues and were investigated by L'he Weld Project, QualiLy 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 as a portion of the Weld Project effort.
1.2 Descr i tion of Issues 1.2
~ 1 Control of Weldin Filler Material 1.2.2 Ins ection of Welds Throu h Carbo-Zinc Primer 1.2.3 Welder ualification Continuit 1.2,4 Ins ection Tools 1.2.5 Ins ector uglification 1.2.'6 Welder Tr'ainin /Ex erience 1.2.7 Im lementation of ualit Assurance Evaluation AE-2
- 1. 2. 8 We ldinc E ui menL And BoL'tied Gases 1.2.9 Structural Steel Preweld Ins ections
)
~ 2.11 Weld Ins ection Procedures 1
~ 2. 13 Ade uac of Procedures 2.0 METHODOLOGY The procedure and specification histories oF Bellefonte Nuclear Plant, from L'he beginning of'orrsL'ruction L'o'he presenL, were reviewed.
These procedures and specifications were compared with the construction codes that wer'e in effect dur ing each phase of the procedure history.
The
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT TYPE:
Subcategory REPORT NUMBER:
50200 REVISION NUMBER:
4 TITLE:
BLN Site Specific Welding Subcategory Report PAGE 3
OF 19 Bellefonte Weld Project Phase I Report (draft) and the Weld Project Evaluation (draft) Reports for Sequoyah, Browns Ferry, and Watts Bar wer'e reviewed.
The expurgated text of the concerns was compared with the requirements 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 the USNRC inspection reports and the 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 Weldin Filler Material The concerns stated that weld rods are not required to be kept in rod ovens after issue; questioned the qualit:y of coated electrodes; questioned the adequacy of welding filler material cont:rol; that ASME deviations and violations for uncontrolled weld rod are reported on "non quality" inspoct,ion reports; and questioned tho administrative 'practices for return of unused and waste welding fi 1 lor mat:oria1 Review of the procedure history for weld filler material control at Bellefonte (BLN) revealed that all of the necessary moisture absorption cont:rois for low hydrogen coated electrodes have been in place throughout the life of the p]<<nt.
The issue of cu<<ted electrodes was only allowed from freshly opened hermetically sealed containers or holding ovens.
By classification, Qualit.y Cont.rol Procedure BNP-QCP-8.
1 established maximum allowable atmospheric exposure times for coated electrodes.
These exposure times were in accordance with The American Welding Society Structural Welding.
- Code, AWS 0 1
. 1.
In 1979, the Structural Welding Code was changed to allow alternative atmospheric exposure time periods for coated electrodes.
These extended exposure periods could be used provided the user established the maximum atmospheric exposure time by performing qualification tests prescribed by AWS ~
G-29M Process Specification 1.M.3.1, "Specification for Welding Materials Control," was revised in 1980 (revision 7) to incorporate the alternative rules of AWS D1.1-1979 and to provide tho requirements for the extended atmospheric exposure test.
In mid 1980, the BLN procedure for control of welding filler materials was also revised to reflect changes in the 1979 edition of the Structural Welding Code.
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT TYPE:
Subcategory REPORT NUNBER:
80200 REVISION NUNBER:
4 TITLE:
BLN Site Specific Welding Subcategory Report PAGE 4
OF 19 The former'ract;ice (prior to mid 1980) for controlling moisture absor ption in E7018 electrodes was replaced with Lhe new AWS rules which permitted TVA to extend the atmospher ic exposure time after performing qualification tests prescribed by the structural
- code, AWS Dl.l.
The changes met all of the requirement:s of. the AWS Dl.l.
Portable rod ovens are used on a limited basis at BLN to protect certain high strength, low alloy electrodes.
Use of t;he por table ovens is provided, For in the TVA Process SpeciFication for welding materials control
~ It is not,
- however, addressed by t:he implementing procedure.
CATO 50201-BLNM1 was issued to recommend that the implementing procedure be revised to lect actual pr acL'!.ce.
Cor rective Action Plan Procedure BNP-QCP-B. 1 will
. r ige ine 'dil;ions urlder'hich Lhe use OF c'L
~v! r exception to the sl.atod maxi p
..i up r
o d electrodes.
The issue 'l~Cg~ 'u lay o
electrodes evolved from the op i+Lyt. >pii781!!ms w
elect.rodos.
The problems were r el o++~<h%p 1"r'a 'Ly l
coaL'ings caus ing Lho c! lee tr'ic arc Lo "wan,rrr",/&hie i
c Mr the arc difficull., andpoade tho elecLr Zi~s l.on to the workpiece.
Additional)y, porosity~
may be gssociaLo h electrode coating problems, especially aL the sL'ar't o 'ho i bead.
In Lwo instances, Lho i!1!!cL'rodos were returned 'e suppliers.
In one case, tesl.ing showed that. tho olecLrodos, while r oquir'ing mur e care in the weldir!g operation, were suitable For use.
These elect,rodes were roLained and used.
The dil'I'iculty in oporabiliLy did not r'esult in harder e defects in the final welds.
Additionally, these electrodes were purchased in accordance witt! Lhe roquiremor!Ls oF ASNE SecLions II and III, and met the code requirements.
Earlier revisions of the filler material control procedure were not as str inger!t in L'he control of waste material as the
<<ur rent procedure.
These earlier revisions did, however, sat,isfy the ASNE and AWS Code requiremenL's.
There was a short period in laLer 1979 and early 1980 when a general laxity on tho par't of the welders in al;L'ending to their filler v!aL'erial and waste was idenLil'ied.
There have been occasional isolated occurrences of failure to follow the conL'r'ol procedur'e.
These problems were pr incipally violations oF cor!struction practices and of a housekeeping
- nature, rather than violations olhe codes.
Where problems have bean ident:ified, corrective and prevent:ive actions were effocLively implemenL'ed.
Control ol'elding filler material at BLN meets the requirements of the ASME and the AWS Codes.
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT TYPE:
Subcategory REPORT NUMBER:
50200 REVISION NUMBER:
4 TITLE:
BLN Site Specific Wel<'ing Subcategory Report PAGE 5 OF 19 The Welding Surveillance Checklist is used in part to report and resolve deviations in the control of welding filler material.
The completed checklists are not routinely distributed to the Authorized Nuclear Inspector (ANI).
The ANI has access to any of the various quality records initiated at BLN.
Certain records are routinely provided to the ANI For his review, establishment of hold points, and in certain instances, his concurrence.
With regard to ANI review and approval, the key element is whether or not a reported deficiency is ASME Code related.
The Welding Surveillance Checklists issued from 1975 through 1985 were reviewed.
Where filler material control deviations were
- reported, they were general in nature.
Examples are stubs laying around the work areas, damaged shipping containers, rod not in the immediate control of the welder, and g<!n<!ral storage practices.
These deviations gave no indication of incorrect, uncontrolled or defective material being used in ASME applications
~
Quality Control Investigation Reports and Nonconforming Condition Reports were also r <~vi<!wed.
Where discrepancies relating to filler material used in ASME applications were reported, the dispositions were presented to Lh<~ ANI for concur r i no<!.
Examples are in<.ur
< ect filler material recorded on process documents, incorrect.
identification on containers for material used in AUMF work, arid discrepancies in certified mill test reports, Review and discussion with cognizant TVA Welding an<< ".<<,<lity Control personnel showed that, where appropriate, the ANI was involved in the resolution of reported problems with welding filler material control.
Discussion with the Bellefonte Authorized Nuclear Inspector revealed that he is in agreement with the reporting methods described above.
- Further, the ANI s.tated that he is aware of the results of the surveillance and has had the opportunity to witness the surveillances being performed.
He also, from time to
- time, reviews the surveillance reports.
- Thus, even where the program does not require ANI review or concurrence, he is aware of any problems relating to filler material control at BLN.
The administrative practices for return of unused and waste filler material were found to have no wel<iing technical significance.
Discussion with the Welding <<<uality Control and Welding Engineering Supervisors indicate that this issue has not been a probl<!m at BLN.
These concerns were originated at Watts Bar and applied to Bellefonte for evaluation for generic applicability.
This part of the filler material control issue is gener ically evaluated in Management and Personnel Subcategory Report Number 70200, and is not addressed further by this report.
Complete details of the evaluation of this issue are discussed in Weld Project Evaluation Report WP-01-BLN
TVA EMPLOYEE CONCERNS SPECIAL P ROG RAM REPORT TYPE:
Subcategory REPORT NUMBER:
80200 REVISION NUMBER:
4 TITLE:
BLN Site Specific Welding Subcategory Report PAGE 6 OF 19 3.2 Ins ection of-Welds Throu h Carbo-Zinc Primer The issue relating L'o L'he process specification allowing inspection of primed welds evolved from a major reinspection effort at WBN.
While the specificaL'ion in question was site unique to WBN, a similar effort did take place at Bellefonte.
Beginning in May 1980, a series of Nonconforming Condition Reports began a major reinspection of fillet welds for leg size and throat depth.
In that these r einspec Lions wer e For configurational attributes which would not be masked by the coatings, an engineering decision was made to perForm the reinspections with the coatings Structural Melding Code.
The reason for the employee concerns relating to inspection of coated welds ~t BLN is L'he application of WBN concerns Lo other T!JA nuclear sites for evaluation for generic implicat.'ions.
While certain reinspectiun of coated welds did occur at BLN, th<!y were performed in accordance with the approved dispositions to Nunconfuriiiirig Curiditiun Repor'Ls, and were not L'he subject oF any employee concerris initial.ed at BLN.
The Amer'iowan Weldirig SucieL'y SL!'uctur'i!1 Melding Cude, AWS Dl.l-)974.
paragrapI! 3.10.1 states in part "...welded joints shall not be painted ur!Lil ef L'er L'he wor k Iias been cumpleL'ed
<<nd ucuepL'ed".
The provisions of AWS Dl.l, Paragraph 3.10.1 are intended t,o prevent cuvtirig pr'iur'u inspecL'iuri Cur'i!ld quality, i.e.,
examinatiun for discontinuiL'ies in the weld.
Weld size and configuration, unlike discoritiriuities, ur'e not masked by primer or paint:.
TVA met the provisions of AWS Dl. 1, Paragraph
- 3. 10. 1 during the initial acceplarice irispecL'ions.
The limited r einspecL'ion uF cunited welds 1'or size and/or configuration is within the authority of the Engineer'rid is nuL considered L'o be a duper ture I'rom L'he requirements of the governing code.
This may be evidenced by the
<<ur rent widespri!~d use ol Nuclear Construction Issues Group Ster!dard NCIG-O), which provides for limited reinspection of coated welds.
Dis<<ussions with cog!!i@ant TVA Welding personnel indicated l.hat these procedures were complied with in that first line acceptance inspecLions performed at Bellel'onte were ul'on coated welds.
Complete details of the evaluation of. this issue are discussed in Weld Project Evaluation Repor t WP-O2-BLN.
IR4 I
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT TYPE:
Subcategory REPORT NUMBER:
502OO REVISION NUMBER:
4 TITLE:
BLN Site Specific Welding Subcategory Report PAGE 7
OF 19 3.3 Welder ualification Continuit The concerns implied that welder s'ualification continuity was updated with inadequate or no evidence that the welder had used a
welding process within the specified Lime frame; that personnel whose duties do not require welding continue to have their qual ifications updated; that welders on restriction (not al lowed to weld) kept their qualification continuity updated; that one welder could weld or complete 'another welder's test plate during qualification testing; and questioned the number of bend test specimens required by Muscle Shoals for qualification testing.
From the beginning of construction, Welding Engineers assigned to the Mechanical Engineering Unit (MEU) were responsible to'verify quarterly that each welder had maintained his qualification by using a welding process For which he was qualified.
This qualification was documented on a Welder Qualification Verifica'tion Card, which was maintained in the MEU Files.
In January
- 1976, BLN changed the documentation of welder qualification continuiLy Prom the manual Welder Qualification Verification Card to a computerized system.
This system was v!ainL'ained by the Welding Engineering Unit, and permiLted timely identification of any welder approaching a qualification continuity renewal date.
In June
This veriFication is documented on the Welding Material Requisition, which then becomes the basis For updating the computer ized welder listing.
Review of the historical file of deficiency reporting documents and USNRC Inspection and Enforcement:
(IE) Reports Failed to identify any violations relative to this issue.
The Bellefonte implementing procedure for Welder Qualification parallels the requirements of ASME Section IX.
The implementing procedure for ASME Section IX and AWS 01.1 specify that, to be qualified, the individual's primary duty v!ust be welding.
The only requiremenL imposed by the codes for remaining qualif'ed is the use of the process or processes within the specific time Frames.
Even though there is not a mandatory requirement, only personnel actively engaged in welding activities ar e qualiFied at BelleFonte.
The qualifications oF individuals in welder foremen positions are not updated even L'hough provided Por in the Bellefonte impleme!!ting procedures
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT TYPE:
Subcategory REPORT NUMBER:
5Q2QQ REVISION NUMBER:
4 TITLE:
BLN Site Specific Melding Subcategory Report PAGE 8
QF 19 Neither ASME Section IX nor AWS Dl. 1 uses the term restriction when referring to welder qualificaL'ion.
The only requirements mandated by the codes relative to qualification continuity update or requalification are the use of the process or processes within the specified time frames and questionable performance.
The Bellefonte implementing procedure for welder qualiFication mandates, in addition to the code requirements, that a welder's qualification is revoked when he/she violates the Quality Assurance Program.
Reinstatement, to include retesting, is up to the discretion of the Welding Engineering Unit.
The only other instance where welders might be considered "restricted" from welding is when L'hey have a personal injury or sickness that prevents them from physically performing the welding activity.
These individuals are allowed to maintain their qualifications up to the time for qualification continuity update.
At this time, iF they have not returned to a welding status and used the process or processes, their qualifications are rescinded.
These individuals must retest For reinstatement of. their qualifications.
The test shop at Bellefonte is relatively small and arranged in such a manner thaL the Weld Test Supervisor or designated assistant always has observation and control of'll activities during testing.
Additionally, if two individuals are observed in the same Lest booth at any time or for any reason during testing, both individuals are immediately suspended From Fur L'her tes ting and denied qual if'ication.
In the 1974 Edition of.
ASME Section IX, paragraph QW-302.3 was omitted.
The omission of QW-302.3 could lead to Lhe interpretation that only two bend test were required.
QW-302.3, which clearly defines the requirement for Four bend test specimens to qualify to the 5G and 6G positions, was reinstated by the Errata to the 1974 Summer Addenda to ASME Section IX. Initial qualiFicatiun of welders at Bellefonte did not begin until early 1975, therefore, the Belief'onte program was set up to the requirements of the 1974 Edition of ASME Section IX Summer Addenda.
Additionally, Welding Engineering at Bellefonte does not certify welders transferred From other sites without reviewing their Performance Qualification Test Record (PQT).
Those we lders without a PQT -are tes ted pr ior to be ing issued a Bellefonte welder certification card.
TVA EMPI OYEE CONCERNS SPECIAL PROGRAM REPORT TYPE:
Subcategory REPORT NUMBER:
50200 REVISION NUMBER:
4 TITLE:
BLN Site Specific Welding Subcategory Report PAGE 9 OF 19
'he implementing procedure for welder performance qualification requires the Welding Engineering Unit to maintain a File for qualification verification for all welders, but the procedure does not provide instructions for updating this file.
The implementing procedure for weld filler material control provides instructions for completing the Weld Material Requisition, which is the basis for updating the welder qualification file, but does not provide the instructions for disposition oF the form.
Currently there are no guidelines in the text of either procedure that shows their.
respective relationship.
As a program enhancement, CA'10 50203-BLN-01 was issued to recommend that. these procedures be revised to provide the instructions for updating the welder qualification file and to provide instructions for disposition of.
the Weld Material Requisition.
Con!
Wel Cor Pro ins ructions f r u
- -'~~'35, CC4!-'X~I.D I
n dure Q(gf+$ gi)/or 10.
w~e r s
t.o cl-discussed xn ify Lhe IRO I
3.4 Ins ection lools The issue that inspectors at Bellefonte were not issued inspection tools ur!tll recently evolved From Watts Bar concerns applied to other TVA nuclear sites for generic applicability.
This issue is partially factual at Bellefonte.
Discussion with cognizant TVA persor!nel revealed that locally fabr icated tools, such as angle, bevel and gap gauges and commercially procured undercut
- gauges, six inch machinist scales.,
and Flashlig'hL's were available at BelleFonte from the beginning of construction.
Further discussion did indicate,
- however, thaI.
commercially procured fillet weld gauges were not available until early 1980 and that the six inch scale was the basic tool used to verify socket and I illet weld size.
All inspection Lools necessary to perform the required weld inspections were available.
IRA IR<
In recent years, as construction has advanced and as Lhe need I'r more precise verifications of weld attributes was ider!Lified through program i!nprovements, more sophisticated inspection tools have beer!
procured and provided to the welding units.
More advanced t.ools such as coenerically manufactured multiple purpose, hi-lo and bevel gauges have been purchased.
This is not to imply that earlier tools issued were not adequate for perfor!ning Lhe intended inspection activity.
TVA Et1PLOYEE CONCERNS SPECIAL PROGRAM REPORT TYPE:
Subcategory REPORT NUMBER:
50200 REVISION NUNBER:
4 TITLE:
BLN Site Specific Welding Subcategory Report PAGE 10 OF 19 The inspection methodology before the 1980's was somewhat different.
From the post 1980 methodology.
The post 1980 methodology is that;-
every lineal increment of all weld segments must be at least the specified weld size.
