ML18036B211
| ML18036B211 | |
| Person / Time | |
|---|---|
| Site: | Browns Ferry  |
| Issue date: | 03/23/1993 |
| From: | Blake J, Coley J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML18036B209 | List: |
| References | |
| 50-259-93-05, 50-259-93-5, 50-260-93-05, 50-260-93-5, 50-296-93-05, 50-296-93-5, NUDOCS 9303300010 | |
| Download: ML18036B211 (12) | |
See also: IR 05000259/1993005
Text
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UNITED STATES
NUCLEAR REGULATORY COMMISSION
REGION II
101 MARIETTASTREET, N.IN.
ATLANTA,GEORGIA 30323
Report Nos.:
50-259/93-05,
50-260/93-05,
and 50-296/93-05
Licensee:
Valley Authority
3B Lookout Place
1101 Market Street
Chattanooga,
TN 37402-2801
Docket Nos.:
50-259,
50-260,
. and 50-296
Facility Name:
Browns Ferry 1, 2,
and
3
License Nos.:
and
Inspector:
J.
Inspection
Conducted:
February
22 - 26,
1993
Coley, Jr.
Date Signed
Accompanying Personnel:
M.
Marshall (Intern)
Approved By:J.'
Blake, Chief
M t
ials
and Processes
Section
ngineering
Branch
ivision of Reactor Safety
SUMMARY
Date Signed
Scope:
This routine
announced
inspection
was conducted
in the areas
of inservice
inspection (ISI) - observation of work and work activities, review of
radiographic film, observation of welding activities, limited review of
turbine cycle piping for erosion/corrosion,
and previously open inspection
findings.
Results:
One violation:
" Failure of Welder to Follow the Parameters
of His gualified
Welding Procedure
Specifications
" was identified.
No deviation
was
identified.
The inspector's
observation of ultrasonic examinations
performed
on
a 26 inch main steam pipe weld to nozzle safe-end
and review of
radiographic film were satisfactory.
However, discussions
were held with
appropriate
personnel
to ensure that:
(1) ultrasonic calibrations
and
equipment preparations
take into account
wide weld re-enforcements
and non-
9303300010
930323
ADOCK 05000259
8
0
parallel
surfaces
in the most conservative
manner,
and
(2) information
observed
on code acceptable
radiographs
indicating
a potential
welding problem
such
as
a .incomplete insert melt or irregular root welds are
passed
on to
welding engineers.
REPORT DETAILS
Persons
Contacted
Licensee
Employees
- R. Albright, Project Engineer,
Plant Managers Staff
- H. Bajestani,
Manager,
Technical
Support
- R. Baron,
Manager,
Nuclear Assurance
and Licensing
- S. Brown, Manager,
Modifications Support Services
- J. Corey,
Manager,
Health Physics
- C. Crane,
Manager,
Maintenance
- F. Frocello, Supervisor,
guality Assurance
(gA) and ISI
- K. Grooms,
Supervisor,
Welding Engineering/Modifications
- H. Herrell, Manager,
Operations
- R. Phillips, Erosion/Corrosion
Engineer
- G, Pierce,
Manager,
Site Licensing
- E. Ridgell, Manager,
Corporate
Licensing
- S. Rudge, Site Support
- J. Rupert,
Manager,
Engineering
and Modifications
- G. Strickland,
Erosion/Corrosion
Engineering Specialist
- H. Turnbow, Manager,
Inspection Services
- 0. Zeringue,
Site Vice President
Other licensee
employees
contacted
during this inspection
included
craftsmen,
engineers,
technicians,
and administrative personnel.
Other Organizations
General
Electric
- R. Cameron,
Manager, guality Control
R. Seals,
Project Manager,
Inspection
Services
NRC Resident
Inspectors
- C. Patterson,
Senior Resident
Inspector
R. Husser,
Resident
Inspector
- Attended exit interview
and initialisms used throughout this report are listed in the
last paragraph.
Observations
of inservice inspection activities
Unit 2 (73753)
The inspector
observed ultrasonic calibration
and examination activities
delineated
below to determine
whether
ISI of pressure
retaining
components
are performed in accordance
with Technical Specifications,
the applicable
American Society of Mechanical
Engineers
(ASME) Boiler
and Pressure
Vessel
(B&PV) Code,
correspondence
between
NRR and the
licensee
concerning relief requests,
and requirements
imposed
by
NRC/industry initiatives, including the
augmented
licensee
inspection
requirements
identified in Generic Letter 88-01.
The licensee
is currently in the first outage
(Cycle 6) of the first
period to the second
inspection interval for Unit 2.
The applicable
Code for this inspection interval is the
1986 Edition of ASME Section
XI.
TVA's second interval ISI program for Unit 2 is contained
in
Surveillance Instruction (SI) 4.6.G.
No. N-UT-18, Revision
14 "Manual Ultrasonic
Examination of Piping Welds
and Vessels with Wall Thicknesses
2 inches
and Less",
was reviewed in preparation for the audit activities.
