ML19305B405
| ML19305B405 | |
| Person / Time | |
|---|---|
| Site: | Phipps Bend  |
| Issue date: | 01/10/1980 |
| From: | Crowley B, Herdt A NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML19305B369 | List: |
| References | |
| 50-553-79-17, 50-554-79-16, NUDOCS 8003190608 | |
| Download: ML19305B405 (7) | |
See also: IR 05000553/1979017
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UNITED STATES
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NUCLEAR REGULATORY COMMISSION
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101 MARIETTA ST., N.W., SUITE 3100
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ATLANTA, G EORGIA 30303
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JAN 101990
Report Nos. 50-553/79-17 and 50-554/79-16
Licensee: Tennessee Valley Authority
500A Chestnut Street
Chattanooga, Tennessee 37401
Facility Name: Phipps Bend Nuclear Plant
Docket Nos. 50-553 and 50-554
License Nos. CPPR-162 and CPPR-163
Inspection at Phipps Bend site near Kingsport, Tennessee
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Inspector:
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B.'R. Crowley
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D' ate Signed
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Approved by'.
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R'. Herdt P
Date' Signed
SUMMARY
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Inspection on December 11-14, 1979
Areas Inspected
This routine unannounced inspection involved 29 inspector-hours onsite in the
areas of containment welding; safety-related pipe welding.
Results
Of the two areas inspected, no items of noncompliance or devirdions were identi~
fied in one area; two items of noncompliance were found in one area (Infraction -
Failure to follow WPS Weave requirements, paragraph 6.b.(1); Infraction - Failure
to follow procedure for documenting fitup inspection results, paragraph 6.b.(2)).
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DETAIIS
1.
Persons Contacted
Licensee Employees
- W. P. Kelleghan, Project Manager
- G. W. Wadewitz, Construction Engineer
- D. E. Hitchcock, Site QA Unit Supervisor
- T. V. Abbatiello, Assistant Construction Engi_cer, QC
- J. C. Cofield, Assistant Construction Engineer, PE
- W. T. Lindemann, Technical Services Supervisor
W. K. Burner, Supervisor Welding QC Unit
R. A. Haygood, Welding Engineer
D. T. Rhea, NDE Group Leader
R. Crouch, Engineering Aide, QC
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R. Brown, Engineer Aide, QC
D. Dutton, Engineering Aide, QC
Other licensee employees contacted included construction craftsmen, technicians,
QC inspectors, security force members and office personnel.
- Attended exit interview.
2.
Exit Interview
The inspector met with the licensee representatives noted in paragraph 1
t'ove at the conclusion of the inspection on December 14, 1979, and sum-
marized the scope and findings of the inspection of containment welding and
safety-related pipe welding. The licensee acknowledged the two noncom-
pliances of paragraph 6 and agreed to pursue resolution of the inspector's
concerns relative to the inspector followup items of paragraph 7.f.
3.
Licensee Action on Previous Inspection Findings
Not inspected.
4.
Unresolved Items
Unresolved items are matters about which more information is reouired to
determine whether they are acceptable or may involve noncompliance or
deviations. New unresolved items indentified during this inspection are
discussed in paragraph 6.b. (l').
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5.
Independent Inspection Effort (Units 1 and2)
The following areas of interest were examined by the inspector:
A general plant tour was made and general construction activities and
a.
conditions observed in the following areas:
- Reactor building _( Units 1 and 2)
- Auxiliary building (Units 1 and 2)
- Fuel handling building (Units 1 and 2)
- Carbon steel pipe welding shop
- Cadweld shop
b.
The inspector observed in process safety-related pipe welding in the
carbon steel pipe shop. The welding is being accomplished in'accor-
dance with the ASME Boiler and Pressure Vessel Code,Section III,1974
Edition including the 1974 summer addenda as required by C. F. Braun
and Company Specification 400-15, " Field Fabrication and Erection of
ASME Section III Piping". Welds POKE 00011, 14, and 16 were observed
at the fitup stage and/or daring welding the first two layers. Weld
appearance, weld fitup, evidence of QC inspections, welder qualifica-
tion, use of correct weld procedure, use of correct filler material,
and filler material control were examined,
The inspector observed in-process welding of cadweld sleeves to the
c.
drywell base plate. This welding was being accomplished in accordance
with Division 2 of the ASME Boiler and Pressure Vessel Code, 1975
issue. Welds IT2302022 and IT2302021 were observed. Weld appearance,
evidence of QC inspections, welder qualification, use of correct weld
procedure and use of correct filler material were examined.