The pre 1980 methodology implied that the norm was to measure socket and fillet welds in three or four places along the length of the weld, especially the low areas, then accept or reject the weld.
Even though this may not be an acceptable practice today, it was not unique L'o any one site, utility or contractor.
Many utilities throughout the country underwent extensive socket and fillet weld reinspection programs in the early 1980's.
From 1980 to 1982 several Nonconforming Condition Reports were issued
<<t BLN to document undersized fillet and socket welds.
Beginning in
- 1980, most utilit:ies, including TVA, procured "GO NO-GO" type fillet:
guage and
<<onducL'ed massive reinspections of I'illet and socket welds.
The reinspection required exact measurement of the entir e length of t:he weld.
I I
IRh I
I I
The root cause for fillet and socket weld size was principally caused by a change in methodology as expl<<ir!ed above.
The extensive reinspections which followed the change ir! measurement practices may
'have been per'ceived
<<s a result of lailure to provide the inspect:or s wiLh adequate measuring devices.
I IR4 I
I I
The reinspection prugr'im resulting From Lhe NCRs not only included a
measurement of the welds using fillet weld gauges, but also required deLailed mapping ul'a<<h weld.
As evidenced by Lhe results oF the reinspection.efl'ort, practically all the welds reject,ed were of nominal size.
These welds had small areas of undersize, which was not: indicative of Lhe entire weld, and areas that. were oversized compensated I'or L'he undersized por tions.
As a result of this effort, a detailed design engineer ing analysis of each weld, to determine suitability for service, has required less than ten welds to be reworked out of the thousands of welds reject,ed.
Complete details of the evaluation of t:his issue are discussed in Meld Project Evaluat.ion Report MP-0!I-BLN.
IRh I
Ins ector uglification The concerns questioned the adequacy of the t:raining received by the welding inspector.
pr ior to 1981 and exceptions taken to ANSI N45.2.6, as specified in TVA's Topical Report (TVA-TR75-1A).
The concerns stated that.
an inspector should be a welder in order t:o know what to look for in a good weld and,that welding inspectors at Bellefonte do not appear Lo be knowledgeable about: welding.
It is true that some welding inspectors were qualified with approximately two months on L'he job training at the beginning of'onstruction.
- This, however, does not represent a problem.
TVA ENPLOYEE CONCERNS
- SPECIAL, PROGRAN REPORT TYPE:
Subcategory REPORT NUMBER:
50200 REVXSION NUNOER:
4 TITLE:
BLN Site Specific Melding Subcategory Report PAGE 11 OF 19 At the beginning of construction at Bellefonte,.inspection personnel were member s of Lhe Nechanical Engineering Unit whose. principal duties were performance of inspection and nondestructive examination.
These inspections were performed to clearly defined acceptance criteria.
Site certification was required for each procedure under which an inspection was performed.
Xnspection personnel received training under the direction of the responsible Engineering Unit Supervisor, and were tested by the Quality Assurance Engineering Unit.
Xnspector qualification has been the subject of Engineering, Super visory and USNRC attention throughout the history oF the plant.'VA at Bellefonte paralleled the general industry practices in the development, improvement and refinement of the programs for training and qualification of welding inspectors.
It is probable that major improvements made during 1981 were seen by some as the beginning of the TVA attention to inspector qualification.
This would possibly lead to a conclusion that prior to 1981, inspectors were not trained or were inadequately trained.
Clearly, this is not Lhe case at Bellefonte Nuclear PlanL.
It is important to note that the commitment made through the Quality Assurance Topics) Report is to USNRC Regulatory Guide 1.58, Revision 1, rather than a direct commitment to ANSX N45,2.6.
The TVA pro'gram For cet tification of weld inspection and examination personnel, with the exceptions taken through the Quality Assurance Topical Repor t, are not a degradation of ANSX N>5.2.6.
These exceptions are provided for by USNRC Generic Letter 81-01, which requires either cummiLment to Regulatory Guide 1.58 or submittal oF an alternate plan.
Topical Report TVA-TR75-1A, which has been approved by the USNRC, satisfies the requirements of Generic Letter 81-01.
There is no code or regulatory requirement for a welding inspector to also be a welder.
In L'he Amer lean Melding Society Certification Manual for Welding Inspectors, it is recognized that experience as a
welder is of benefit to the inspecLor.
It is, however, also stated that whether or not this is a requirement is the employer's option.
With regear d to the concer n which s LaLes that L'he welding inspector s at Bellefonte do not appear to be knowledgeable about welding, there is insufficient detail in the L'ext of the concern Lo determine what the perceived problem is, i.e.,
what welding knowledge the inspector does not possess.
The material issue
- then, must be whether or not the TVA welding inspector at BLN has sufficient welding related knowledge to adequately perform his duties.
IF the competence oF the welding inspector is th'e material issue, the concern is not Factual.
TVA EMPLOYEE CONCERNS REPORT NUMBER:
50200 SPECIAL PROGRAM REPORT TYPE:
Subcategory REVISION NUMBER:
4 TITLE:
BLN Site Specific Welding Subcategory Report PAGE 12 OF 19 The evaluation, including discussions with engineering and inspection personnel, review of the program, nonconformance
- history, and Lhe USNRC inspection and enforcement history at Bellefonte clearly shows that the welding inspector s are adequately trained and tes ted.
With one exception, no evidence was identified to suggest a problem with the competence of the welding inspectors at Bellefonte.
This one exception involved a, single inspector, and was identified and corrected through the ongoing site Quality Assurance Program.
Complete details oF the evaluation of this issue are discussed in Project Weld Evaluation Report WP-06-BLN.
IR4 I
3.6 Welder Trainin /Ex erience The concern stated that subjourneymen perform work for which they are not qualified (pipe fit-ups and welds) and questioned the TVA welder training program.
This concern was a Watts Bar concern applied to Bellefonte for evaluation for generic applicability.
A review uf Lhe historical welder qualification records revealed that none of the individuals identified as subjourneymen, who had been employed at BelleFonte, were ever qualified as welders.
TVA utilization of subjourneymen is in accordance with the trade labor agreement and commensurate with management practices throughout the construction industry.
The TVA welder training program at BLN requires that the individuals who perform production welding be qualified in accordance with the requirements of ASME Section IX or AWS D1.1, as applicable.
Additionally, these individuals are tested when reFerred to the weld test shop by craFt supervision.
This referral is based on the craft supervision's judgement that the individual has acquired the skills and ability necessary to satisfactorily complete the performance qualification and to produce sound weld'omplete details of the evaluation of this issue are discussed in Weld Project Evaluation Report WP-07-BLN ~
IR4 I
3.7 Im lementation of ualit Assurance Evaluation No.
AE-2 The concern stated that the welding and NDE corrective action
- programs, as identified in Office of Engineering Design and Construction (OEDC) Quality Assurance Evaluation No. QAE-2, dated September
- 1980, may not have been implemented for Bellefonte as the same/uncorrected problems were found toi exist years later, and may still exist today'
TVA ENPLOYEE CONCERNS REPORT NUNBER:
50200 SPECIAL PROGRAM REPORT TYPE:
Subcategory REVISION NUNBER:
4 TITLE:
BLN Site Specific Melding Subcategory Report PAGE 13 OF 19 QAE-2 did not identify welding and NDE correct."ive action, but identil'ied recommendations For progr am impr'ovemenL.
This QA evaluation was conducted upon t:he r'equest: of the TVA Manager of Construction and the Manager of' Engineering Design.
The objectives of the review were to look at the adequacy and effectiveness of the welding and NDE programs and to repor t the Findings of the review with the appropriate recommendations for improvement.
During this review only one observation/del'iciency was identil'ied which specifically required corrective action.
This deficiency was not issued with report QAE-2, but was identified as a significant deficiency by QA Audit Report, BN-W-80-08.
Additionally, many of-the r ecommendaLions are adminis tr'ative in nature or relate Lo management pract:ices and have no technical welding r'elated significance.
These recommendaLions will not be addr'essed ir! this rt!port.
All technically relat.ed welding recommendat:ions ol'AE-2 have been implemenL'ed in some l'or v! aL Bellel'onL'e or t:her e were programs already in ef'feet that. preempted the necessity for implementation of t:he recommendations.
Complet:e details of'he evaluat.ion of this issue are discussed in IR4 Weld p'roject Evaluation Report WP-10-BI.N.
I 3.8 Weldin E ui ment. and Bottled Gases The concerns sL'aLed that welding ma<<hines do not have suiLable amperage seL'tings for welding wit.h 3/32 inch diameter elect.rodes which leads t.o porosity and pinholes; welding machines should have Lhe remote switches to prevent tungst;er! inclusions; and t,he cleanliness/purit.y of bottled gases is questionable.
Bellefonte utilized throe types of welding equipmenL, two of which (Lin<<oln Idealarc 300 and Niller Gold Star 300) have current ranges exceeding 300 amperes and have optional feat:ures such as the vernier type current adjustment;.
The oLher type of equipment used was t:he Ilobar.t grid bank/multiple operator unit..
These machines have a history of saL'isfacL'or'y per for man<<e throughout the industry.
The Lincoln Idealarc TIG 300 and the Niller Gold Star 300 do have the remote switches for arc star ting and <<urrent control adjustment.
The Hobart machines used do not have these features.
Tungsten inclusions are reduced significant,ly,
- however, by employing good welding Lechnique
- and, iF ne<<essary, by using strike plates immediately outside the weld.
Comments l'rom the Bellefonte QualiLy Assurance Unit (QAU) did indicate a
concern relative to the TVA requirements for procurement. of welding gases.
Comments Prom the Welding Engineering SLal l'F, the Ol'l'ice of Const:ruction (OC) and a subsequer!t memorandum from the Chief, Quality Assurance, to the OC Bellefont;e Project: Manager resolved the issue.
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT TYPE:
Subcategory REPORT NUMBER:
50200 REVISION NUMBER:
4 TITLE:
BLN Site Specific Welding Subcategory Report PAGE 14 OF 19 Bellefontu employed welding equipnient fully capable of producing satisfactory weldmenL's.
Bottled gases aro proporly conLrollod and purchased in accordance with procurement requirements.
Complete details of the evaluation of this issue are discussed in Weld Project, Evaluation Report WP-13-BLN.
IR4 I
3.9 Structural Steel Preweld Ins ections The concerns stated that allowing uncertified welder foremen to perform preweld inspections is in conflict with the TVA Quality Assurance Commitments, ANSI requirements and AWS Dl. 1 and that when a welder welds the wrong two sides of square
- Lubing, he goes back and welds the other two
- sides, thus making an all arourid wold, which is not in accordance with the d raw farl'g AWS Dl. 1 allows proweld inspections to be cor)ducted or) a sampling basis.
This is claril iud in Lho Comment'ar'y to Lho 1986 Edition to AWS Dl.l.
As a result of a Quality Assurance audit finding, TVA reported the preweld inspection issue Lo L'ho USNRC in accordance wiL'h 10 CFR 50.55(o).
In the final report.
Lo Lhe NRC it was stated that the TVA was meeting the inLunt of ANSI N45.2.5 as iridividual ruquir'einunts oi the staridard aro applied depending upon the nature arid scvpe of Lhe work to be per.formed and L'Iiu importance uf Lhe item orIie sur'vice irivolved.
The NRC approved the final report and closed the unresolved item.
One concorri raised tho issue that the 050 notus (Genoral Notes to Drawing 47A-050) allow 'fillet welds to bu 100K oversized and craft to determine the length.
Therefore, when a drawing requires two sides of square tubing to be welded and Lho welder wulds the wrong
AWS Dl. 1 requires in part that the size and length of welds shall not be substantially in excess of design requirements nor the location of welds be changed without approval.
The TVA General Construction Specification G-29C cites the same requirements foi the installation of structural wolds.
This concern was a WaLts Bar coricern evaluated at Bellefontu for generic implication.
Discussion with TVA Engineering personnel revealed that the 050 notes are applicable Lo WatLs Bar and aro not used at'ollefonte.
Further discussion with TVA Quality Control personnel at Bollefonte revealed that all welds not meeting the design drawing are reported in accordanco with the Bellefonte Qua'liL'y Assur'an<<u Pr ograni.
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT TYPE:
Subcategory REPORT NUMBER:
50200 REVISION NUNBER:
4 TITLE:
BLN Site Specific Melding Subcategory Report PAGE 15 OF 19 No significant effect on hardware or the welding program ai.
BelleFonte was identified.
TVA rules for structural steel preweld inspections are in compliance with its Quality Assurance commi tments, ANSI N45. 2. 5 and AWS D1
. 1.
Ex Lra weld s are appropriately reported under the site Quality Assurance Program.
Complete deL'ails oF the evaluation oF this issue are discussed in Weld Project Evaluation Report WP-16-BLN.
IR4 I
The concerns stated that there are bad welds on hangers in the Essential Raw Cooling Water (ERCM) tunnel, cable Lrays and a duct support in the Control Building; questioned i.he grinding of welds; and raised L'he issue ol excessive circumFerential shrinkage in stainless steel butt joints.
Welds (ERCW tunnel hanger s, cable trays and a duct support) not meeting accept. ance standards were found in Lhe areas identified by the concerned
<!mployees.
All suppor t welds, duct suppur t welds and miscellaneous structural welds have been reinspected and reworked as required.
This reinspection efFor t was accomplished in accordance with the disposit.ions of numerous nonconforanances which we! e considered signifi<<anL and repor ted L'o Lhe USNRC in accordance with 10 CfR 50. 55(e)
Grinding oF welds is not a violat.ion of codes, sLandards or BLN procedures.
- Rather, in many cases L'hose siandards require gr inding to obtain suitable surfaces for i.he proper inLerpreLation of i.he speciFied NDE and Lo eliminaie or reduce sur fa<<e imperfections.
The construction
- codes, speciFications and procedures do not quantiFy en accepL'ance criteria For circumFerential shrinkage in welded butt joints.
Distortion, including shrinkage, is inherent in sLainless sLeel weldmenL's.
FucLors 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 sLeels.
Complete details of the evaluation of this issue are discussed in Meld Project Evaluation Report WP-34-BLN.
IR4
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT TYPE:
Subcategory REPORT NUMBER:
50200 REVISION NUMBER:
4 TITLE:
BLN Site Specific Welding Subcategory Report PAGE 16 OF 19 3.11 Weld Ins ection Procedures The concerns questioned Lhe deletion of welding and brazing inspection of safety related HVAC ductwork; the acceptance of.
previously reject:ed hanger welds by someone ot:her than a supervisor; weld records reviewed by the ANI which had heat numbers marked "NA" and when checked lat:er had heat numbers entered; and stated that an individual falsified containment wall weld records.
The inspection requiremenLs For saf'ety relaLed ductwork were deleted from the Quality Assurance Program subsequent Lo 1981.
This is a Matts Bar Concerri, and is not Factual at Bellel'onte.
Bellefonte has had an inspection program for safety related ductwork from the
. beginning of cons L'ruction Lo the presenL tivie.
The weld inspection program at Bellefonte requires that rejectable iteiss be documented, and reinspectivri is accomplished only aI'ter the corrective action has been provided.
The reinspection may or may noL'e per'I'ormed by an inspecLor aL Lhe same certificativn level as the inspector that previously rejected the it:em.
This issue is a Watts Bar cvncerm applied to other TVA sites I'or gener ic applicability.
Weld records reviewed by the ANZ had heat:
numbers marked "NA" and when checked laL'erhe heat nuviber's had bi!en entered.
This issue has been closed by the Office of the Inspector General and will not be addressed by LI!is r'<!porL'.
Two concerns st:ated that weld records ori the containment wall had beeri falsil'ied.
This issue is IacL'ual arid was or iginally repor ted as an allegat,ion in 1980.
TVA pi!rsonnel at, BellefonLe issued a
Nonconforasance Report relative to t.he issue and r epor ted I.t: as significant to the NRC under 10 CFR 50.55(e).
CompleL'e deL'ails ol'he evaluation vf L'his issue are discussed in Meld Project Evaluation Report WP-35-BLN.
3.12 Weld Re air's The concerns stated that; TVA makes repairs which are not in accordance with l.'he ASME Code~,
such as overlays, patches and furmanite (viscous sealing compound) and a Four inch st,ainless steel pipe ia ttie SpenL Fuel Cooling (NM) SysLem was improperly repaired.
The pipe was damaged while torch cutt:ing a sleeve.
The issue r elaLing L'o the use oI'ver lays and patches, while
- factual, has rio applicability to Bellefonte Nuclear Plant.
These L'einporar'y repair's ar'e service r'elaL'ed, arid are performed under approved programs at: Browns Ferry and Sequoyah Nuclear Plants.
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REpORT TYPE:
Subcategory REPORT NUMBER:
50200 REVISION NUMBER:
4 TITLE:
BLN Site Specific Welding Subcategory Report PAGE 17 OF 19 That part of the concern relating to TVA making repairs using viscous sealing compounds is addressed by Operations Subcategory Report
- 30800, and is not considered further by this evaluation.
The concern which stated that a four inch stainless steel pipe was improperly repaired evolved from oxy-fuel cutting of a carbon steel pipe sleeve through which the subject stainless steel pipe passed.
This concern was investigated by the site Quality Control and Welding Engineering Units.
The evaluation included chemical and magnetic tests of the pipe to check For the presence oF weld metal and for residue from a flame cutting operation.
No evidence could be found indicating that a repair was ii:.vie! Lo the pipe identified by the concerned individual.