The inspector
observed
the licensee
performed calibration
and
examination activities associated
with the inspection of Welds
Nos.
GMS-2-08 and GMS-2-08-LS-U.
The examination
was
a 26 inch diameter
by
1
inch thick main steam pipe weld to a nozzle safe-end
and
12 inches of
the adjoining longitudinal pipe weld.
The examination
was performed
successfully
and
no recordable
indications
were detected
in the required
area of interest.
The only concern
noted
by the inspector
was that the licensee
elected to
use
a 45'ngle
beam transducer
and perform
a
1 1/2 node examination
on
a weld which had
a wide weld reinforcement
and
a safe-end
which had non-
parallel
surfaces.
Figure
2 of N-UT-18 illustrated
a 3/4 node technique
examination for welds with physical interferences
and
by
utilizing an
increased
angle transducer
(60')
as delineated
in paragraph
6.3.2 of the
procedure,
the weld reinforcement
and the non-parallel
surfaces
would
not be
a factor in the examination
coverage
or evaluation of
indications.
The examiner
had calibrated
a 60'ngle
beam transducer
but had elected to use the 45'ransducer
which in this specific
application
was adequate.
The inspector
also verified the examiners
certification records
and reviewed the complete reports for these
Within the areas
examined,
no violation or deviation
was identified.
Review of Radiographic
Film
,Units
2 and
3
(57090)
The inspector
reviewed
'a sample of radiographic film and accompanying
records to determine
whether they were prepared,
evaluated,
and
maintained
in accordance's
with TVA's approved
Radiographic
Procedure
No. N-RT-1, Revision
16, which include Technical
Changes
92-70,
92-77,
and 93-06.
Radiographs for the welds listed below were
specifically
reviewed to verify penetrameter
type, size,
and placement,
penetrameter
sensitivity, film density, film identification, film quality, weld
coverage,
and proper interpretation of welding discontinuities.
Weld Identification
Work Plan
No.
HPC I-3-003-001
HPCI-3-003-002
WP-3749-92
WP-3749-92
14" Dia.
Pipe/Pipe
14" Dia.
Pipe/Valve
Continuation of Radiographic
Film Examined
Weld Identification
Work Plan
No.
HPCI-3-003-003
RCIC-3-004-001
RCIC-3-004-004
RCIC-3-004-005
RWCU-3-007-G001
RWCU-3-007-G002
RWCU-3-007-G003
PCI-2-001-007
CO-R1
PCI-2-001-010
CO-R1
RWCU-3-001-G026
WP-3749-92
WP-3750-92
WP-3750-92
WP-3750-92
WP-3704-92
WP-3704-92
WP-3704-92
WP-2503-92
WP-2503-92
WP-3634-92
14" Dia.
14" Dia.
14" Dia.
14" Dia.
4" Dia.
4" Dia.
4" Dia.
14" Dia.
14" Dia.
6" Dia.
Pipe/Valve
Pipe/Valve
Pipe/Valve
Pipe/Valve
Pipe/Valve
Pipe/Valve
Valve/Tee
Pipe/Elbow
Pipe/Flange
Pipe/Sweep-o-let
The review of the
above film revealed that film quality and defect
evaluations
were acceptable.
However, the inspector
held discussions
with the
TVA Level III examiner concerning
noted root irregularies.
The
inspector's
concern
was that although the welds were acceptable
they
indicated that
some welders
were having problems
applying the root pass.
The inspector felt this problem should
be brought to the attention of
the welding engineer
in order that corrective
measures
could be taken to
ensure
weld quality.
The Level III examiner
assured
the inspector that
these conditions were discussed
with the welding engineer.
Subsequent
discussions
with the welding engineer verified this channel
of
communications
and the welding engineer
also provided the inspector with
the corrective
measures
presently
being taken to improve welding
proficiency.
These
measures
included
enhanced
training
and requiring
welder test
specimens
to meet radiographic
standards
as well as
bend
tests.
In addition to the above the inspector verified the calibration of the
X-Rite densitometer
(S/N E16964)
and reviewed examiners'ertification
records for Level I, II, and III examiners
involved in preparation,
examination,
evaluation,
and documentation of the radiographic film for
the
above welds.
Within the area
examined,
no violation or deviation
was identified.
Observation of Welding Activities
Unit 2 (55050)
The inspector held discussions
with welding engineers,
quality assurance
managers,
welding project engineers,
supervisors,
issue station
attendants,
welding instructors,
and welders,
observed
welder
qualification activities, production welding activities,
reviewed
welding specifications,
procedures,
checked
production equipment
adequacy
and verified weld material
issue,
handling,
and storage
control
for TVA/Stone and Webster welding activities
as well as those
conducted
by General
Electric.
These discussions,
reviews
and observations
were
performed to ensure that welding activities were being conducted
in
accordance
with applicable
Regulatory requirements,
and licensee
contract requirements
and commitments.
The following Documents
were
reviewed
as part of the inspection effort.
