ML19309F594
| ML19309F594 | |
| Person / Time | |
|---|---|
| Site: | Yellow Creek  |
| Issue date: | 02/27/1980 |
| From: | Herdt A, Kleinsorge W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML19309F585 | List: |
| References | |
| 50-566-80-03, 50-566-80-3, 50-567-80-03, 50-567-80-3, NUDOCS 8004300108 | |
| Download: ML19309F594 (8) | |
See also: IR 05000566/1980003
Text
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UNITED STATES
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NUCLEAR REGULATORY COMMISSION
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REGION 11
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101 MARIETTA ST., N.W.. SUITE 3100
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ATLANTA, GEORGIA 303o3
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Report Nos. 50-566/80-03 and 50-567/80-03
Licensee: Tennessee Valley Authority
500A Chestnut Street
Chattanooga, TN 37401
Facility Name: Yellow Creek Nuclear Plant
Docket Nos. 50-566 and 50-567
License Nos. CPPR-172 and CPPR-173
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Inspection
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~e75ite near Iuka, Mississippi
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Inspector:
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N. ii. )fle'insorge
Date Signed
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Accompanying Pers nne),.
J. L. Coley (Training)
Approved by:
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A./R Herdt, Section Chief, RCES Branch
Date Signed
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SUMMARY
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Inspection on February 5-8, 1980
Areas Inspected
This routine, unannounced inspection involved 48 inspector-hours on site in the
areas of nondestructive examination, steel structures and supports witcin the
containment - observation of welding activities, weld heat treatment, we? der
qua.ification, and review of QA Manual.
Results
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Of the three areas inspected, n. items of noncompliance or deviations were
identified in two areas; one item of noncompliance was found in one area
[ Infraction - Failure to establish adequate measures to control Radiography -
Paragraph 5b(2)(a)].
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DETAILS
1.
Persons Contacted
Licensee Employees
M. M. Price, Project Manager
- J. N. Holladay, QA Staff
- L. S. Cox, Construction Engineer
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- C. G. Wages, Asst. Construction Engineer - QC
- S. P. Watson, ES - DCU
- L.
C. Marshall, PE - Mech.
- S. A. Blount, ES - TS
- M. F. Steakley, Supervisor Welding QC Unit
,
Other licensee employees contacted included 2 technicians, 2 security force
members, and 3 office personnel.
Other Organizations
C. L. Spears, Jr.
- Project Welding and QA Superintendent
L. S. Savage, QA Technician
- Attended exit interview
2.
Exit Interview
The inspection scope and findings were summarized on February 8, 1980 with
those persons indicated in paragraph 1 above. The inspector identified the
areas inspected and discussed the item of noncompliance. No dissenting
comments were received from the licensee.
3.
Licensee Action on Previous Inspection Findings
'
(Closed) Infraction 566-567/79-17-01, " Failure to Perform Proper Chemical
Analysis on Submerged Arc Welding Materials". TVA letter of response dated
December 21, 1979 has been reviewed and determined to be acceptable by
Region II. The inspector held discussions with the licensee and examined
the corrective actions as stated in the letter of response. The inspector
concluded that TVA had determined the full extent of the subject noncompli-
ance, performed and developed the necessary corrective actions to preclude
recurrence of similar circumstances. The corrective actions identified in
the letter of response have been implemented.
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4.
Unresolved Items
Unresolved items were not identified during this inspection.
5.
Independent Inspection Effort
The following areas of interest were examined by the inspector:
a.
The inspector conducted a general inspection of the TVA fabrication
shop, CB&I subassembly area, reactor building sites (units 1 and 2)
CBLI and TVA weld material issue stations and CB&I radiographic labor-
atory to observe construction progress and such activities as welding,
saterial handling and control, housekeeping and storage.
b.
The steel containment structures are being fabricated by CB&I. The
applicable code for this welding is the ASME B and PV Code, Section
III Subsection NE, 1974 edition with addenda through the Summer of
1976.