Complete details of the evaluation of this issue are di: cussed in Weld Project Evaluation Report WP-36-BLN.
- 3. 13 Ade uac of Procedures The concerns stated that prior to 1979 there was no specific inspection criteria for use by inspection personnel; that the visual examination procedure which covers ASME Section III is nonspecific; that NDE inspectors can only write a Notice of Inspection For inservice related deFects and preservice defects can only be identified on a Maintenance Request; and an individual was told to start using a different heat treating process with no explanation.
The issue relating to the adequacy of the weld inspection procedures evolved from two employee concerns originated at Browns Ferry and Watts Bar.
One vt the concerned indiv idu.il>> br lieved that the problems were TVA wide.
Relative to Bellefonte Nuclear Plant, these concerns are not factual.
Quality Control Procedure BNP-QCP-7.5, "Visual Examination of Weld Joints,"
was issued in December, 1975.
This procedure, with one exception, adequately provided all of the required inspection and acceptance criter ia.
Due to an omission in an upper tier document, the inspection procedure QCP-7.5 did not provide the required weld size for socket welded flanges.
In May, 1980 a Nonconforming Condition Report was issued.
The corri <.tive and preventive actions mandated through NCR 1188 adequately resolved the procedural deficiency and any resultant hardware effects.
TVA EMPLOYEE CONCERNS SPECIAL PROGRAM REPORT TYPE:
Subcat.egory REPORT NUMBER:
50200 REVISION NUMBER:
4 TITLE:
BLM Site Specific Melding Subcategory Report PAGE 18 OF 19 The issue involving the methods used by t:he ISI Inspectors to report inser vice ar!d pr ever'vice i!!specL'ion f'indings ur'iginated at Brvwns Ferry and Sequoyah.
These concerns are partially factual, in that L'he Motif'ication of'ndication is the speciFied I'orm f'r reporting oF indications found during nondestructive examination.
This is in accordance wiL'h L'he TVA Nuclear Quality Assurance Manual.
One concerned individual stated that he was told to start using a
dii'f'erent heat LreaL'ing process with no explanat:ion.
This issue had been previously invest,ig'ated and resolved through a sit:e implement:ed employee concerns pr'ogram.
The process in question was in accordance with the speciFication.
Complete deL'ails of. the evaluat:ion oF t:his issue are discussed in Weld Project: Evaluat.ion Report tJP-.43-BLN.
IRn I
- 4. 0 COLLECTIVE SIGNIFICANCE Through the subcategory overview oF the evaluation report Findings and the IR4 subsequer!L'nLegraLion of'nformaL'ion, r!o new signiFicant it:ems were ident:i fied.
The evaluation report. investigations and the subcategory overview indicated IR4 that the pr'ucedur es and L'he pr'acL'ices used at:
BLN wer'e consistent:
wiL'h good pract:ices used throughout: the nuclear indust,ry.
TVA's welding cunL'r'ol pracLices were ad!!quaL'e and r ef'lected common nuclear indust:ry practices.
Some problems were identified, as one would expect wilh 0!e size of l'he oper aL'ion ar!d L'he L'ime I'r arne, ar!d vier e addressed by the ongoing QA program and the Weld Project Evaluat;ion Repor t Inves tigal:ions.
IR4 5 0 CAUSE The cause of a perceived problem or the cause of a problem which initiated a CATO is l'imited t.o L'he cause idenL'ified in the evaluation report:.
IR4 6.0 CORRECTIVE ACTION No corrective action is specified as a result oF this subcategory report..
CorrecLive acL'ions'or 'prublev!s or perceived problems are limited Lo the CATDs issued as a portion of the Weld Project Evaluation Reports.
Discussions ol'enhar!cemenL's Lo L'he exisLing TVA sysL'ev!,
oLher L'han the enhancements speciFied by CATDs 50201-BLM-01 and 50203-BLM-01 will be def'er red to t:he caL'egory repor t:.
CATO 50201-BLN-01 was issued to recommend t;hat: t.he implement:ing procedure be revised to reflect actual IR4
TVA EMPLOYEE CONCERNS SPECIAL PROGRAN REPORT TYPE:
Subcategory REPORT NUMBER:
50200 REVISION NUNBER:
4 TITLE:
BLN Site Specific Welding Subcategory Report PAGE 19 OF 19 0
practice and CATO 50203-BLN-Ol was issued to recommend that the implementing procedure for welder performance qualification and the implementing procedure for weld filler material control be revised to show their respective relationships.
7.0 ATTACHNENTS A.
Subcategory Summary Table Summary of Issues 8.0 REFERFNCE A.
Welding Project Evaluation Reports IR4
REFERENCE ECPS120 J-ECPS121C FREQUENCY
" REQUEST OWP - ISSS - RIIN CATEGORY'IE WOW QA/QC IIELDIHG TENNESSEE VALLEY AUTHORITY OFFICE OF tlUCLEAR POHER EHPLOYEE CONCERN PROGRAM SYSTEtt (ECPS)
EHPLOYEE COWCERII IHFORHATIOW BY CATEGORY/SUBCATEGORY SUBCATEGORY'0201 CONTROL OF IIELDIHG FILLER IIATERIAL PAGE 26 RUW TINE - lla45s02 RUH DATE 12/17/87 COHCERII WUHBER CAT SUB CAT S
H R PI.T D LOC 1
REPORT APPL 2 SAF RELATED BF BL SQ IIB HISTORICAL CDWCERH REPORT ORIGIII COHCERH DESCRIPTION EX "85-039" 00101 T50146 IIE 50301 S
flBW 02 IIE 50101 S IIBH 03 HE 50201 S
IIBW 04 IIE 50401 S flBtl BI.H-86-015-00101 IIE 50201 W BLH 1 tl Y
tl H
2 HA SS HA IIA 1
N H
Y H
2 WA WA SR HA 1
Y tl tl tl 2
SR HA HA WA 1H Y
W tl 2
HA SR WA HA 1
W W
W Y
2 HA WA WA SR HSRS itI-85-053"004 QTC DURItlG A CONTACT IttTERVIEI)i THE CI EXPRESSED HIS C OHCERH RELATIVE TO IIELD ROD COHTROL.
HELD RODS AR E LEFT IH ROD CAIIS IH A UNCONTROLLED AREA HHERE AH OTHER PERSON COULD PICK UP AtlYOHE'S RODS.
IIELD CE RTIFICATIOH CARDS ARE LEFT IW THE CANS OVERNIGHT.
CURREtlT PRACTICE VIOLATES PROCEDURES.
IIBtlPi THERE ARE tlO PORTABLE OVENS FOR STORItlG tIEL D ROD AFTER IT HAS BEEN ISSUED TO THE IIELDER AHD THE IIELD ROD IS tlOT ADEQUATELY ACCOUIITED FOR IIHEtl IT IS RETURNED'.E.
ROD STUBS AtlD UtlUSED ROD.
CO IIST.
DEPT.
COtlCERtl.
CI HAS IIO FURTHER IIIFORNATIOW HO FOLLOIIUP REQUIRED.
(SQH ISSUES ADDRESSED IW RPT IIP"01 "SQH R3) 1H 234-00101 T50027 03 04 IIE 50301 S
IIBW IIE 50101 S HBII IIE 50201 S
HBH IIE 50401 S IIBN 1N tl 2
HA WA 1Y tl 2
SR NA 1
H Y
2 HA SR 1W tl 2
HA WA Y
tl SR WA tl tl WA HA H
W WA WA H
Y WA SR EX-85"021 "001 QTC IIELD RODS ARE HOT REQUIRED TO BE KEPT IW ROD OVEHS AFTER ISSURAIICE TO STEA(IFlTTER IIELDERS.
THE ROD CAW BE KEPT UtlHEATED FOR 8
HOURS AT A TINE Itt A LE ATHER POUCH.
(SQH ISSUES ADDRESSED IH RPT IIP"01-SQ tl R3)
IW 247-00101 T50022 IIE 50312 S flBtl 1tl HY 2
WA WA,SR N
IH-85-284-001 QTC WA 7018 RODS (PURCHASED)
ARE OF POOR QUALITY. THIS CO HTRIBUTES TO POROSITY AWD PIWHOLES.
(SQH 1SSUES AD DRESSED IH RPT IIP-12-SQW R2) 02 HE 50101 S
HBH 1
Y H
H 2
SR HA WA tl HA 03 IIE 50412 S
IIBW 04 IIE 50201 S IIBH 1 tl H
tl Y
2 HA WA HA SR 1 tt Y
It H
2 WA SR tlA
<'IA
REFERENCE
- ECPS120J-ECPS121C FREQUENCY REQUEST OHP - ISSS - RIIII CATEGORYa IIE tlOH QA/QC IIELDIWG TENNESSEE VALLEY AUTHORITY OFFICE OF tlUCLEAR POllER EtIPLOYEE CONCERN PROGRAH SYSTEtt (ECPS)
ENPLOYEE CONCERN IWFORNATIOH BY CATEGORY/SUBCATEGORY SUBCATEGORY'0201 COtlTROL OF IIELDIHG FILLER HATERIAL PAGE
27 RUH TlHE - llc65c02 RUW DATE 12/17/87 COHCERtl HUHBER CAT SUB CAT S
H R PLT D LOC REPORT APPL 2 SAF RELATED BF BL SQ IIB HISTORTCAL REPORT CONCERN ORIGIII CONCERN DESCRIPTION IH 352-00201 T500CIO HE 50301 S
PIBH 02 IIE 50101 S IIBtl 03 IIE 50201 S
IIBW 06 IIE 50601 S IIBtl IH 626-00101 T500ci1 IIE 50301 S
IIBH IN "85-426-00601 T500CIO tIE 50301 S
HBH 02 IIE 50101 S
IIBH 03 I.IE 50201 S IIBII 06 IIE 50401 S IIBtl 02 IIE 50101 S IIBH 03 HE 50201 S IIBH 04 tIE 50401 S IIBtl 1 tl tl Y
tl 2
HA HA SR HA 1
Y tl H
tl 2
SR WA WA WA 1
N Y
H H
2 WA SR WA WA 1 tl 2 IIA H
H Y
HA HA SR 1
H tl Y
tl 2
WA WA SR WA 1
Y tl tl H
2 SR WA HA WA H
Y tl H
2 HA SR HA WA 1
H tl tl Y
2 HA WA IIA SR 1
H H
Y H
2 HA WA SR HA 1
Y tl tl H
2 SR WA WA HA 1 tl Y
W H
2 WA SR HA WA 1 tl tl H
Y 2
WA WA HA SR EX-85-021-001 QTC EX-85-021-001 I
QTC I
EX-85-021-001 QTC tl0 PORTABLE OVENS ARE USED OH HATTS BAR.
IIELD ROD CAW BE KEPT OUT OF OVEII FOR AH ENTIRE SHIFT AHD R ETURHED TO OVEN FOR LATER USE.
(SQW ISSUES ADDRESS ED IW RPT HP"01-SQH R3) tlO PORTABLE OVENS USED/REQUTRED OH IIATTS BAR.
THE ROD OFTEtl COLLECTS HOISTURE AtlD SHOULD NOT BE USE D.
(SQH ISSUES ADDRESSED IH IIP-01-SQH R3)
QA TRAItllHG CLASS, 6"5-85, IIIFORHED CRAFT THAT STE ANFITTERS COULD IIITHDRAIIAtlD CONTROL IIELD ROD IF T HEY HAD A IIELDER SIGtlED FIELD SLIP AtlD THE IIEDERS C
ARD.
(SQtl ISSUES ADDIIESSED Itl RPT IIP"01-SQW R3)
REFEREIICE ECPS120 J-ECPS121C FREQUENCY
- REQUEST OHP - ISSS - RIIN CATEGORYi IIE tlOH QA/QC klELDIIIG TENNESSEE VALLEY AUTHORITY OFFICE OF tlUCLEAR POllER EHPLOYEE CONCERN PROGRAI< SYSTEN (ECPS)
EHPLOYEE COHCERtl IHFORNATIOW BY CATEGORY/SUBCATEGORY SUBCATEGORY) 50201 CONTROL OF HELDIHG F1LLER IIATERIAL PAGE 28 RUH TINE - 11!45:02 RUH DATE 12/17/87 CONCERN HUNBER CAT SUB CAT S
H R PLT D LOC 1
REPORT APPL 2
SAF RELATED BF BL SQ IIB HISTORICAL REPORT CONCERN ORIGIN CONCERH DESCRIPTIOH TN l2I-00601 T500CIO IIE
'50301 S
SIBN 1
2 H
H Y
II EX-85-021-001 WA IIA SR HA QTC HO ACCOUIITABILITYOF IIELD ROD DURING ISSUANCE OR R
ETURtl OF UNUSED ROD AtlD STUDS.
(SQH ISSUES ADDRESS ED IH RPT IIP-01-SQH R3) 02 HE 50101 S
HBH 03 I)E 50201 S
HBH 06 IIE 50401 5 IIBtl Itt 424" 00701 T50102 IIE 50301 S IIBH 02 HE 50101 S
HBH 03 l<E 50201 S
HBH 04 HE 50601 S HBtl IN 426-00101 T50065 IIE 50301 S IIBH 02 tIE 50101 S IIBH 03 IIE 50201 S IIBH 06 IIE 50601 S IIBH 1
2 W
Y HA SR tl H
WA HA W
H HA WA H
Y HA SR 1
Y H
H H
2 SR HA HA HA 1
N Y
tl tl 2
HA SR HA HA 1
H tl tl Y
2 IIA HA HA SR 1
N H
Y H
EX-85-021-001 2
HA HA SR HA 1YHW tl 2
SR WA HA HA 1N Y
H tl 2
HA SR WA HA 1H tl H
Y 2
HA HA HA SR 1
H H
Y H
'X-85"021-001 2
WA HA SR HA 1
Y H
H H
2 SR HA HA WA QTC LACK OF IIELD ROD CONTROL)
HELDORS GET ADDITIOIIAL R OD FROII OTHER IIEI.DORS RATHER THAW GOING BACK TO TH E
ROD ROOII FOR NORE.
SITE POLICY ALLOWS LEAVItIG R OD I)ITII OTHER I<ELDORSi OR LETTING SUB-JOURtlEYIIEH C HECK-OUT ROD AWD RETURN ROD.
(CAH ALSO LEAVE ROD IH TOOL BOXES).
THE ROD ROON DOES IIOT COUIIT ROD H HEtl IT 1S ISSUED AHD DOES IIOT REQUIRE ACCOUNTIIIG FOR ROD STUDS.
OCCASSIOWALLYp IIELDORS ARE REPRIHA tlDED FOR HOT TURtlIHG It( ROD l)ITHDRAIIAL SLIPS, EVEtl THOUGH (SQH ISSUES ADDRESSED IH RPT IIP-01-SQtl R3)
QTC PORTABLE OVEtlS ARE HOT REQUIRED.
WELD ROD IS KEPT OUT OF OVEN FOR AH ENTIRE SHIFT.
WO FOLLOII-UP. (
SQH ISSUES ADDRESSED Itt RPT NP"01-SQtl R3)
4 ]'
i
'Jl i.
~
~
h REFERENCE ECP 5120 J-ECP S121C FREQUEtlCY REQUEST OtlP - ISSS
-'ABIN CATEGORY) IIE tlOH QA/QC NELDIIIG TEHHESSEE VALLEY AUTHORITY OFFICE OF NUCLEAR POINTER ENPLOYEE COtlCERW PROGRAI1 SYSTEH (ECPS)
ENPLOYEE CONCERN IWFORNATIOII BY CATEGORY/SUBCATEGORY SUBCATEGORY) 50201 COtlTROL OF HELDIIIG FILLER NATERIAL PAGE
29 RUW TINE - llc45i02 RUII DATE " 12/17/87 CONCERN IIUNBER CAT SUB CAT S
N R PLT D LOC 1
REPORT APPL 2 SAF RELATED BF BL SQ NB HISTORICAL REPORT CONCERN ORIGIN CONCERN DESCRIPTIOH IN 461-00301 T50010 IIE 50301 S IIBtl 1tl 653-00901 T50030 tlE 50301 S IIBII 02 IIE 50101 S
NBW 03 HE 50201 S NBII 04 NE 50601 S IIBII 02 IIE 50101 S NBII 03 IIE 50201 5 IIBH 0%
IIE 50601 S IIBII N
H Y
H EX-85-021-001 WA WA SR IIA 1
2 1
Y tl H
tl 2
SR IIA WA WA 1
N Y
W N
2 WA SR HA IIA 1 tl H
tl Y
2 WA IIA WA SR 1W H
Y tl 2 IIA HA SR HA lYHH tl 2
SR HA WA HA 1
N Y
N H
2 HA SR WA WA 1
H H
H Y
2 HA HA WA SR QTC IIO PORTABLE OVENS ON flATTS BAR.
TIIE ROD SOIIETINES COLLECTS NOISTURE BY THE EIID OF THE SHIFT AWD CAII HOT BE USED.
(SQII ISSUES ADDRESSED IN RPT IIP-01 "SQ W R3)
EX-85-021-001 QTC NELDERS FREQUENTLY GIVE IIELD ROD TO OTHER WELDERS.
(SQW ISSUES ADDRESSED IH RPT WP-01-SQH R3)
Itt %56-00601 T50030 NE 50301 S IIBH 02 IIE 50101 S IIBII 03 NE 50201 S
PIBII 06 flE 50601 S IIBII 2
1 2
H Y
WA SR tl H
WA HA tl tl WA WA tl Y
WA SR 1 tl II Y
tl 2 IIA HA SR WA 1
Y H
tl tl 2
SR HA WA HA EX-85-021 "001 QTC IIELDERS FREQUENTLY GET ROD FROH EACH OTHER It/STEAD OF.IIITHDRAHTHG FOR ROD ROON.