Within the areas inspected, no items of noncompliance or deviations were
identified.
6.
Steel Structures and Supports - Observation of Welding Activities Within
Containment (Unit 1)
The inspector observed field welding of containment shell plates and base
liner plates at various stages of weld completion. The applicable code for
shell plate welding in the ASME Boiler and Pressure Vessel Code, Section
III, Division 1, Subsection NE, 1974 Edition including the Summer of 1974
Addenda. The applicable Code for the base liner plate welding is the ASME
Boiler and Pressure Vessel Code,Section III, Division 2, 1975 issue.
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a.
The following welds were observed at the fabrication status indicated:
Part
Status
IT2300023
Base liner Plate
In-process welding
IT2300030
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Fitup
IT2300051
Fitup & Inprocess welding
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IT2300029
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Fitup
IT2300075
Fitup
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IT2301629
Shell Plate
Grinding Finished Weld
IT2301631
Backgouging
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IT2301630
Capping Weld
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The inspector examined the above work to determine whether:
(1) Work is conducted in accordance with a document which coordinates
and sequences operations, references procedures, establishes hold
points, and provides for hold points.
(2) Procedures, drawings, and other instructions are at the work
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station and readily available.
(3) Welding technique and sequence are specified and adhered to.
(4) Weld joint geometry is in accordance with applicable procedure
and inspected.
(5) Alignment of parts is in accordance with applicable requirements.
(6) Electrodes are used in positions and with electrical character-
istics specified.
(7) Welding equipment is in good working condition.
b.
During observation of the above welding, the following problems were
found:
(1) For containment shell plate welds IT2301629 and 1631, weave beads
were observed 3/4" to 7/8" wide. Discussions with inspection
personnel revealed that the weave bead technique had been used
for all shell welds in the past, except the first two, until the
weld grooves are full. This results in a weave width of 1" or
greater at the top of the groove. Paragraph 14.9 of process
specification 1.M.I.2(b) of " General Construction Specification"
G29M limits the bead width resulting from weaving to 5/8" maximum
for the gas metal arc (including flux cored) process. This
failure to follow procedure is considered to be noncompliance
with Criterion V of 10 CFR 50 as implemented by paragraph 17.1A.5
of PSAR and is identified &s item 553/79-17-01, " Failure to
Follow WPS Weave Requirements".
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(2) For containment base liner plate weld IT2300029, fitup was signed
off as being acceptable when in fact, the root opening exceeded
drawing dimensions. Discussions with QC inspection personnel
revealed that the intent was to butter the plate edge prior to
welding to obtain the proper root opening. The inspector agreed
that the fitup should not have been signed off until after correc-
tion of the root opening. Paragraph A.0 of QCI N-501, Revision
1, requires in part that, "All welds requiring fitup examination
shall be examined for compliance with the applicable welding
procedures, drawings ...".
Paragraph 7.0 of the QCI requires in
part that, "As a minimum the following information shall be
recorded for each examination for which documentation is required
by the Quality Assurance Procedures
.a. , b.
.i. - Results of
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Inspections." This failure to accurately record inspection results
is considered to be noncompliance with Criterion V of Appendix B
to 10 CFR 50 as implemented by paragraph 17.1A.5 of the PSAR and
is identified as item no.
553/79-17-02, " Failure to follow
procedure for accurately documenting fitup inspection reuslts."
(3) During the inspection of the noncompliance relative to fitup of
weld IT2300029, the inspector noted that instructions for butter-
ing the plate edge-to obtain the proper root opening were issued
to the field on a plain sheet of paper with only a signature at
the bottom of the sheet (the signature was determined to be that
of a mechanical engineer). This sheet was included in the field
work package folder.
Issuing instructions to the field using
this method does not appear to satisfy quality requirements.
However, site personnel were not definitive and the procedures
(Work Package and other applicable procedures) were not clear as
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to the correct method for issue of this type'af information to
the field.
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Another problem relative to this particular occurrence is the
authority for buttering to correct root opening. Welding engi-
neering personnel indicated that paragraph 11.2 of Addendum 1 to
process specification 1.M.I.2(b) is the Engineering Authority.