(1) The inspector reviewed CB&I procedure No. RT-2X Rev. 2, "100%
Radiographic Examination Procedure for Welds" for technical
content in the areas of type of material radiographed, material
thickness range, type of radiation source, film brand / type,
minimum source to film distance, blocking or masking technique,
type and thickness of screens, exposure conditions, material weld
surface condition, radiographic film processing requirements,
quality of radiographs, film density limits, use of densitometer,
method of identification, location markers, film location method-
ology, and use and selection of penetremeters.
(2) The inspector observed radiographic inspection in progress for
containment longitudinal butt-welds seam A2, assembly No. D5
increment 35 to 36 and 37 to 38 and reviewed the radiographs for
containment longitudinal butt-welded seam A2 assembly D2 and seam
Al assembly D2.
The above inspections were compared with the applicable procedure
<
in the areas of type of material, material surface condition,
material thickness', type of radiation source, film brand / type,
minimum source to film distance, type and thickness of screens,
exposure condition, radiographic film processing, quality of
radiographs, film density, use of densitometer, radiographic
identification, use of location markers, method of reducing and
testing for back scatter, selection and use of penetreeters, and
evaluation and disposition of radiographs.
(a) The inspector, on February 7,1980, noted penetrameters and
shims extending into and obscuring the area of interest (the
weld) on the final accepted radiographs for assembly D2,
Sean Al increments 0 to 1, 1 to 2, 37 to 38 and seam A2
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increments, I to 2, 8 to 9, 20 to 21 and 21 to 22.
The
licensee stated there were no additional radiographs of the
above intervals for evaluation of the obscured areas. ASME
B and PV code Section III paragraph X3334.4 requires that
penetremeters be placed adjacent to the weld seam, in addition
paragraph NE-5211 requires full radiography for the above
longitudinal butt-welded containment joints. Failure to
establish adequate measures to assure that special processes
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including nondestructive testing be accomplished in accordance
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with applicable codes is in non' compliance with 10 CFR 50,
Appendix B, criterion IX.
This is an infraction and is
assigned item Nos. 50-566/80-03-01 and 50-567/80-03-01 -
" Failure to Establish Adequate Measures to Control Radiography".
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(3) The inspector observed magnetic particle inspection of temporary
attachment sites after removal on assembly B22 and compared those
inspections with the applicable procedure in the areas of examin-
ation by continuous method, particle color contrast, sufficient
overlap, pole spacing and results consistant with acceptance
criteria.
c.
The inspector observed activities at weld material issue stations to
determine adequacy of: weld material storage / segregation, oven
temperatures, issue records and return of unused weld material. The
inspector also observed work areas for uncontrolled weld material.
No items of noncompliance or deviations except as described in para-
graph 5b(2)(a) were identified.
6.
Steel Structures and Supports - Observation of Welding Activities within
the Containment (Unit 1)
The inspector observed in-process welding activities of containment struc-
tural field welds as described below to determine if applicable code and
procedure requirements were being met.
See paragraph 5 above for applicable
code.
a.
Welding
The following welds were examined in process to determine; work con-
ducted in accordance with traveler, welding procedures available;
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welding technique and sequence; weld geometry, fit-up electrical
characteristics; equipment condition; voltmeters for automatic welding
calibrated:
Assembly
Seam
Process *
Eeld Type
D9
A2
ASAW
Containment Butt
D7
A2
ASAW
Containment Butt
A4
201A
Containment Butt
B20
42A
Containment Butt
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D4
A2R1
Containment Butt Repair
- ASAW-Automatic Submerged Arc Welding, SMAW-Shielded Metal Arc Welding
b.
Weld Heat I at
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The welds listed in paragraph 6a above were examined in process rela-
tive to weld joint preheating to determine; procedures available;
procedures specify acceptable preheating method; procedures provide
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monitering and recording requirements and procedure compliance.
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c.
Welder Qualification
The inspector reviewed the CB&I program for qualification of welders
and welding operators for compliance with QA procedures and ASME code
,
requirements.
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(1) The following welders and welding operators qualification status
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records and " Records of Performance Qualification Test" were
reviewed relative to the weld joints listed in paragraph 6a
above: WCW, RAM, LEA, JEG, and WLS.
(2) The below listed radiographs of production automatic submerged
arc welds used to quality the below listed welding operator were
reviewed;
Welder
Assembly No.