(SQW ISSUES ADDRESSE D Itl RPT IIP-01 "SQH R3)
.0 REFERENCE
- ECPS120J-ECPS121C FREQUENCY
- REQUEST OHP ISSS - RIIH CATEGORY) IIE tlON QA/QC WELDING S
H SUB R PLT CONCERN HUHBER CAT CAT D LOC 1
REPORT APPL 2 SAF RELATED BF BL SQ HB II TEtltlESSEE VALLEY AUTHORITY OFFICE OF IIUCLEAR POllER EHPLOYEE COtlCERtl PROGRAH SYSTEN (ECPS)
ENPLOYEE COHCERtl ItlFORIIATIOtl BY CATEGORY/SUBCATEGORY SUBCATEGORY 50201 COIITROL OF IIELDIIIG FILLER flATERIAL I
HISTORICAL CONCERN REPORT ORIGIII PAGE 30 RUtl TINE llsl5s02 RUtl DATE - 12/17/87 CONCERN DESCRIPTIOH IH -.85-501-00101 T50031 IIE 50319 S
I.IBW 02 IIE 50101 S
IIBH 03 IIE 50201 S HBtl 04 IIE 50401 S
IIBH H
H Y
W '
WA WA SR WA 1 Y H
H W
2 SR WA HA WA 1H Y
N tl 2
WA SR WA WA 1
N H
H Y
2 HA HA WA SR IH-85-501-001 QTC UNUSED BUNDLES OF IIELD ROD FREQUENTLY FOUIID IH TRA SH CAtlS I ~ E ~ TURBIIIE BLDG ~ p 708 p 729 z
AIID 755 E
LEVATTOIISp UIIIT $ 2 (15"20 RODS FOUtlD 6"7-85)
(SQII ISSUES ADDRESSED IH RPT HP-19-SQN R1)
IH 672-00301 T50207 HP 70202 5
WBH 02 HE 50301 S
HBN 03 IIE 50101 S IIBH 06 IIE 50201 S IIBtl 05 HE 50601 S flBII tl H.
NA HA tl H
IIA WA N
Y HA SR H
H WA HA H
H HA WA W
Y WA SR 1 tl tl Y
tl 2
WA WA SR HA 1
Y tl H
tl 2
SR WA HA WA QTC:
I 1
I l
1 AT SH1FT ENDi IIELD ROD SLIPS ARE TURNED Itl.
THE S
LIPS ARE CHECKED THEN THROWN AIIAY.
IF THE ISSUE R
OOII DETERNIHES AT A LATER DATE THAT A WELDER DID N OT COIIFDRI4 TO "TURN Itl" PROCEDURES, IT IS HIS IIORD AGAINST THEIRS AHD HE GETS THE IIARHIIIG LETTER.
T NESE LETTERS HAVE BEEtl ISSUED IIITHOUT PROOF OF flRO WGDOI WG.
COIISTRUCTIOW DEPT.
CONCERN.
(SQW 1SSUES ADDRESSED 1W RPT IIP-01-SQH R3)
IH 067-00101 T50110 PIE 50314 S
IIBH 02 IIE 50101 S
HBW 1
H W
Y H
2 WA WA SR WA 1YH II H
2 SR WA WA HA 03 HE 50201 S
IIBtl 1 tl Y
tl tl 2
HA SR tIA HA QTC' SYSTEN IS HEEDED THAT VERIFYS THAT THE WELDER DI D RETURII THE UNUSED IIELD ROD AIID STUBS AtlD IPTLL PR OVIDE THE IIELDER A RECEIPT SO THAT T'E IIELDER CAII PROVE HE DID RETURtl THE HATERIAL Itl CASE AN ERROR HAS HADE.
CI HAS tlO ADDITIOIIAL IIIFORIIATIOW.
COIIS TRUCTIOII DEPARTHEHT.
(SQtl ISSUES ADDRESSED IW RPT IlP-14-SQII Rl )
04 IIE 50601 S
PIBW H
tl HA WA tl Y
HA SR
REFERENCE
- ECPS120J-ECPS121C FREQUENCY
- REQUEST OIIP - ISSS - RNN CATEGORYa IIE tl0tl QA/QC WELDIIIG TEIIHESSEE VALLEY AUTHORITY OFFICE OF tlUCLEAR POllER ENPLOYEE CONCERN PROGRAN SYSTEN (ECPS)
ENPI.OYEE CONCERN IWFORNATION BY CATEGORY/SUBCATEGORY SUBCATEGORY) 50201 CONTROL OF IIELDItlG FILLER tlATERIAL PAGE 31 RUtl TINE - I 1 s A5 s 02 RUW DATE 12/17/87 CONCERN WUNBER CAT SUB CAT S
N R PLT D LOC 1
REPORT APPL 2 SAF RELATED BF BL SQ IIB HISTORICAL CONCERN REPORT ORIGIN COtlCERN DESCRIPTIOH III 053" 00(101 T50135 IIE 50301 S
IIBW 02 IIE 50101 S
NBW 03 Hf 50201 S
HBH 04 IIE 50601 S IIBH 1
H H
Y W
2 HA WA SS WA 1 Y tl tl tl 2
SS WA HA WA 1 tl Y
tl H
2 tIA SS HA WA 1
H W
H Y
2 HA WA WA SS III-85-053-006 QTC IIELD ROD COtlTROL DOES tlOT SATISFY CODE REQUIRENEHT S.
TVA ATTITUDE IS "ALL NATERIAL IS CODE NATERIAL COIISTRUCTIOH DEPT COtlCERW.
CI HAS NO FURTHER INFORNATIOtt. (SQH ISSUES ADDRESSED Itl RPT IPP-Ol-SQ tl R3)
XX -85"068-00301 T501CIO NE 50201 N BLH 1 tl Y
tl tl 2
HA SR WA HA QTC I
BELLEFOWTE ASNE DEVIATIONS/VIOLATIONS (UHCONTROLLE D HELD ROD)
ARE REPORTED OH NOtl-QI REPORTS'HERE FORE PROBLENS DO HOT GET TO THE AUTHORIZED NUCLEAR INSPECTOR (AHI).
DETAILS KNOIIII TO QTC, NITHHELD DUE TO CONFIDENTIALITY.
CONSTRUCTION DEPT.
COHCER tl ~
C/I HAS NO FURTHER IHFORNATIOH.
XX 068-00601 IIE 50301 S
BLH 1
H tl Y
W T50138 2
WA WA SS WA 02 IIE 50201 S
BLW 1
H Y
W H
2 WA SS WA WA 19 CONCERNS FOR CATEGORY NE SUBCATEGORY 50201 QTC BELLEFOHTE IIELD ROD CONTROL DOES HOT SATISFY CDD E REQUIREIIEIITS.
TVA ATTITUDE IS "ALL tlATERIAL IS CODE NATERIAL".
COIISTRUCTIOtl DEPT.
CONCERN.
CI N
AS HO FURTHER ItlFORtlATIOH.
tlO FOLLOW UP REQUIRED.
(SQtl ISSUES ADDRESSED Itl RPT IIP-01-SQtl R3)
REFERENCE ECPS120 J-ECPS12IC FREQUEIICY
- REQUEST OHP - ISSS RIN CATEGORY)
WE tlOtl QA/QC WELDItlG TENNESSEE VALLEY AUTHORITY OFFICE OF tlUCLEAR POWER EHPLOYEE CDtlCERtl PROGRAH SYSTEtt (ECPS)
EHPLOYEE COIICERtl IIIFORtIATIOtl BY CATEGORY/SUBCATEGORY SUBCATEGORY< 50202 ItlSPECTIOtl OF IIELDS THROUGH CARBO-ZItlC PRIHER PAGE 32 RUW TINE llc45a02 RUII DATE - 12/17/87 CONCERN tlUHBER CAT SUB CAT S
H R PLT D LOC 1
REPORT APPL 2 SAF RELATED BF BL SQ IIB HISTORICAL COIICERH REPORT ORIGIN CONCERN DESCRIPTIOH Itl 458-00101 T50105 WE 50102 S
WBtl 02 WE 50202 5
WBH 03 WE 50302 S
WBN 06 WE 50602 S ftBtl IN 019-00101 T50219 WE 50102 S
WBtl 02 WE 50202 S
iIBW 03 WE 50302 S
WBtl 06 PIE 50602 5
WBII 1
Y H
H H
2 SS HA WA WA 1
H Y
tl tl 2
HA SS WA IIA 1 tl tl Y
H 2
HA HA SS IIA 1 tl W
tl Y
2 HA HA HA SS 1
Y tl H
tl 2
SR WA IIA HA 1
H Y
H H
2 IIA SR WA WA 1N tl Y
H 2
HA WA SR WA 1N tl H
Y 2
WA HA WA SR It(-85-458-001 QTC I
I QTC I
TVA USED INPROPER INSPECTION CRITERIA FOR AWS WELD S - HEIIO FROW KtlOXVILLE (POSSIBLY EIIDESp 1980 OR 1
981)
ALLOWED ItlSPECTIOH THROUGH PAIIIT.
It(DIVIDUAL FROH KNOXVILLE (KNOWN) INVESTIGATED THIS, BUT RES ULTS ARE UNKNOWN.
CI HAS NO WORE IHFORHATIOW. (SQ N ISSUES ADDRESSED IH RPT WP-02"SQW R2)
CI IS CONCERNED THAT WELDS WERE ACCEPTED THROUGH C ARBO-ZINC.
INSPECTORS IIERE DIRECTED VIA HEHO TO A
CCEPT IIELDS THROUGH PAINT.
CI COULD NOT PROVIDE A IIY ADDITIONAL IHFORHATION.
UtIIT 1.
CONSTRUCTION DEPT.
CONCERN.
(SQW ISSUES ADDRESSED IN RPT NP SQH R2)
NS 001-00101 T50022 02 03 06 WF.
50102 S
WBW 1
Y W
W H
2 SR IIA HA HA WE 50202 S
WBW 1
N Y
H H
2 HA SR HA WA WE 50302 S
WBH 1
N H
Y H
2 HA WA SR HA WE 50602 S
WBW 1
H H
N Y
2 WA WA WA SR HS-85-001-001 QTC WELDS (AWS) INSPECTED SUBSEQUENT TO PROTECTIVE COA TItlG (CARBOZIHC PRItIER) APPLICATIOtlJ FIHAL VISUAL IIELD EXAIIIHATIOH OF STRUCTURAL WELDS IH CATEGORY I STRUCTURES'tlCLUDItlG PIPE HANGERS'ABLE TRAY SU PPORTS AHD DUCT SUPPORTSJ UNIT 1
& 2 (SQW ISSUES A
DDRESSED IH RPT WP-02-SQH R2)
~
'))
L e II REFERENCE
- ECPS120J-ECPS121C FREQUENCY
- REQUEST OWP - ISSS RIIH CATEGORY) IIE tlOtl QA/QC IIELDIIIG.
TEtltlESSEE VALLEY AUTHORITY OFFICE OF NUCLEAR POllER EtIPLOYEE COIICERW PROGRAI< SYSTFtl (ECPS)
EHPLOYEE COHCERW 1WFORIIATIOH BY CATEGORY/SUBCATEGORY SUBCATEGORYi 50202 IIISPECTIOW OF IIELDS THROUGH CARBO"ZIIIC PRIHER PAGE 33 RUtl TINE lli65i02 RUW DATE - 12/17/87 CONCERN tlUHBER CAT SUB CAT S
H R PLT D LOC 1
REPORT APPL 2
SAF REI.ATED BF. BL SQ HB HISTORICAL CONCERN REPORT ORIGIN COtlCERH DESCRIPTIOW PH 040-00101 T50203 02 WE 50102 S
IIBW HE 50202 S
IPBH 03 HE 50302 S
HBN 04 HE 50602 S IIBtl 1 Y N
W W
2 SR WA WA IIA 1N Y
H tl 2 tIA SR WA WA 1 tl N
Y tl 2
WA tIA SR WA 1 tl W
tl Y
2 WA WA WA SR IW-85-658-001 QTC QA HAtlGERS HERE FREQUEtlTLY PAINTED BEFORE THE HELD S IIERE ItlSPECTED.
AUX. BUILDIIIGi REACTOR BUILDItIG ali ELEV. 742'-0" i 8 745'-0".
1983.
COIISTRUCTIO W DEPT.
CONCERN.
CI HAS WO FURTHER DETAILS. (SQII ISSUES ADDRESSED IH RPT HP-02-SQW R2)
I65)02 RUtl DATE 12/17/87 CONCERN tlUMBER CAT SUB CAT S
H R PLT D LOC 1
REPORT APPL 2 SAF RELATED BF BL SQ MB HISTORICAL CONCERN REPORT ORIGIN CONCERN DESCRIPTIOH HT 030-00801 T50185 llE 50319 S
ISBN ftI 061-00601 T50193 ME 50102 S
HBII 02 tIE 50202 S
HBII 03 IIE 50302 S
IPBII OC4 IIE 50CI02 S
HBH 02 tIE 50102 S
NBH 03 IIE 50202 S IIBH 04 IIE 50602 S IIBtl 1H tl Y
H 2
HA WA SR WA 1 Y tl tl W
2 SR HA tlA NA 1H Y
H tl 2
WA SR WA WA 1
N tl tl Y
2 WA WA WA SR 1
Y tl II.
tt 2
SS WA WA HA 1
W Y
tl II.
2 WA SS WA WA 1 tl tl Y
tl 2
WA IIA SS WA 1 tl tl tl Y
2 HA WA HA SS QTC EX-85-052-005 QTC THERE MAY HAVE BEEN THOUSANDS OF WELDS INSPECTED T
IIROUGH CARBO"ZINC PRIMER.
HOI<EVERi TVA REPORTS IH DICATE THAT OWLY 100-150 IPELDS HERE INSPECTED IH T
}IIS MAtlWER EVEN THOUGH THERE IS tl0 DOCUMENTATION I DEHTIFYIWG IIHICH IIELDS IIERE INSPECTED THROUGH CARB 0-ZIIIC PRIMER.
HUC.
POWER CONCERN.
CI HAS HO ADDI TIOHAL IWFORIIATIOW. (SQH ISSUES ADDRESSED 1H RPT II P-19-SQW R1)
AI<S IIELD INSPECTOR(S)
(UNKNOWN) DID HOT UHDERSTAIID THE "5 MIL" PROVISION FOR IIISPECTIOII OF COATED (C ARBO"ZINC PRIIIER) IIELDS AS CONTAINED IW REVISIONS OF SPECIFICATIOtl 0-29Cp PROCEDURE QCP-4.13, AtlD tlE IIORAIIDUII DATED tlOVEMBER 1981.
INSPECTOR(S)
RfFERR ED TO CRITERIA AS "MILLTAI'iPS"AtlD THEREFORE COULD tIOT HAVE Il'IPLEt'IEIITED/INSPECTED FOR COIIFORIIAHCE.
C I HAS IIO ADDITIONAL IWFORMATIOII.
IIUC POIIER DEPT.
CONCERN."(SQN ISSUES ADDRESSED IN RPT NP-02-SQH R2
)
III 041-00801 T50193 02 03 06 IIE 50102 S
WBH PIE 50202 S IIBH IIE 50302 S I)BII IIE 50402 S IIBtl 1
Y H
2 SS WA 1
H Y
2 WA SS tl H
HA tlA 1H tl 2
WA WA tl II WA HA H
H WA WA Y
tl SS WA tl Y
HA SS Itt-85-658-001 QTC PROCESS SPECIFICATIOH %3.C.5.6 OF G-29C PERMITTED IIISPECTIOH OF AMS NELDS THROUGH COATING (CARBO-ZItl C PRIIIER)
FOR ELEVEN MONTHS AFTER EWGIWEERIWG EVAL UATIOW/TEST SHOIIED THAT IIELD QUALITY (POROSTTY, CR
- ACKS, ETC)
COULD HOT BE INSPECTED TtIROUGH PAItlT.
WUC POIIER DEPT.
CONCERN.
CI HAS WO ADDITIONAL 1HF ORI'IATIOW. (SQW ISSUES ADDRESSED IW RPT IIP-02-SQII R
2) 9 CONCERNS FOR CATEGORY HE SUBCATEGORY 50202
REFERENCE ECPS120J-ECPS121C FREQUENCY
- REQUEST ONP - ISSS - RIIN CATEGORY'E tlON QA/QC HELDIIIG TENNESSEE VALLEY AUTHORITY OFFICE OF NUCLEAR POIIER ENPLOYEE COtICERtl PROGRAN SYSTEN (ECPS)
ENPLOYEE COIICERtl IIIFORI'IATTOII BY CATEGORYiSUBCATEGORY SUBCATEGORY 50203 IIELDER QUALIFICATIOW COtlTItlUlTY AT BLHP PAGE 35 RUH TINE - llsl5s02 RUW DATE - 12/17/87 CONCERN WUNBER CAT SUB CAT S
N R PLT D LOC 1
REPORT APPL 2 SAF RELATED BF BL SQ flB HISTORICAL REPORT CONCERN ORIGIN COtlCERtl DESCRIPTIOtl EX 021-00201 T50069 IIE 50103 S
flBW 02 tIE 50203 S IIBtl 03 IIE 50303 S
IIBW 04 IIE 50603 S IIBtl 1
Y W
tl tl 2
SR WA WA WA 1 tl Y
N tl 2
HA SR HA HA 1
W H
Y H
2 WA HA SR WA 1
W H
H Y
2 WA WA HA SR IN-85"552"001 QTC THERE IS tlO NETNOD/OBJECTIVE EVIDEtlCE TO VERIFY TH AT A IIELDER HAS USED A SPECIFIC PROCESS WHEW THEIR HELD CARDS ARE STAIIPED/UP-DATED BY QC.
