ML19323J226

Responds to NRC 800521 Ltr Re Violation Noted in IE Insp Repts 50-553/80-07 & 50-554/80-06.Corrective Actions: Procedure for Controlling Submerged Arc Welding Flux Has Been Made Available to Craft Personnel

ML19323J226
Person / Time
Site:	Phipps Bend
Issue date:	06/12/1980
From:	Mills L TENNESSEE VALLEY AUTHORITY
To:	James O'Reilly NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
References
NUDOCS 8006190466
Download: ML19323J226 (3)

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TENNESSEE VALLEY AUTHORITY CHATTANCOG A. TENNESSEE 374ot 400 Chestnut Street Tower II June 12, 1980 Mr. James P. O'Reilly, Director Office of Inspection and Enforcement U.S. Nuclear Regulatory Couission Region II - Suite 3100 101 Marietta Street Atlanta, Georgia 30303

Dear Mr. O'Reilly:

Enclosed is our response to C. E. Murphy's May 21, 1980, letter, RII:WPK 50-553/80-07 and 50-554/80-06, regarding activities at the Phipps Bend Nuclear Plant which appeared to have been in violation of NRC regulattens.

We hevs reviewed the subject inspection report and find no proprietary information in the report. If you have any questions regarding this matter, please call Jim Domer at FTS 857-2014.

Very truly yours.

TENNESSEE VALLEY AUTHORITY L. M. Mills, Manager  !

Nuclear Regulation and Safety Enclosure cc: Mr. Victor Stello, Director (Enclosure)

Office of Inspection and Enforcement U.S. Nuclear Regulatory Commission 1 Washington, DC 20555 l

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ENCLOSURE RESPONSE TO NRC-0IE LETTER FROM C. E. MURPHY TO H. G. PARRIS DATED MAY 21, 1980

REFERENCE:

RII:WPK 50-553/80-07, 50-554/80-06 Noncompliance Item - Infraction 50-553/80-07-02; 50-554/80-06-02 As required by 10 CFR, Appendix B Criterion V and implemented by Phipps Bend PSAR Paragraph 17.1A.15, activities affecting quality shall be prescribed by documented procedures and shall be accomplished in accordance with those procedures. Phipps Bend Construction Engineering Procedure CEP 8.03 Revision 10, " Control of Welding Materials", paragraph 3, requires Welding Material Requisition (WMR) forms to be completed and to include the welder's signature, foreman's signatura, issue date and return due time. CEP 8.03, paragraph 6, requires all electrode oven thermometers to be calibrated. CEP 12.01, Revision 6, " Control of Measuring and Test Equipment", paragraph 2.4, requires measuring and test equipment that is not calibrated, not to be used until calibrated and to be so tagged. .

Contrary to the above, on April 29 to May 2, 1980, the following examples were noted:

1. The site did not have a documented procedure, to control submerged arc welding flux, available to personnel accomplishing that activity.

2. Approximately 15 WMR forms were completed with missing or incorrect issue dates, missing return time or printed welder and foreman names vice signatures.

3. Two velding electrode issue oven thermometers were not calibrated and were not properly tagged.

This is an infraction. A similar item was broght to your attention in our letter dated July 11, 1979.

Corrective Action Taken

1. During the inspection a copy of the procedure for controlling submerged are welding flux could not be produced for the inspector. In fact, TVA provides for controlling submerged are welding flux in G-29M, Process Specification 1.M.3.1(f), paragraph 5.4.1. This procedure I has been made available to craf t personnel who use the submerged arc welding process.

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2. Concerning Weld Material Request forms, a memorandum dated May 30, 1980, was sent from Project Engineering Welding to Quality Control Welding which addressed the problem of incomplete forms.

The welding inspectors were instructed to comply with all requirements specified in the Detail Welding Procedures. The inspectors were also instructed to take special care in verifying that the forms are properly filled out.- Responsible craft supervision was also instructed to ensure that the correct filler materials, as specified in the related Detail Weld Procedures, are requested on the filler material issue slips before being submitted to the rod control centers.

3. Concerning the uncalibrated rod ovens, Construction Engineering Procedure 8.03 and Standard Operating Procedure QC-5 are now being complied with. All rod oven thermometers have been calibrated and a calibration sticker was affixed to the thermometers before the ovens were put into service. All ovens which were found to be out of the specified calibration range or that_did not have the thermometers calibrated now have a not to be used tag affixed ,

to the ovens. Calibration stickers have been affixed to all rod ovens which are in use.

Action Taken to Prevent Recurrence

1. Project Engineering Welding has made a survey to ensure that the proper specifications for the submerged are welding process are available to craft personnel. In addition, craft personnel have been made aware of these specifications and their location on the project.

2. The inspectors will be reminded on a periodic basis of their responsibilities in this area. In addition, date stamps were issued to all rod issue centers and dates are now stamped on weld material requisitions.

3. A meeting was held on Monday, May 5,1980, in the of fice of the Quality Control Welding Unit. All Quality Control Welding Inspectors were instructed to comply with the Tennessee Valley Authority CEP 8.03-and SPO QC-5 concerning rod oven calibration.

Date of Full Compliance l

Full compliance was' achieved on Friday, May 30, 1980.

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