Seam No.
Increment No.
Symbol
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B8
A1
0 to 3
WLS
B1
A1
0 to 3
JEG
Within the areas inspected no items of noncompliance or deviations'
were identified.
7.
Review of QA Manual - Welding Activities
The "0EDC Quality Assurance Program Requirements Manual for Design Procure-
ment and Construction" (PRM) references requirements and committments. The
" Quality Assurance Program Manual" (QAP) and " Quality Assurance Program
Procedures" (QAPP) defines the QA program, defines requirements and requires
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that programs be established to control specified elements. The "Construc-
tion Engineering Manual" (CEP) expends and implements the QAP's and QAPP's
for construction site use.
The following documents control Quality Requirements:
a.
QAPP 3, Rev. 1, " Design Control"
QAPP 4, Rev. 1, " Procurement Document Control"
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QAPP 7, Rev. 2, " Control of Purchased Material, Equipment and Services"
QAPP 8, Rev. O, " Identification and Control of Materials, Parts and
Components"
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CEP 4.01, Rev. 9, " Procurement Document Control"
CEP 7.02, Rev. 5, " Receiving Inspection"
CEP 3.01, Rev. 2, " Identification and Marking of Materials, Parts and
Components"
CEP 17.01, Rev. 2, " Quality Assurance Records"
b.
The following documents control work and quality inspection procedures:
QAPP 5, Rev. 1. " Instructions, Procedures and Drawings"
CEP 5.01, Rev. 7, " Construction Engineering Procedures:
Quality
Control Instructions; and Receiving Inspection, Storage, and Preventive
Maintenance Instructions"
CEP 5.04, Rev. 3, " Work Packages"
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CEP 6.02, Rev. 7, " Control and Distribution of Construction Engineering
Procedures, Quality Control Instructions, Receiving Inspection, Storage
and Preventive Maintenance Instructions; and Manuals"
c.
The following documents control control of material:
QAPP 7, Rev. 2, " Control of Purchased Material, Equipment and Services"
QAPP 8, Rev. O, " Identification and Control of Material, Parts and
Components"
QAPP 13, Rev. O, " Handling, Storage and Shipping"
QAPP 15 Rev. 1, " Nonconforming Material, Parts, and Components"
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CEP 7.02, Rev. 5, " Receiving Inspection"
CEP 8.01, Rev. 2, " Identification and Markings of Materials, Parts,
and Components"
CEP 8.02, Rev. 4, " Warehouse Control Materials, Parts, and Components"
CEP 8.03, Rev. 10, " Control of Welding Materials"
CEP 13.01, Rev. 2, " Handling of Nuclear Components"
CEP 13.02, Rev. 2, " Storage and Preservation of Materials, Components
and Systems"
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CEP 13.03, Rev. 1, " Warehouse Storage area Inspection"
CEP 14.01, Rev. 1, " Inspection and Test Status"
CEP 15.01, Rev. 13, "Conttol of Quality Control Investigation Reports"
CEP 15.03, Rev. 2, " Control of Nonconformance Report"
d.
The following documents control special process:
QAPP 9, Rev. O, " Control of Special Process"
CEP 2.05, Rev. 5, " Qualification, Training, and Certification NDE
Personnel"
CEP 2.10, Rev. 4, " Qualification and Certification of Inspection, and
Testing Personnel"
CEP 2.11, Rev. 3, " Qualification of Welders and Welding Operators"
CEP 9.01, Rev. 5, " Release for Drilling, Chipping, Excavation, Cutting
Welding, Bonding and Sandblasting of Permanent Plant Features",
CEP 9.03, Rev.
O, " Qualification of Welding Procedures"
CEP 9.08, Rev.
O, " Process Control"
e.
The following documents control test equipment:
QAPP 11, Rev. O, " Test Control"
QAPP 12, Rev. O, " Control of Measuring and Test Equipment"
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CEP 12.01, Rev. 5, " Control of Measuring and Test Equipment"
CEP 12.02, Rev. O, " Control of Certified Tools Used for Quality Work"
Within the area inspected, no items of noncompliance or deviations
were identified.
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