WO FOLLOII
-UP REQUIRED -
HO ADDITIONAL 1NFORNATION AVAILABLE (SQW ISSUES ADDRESSED Itl RPT IIP-03-SQN R3)
IN 113"00301 T50020 WE 50203 S
NBH 02 tIE 50303 S
HBW 03 NE 50CI03 S
WBN 1
N Y
H W
2 HA SR HA HA 1ti WYH 2
HA WA SR WA 1tl W
H Y
2 WA HA HA SR IH-85-113-003, QTC; IIELDERS ONLY NAVE THEIR CERTIFICATION CARDS STANPE D EVERY 90 DAYS.
IIELDERS ARE NOT REQUTRED TO BURN ROD AWD HAVE IT INSPECTED IW ORDER TO NAIHTAIN TH EIR CERTiFICATION.
(SQW ISSUES ADDRESSED IW RPT IIP SQtl R3)
I W 335-00201 IH 60600 S flBtl 02 NE 50319 S
IIBW 03 IIE 50203 S
IIBW 06 IIE 50403 S
IIBW 1
W tl tl Y
2 HA WA WA HO 1 tl tl Y
tl 2
WA WA SR WA 1
W Y
W W
2 HA SR WA HA 1 tl tl tl Y
2 WA WA WA SR IW-85-335-002 QTC I<ELDERS OH "RESTRICTIOtlS" (tlOT ALLOIIED TO WELD) AR E TOLD TO KEEP THEIR CERTiFICATIONS UPDATED EVEN II ITHOUT USItlG THE PROCESS OR TTHE IW THE TEST SHOP
~
(IIANES ARE KWOlltl) (SQtl ISSUES ADDRESSED IH RPT II P-19-SQtl Rl )
Ci
~
~ p1 1'.
~
~I,
~
I,I I
, ~
~
~
E REFERENCE ECPS120 J-ECPS121C FREQUENCY
- REQUEST OIIP - ISSS RIIH CATEGORY s IIE tlOW QAiQC IIELDIIIG TENNESSEE VALLEY AUTHORiTY OFFICE OF tlUCLEAR POIIER EtlPLOYEE COtlCERW PROGRAH SYSTEH (ECPS)
EHPLOYEE COHCERtl IWFORIIATTOH BY CATEGORY/SUBCATEGORY SUBCATEGORY) 50203 IIELDER QUALIFICATIOW COWTItlUITY AT BLIIP PAGE 36 RUtl TINE - lli45~02 RUH DATE - 12r17i87 CONCERtl tlUHBER CAT SUB CAT S
H R PLT D LOC 1
REPORT APPL 2 SAF RELATED BF BL SQ IIB HISTORICAL REPORT CONCERN ORIGItl CONCERN DESCRIPTIOH I W CI26-00201 T50065 IIE 50103 S
IIBW 02 IIE 50203 S
IIBW 03 IIE 50303 S IIBtl 06 IIE 50403 S
IIDW iN 480-00401 T50031 HE 50103 S
WBH 02 IIE 50203 S
IIBW 03
)IE 50303 S IIBtl 04 flE 50603 S:IBH 1Y tl HH 2
SR WA WA WA 1
H Y
tl tl 2
WA SR HA WA 1
H W
Y H
2 WA HA SR WA 1
N tl tl Y
2 WA WA WA SR 1YHW tl 2
SR HA HA HA 1
W Y
N H
2 HA SR WA tIA 1
H H
Y H
2 HA HA SR HA 1 tl tl tl Y
2 WA WA HA SR IH-85-770-002 QTC WELDER CERTIFICATION UPDATE IS INADEQUATE.
PERSON HEL HAY IIORK IN A POSITION THAT DOES HOT REQU?RE A
HY HELDIHG FOR 5-6 YEARS BUT CERTTFICATIOHS ARE CO HTIWUALLY UPDATED.
tIHEN THESE PERSONS RETURN TO H ELDIWG HO TESTS ARE CONDUCTED.
THEY JUST RUH STRI ttGERS TO UPDATE CERTIFICATIOIIS. (SQtl ISSUES ADDRES SED Itt RPT IIP-03-SQtl R3)
Itl-85-352"001 QTC UPDATItlG OF WELDER CERTIFICATIOIIS IS It(ADEQUATE itt THAT A IIELDER IS OWLY REQUIRED TO PRESEHT THEIR C ARD FOR UPDATING AHD SONETIHES IS ASKED TO RUH A B
EAD" IIEVER A CONPLETE IIELD.
IIO FOLLOII-UP.
(SQN IS SUES ADDRESSED IW RPT IIP-03-SQII R3)
IH 725-X1501 T50167 IIE 50319 S
IIBW 04 IIE 50603 5
)IBW 02 IIE 50103 S
IIBW 03 IIE 50203 S
IIBW 1
W H
Y N
2 WA HA SR HA 1YWH tl 2
SR WA WA WA W
Y tl tl WA SR WA WA 1tl WHY 2
HA WA HA SR IH-85-725-X15 QTC THE CONTROL OF HELDER RECERTIFjCATION TEST PLATES IIAS IIIADEQUATEs TEST PLATES BEGUtl BY OWE IIELDER C OULD HAVE BEEII COHPLETED BY ANOTHER IIELDER.
DETAI L
KWOIIW TO QTC-IIITWELD TO HATHTAIW COIIFIDEHTIALITY o
(SQH ISSUES ADDRESSED IW RPT IIP-lg-SQII Rl)
REFERENCE
- ECPS120J-ECPS121C FREQUENCY
- REQUEST OHP " ISSS - RIIM CATEGORY> ltE tlOtl QA/QC llELDItlG TEWtlESSEE VALLEY AUTHORITY OFFICE OF tlUCLEAR POllER EMPLOYEE CONCERN PROGRAM SYSTEM (ECPS)
EMPLOYEE COtlCERH IWFORllATIOW BY CATEGORY/SUBCATEGORY SUBCATEGORY 50203 IlELDER QUALIFICATIOW COWTItluITY AT BLNP PAGE 37 RUtl TIME - 11)45)02 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 llB HISTORICAL REPORT CONCERN ORIGIN CONCERN DESCRIPTIOW IN 940-X0401 T50258 llE 50203 S IIBtl 02 llE 50303 S
IIBW 03 IIE 50CI03 5
ltBW 1 tl Y
N tl 2
WA SR WA WA 1
W W
Y W
2 HA WA SR WA 1 tl tl W
Y 2
WA WA WA SR QTC UtlTIL RECENTLY' ltELDER COULD HAVE NELDItlG CERTIF ICATIOtlS UPDATED BY MERELY HAVING THE CERTIFICATIO W CARD INITIALED BY Atl ItISPECTOR.
THIS PRACTICE M
AY WOT HAVE ASSURED THAT THE UPDATE lIAS BASED OH 0 BJECTIVE EVIDEtlCE OF UTILIZATIOtt OF THE REQUIRED P
ROCESS IIITHIN THE SPECIFIED TIME PERIOD.
COWSTRUC TIOtl DEPARTHEtlT COtlCERtl.
CI HAS tlO FURTHER ItlFORl'l ATIOW.
(SQW ISSUES ADDRESSED IN RPT IIP-03-SQN R3)
JLH-85-002 01 IIE 5012CI S
SQW 1
Y N
W N
2 SS WA WA WA 02 ME 50203 S
SQN 1
H Y
W W
2 WA SS WA WA 03 tlE 50324 S SQtl 1
H tl Y
tt 2
WA WA SS WA 06 IIE 50624 S
SQtl 1 tl tl tl Y
2 WA WA WA SS 8
CONCERNS FOR CATEGORY lIE SUBCATEGORY 50203 OECP THIS CONCERN WAS NOT DOCUMENTED PER SQA166 BUT HAS BEEtl INCLUDED Itl THE EMPLOYEE COWCERtl LOG.
flELDE RS FROM MUSCLE SHOALS MAY tlOT HAVE RECEIVED THE AP PROPRIATE tlUllBER OF BEtlD TESTS llHEtl TAKIttG IlELD QU ALIFICATIOW TESTS.
(SQW ISSUES ADDRESSED IN RPT MP SQtt RO)
REFERENCE ECPS120 J "ECPS121C FREQUENCY
- REQUEST OIIP - ISSS - RIIN CATEGORY kIE NOW QA/QC HELDTHG TEWIIESSEE VALLEY AUTHORITY OFFICE OF NUCLEAR POIIER EHPLOYEE COHCERII PROGRAH SYSTEI'I (ECPS)
EtIPLOYEE COWCERtt ItlFORNATIOH BY CATEGORY/SUBCATEGORY SUBCATEGORY'0204 IIISPECTIOtl TOOLS AT BLtlP PAGE 38 RUtl TIIIE - lli%5) 02 RUII DATE - 12/17/87 COtlCERtl IIUIPBER SUB CAT CAT S
N R PLT D I.OC
- 1 REPORT APPL 2 SAF RELATED BF BL SQ IIB HISTORICAL REPORT CONCERN ORIGIN CONCERN DESCRIPTIOH IH 007-00101 T50001 IIE 5010CI S
IIBW 02 IIE 50204 S IIBtl 03 IIE 50306 S
WBII 04 IIE 50604 S flBN 1
Y H
N W
2 SR WA WA WA 1WYH tl 2
WA SR WA WA 1H H Y,H 2
WA WA SR HA 1
H H
H Y
2 HA WA WA SR QTC INSPECTION TOOLS FOR NELDIWG INSPECTORS HERE NEVER ISSUED.
I ~ E. FILLET IIELD SIZE GAGES, FIT"UP GUAG ESe ETC (SQtl ISSUES ADDRESSED Itl RPT NP-04-SQtt R2
)
5010CI S
02 IIE 50206 S
03 flE 50306 S
OA IIE 50606 S
IN 13%"00201 HE T50050 IIBII IIBII HBII WBW 1Y H
H tl 2
SS WA HA WA 1
H Y
H H
2 HA SS HA WA 1
H tl Y
tl 2
HA WA SS HA 1tl W
H Y
2 WA WA WA SS QTC UNTIL RECENTLY (PAST 2 YEARS)i TVA DID HOT PROVIDE QC INSPECTORS HITN HELDIWG iNSPECTION TOOLS.
Sott E INSPECTORS PROVIDED THEIR OIHI TOOLS BUT OTHERS D
ID HOT.
CI HAS PASSED AIAAYi IIO FURTHER DETAILS AV AILABLE. (SQII ISSUES ADDRESSED IW RPT IIP-OCI-SQH R2
)
50104 S
02 flE 50206 S
03 WE 5030CI S
04 IIE 50401 S
Itl 606-00301 IIE T50013 IIBH NBII IIBN WBII 1
Y tl tl tl 2
SS WA WA WA 1H Y
H tl 2
WA SS WA WA 1 tl tl Y
H 2
WA WA SS HA 1 tl tl W
Y 2
HA IIA IIA SS QTC PRIOR TO 1979'O HELD INSPECTION TOOLS IIERE ISSUE D
TO INSPECTORS.
(SQH ISSUES ADDRESSED IH RPT WP-0 A"SQII R2) 3 COtlCERIIS FOR CATEGORY IIE SUBCATEGORY 50204
REFERENCE
- ECPS120J-ECPS121C FREQUENCY
- REQUEST OWP - ISSS - RIIH CATEGORY'lE tlON QA/QC YIELDING TEHtlESSEE VALLEY AUTHORITY OFFICE OF NUCLEAR POIIER EHPLOYEE CONCERN PROGRAH SYSTEH (ECPS)
EHPLOYEE CONCERN IHFORHATIOH BY CATEGORY/SUBCATEGORY SUBCATEGORY: 50206 INSPECTOR QUALIFICATIOH AT BLHP PAGE 39 RUtl TINE.,"
1 1 s 65 i 02 RUII 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 H 1 STOR ICAL REPORT CONCERN ORIGIII CONCERN DESCRIPTIOH IN 476-00602 T50037 1lE 50206 S IIBII 03 HE 50106 S IIBN 0%
IIE 50306 S IIBtl 05 HE 50406 5
HBW IN 981-00102 T50111 IIE 50206 S
HBW 03 IIE 50106 S IIBN 06 IIE 50306 S IIBtl 05 IIE 50406 S IIBII 1.H Y
H H
2 WA SR WA IIA 1Y N
H tl 2
SR WA HA WA 1 tl tl Y
tl 2
WA HA SR WA 1II H
N Y
2 WA WA IIA SR 1II YHH 2
HA SR IIA WA 1Y tl H
H 2
SR HA HA WA 1
H H
Y H
2 WA WA SR WA 1II W
H Y
2 WA WA WA SR EX-85-052-005 QTC EX-85-052"005 QTC APPROX. 1980'VA IIIPLEHEHTED A HELDIIIG INSPECTORS TRAIHIWG PROGRAH AWD PEOPLE WITH A GROCERY CLERK BACKGROUND HERE INSPECTING IIELDS HITHIH THO HEEKS.
(SQtl ISSUES ADDRESSED III RPT HP"06-SQH RO)
HELD?IIG INSPECTORS HERE INADEQUATELY TRA1NED PIROR TO 198li I.E.i PERSOtltlEL IIITH HO EXPERIEIICE ?tlVOL VIHG IIELDING HERE SENT TO A TIIO IIEEK TRAIHIHG CLAS S
AIID THEW FUIICTIOHED AS A HELDIIIG INSPECTOR.
CI HAS IIO IIORE ?HFORHATIOH.
HO FOLLOII UP REQUTRED.
(
SQII ISSUES ADDRESSED IH RPT WP-06-SQH RO)
HI "85-061-00202 T50103 IIE 50206 S IIBH 03 IIE 50106 S IIBII 06 PIE 50306 S IIBtl 05 HE 50606 S IIBH W
Y tl tl' WA SS HA WA 1
Y tl tl tl 2
SS WA WA WA 1
H H
Y W
2 HA HA SS.WA 1
W H
W Y
2 WA HA IIA SS EX-85-052-005 QTC QUALIFICATIOII/TRAIIIIHGOF 1tlSPECTORS FOR STRUCTURA L (AI'IS) I'IELD VISUAL EXAIIIIIATIONIS QUESTIOIIABLE) L EVEL TI CERTIFICATIOII IS GRAIITED HITH OWLY TIIO HOH THS. OF OJTi HHICH IS HOT DOCUHEIITED) THE TOPICAL R
EPORT HAS "BAStARDIZED" AtlSI HA5.2.6, REGARDIHG QU ALIFICATIOH OF IIISPECTIOW/EXAIIIIIATIOIIPERSOtlWEL
~
CI HAS tlO FURTIIER IIIFORHATIOW.
tlO FOLLOII UP REQUI RED.
(SQII ISSUES ADDRESSED IH RPT IIP-06-SQtl RO)
UI REFERENCE
- ECPS120J-ECPS121C FREQUENCY
- REQUEST OHP " ISSS -
RI1N CATEGORY ltE HOW Qa/QC IIELDING TENNESSEE VALLEY AUTHORITY OFFICE OF NUCLEAR PollER ENPLOYEE CotlCERtl PROGRAH SYSTEH (ECPS)
ENPLOYEE COHCERtl IHFORllATION BY CATEGORY/SUBCATEGORY SUBCATEGORY) 50206 ItlSPECTOR QUALIFICATIOH AT BLHP PAGE 60 RUtl TINE - lls45a02 RUH DATE " 12/17/87 CONCERN IIUNBER CAT SUB CAT S
H R PLT D LOC 1
REPORT APPL 2 SAF RELATED BF BL SQ llB HISTORICAL CDHCERtl REPORT ORIGIN COHCERN DESCRIPTION 1 tl Y
N tl 2 lIA SR HA HA lY tl N
H 2
SR HA HA lIA HI 081-00702 lIE 50206 T50237.
S l.IBII 03 HE 50106 S HBtt 04 llE 50306 S llBH 05,HE 50606 S
PIBtt 1H tl Y
H 2 tIA HA SR HA ltl HNY 2 lIA HA tIA SR 5 CotICERHS FOR CATEGORY HE SUBCATEGORY 50206 I
XX 107-00101 HE 50206 H BLH 1
H Y
N N
T50185 2 IlA SR HA lIA EX-85-052"005 QTC.
CI EXPRESSED THAT HELDING INSPECTORS ARE HOT QUALI FIED FOR THE JOB.
CI STATED THAT AN INSPECTOR HEE DED TO BE A HELDER SO THE INSPECTOR IloULD KWON IIHA T TO LOOK FOR IH A GOOD IIELD.
CI DECLIlIED TO PROV IDE AtlY ADDITIONAL IHFORNATIOH.
CONSTRUCTION DEPA RTllEtlT CotlCERtl.
tlo FOLLOW UP REQUIRED.
(SQtt ISSUE S
ADDRESSED IH RPT HP-06-SQH RO)
QTC BELLEFotlTE - HELDItlG INSPECTORS AT BELLEFOHTE Do tl OT APPEAR TO BE KlIONLEDGEABLE ABOUT HELDIHG.
Colts TRUCTIOH DEPT.