Document Identification
Title of Document
GE-TVA-21-0 Revision
0
TVA-SSP-7.52 Revision
1
TVA-SSP-7.50 Revision
1
TVA-SSP-7.51 Revision
2
Weld Material Issue,
Storage
and Control
qualification, Certification,
and
Continuity of Personnel
Performing
Welding, Brazing,
and Soldering
(WBS)
Controlling
WBS Processes
Controlling Welding, Brazing,
and
Soldering,
and Soldering
(WBS) Materials
The inspector
observed
in-process
welding activities for the
ASME Class
2
(TVA Class
D) Hardened
Wet Well Vent
(HWWV) piping which is addressed
in TVA's Design Notice Change
W17491A and Work Plan 2503-93.
During the
inspector's
observation of a 20"
X 14" diameter
HWWV pipe to weld-o-let
weld repair
on Weld No. PCI-2-001-001
the inspector requested
that the
welding current
and voltage
be checked to determine
whether the welder
was working within the qualified welding parameters
of the welding
procedure specification
(GT11-0-1-N. Rev.
0) since the equipment
used
(PowCon
300SS)
did not directly make these determinations.
The result
of this verification action
was that the welder
was welding 45 Amps
above the upper limit of 120
Amps allowed by the welding procedure
specification.
The inspector
also noted that the welder had set his
shielding
gas flow at 30 cubic feet per hour
(CFH)
and the upper limit
of the welding specification
was
25
CFH.
Although, in this instance,
failure to follow procedure
did not render the weld unsuitable, it could
in some future work.
Failure of the welder to follow the parameters
of
the qualified welding procedure specification
was reported
as violation
50-260/93-05-01.
In addition to the above,
the inspector
also verified
welding
parameters
for
a welder working on structural
Weld No. 33.
This weld is
part of
Design
Change Notice W12579 which replaces
an
ASME Class
2,
Flow Control Valve (2-FCV-90-254)
and
adds
a new strengthened
support
for the valve.
This welder was using
a Miller welding machine which has
an Amperage setting but no voltage setting since the amperage
and
voltage are aligned.
The inspector's verification of the equipment
settings
revealed that the
amperage
at the work was what was set at the
machine
and in accordance
with the approved welding procedure
specification,
Within the areas
examined,
one violation was reported,
no deviation
was
identified.
Erosion/Corrosion
(E/C)
Units 1, 2,
and
3
(49001)
Although E/C activities could not be audited in detail this inspection,
the inspector
requested
that the licensee
provide
a list of through-wall
failures
on steam
turbin
. piping which had to be repaired 'with liquid
sealants
for Unit 2, cycle 5.
This list revealed that two
2 inch piping
lines developed
through-wall leaks during this time period.
The
E/C
engineer
also provided program information to the inspector which
indicated that the licensee
had evaluated
a great deal of this piping
which included all sizes.
In addition the morning Plan-of-the-Day for
February
22,
1993,
indicated that the licensee
would be increasing
the
E/C inspection
scope for Unit 2,
by
100% this outage..
The inspector
will review the
E/C program data received in detail
and will conduct
a
comprehensive
audit of E/C activities at Browns Ferry in a future
inspection.
Within the limited areas
examined,
no violation or deviation
was
identified
Licensee Action on Previous
Inspection
Findings
(92701)
(Closed)
Unresolved
Item 50-259,260,296/92-38-03,
"Evaluation of Weld
Conditions.
The inspector review of the licensee's
corrective action
revealed that the licensee
investigated
the welding concerns
addressed
by the inspector including reinspection
where applicable
and
no
Code
rejectable
indications
were identified.
(Closed)
Unresolved
Item 50-296/92-23-01,."
Identification of
Longitudinal
Examined
on Unit-3", Interval
1 ".
The Inspector
verified that
TVA had identified all (109) Class
1 Longitudinal
examined in Unit 3.
TVA intends to identify these
welds with specific
weld numbers similar to the method
used in Unit 2 for the next
inspection interval.
Within the areas
examined,
no violation or deviation
was observed.
Exit Interview
The inspection
scope
and results
were summarized
on February
26,
1993
with those
persons
indicated in paragraph
1.
The inspector described
the areas
inspected
and discussed
in detail the inspection results
listed below.
Proprietary information is not contained
in this report.
Dissenting
comments
were not received
from the licensee.
(Open) Violation 50-260/93-05-01,
"Failure of Welder to Follow the
Parameters
of His gualified Welding Procedure
Specifications"
and Initialisms
Amps
ASt1E
GT
No.
Nos.
NRC
=
S/N
U
WP
Amperage
American Society of Hechanical
Flow Control Valve
General
Electric
Gas Tungsten
High Pressure
Coolant Injection
Inservice
Inspection
Longitudinal
Seam
Number
. Numbers
Nuclear Regulatory
Commission
Nuclear Reactor Regulations
Quality Assurance
Quality Control
Reactor
Core Isolation Cooling
Radiographic Testing
Reactor
Water Clean
Up
Serial
Number
Site Standard
Practice
Valley Authority
Upper
Ultrasonic Testing
Work Plan
Engineers