However, this paragraph covers joints with root opening exceeding
3/8".
Therefore, it is not clear whether the joint in question
which has a maximum root opening of 1/4" by drawing is covered by
this paragraph. Also, the paragraph does not specify the maximum
root opening that can be repaired by this method.
This matter (method of issuing instructions and authority for
repair) is considered unresolved, will be reviewed at a future
inspection, and is identified as item number 553/79-17-03.
Within the. areas inspected, no items of noncompliance, except as
noted in paragraphs b(1) and b(2), or deviations were identified.
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7.
Steel Structures and Supports - Welding Material Control (Unit 1)
The inspector reviewed TVA's program for control of welding materials to
determine whether materials are being purchased, accepted, stored, and
handled in accordance with QA procedures and ASME code requirements. See
paragraph 6 above for the applicable code. The applicable TVA procedures
are:
CEP 4.01, Rev.
8, " Procurement Document Control"
CEP 8.03, Rev.
10, " Control of Welding Material"
NCM Section 3.6, Rev.
9, " Receiving Inspection, Storage,
Preservation, and Issuing of Code Items"
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Process Specification 1.M.3.1(f),'" Process
Specification for Welding Material Control"
CEP 7.02, Rev. 4, " Receiving Inspection"
The following specific areas were examined:
Purchasing Procedures
a.
b.
Receiving, storing, distributing and handling procedures
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Material identification
d.
Inspection of welding material issue stations - Rod Control Centers 1,
2, 3, and 4 were inspected. The inspector looked at the control of
electrode stubs and damaged electrodes. The problem discussed in
report 553/554/79-07 relative to electrode stub control has been
corrected. Therefore, inspector followup item 553/554/79-07-01 is
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closed.
Welding material purchasing and receiving records for the following
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materials were reviewed for conformance with applicable procedures and
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code requirements:
(1) Shield Metal Arc - E7018:
Lot 7354F22143
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(2) Flux Cored - E70T1: Lot 1017A
f.
During review of the above welding material records, the following
problems were identified:
(1) The procurement specification (PF-1012) for E7018 electrodes
requires as welded and stress relieved mechanical properties.
Review of the " Electrode Test Report" for the above listed lot of
E7018 electrodes revealed that the as-welded tensile strength was
not reported. Review of the receipt Inspection Procedure (RIS&PM)
M-904, dated 12/14/77) in effect at the time the material was
received reveals that the procedure was followed for receipt
inspection. This procedure has since been changed to more clearly
define requirements to the receiving inspector. The vendor was
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contacted about the as-welded tensile test for the lot of material
in question and stated that the test was conducted, but inadver-
tently omitted from the test report. This item will be identified
as inspector followup item 553/79-17-04 and the corrected test
report will be reviewed by the inspector at a later inspection.
(2) The material procurement and certification documentation does not
reference a specific code date and addenda. Although the procure-
ment system as specified in above referenced procedures should
insure that the requirements of the applicable code (date and
addenda) are met, the documentation should state the code date
and addenda that the material is procured to.
The licensee
agreed to evaluate this problem and consider adding the informa-
tion to the procurement documentation for future procurements.
This item is identified as inspector followup item 553/79-17-05.
Witin the areas inspected no items of noncompliance or deviations were
identified.
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8.
Steel Structure and Supports - Welder Qualification (Units 1 and 2)
The inspector reviewed TVA's program for qualification of welders to
determine whether welders are being qualified in accordance with applicable
QA procedures and code requirements. See paragraph 6 above for the applicable
code. The applicable TVA procedures are:
Process Specification 1.M.2.2(a), " Welder and Welding Operator Performance
Qualification"
NCM Manual Section 5.1, " Welding Control"
The following specific areas were examined:
a.
Procedures for qualification of welders
b.
System for maintaing a continuous record of qualification status
Qualification status records and initial qualification records for
c.
welders B019, B053, F053, B045, B069 and B021, as applicable to the
production welds of paragraphs 5 and 6, were reviewed.
d.
In process welder qualification activities were observed as follows:
(1) Welder in process of welding qualification test assem)1y in the
horizontal position for test SM-4-B-H
(2) Bend tests in process for vertical position for test SM-4-B-H
Within the areas inspected, no items of noncompliance or deviations were
identified.
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