CONCERN.i CI HAS tlo ADDITIotlAL ItlFO RUAT I ott.
REFERENCE
- ECPS120J-ECPS121C FREQUEtlCY REQUEST OHP ISS 5 RI IN CATEGORYs flE tlOII QA/QC flELDItlG TEIIIIESSEE VALLEY AUTHORITY OFFICE OF tlUCLEAR POIIER EHPLOYEE COtlCERtl PROGRAH SYSTEM (ECPS)
Et'IPLOYEE CONCERN IWFORHATIOH BY CATEGORY/SUBCATEGORY SUBCATEGORYs 50207 WELDER TRAItlltlG/EXPERIEtlCE AT BLHP PAGE
ss1 RUtl TINE - llsss5s02 RUII DATE - 12/17/87 CONCERN IIUHBER CAT SUB CAT S
H R PLT D LOC 1
REPORT APPL 2
SAF RELATED BF BL SQ WB HISTORICAL COHCERII REPORT ORIGIN CONCERN DESCRIPTIOH EX 008-00101 T50051 WE 50107 S flBtl 02 WE 50207 S 'WBH 03 WE 50307 S
WBW Oss WE 50ss07 S IIBtl IH 706-00101 T5006ss WE 50107 S
WBH 02 WE 50207 5
WBII 03 WE 50307 S
WBH Oss WE 50ss07 S flBtl IN 158-00601 T50180 WE 5031ss S
WBW 03 WE 50207 S lISH Oss IIE 50ss07 S
I.IBII 1
Y H
H N
2 SR WA tIA IIA 1 tl Y
tl tl 2
HA SR HA HA H
tl Y
H 2
HA WA SR IIA ill H
H,Y 2
HA WA IIA SR 1
Y tl H
tl 2
SR WA WA WA 1
H Y
H H
2 HA SR HA HA 1
H H
Y H
2 HA WA SR HA 1 tl Il tl Y
2 HA HA IIA SR 1
H tl Y
tl 2
HA WA. SR WA 1Y tl H
H 2
SR IIA IIA IIA 1
H Y
tl tl 2
HA SR WA HA 1 tl tl tl Y
2 WA WA WA SR EX-85-010-002 QTC SUBJOURIIEYHEN USED TO DO WORK THAT THEY'E HOT QUA LIFIED TO DOs THEY tlEEDtl'T HAVE ANY SPECIFIC TRAI IIIIIGi BUT DO WORK (EG PIPE FIT-UPS AHD WELDS ON 1/
6" LItlES) HORIIALLY DOHE BY A JOURtlEYtlatl WITH 5 YEA RS IIIHIHUH EXPERIEIICE.
SUBJOURHEYHEW REQUIRE CLOS ER TECHIIICAL SUPERVISIOH THAW TVA PROVIDES.
IIHEH CRAFTS COIlPLAI!l, THEY ARE "CHEWED OUT" BEYOND ALL REASOIIABLE LIHITS.
NO 140RE DETAILS KtlOWN.
(SQW IS SUES ADDRESSED IN RPT WP-07-SQN Rl)
QTC UNTIL 1973 TVA DID NOT LET THEIR APPRENTICESHIP PE OPLE WELD.
DURING THAT YEAR, EVEN WITH TWO OR THR EE HOttTIIS EXPERIEtlCE, AN APPREIITICE COULD TAKE THE TESTi
- PASS, AHD BE ABLE TO IIELD IN THE FIELD.
TH E SYSTEN HAS WORKED THAT WAY EVEtl SINCE 1973.
COII ST.
DEPT.
CONCERN.
C/I HAS HO FURTttER IIIFORHATIOtl (SQH ISSUES ADDRESSED IH RPT WP-Iss-SQN Rl)
QTC WELDERS WHO WEtlT THROUGH TVA'S WELDER TRAItlItlG PRO GRAII WAVE ItlSUFFICIEHT TRAIIIIIIG AHD EXPERIENCE TO HANDLE ALL VARIABLES ItlVOLVED TO PERFORN ADEQUATE IIELDS FOR A tlUCLEAR INSTALLATIOtl.
THIS It(ADEQUACY HAS CREATED A LOT OF REIIORK.
CI HAS tlO IGNORE DETA ILS.
(SQH ISSUES ADDRESSED IN RPT WP"07-SQII Rl)
REFERENCE ECPS120 J-ECPS121C FREQUENCY REQUEST OWP ISSS - RHN CATEGORYi IIE tlOH QAJQC HELDItlG TEHtIESSEE VALLEY AUTHORITY OFFICE OF tlUCLEAR POllER ENPLOYEE COHCERtl PROGRAH SYSTEH (ECPS)
Et4PLOYEE COtlCERN ItlFORHATIOtl BY CATEGORY/SUBCATEGORY SUBCATEGORY s 50207 l4EL DER TRAIttIttG/EXPERIEllCE AT BLtlP PAGE 62 RUtl TINE - lls65s02 RUtl DATE - 12rl7i87 CONCERN ttUHBER CAT S
H SUB R PLT CAT D LOC 1
REPORT APPL 2
SAF RELATED BF BL SQ flB HISTORICAL REPORT CONCERN DRIGIW CONCERN DESCRIPTIOH XX 045-00101 T50075 t4P 71701 S
BLN 02 HE 50207 S
BLW 03 tlE 50307 S
BLN 1HHW tl 2
HA HA HA HA 1 tl Y
tl tl 2
WA SR WA lIA 1 tl tl Y
N 2 IlA IlA SR WA QTC BELLEFONTE-TVA POLICY ALLOHS FOR PERSOHEL TO BE SE tIT TO THE TEST SHOP AHD IN A SHORT TINE BE CERTIFI ED AS AW ELECTRICAL ilELDER.
THESE l4ELDERS DO PASS A STRICT TEST BUT THE TEST DOES NOT TEST THEIR AB ILITY WHEW DEALING WITH ALL THE VARIABLES AH EXPER IEHCED llELDER CAtl HANDLE.
ItlSUFFICIEWT llELDER TRA ItlIWG. (SQH ISSUES ADDRESSED IN RPT HP-07"SQH Rl)
CI CONCERNS FOR CATEGORY HE SUBCATEGORY 50207
REFEREHCE
- ECPS120J-ECPS121C FREQUENCY
- REQUEST OtlP - ISSS - RNt<
CATEGORYs flE HOH QA/QC ttELDING TEWtIESSEE VALLEY AUTHORITY OFFICE OF NUCLEAR POllER ENPLOYEE CONCERN PROGRAt) SYSTEN (ECPS)
ENPLOYEE COtlCERtl IWFORNATIOtl BY CATEGORY/SUBCATEGORY SUBCATEGORY s 50210 IllPLEllftlTATIOtlOF QAE"2 AT BLtlP PAGE RUN TIttE - I 1 s ss 5 s 02 Rutl DATE - 12/ll/87 S
H SUB R PLT CONCERN ttUNBER CAT CAT D LOC 1
REPORT APPL 2 SAF RELATED BF BL SQ NB HISTORICAL REPORT CONCERN ORIGIN CONCERN DESCRIPTIOH XX 110-00101 NE 50210 H
BLW T50187 1 tl Y
N tl 2
WA SR HA WA QTC
= BELLEFOtlTEs IIELDING AHD NDE PROGRAN CORRECTIVE ACT IOtl.
AS IDEtlTIFIED Itl OEDC QUALITY ASSURAtlCE EVAL UATIOW tlO.
QAE-2p DATED SEPTENBER 1980'lAY NOT NA VE BEEN II'1PLEtlEtlTED FOR BELLEFOtlTEt THE SAI'lE/UtlCOR RECTED PROBLEtlS l'IERE FOUtlD TO EXIST YEARS LATERs A
HD tIAY STILL EXIST TODAY.
CI HAS HO ADDITIONAL IW FORllATION.
HUC PllER DEPT COtlCERtl.
1 CONCERNS FOR CATEGORY NE SUBCATEGORY 50210
REFERENCE
- ECPS120J-ECPS121C FREQUENCY
- REQUEST ONP - ISSS - RIIM CATEGORY IIE NON QA/QC IIELDItlG TEWtlESSEE VALLEY AUTHORlTY OFFICE OF IIUCLEAR POHER EMPLOYEE CONCERN PROGRAM SYSTEM (ECPS)
EMPLOYEE COIICERH IWFORMATIOtl BY CATEGORY/SUBCATEGORY SUBCATEGORY) 50213 IIELDItlG EQUIPMEHT AWD BOTTLED GASES AT BLHP PAGE RUN TIME - lli45i02 RUII DATE - 12/17/87 CONCERN NUMBER CAT SUB CAT 5
H R PLT D LOC 1
REPORT APPL 2 SAF RELATED
, BF BL SQ IIB HISTORICAL COtlCERH REPORT ORIGIII CONCERN DESCRIPTIOII IN 2CI7-00201 T50022 flE 50113 5 IIBII 02 IIE 50213 S
I4BW 03 IIE 50313 S
IIBW 1Y II N
W 2
SR WA WA WA 1
W Y
W W
2 WA SR tIA WA
.1 tl II Y
W 2
WA WA SR WA QTC IIELDItlG MACHIHES (MCKAY & HOBART) USED Itl FIELD BY STEAII FITTERS HAVE 2 SETTINGS 50
& 100 AMPS BOTH OF IIWICH ARE UNSUITABLE FOR YIELDING WITH 3/32" ROD THIS CONTRIBUTES TO POROSITY AHD PINHOLES.
(SQW ISSUES ADDRESSED IW RPT HP-13-SQII RO) 06 HE 50613 S
WBII 1
N tl H
Y 2
HA WA WA SR IH 303-00101 T50 021 IIE 50113 S
WBtt
)IE 50613 S IIBII 02 IIE 50213 S
WBII 03 IIE 50313 S
HBH 1Y tl H
H 2
SR WA HA IIA 1'i Y
N H
2 WA SR WA WA
'1N H
Y H
2 WA WA SR.WA 1 tl tl tl Y
2 WA WA WA SR QTC,.
ALL THE MELDING MACHINES SHOULD HAVE REMOTE SNITCH ES SO THAT THE TUNGSTEN TIP DOEStl'T HAVE TO TOUCH THE BASE METAL TO START THE HELD.
PRESEtlTLY THE N
Otl-HOBART IPELDERSi ilHEH USED, MAY CAUSE TUtlGSTEtl T 0
BE LEFT IH THE IIELD. (SQN ISSUES ADDRESSED IH RP T IIP-13-SQH RO)
XX -85"068-00801 flE T50138 50213 W
BLW 1
H Y
H H
2 WA SR WA WA QTC BELLEFOtlTE COHCERtlS OVER THE CLEAIILIIIESS/PURITY OF BOTTLED GAS USED Itl HELDItlG AWD PtlEUMATIC TESTI WG HERE EXPRESSED BY tlRC TIISPECTOR IW 1982-1983.
IIO CORRRECTTVE ACTIOtl IS KtlOIIW TO HAVE BEEtl TAKEN.
DETAILS KtlOIIH TO QTCi IIITIIELD DUE TO COIIFlDEIITIA LITY.
COtlSTRUCTIOtl DEPT.
COIICERtl.
CI HAS tlO FURT HER IHFORAMTIOH.
WO FOLLOH UP REQUIRED.
3 CONCERNS FOR CATEGORY HE SUBCATEGORY 50213
REFEREIICE
- ECPS120J-ECPS121C FREQUEtlCY
- REQUEST OHP - ISSS - RIIH CATEGORY'E HOH QA/QC flELDING TENNESSEE VALLEY AUTHORITY OFFICE OF NUCLEAR POINTER EHPLOYEE CotlCERH PROGRAH SYSTEH (ECPS)
EHPLOYEE CONCERN IHFORtlATIOH BY CATEGORY/SUBCATEGORY SUBCATEGORY) 50216 STRUCTURAL STEEL PREIIELD IWSPECTIotl AT BLtlP PAGE 45 RUH TINE " lls45s02 RUII DATE - 12/17/87 CONCERII IIUHBER CAT SUB CAT S
H R PLT D LOC 1
REPORT APPL 2
SAF RELATED BF BL SQ IIB HISTORICAL CONCERN REPORT ORIGIN CotlCERN DESCRIPTIotl BEH-85-001-00101 T50227 IIE 50116 S
BLH 02 HE 50216 S
BLW 03 HE 50316 S
BLN 04 PIE 50416 S
BLH 1
Y tl N
tl 2
SR HA WA WA 1
H Y
H H
2 HA SR HA WA 1
N W
Y W
2 NA WA SR HA 1
W W
H Y
2 HA WA HA SR QTC BELLEFOHTE - THE GEtlERAL CONST.
SPEC.
O.C.1.1 IS IH CONFLICT HITN THE TVA QUALI TY ASSURANCE COHHITHEWTS AS STATED BY TNE TVA TOPI CAL REPORTS TVA-TR75"IAAF Itl THAT PROCESS SPEC.
O.C
.1.1p SECTION 6.0 ALLOIIS UNCERTIFIED WELDER FOREHE tip IIHO NAVE DIRECT RESPOtlSIBILITY FOR THE IHSTALLA
- TIOII, TO PERFORH PREIIELD INSPECTIONS.
NUCLEAR PON ER CONCERN.
CI HAS WO FURTHER IHFORHATIOH. (SQtl I SSUES ADDRESSED IW RPT NP-16-SQH R2)
BEH-85"001-00201 T50227 HE 50116 S
BLN 02 HE 50216 S
BI.W 03 IIE 50316 S
BLW 1 Y tl tl tl 2
SR WA WA WA 1 tl Y
tl tl 2
HA SR HA WA 1
H H
Y W
2 WA HA SR WA QTC BELLEFotlZE UtlCERTIFIED IIELDER FOREHEN ARE REQUIR ED BY TVA TO PERFORH PREHELD IIISPECTIOHS OH IHSTAL LATIOHS THEY ARE DIRECTLY RESPONSIBLE FOR IIHICH IS A VOILATIOH OF ANSI REQUIREHEtlTS.
NUCLEAR POllER CONCERN.
CI HAS Ho FURTHER IHFORIIATION. (SQH ISSU ES ADDRESSED Itl RPT NP-16 "SQtl R2)
BFH-85-001-00101 T50221 02 flE 50116 S
BLH IIE 50216 S
BLH 03 IIE 50316 S
BLW 04 I<E 50416 S BLtl 04 IIE 50416 S
BI.W H
H WA WA 1
Y H
2 SR WA 1
H Y
2 WA SR W
Y HA SR tl W
HA tIA H
H WA WA H
H HA WA H
Y WA SR 1
H W
Y W
2 WA HA SR WA QTC BELLEFotlTE TtlE GEtlERAL CotlST.
SPEC.
G-29Cp PROCE SS SPEC.O.C.1.1 IS IH CONFLICT WITH THE TVA QUALIT Y ASSURANCE COHttITHEHTS AS STATED BY TIIE TVA TOPIC AL REPORTS TVA-TR75-IAAF Itl THAT PROCESS SPEC.
O.C.
1 1 z SEC II OH 6 0
ALLOllS UWCERTI FIED I'IELDER FORHEWe IIHO WAVE DIRECT RESPONSIBILITY FOR THE IHSTALLATIO lt, TO PERFORII PREIIELD INSPECTIONS.
NUCLEAR POIIER CONCERN.
CI HAS WO FURTHER IWFORHATIOH. ~ (SQW ISSU ES ADDRESSED IW RPT IIP-16-SQN R2)
REFERENCE ECPSI20J-ECPS121C FREQUENCY
" REQUEST OHP ISSS - RlIM CATEGORY'lE tlOtl QA/QC llELDItlG TEtIHESSEE VALLEY AUTHORITY OFFICE OF ltUCLEAR POWER EMPLOYEE COtlCERtl PROGRAM SYSTEM (ECPS)
EMPLOYEE CONCERN ItlFORltATIOtl BY CATEGORY/SUBCATEGORY SUBCATEGORYa 50216 STRUCTURAL STEEL PREIIELD IHSPECTIOtl AT BLNP PAGE
46 RUH TItkE - lls45c02 RUH DATE - 12/17/87 CONCERN NUMBER CAT S
M SUB R PLT CAT D LOC 1
REPORT APPL 2 SAF RELATED BF BL SQ llB HISTORICAL REPORT CDHCERtt ORIGIN CONCERN DESCRIPTIOH BFM-85-001-00201 T50221 HE 50116 S
BFH 02 ME 50216 S Bjtl 03 llE 50316 S
BFH 06 flE 50016 S BFtl 1Y W
H tl 2
SR WA WA WA 1 tl Y
N tl 2
HA SR WA WA 1 tl tl Y
H 2
HA WA SR WA 1N tl H
Y 2
WA HA WA SR QTC BROHtl'S FERRY - UNCERTIFIED FIELDER FOREMEN ARE REQ UIRED BY TVA TO PERFORM PRE-IIELD ItlSPECTIOtlS Otl IH STALLATIONS THEY ARE DIRECTLY RESPONSIBLE FOR NHIC H IS A VIOLATIOtl OF AtlSI REQUIREtlENTS.
NUCLEAR PO IIER COHCERH.
CI HAS tlo FURTHER INFORMATION. (SQW ISSUES. ADDRESSED Itl RPT MP-16-SQN R2)
IH 026-00101 T50002 02 IN "85-212-00101 T50152 02 03 HE 50216 S
NBH 1
N Y
H H
2 HA SR HA HA llE 50616 S
t<&tt 1
N tl tl Y
2 HA WA WA SR llE 50216 S lt&H 1 tl Y
2 HA SR IlE 50316 S
MBH 1
W H
2 HA HA tl tl WA tlA Y
H SR WA HE 50616 S N&tl 1 tl H
H Y
2 WA WA WA SR I-85-108-l IIITtlHELD DUE TO COtlFIDEHTIALITY.
tlo FOLI.OlIUP REQUIRED.
(SQH ISSUES ADDRESSED IH RP T lIP-16-SQH R2)
Itl 682-00201 NE 50216 S
NBH 1
H Y
H H
T50116 2
HA SR HA WA 02 lIE 50CI16 S
MBH 1
W H
H Y
2 WA WA WA SR QTC ANS llELD INSPECTION METHOD IS QUESTIONABLE.
EXAMP LEs AMS IIELDS ARE ItlSPECTED FOR VISUAL FINAL APPEA RAtlCE OWLY (REFT QCP 6.13 VTC).
HO FITUP OR FULL PEHETRATIOtl IHSPECTIOWIS PERFORMED OTHER THAW BY T ItE CRAFT.
EXAttPLEi 050 tlOTES ALLOll 100%
OVER Otl A
LL FILLET MELDS AWD LENGTH IS TO BE DETERMINED BY flELDER.
COtlSEQUEWTLY NltEII DRAWIt!G REQUIRES 2 SIDE S
OF SQUARE TUBItlG TO BE llELDED AtlD WELDER IIELDS T HE IIROtlG 2 SIDES, HE GOES BACK AtlD llELDS THE OTHER 2 SIDES THUS tIAKIWG AH ALL AROUND IIELD lIHICH IS tl
REFERENCE
- ECPS120J-ECPS121C FPEQUEHCY REQUEST OtlP ISSS -
RWN CATEGORYi IIE tlOtl QA/QC IIELDIWG TENNESSEE VALLEY AUTHORITY OFFICE OF tlUCLEAR POllER EHPLOYEE CONCERN PROGRAI'I SYSTEN (ECPS)
EHPLOYEE CONCERN IHFORIIATIOW BY CATEGORY/SUBCATEGORY SUBCATEGORY'0216 STRUCTURAL STEEL PREIIELD IIISPECTIOII AT BLIIP PAGE
ci7 RUtl TINE lls45s02 RUW DATE " 12/17/87 CONCERN WUNBER CAT SUB CAT S
H R PLT D I.OC 1
REPORT APPL 2
SAF RELATED BF BL SQ WB HISTORICAL REPORT COHCERtl ORIGIN CONCERN DESCRIPTIOH WBH-85-001-00102 T50227 WE 50116 S
WBW 03 WE 50216 S
WBN 06 WE 50316 S flBtl 05 WE 50616 S flBH 1Y H
H tl 2
SR WA HA WA 1N Y
~ tl H
2 WA SR HA WA 1
H H
Y tl 2
WA WA SR WA 1
H tl W
Y 2
HA WA WA SR QTC WATTS BAR - THE GENERAL COtlST.
SPEC.
G-29Cp PROCES S
SPEC.
O.C.1.1 IS IH CONFLICT WITH THE TVA QUALIT Y ASSURANCE CONHITtIEHTS AS STATED BY THE TVA TOPIC AL REPORT, TVA-TR75-IAp IN THAT PROCESS SPEC.
O.C.
l.li SECTION 6.0 ALLOWS UNCERTIFIED WELDER FOREHEII fllIO HAVE DIRECT RESPONSIBILITY FOR THE IIISTALLAT IOIIi TO PERFORN PREWELD INSPECTIONS.
NUCLEAR PONE R CONCERN.
CI HAS HO FURTHER IWFORHATION. (SQW IS SUES ADDRESSED IH RPT WP-16-SQH R2)
WBN-85-001-00201 T50227 02 03 06 flE 50116 S
SQtl WE 50216 S
SQtl WE 50316 S
SQH WE 50416 S
SQN 1
Y H
H H
2 SR WA WA HA 1 tl Y
tl tl 2
WA SR HA WA 1
H H
Y H
2 WA HA SR WA 1 tl tl H
Y 2
WA WA HA SR QTC SEQUOYAH UNCERTIFIED WELDER FOREHEII ARE REQUIRED BY TVA TO PERFORN PREWELD INSPECTIONS OH IHSTALLA TIOHS THEY ARE DIRECTLY RESPONSIBLE FOR WHICH IS A
VIOLATION OF Atlsl REQUIREMENTS.
NUCLEAR POllER CO HCERH.
CI WAS HO FURTHER ItIFORNATIOH. (TRAHSFERRE D TO WBH"85"001-003, COtlCERW WAS ADDRESSED BY WELD IWG CATEGORY BEFORE TRANSFER WAS DOCUIIENTEDi AtlD W ILL HOT BE INPUT TO GH CATEGORY, SQH ISSUES ADDRES SED IW RPT WP-16-SQW R2)
WI 030-00?01 T50185 WE 50116 S
WBII 02 WE 50102 S
WBII 03 WE 50216 S
WBH OCI WE 50316 S
IIBW 05 flE 506]6 S
WBtl 06 flE 50202 S
FIBW 08 WE 50402 S
WBII r
1 Y
tl tl tl 2
SR IIA HA WA 1Y tl WH 2
SR WA WA WA 1H Y
H tl 2
WA SR WA WA ill WYW 2
WA WA SR WA 1
H H
W Y
2 WA WA WA SR 1 tl Y
tl W
2 WA SR WA WA 1H tl N
Y 2
WA HA WA SR QTC THE I'IBH FSAR.COIIMITS TVA TO THE REQUIREHEtlTS OF AW S D.l.l FOR STRUCTURAL WELDING.
CONTRARY TO THESE REQUIREHEIITSi THE G-29C PROCESS SPECIFICATIOtl WAS tlODIFIED TO REFLECT LESS STRItlGEIIT ItlSPECTIOW REQ UIREHEHTS (E.G.
VISUAL INSPECTION OF IIELDS THROUGH PAINT (CARBO ZINC PRIHER)
AWD HO DOCUNENTED IWSPE CTIOtl BY CERTIFIED VISUAL IIISPECTORS (FIT-UP, Itl-P ROCESS)
PRIOR TO FINAL IIISPECTIOW.) CI HAS WO ADDI TIOWAL IWFORNATIOH.
HUC.
POWER DEPT.
CONCERN
~
(SQ W ISSUES ADDRESSED IH RPT IIP-16-SQW R2)
10 COIICERIIS FOR CATEGORY IIE SUBCATEGORY 50216
REFERENCE
- ECPS120J-ECPS121C FREQUEtlCY
- REQUEST ONP - ISSS - RIIH CATEGORY'E NOtl QA/QC NELDItlG TEtltlESSEE VALLEY AUTHORlTY OFFICE OF tlUCLEAR POHER EHPLOYEE COWCERII PROGRAH SYSTEH (ECPS)
EHPLOYEE COtlCERII IIIFORHATIOII BY CATEGORY/SUBCATEGORY SUBCATEGORY'0234 IIELD QUALITY AT BLtlP PAGE 48 RUW TTME - lls45s02 RUH DATE 12/17/87 CONCERN WUHBER CAT SUB CAT 5
H R PLT D LOC 1
REPORT APPL 2
SAF RELATED BF BL SQ IIB HISTORICAL CONCERtl REPORT ORIGIII CONCERN DESCRIPTIOII IN 282-00202 T5001%
NE 50111 S IIBII 03 IIE 5023%
S IIBtl OCI I.IE 50311 S IIBN 05 IIE 50611 S flBtl IN 299-00301 I
T50188 IIE 50319 S IIBN 02 NE 5023CI S
WBN 03 flE 50111 S IIBtl 0%
HE 50%32 S IIBtl 05 IIE 50611 S
flBW BNPQCP10.35-1201 HE 5023CI N BLH 1
H Y
tl tl 2
WA SS WA WA 1Y W
tl W
2 SR WA IIA WA 1 tl Y
N tl 2
WA SR WA WA 1 tl W
Y tl 2
WA WA SR WA 1 tl W
tl Y
2 WA WA WA SR 1 tl II Y
H 2
WA WA SR WA 1
N Y
N N
2 WA SR WA WA 1 Y tl W
i'I 2
SR WA WA WA 1 tl tl W
Y 2
WA WA IIA SR 1WW'WY 2
WA WA WA SR OECP IN"85"282-002 QTC CABLE TRAYS IN CONTROL BUILDING HAVE WELDS BELIEVE D TO BE OF LOI< QUALITY EL 629 C-8 TO C-10.
j~~'~
UtlTIL RECEIITLY, TVA WELD IIISPECTORS REQUIRED"'ALL P IPE HELDS TO BE SURFACE GROUND TO A SHOOTH F1HISH.
THE CONCERN IS THAT SNOOTH GRINDING ttAY ACTUALLY IIASK A SURFACE DEFECT IIHICH IIOULD OTHERIIISE'"'BE DE TECTABLE.
WO FURTHER DETAILS IIERE AVAILABLE. (SQN ISSUES ADDRESSED IW RPT HP"11-SQW R1)
QTC SS NELDS SEEN TO HAVE EXCESS HETAL REHOVED AT BUTT HELD JOINTS'LSO THE WELDS EXHIBIT EXCESSIVE SHR IIIKAGE AT JOINTS.
THIS CONCERN IS GENERIC BUT HAV E EXAHPLES.
THTS HAS BEEN NOTICED FOR THE PAST 6
YEARS It( BOTH UIIITS. DETAILS KtlOHII TO QTC, IIITHHEL D DUE TO COHFIDEIITIALITY.
CONSTRUCT?OII DEPT COIICE R.
(SQW ISSUES ADDRESSED IW RPT IIP"19-SQN R1)
QCP10. 35-8-11 01 IIE 50236 tl Bl Il QCP10.35-8-3 01
" IIE 50234 tl BLtl 1
W Y
tl tl 2 IIA SR WA WA 1 tl Y
tl II 2
WA SS WA WA OECP OECP A HELD OW A DUCT SUPPORT HANGER HAS WOT BEEN CONPL ETED AIID IS OF POOR HORKHAWSHIP.
EL 610 RB tlEAR C
-10 8 C-ll.
HAHGERS IW ERCN TUtltlEL tlOT SAFE BECAUSE HELDS llERE IIOT IIADE BY QUALITY HELDERS (ALTHOUGH THEY IIERE C ERTIFIED IIELDERS).
THESE BAD IIELDS PASSED INSPECT IOW.
5 CONCERNS FOR CATEGORY HE SUBCATEGORY 5023CI
REFERENCE
- ECPS120J-ECPS121C FREQUENCY
- REQUEST OWP - ISSS RWW CATEGORYa IIE Wotl QA/QC WELD(WG TENNESSEE VALLEY AUTHORITY OFFICE Of NUCLEAR POWER EHPLOYEE CONCERN PROGRAH SYSTEH (ECPS)
EttPLOYEE COWCERtl IHFORHATIOW BY CATEGORY/SUBCATEGORY SUBCATEGORY) 50235 WELD INSPECTION PROCEDURES AT BLWP PAGE 49 RUtl TINE -
1l s 65 i 02 RUW DATE - 12/17/87 COtICERN WUWBER IH 230-00301 T5019CI CAT SUB CAT S
H R PLT D Loc WE 50414 S
WBtl 02 WE 50235 S
WBH PH 012-X0301 T50077 WE 50135 S
WBW 02 WE 50305 S
WBtl 03 WE 50235 S
WBtl OCI "WE 50CI05 S
WBW 1 tl W
2 WA WA 1 tl Y
2 WA SR W
Y WA SR H
tl WA WA 1
Y W
tl tl 2
SR WA WA WA N
W Y
W 2
HA WA SR HA 1 tl. Y tl tl 2
WA SR NA WA 1
W W
W Y
2 WA WA IIA SR 1
REPORT APPL 2 SAF RELATED BF BL SQ WB HISTORICAL CONCERN REPORT ORIGIN QTC PH-85-012"X03 QTC CONCERN DESCRIPTION I'REVIOUSLY REJECTED ITEHS (HANGER WELDS)
ARE FREQU EWTLY ACCEPTED BY SOHEotlE OTHER THAII A SUPERVISOR OR HIGH LEVEL (GRADE) PERSONNEL.
DETAILS KNOWN To
- QTC, IIITHHELD DUE To CONFIDENTIALITY.
tlUC.
POWER DEPT.
COWCERtt.
CI WOULD HOT PROVIDE FURTHER ItlFO RWATIOW.
IIELDIWG AIID BRAZING INSPECTIOII OF SAFETY"RELATED H VAC DUCTWORK WAS DELETED SUBSEQUENT TO 1981 FROW T HE QA PROGRAN WlTHOUT ADEQUATE JUSTIFICATIOII.
WAT TS BAR UtlITS 1
& 2>
SAFETY RELATED DUCTWORK.
ADDI TIOWAL DETAILS ARE AVAILABLE IW FILE.
(SQW ISSUES ADORESSED IN RPT WP-05-SQN R1)
XX 036-X0201 IH 60300 S
BLN 1
N Y
H H
T50138 2
WA Ho WA WA
"'02 WE 50235 S
BLH 1
W Y
W W
2 WA SR WA WA QTC EHPLOYEE (KtloWtl) FALS1FIED WELD RECORDS.
BELLEFOW TEs Utl IT al u 1977 1 980 'OWTAItlHEWT I'IALL ~
COIISTRU CTiotl OEPT.'COtlCERII.
CI HAS tlO I<ORE TIIFORAInzOII.
tlo FOI.LOW UP REQUIRED.
XX 034-00101 IIE 50235 W
BLW 1
W Y
W W
T50137 2
WA SR JIA WA XX 068-00501 IH 60300 S
BLW 1
W Y
H N
T50138 2
WA No WA WA 02 WE 50235 S
BLN 1
W Y
W N
2 IIA SR WA WA 5
CONCERNS FOR CATEGORY WE SUBCATEGORY 50235 QTC QTC BELLEFOWTE QC INSPECTOR (NAHE KtloWII) SIGNED OFF WE LDS FOR COWTAIWI1EWT WALL (APPROX.
DATES KNOWN) WIT HOUT PHYSICALLY TWSPECTIWG THEW. CI IS AHOWYI10US.
REASOII~ THIS CotlcERtl HAS BEEN REVISED TO DELETE A II ADDjTIOWAL COIICERN IIHICH HAS BEEN ADDRESSED.
ST ATUS: THIS CONCERN WAS ASSIGNED To WSRS To IWVESTI GATE OW 8-8 "85.
Wo FOLI.OW-UP REQUIRED.
BELLEFOIITE - DURING A REVIEW OF WELD CARDS BY THE AUTHORIZED NUCLEAR INSPECTOR (AtlI)p IT WAS OBSERVE D THAT THE HEAT WutlBER WAS ftARKED "W/A".
TIIO WEEK S
LATER HEAT WUHBERS WERE FOUtlD To IIAVE BEEN EtlTER ED Otl TIIE DOCUI1EIITS.
WHEN THE AIII QUESTlotlED WHER E TtIE WUtlBERS CAINE FROII, tlo EXPLAWAT10tl WAS PROVID ED.
COWSTRIICTIOW DEPT.
COWCERII.
CI HAS Wo FURTHE R 1WFORI1ATIOW.
WO FOLLOW UP RL'UIRED.
REFERENCE
- ECPS120J-ECPS121C FREQUENCY REQUEST OHP " ISSS RHN CATEGORY IIE tlOH QA/QC NELDI(G TENNESSEE VALLEY AUTHORITY OFFICE OF NUCLEAR PONER EtIPLOYEE CONCERN PROGRAH SYSZEtt (ECPS)
EIIPLOYEE CotlCERH IHFORIIATIOtl BY CATEGORYiSUBCATEGORY SUBCATEGORY! 50236 IIELD REPAIRS AT BLHP PAGE 50 RUH TIIIE -
1 1 a 45 i 02 RUH DATE - 12/17/81 S
II SUB R PLT CONCERN HUIIBER CAT CAT D LOC 1
REPORT APPL 2
SAF RELATED Bf BL SQ IIB HISTORICAL REPORT CONCERN ORIGIN CONCERN DESCRIPTIOH BHPQCP10.35-2101 NE 50236 H BLH 1
H Y
tl tl 2
HA SR HA IIA OECP A" SS PIPE Otl IN SYSTEN IIAS INPROPERLY REPATRED.
PIPE IIAS DANAGED NNILE CUTTING A SLEEVE.
2850162005 01 OP 30803 S tlPS 1
Y Y
Y Y
HPS 1 Y H
tl H
2 SS HA HA HA 03 HE 50236 S
HPS 1
H Y
N H
2 HA SS HA HA 06 NE 50325 S tlPS 1 tl N
Y H
2 HA IIA SS HA 05 NE 50025 5
NPS 1
H H
H Y
2 HA HA HA SS NRC TVA HAKES REPAIRS TO THEIR NUCLEAR PLANTS IIHICN AR E IIOT ?II ACCORDAtlCE WITH ASIDE CODES'UCH AS OVERL AYSe PATCHES'tlD EVEtl FURIIATITE (SOPHISTICATED GL UE).
(SQN ISSUES ADDRESSED Itt RPT NP-25-SQH RO) 2 CONCERNS FOR CATEGORY IIE SUBCATEGORY 50236
REFERENCE
- ECPS120J-ECPS121C FREQUENCY
- REQUEST OWP - ISSS - RIIN CATEGORY'lE HOtl QArQC flELDItlG TEtltlESSEE VALLEY AUTHORITY OFFICE OF llUCLEAR POllER EHPLOYEE COtlCERtl PROGRAM SYSTEN (ECPS).
ENPLOYEE COIICERtl IttFORHATIOH BY CATEGORYrSUBCATEGORY SUBCATEGORY< 50243 ADEQUACY OF PROCEDURES AT BLtIP PAGE 51 RUtl TINE - II s 45 i 02 RU!I DATE - 12rl?r87 CONCERN ttUNBER CAT SUB CAT S
H R PLT D LOC 1
REPORT APPL 2 SAF RELATED BF BL SQ lIB.
HiSTORICAL REPORT COHCERtl ORIGIN CONCERN DESCRIPT IOIl Itl 406-00201 T50013
, NE 50135 S llBtl 02 HE 50309 S
NBH 03 flE 50263 S HBti 04 WE 50932 S llBH I
XX 102-00601 T50172 QA 80201 S
BFtl 03 llE 50135 S Bftl
=04 llE 50243 S
BFtl
-05 flE 50632 S
BFH 06 QA 80252 S
BFH QCP10.35-8-4 01 HE 50263 N BLH 1Y tl HN 2
SS ItA WA tIA 1
N tl Y
tl 2
HA tIA SS IIA 1tl YHH 2
HA SS HA IIA
, 1 tl ll N
Y 2 tIA IlA HA SS 1 tl Y
tl tt 2
HA SR HA HA 1 tl II Y
H 2
HA HA SR ItA 1
Y W
tl tl 2
SR HA lIA HA tl Y
tl tl 2
HA SR IIA lIA 1
H H
H Y
2 IIA WA HA SR 1
H N
Y H
2 HA HA SR WA QTC PRIOR TO 1979 THERE WAS tl0 SPECIFIC HELD INSPECTIO H CRITERIA FOR USE BY INSPECTION PERSOtINEL.
IT IS BELIEVED THAT THIS PROBLEH HAS VALID TVA SYSTEN ll IDE-ALL PLANTS.
(SQH ISSUES ADDRESSED Itl RPT tIP-0 9-Sqtl Rl)
DECO CI TOLD TO START USING A DIFFERENT HEAT TREATING P ROCESS IIITH NO EXPLAWATIOW.
QTC BROlltl'S FERRY)
THE VISUAL EXANIHATIOtl PROCEDURE llH ICH COVERS ASNE SECTIOtl II IS VERY tlOtl SPECIFIC.
NUCLEAR POHER DEPT.
CotICERH.
CI HAS HO ADDITIONAL ItlFORllATIOtl.
HO FOLLOW UP REQUIRED.
XX -85"102-00701 T50172 02 HE 50243 S
BFtl 1 tl Y
2 tIA SR tl tl HA tlA HE 50135 S
BFW
~
1 Y tt N
H 2
SR tIA lIA lIA QTC BROllttiS FERRYi tlDE INSPECTORS CAN OtlLY IPRITE A tlOT ICE OF IIISPECTIOH Ott IH-SERVICE RELATED DEFECTS.
PRESERVICE DEFECTS CAtl OWLY BE IDEtlTIFIED BY A tlAI tlTEHAIICE REQUEST.
tlUCLEAR POIIER DEPT.
COtlCERH.
C I NAS HO ADDITIONAL IlIFORHATIOtt.
tlo FOLLOII UP REQ UIRED.
03 tAE 50026 S
BFH 1
N W
2 IlA WA tl Y
WA SR
REFERENCE
- ECPSI20J-ECPS121C FREQUENCY REQUEST OWP - ISSS - Rtttt CATEGORY, llE WOtl QArQC IIELDItlG TENNESSEE VALLEY AUTHORITY OFFICE Of tlUCLEAR POIIER EHPLOYEE COtlCERH PROGRAN SYSTEH (ECPS)
EHPLOYEE COtlCERtl ItlFORHATIOH BY CATEGORY/SUBCATEGORY SUBCATEGORY) 50243 ADEQUACY OF PROCEDURES AT BLtlP PAGE 52 RUtl TINE - lie%5:02 RUtl DATE " l2/17/87 CONCERN WUIIBER S
H SUB
,R PLT CAT CAT D LOC 1
REPORT APPL 2
SAF RELATED BF BL SQ HB HISTORICAL REPORT COtlCERtl ORIGIN CONCERN DESCRIPTION XX 102-01101 T50172 HE 50263 S
SQH 02 HE 50399 5
SQII 03 NE 50135 S
SQtl 06 PIE 50426 S
SQtl 1
H Y
H H
2 HA SR IlA HA 1 tl H
Y tl 2
HA lIA SR HA 1
Y tl N
tl 2
SR WA lIA HA 1 ll W
tl Y
2 tIA WA HA SR I-85-735-SQW QTC SEQUOYAHs tlDE INSPECTORS CAN OtlLY 1<RITE A NOTICE 0 F INSPECTION Otl IH-SERVICE RELATED DEFECTS.
PRESE RVICE RELATED DEFECTS CAH OtILY BE IDENTIFIED BY A ttAItITElIAtICE REQUEST.
tIUCLEAR POHER DEPT.
CotlCERtl.
CI HAS tlO FURTHER IWFORNATIOH.
tlO FOLLOW UP REQU IRED.
(SQH ISSUES ADDRESSED IW HSRS RPT I"85"735-S Qtl) 5 CONCERNS FOR CATEGORY llE SUBCATEGORY 502CI3
ATTACHMENT B CONCERN BLM-86-015-001 EX-85M39-001 IN-85-234-001 IN-85-352-002 Dl-85-424-001 IN-85-424-004 IN-85-424-006 IN-85-424-007 IN-85-426W01 IN-85-441-003 IN-85-453-009 IN-05-454-004 IM-85-501-001 IM-85-672W03 IN-86-047-001 Wl-85-053-004 XX-85-068-003 XX-85-068-006 IN-85-247-001 OESCRIPTIOM OF ISSUES Inadequate control of-weld I
rod.
I I
I I
I I
I Lack of portable rod ovens I
to protect coated electrodesl from moisture absorption.
Poor quality E7018 electrodes.
Administrative practice for the return of filler material.
CONTENTS The Bellefonte program for control of welding filler material meets the requirements of ANSI/AWS Dl. 1 Section 4
and ASIDE Section III NB-4000.
Atmospheric exposure times are controlled by BNP-QCP-8. 1.
- Also, electrodes are qualified for extended
- exposure, making the use of port-able ovens unnecessary.
Electrode operability is a subjective evaluation for which there is no quantitative industry standard.
OMC requires a series of operability tests pr ior Lo award of a,contract to supply coated electrodes.
All welding mater ia1 used for permanent plant features meets the re-quirements of ASME Section II and Section ill.
The administrative prac-tices for return of fi 1 ler material have no welding related techni-cal significance, and are addressed by ECTG Subcategory
- 70200, "Work Rules".
This issue has been addressed by Meld Project Evaluation Report NP 01-BLN.
Page 1 of 9
ATTACHNENT 8 CONCERN IN-85-.458-001 IM-86-019M01 NS-85-001-001 PH-85-040-001 WI-85-013-003 WI-85W30-007 WI-85-030-008 WI-85-041-006 WI-85-041-008 OESCRIPTION OF ISSUES The Process Specification permitted inspection of AWS welds through coating of carbo-zinc primer.
Thousands of welds may have been inspected through primer.
There is no docu-mentation to show which welds were involved.
Inspectors did'ot under-stand the coating thickness limit for inspecting primed welds.
C(FV1ENTS The Process Specifica-tion in question was site unique for Watts
- Bar, and was never implemented at Bellefonte.
The BLN specification and proce-dures meet the require-ments of ANSI/AWS 01. 1.
This issue has been addressed by Weld Pro-ject Evaluation Report WP-02-BLN.
EX-85-021-002 IM-85-113-003 IN-85-335-002 IM-85-426-002 IM-85-480-004 IN-85-725-X15 IM-85-940-X04 JLH-85-002 Inadequate basis for welders l qualification continuity updates.
Personnel whose duties do not require welding continue l to have their iIuwlification I updated.
I I
I I
I I
I From the beginning of construction until 1976 NEU verified each welder quarterly, either by direct observation or based on written state-ments by Craft Supervis-ion.
From 1976 to date, verification of process usage has been based on rod withdrawal slips.
Since
- 1982, a statement of process usage has been entered on the rod slip.
These methods satisfy the requirements of ASIDE Section IX and AWS Ol. 1 and parallel industry practices.
Only personnel actively engaged in welding activities are qualified at BLN ~
The qualifica-tions of individuals in welder foremen positions are not updated even though provided for in the BLN implementing procedures Page 2 of 9 I
ATIACHNENT 0 CONCERN DESCRIPTION OF ISSUES Welders on restriction (not allowed to weld) kept their qualification continuity updated.
The possibility exists that one welder could weld or complete a test plate for another Welders qualification at Muscle Shoals may not have ted the required number of bend tests.
CONMENTS Neither ASNE Section IX nor AWS Dl. 1 uses the term restriction when referring to welder qualification.
The only other instance where welders might be consid-ered "restricted" from welding, is when they have a personnel injury or sickness that prev-ents them from physica-lly performing the weld-ing activity.
These in-dividuals are allowed to maintain their qualifi-cation up to the time for continuity update.
IF two individuals are observed in the same test booth at any time or for any reason during
- testing, both individ-uals are immediately suspended From further testing and denied qualification I'
Welding Engineering at BLN does not certify welders transferred From other sites without re-viewing their Perfor-mance Qualification Test record(s).
This issue has been addressed by Weld Pro-ject Evaluation Repor t WP-03-BLN.
XN-85-007-001 IN-85-134-002 IN-85-406-003 Availability of inspection tools.
Page 3 oF 9
I I
I I
I I
I I
I I
I Inspection tools have been available since the beginning of construc-tion.
These tools were both site fabricated and commercially procured.
This'ssue has been addressed by Weld Pro-ject Evaluation Report WP-04-BLN.
ATTACHMENT B CONCERN IN-85-476-004 IN-85-981-001 XX-85-107-001 WI-85-041-002 WI-85-081-007 EX-85-008-001 IM-85-706-001 IN-86-158-006 XX-85-045W01 DESCRIPTION OF ISSUES Qualification of Welding Inspectors.
Topical Repor t not in com-pliance vIith ANSI N45.2.6.
Qualification and experiencel of Subjourneymen.
Adequacy of TVA Welder Tr aining Program.
CONTENTS Welding Inspectors are qualified in accordance with the TVA Quality Assurance program.
Welding Inspectors are qualified and certified using SNT-TC-1A as a
- guide, r ather than ANSI N45.2.6.
Exceptions to Reg.
Guide 1.58 are made in the Topical Repor t.
This issue has been addressed by Weld Pro-ject Evaluation Report WP-06-BLM.
Subjourneymen are utili-zed in accordance with the applicable labor agreement and good management practices.
Welders are tested and qualified in accordance with AMS Dl. 1 and ASNE Section IX.
XX-85-110-001 I'
I I
I I
QAE-2 may not have been implemented at BLN.
This issue has been addressed by Meld Pro-j ec t Evaluation Report WP-07-BLM.
QAE-2 was a study to identify improvements that would make the overall welding and NDE program more effective.
The one deficiency at BLN was previously id-entified, tracked and resolved as finding num-ber 1 in audit BNW-80-08.
This issue has been addressed by Weld Pro-ject Evaluation Report WP-10-BLN.
Page 4 of 9
ATTACHMENT B CONCERN IN-85-247-002 XN-85-303M01 XX-85-068-008 BEM-85-001-001 BEM-85W01-002 BFM-85-001-001 8FM-85-001-002 WBM-85-001-001 WBM-85-001-002 WI-85-030-007 IN-85-026-001 XN-85-212-001 IN-85-682-002 IN-85-282-002 I
XN-85-299-003 I
BNPQCP10. 35-12 I
BNPQCP10. 35 8-11 I BNPQCP10.35-8-3
'ESCRZPTION OF ISSUES I
I I
I I
I I
I Purity of bottled gases usedl in welding and pneumatic I
testing.
I I
I I
I I
I I
Suitability of welding equipments Foremen perform pre-weld I
inspections, which is not I
in accordance with the I
Topical Report, ANSI N45.2.5I and AWS Dl. 1.
I I
I I
I I
I I
I I
I I
Surface grinding of welds.
I I
I I
I Shrinkage of stainless steell butt joints' I
I I
I I
I I
I COMMENTS The equipment used at BLN has sufficient fea-tures to operate within the parameters of the approved welding proce-dures and to make ~!ccep-table welds.
The procurement specifi-cation requires a -40~F dew point.
Test reports are only required at the option of DNC.
This issue has been addressed by Weld Pro-ject Evaluation Repor t WP-13-BLN.
AWS D1
. 1 allows pre-weld activity examin-ations to be on a sampl-ing basis.
Rellefonte procedures and specifi-cations mandated survei-llancee programs of all welding activities.
Practice at BLN does not violate Lhe TVA Topical Report or ANSI N45.2.5.
This issue has been addressed by Weld Pro-ject Evaluation Report WP-16-BLN.
Surface grinding of welds is provided for by the
- ASME, ANSI and AWS codes.
Some shrinkage is inher-ent in girth butt welded joints in stainless steels.
To minimize shrinkage, heat input during welding is con-trolled by adherence to approved welding proce-dures
~
Page 5 of 9
ATTACHMENT B CONCERN I
DESCRIPTION OF ISSUES I
COMMENTS I Safety of the hanger welds I in the ERCW tunnel, quality I of cable tray welds in the I control building, and in-I complete weld(s) on a duct I support.
I I
I I
I I
I I
I I
I I
I I All support welds, duct I support welds and misce-I llaneous structural I welds have been reinspe-I cted and reworked as re-I quired.
This reinspec-I tion effort was accompl-I ished in accordance with I the dispositions of num-I erous nonconformances I which were considered I significant and reported I to the USNRC under 10 I
CFR 50.55(e).
I I This issue has been I addressed in Weld Pro-I ject Evaluation Report I WP-34-BLN.
PH-85-012-X03 IN-86-230-003 XX-85M34-001 XX-85-034-X02 XX-85-068'-005 I Welding and brazing inspec-I Procedure BNP 6.4, Rev 1
I tion of safety related duct-I establishes inspection I work deleted from the QA I criteria for safety I Program.
I related ductwork.
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CONCERN ATTACHMENT 8 OESCRIPTION OF ISSUES Ouring review of weld cards by the ANI, it was noted that the heat number was marked N/A.
Two weeks laterl the ANI found that the heat number had been entered on the cards.
Falsification of weld re-cords for Containment wall.
Rejected hanger welds being accepted by personnel other than the Supervisor or higher level Inspector.
COMMENTS Based on the fact that this issue provided insufficient information on which to base an investigation, the con-cern was administrat-ively closed by the OXG.
Issue is factual and was originally reported as an allegation in 1980.
TVA personnel at Bellefonte issued a Non-conformance Report which was reported to the NRC under 10 CFR 50.55 (e).
The weld inspection pro-gram at BLN requires that rejectable items be documented.
Reinspec-tion is accomplished only after disposition of corrective action has been made.
The reinspec-tion may or may not be performed by an inspector of the same certifi-cation level as the in-spector that previous ly rejected the item.
2850162005 I
BNPQCP10.35-21 I
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I Weld repairs such as over-
- lays, patches and Furmanite (viscous fluid -:"aslant) are not in accordance with the ASME Code.
This issue has been addressed in Weld Pro-ject Evaluation Report WP-35-BLN.
Overlay welding and temporary repairs by patching are approved methods in use at BFN and SQN.
They are not used at BLN.
=Use of viscous sealant is outside the scope of the Weld Project, and has been addressed by Opera-tions Report 30800.
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ATTACHMENT B CONCERN DESCRIPTION OF ISSUES I
COt'lMENTS I This issue was investi-I gated by the site I Quality Control and I Melding Engineering I Units.
The evaluation I included chemical and I magnetic tests to check I for residue from a flame I cutting operation.
No I evidence could be found I indicating that a repair I was made to the pipe I identified by the I concern.
I I This issue has been I addressed by Meld Proj-I ect Evaluation Report I MP-36-BLN.
Four inch stainless steel pipe on Spent Fuel Cooling (NN) system improperly repaired.
0N-,85-406W02 XX-85-102-007 XX-85-102-011 XX-85-102-006 BNPQCP 10. 35-BM I No specific inspection criteria prior to 1979.
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Reporting of inservice and I
preservice defects.
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Adequacy of visual examinat-I ion procedure for ASNE I
Section XXI.
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I Adequacy of visual examinat-I ion procedure For ASIDE I
Section IIX.
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BLN has had a network of procedures in place throughout construction.
These procedures provide all of the necessary in-.
spection criteria.
The Notice of Indication is used to report de-fects identified within the
~I~.I i.ned scope of an inspection, inservice or preservice; The t1aint-enance Request is used to report observations identified outside the defined scope of an inspection.
Procedure BNP-QCP-7.5 was issued on 12-3-75.
This procedure provides all of the necessary in-structions and criteria for visual examination of welds.
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ATIACHMENT B CONCERN COMMENTS I This issue had been pre-I viously investigated and I resolved through a site I implemented employee I concerns program.
The I process in question was I in accordance with the I specification.
~ I I This issue has been I addressed by Weld Pro-I joct Evaluation Report I WP-43-BLN.
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I CX told to change heat I treating process with no I explanation.
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DESCRIPTION OF ISSUES I
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