ML19345C339

Forwards First Interim Deficiency Rept Re Inadequate Welds on Embedded Pipe Sleeves to Plates.Initial Notification Made on 801024.Sleeves Having End Plates Installed Before 801024 Placed on Hold.Util Reworking Accessible Sleeves

ML19345C339
Person / Time
Site:	Phipps Bend
Issue date:	11/24/1980
From:	Mills L TENNESSEE VALLEY AUTHORITY
To:	James O'Reilly NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
References
10CFR-050.55E, 10CFR-50.55E, NCR-PBNP-160, NUDOCS 8012040435
Download: ML19345C339 (3)

Text

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TENNESSEE VALLEY AUTHORITY ,

CHATTANOOGA. TENNESSEE 374ot J 400 Chestnut Street Tower II )s

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November 24, 1980 .

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Mr. James P. O'Reilly, Director d 'Ti Office of Inspection and Enforcement U.S. Nuclear Regulatory Commission Region II - Suite 3100 10? Marietta Street Atlanta, Georgia 30303

Dear Mr. O'Reilly:

PHIPPS BEND NUCLEAR PLANT - REPORTABLE DEFICIENCY - INADEQUATE WELDS ON EMBEDDED PIPE SLEEVES TO PLATES (NCR PBNP-160 AUDIT PB-G-80-14 DEFICIENCY NO. 2)

Initial notification of the subject deficiency was made to NRC-0IE, Region II, Inspector R. W. Wright on October 24, 1980. In compliance with paragraph 50.55(e) of 10 CFR Part 50, we are enclosing the first interim report on the subject deficiency. TVA anticipates transmitting the final report on or before February 23, 1981. If you have any questions regarding this subject, please call Jim Domer at FTS 857-2014.

Very truly yours, TENNESSEE VALLEY AUTHORITY W. &

L. M. Mills, Nanager Nuclear Regulation and Safety Enclosure ec: Mr. Victor Stello, Director (Enclosure)

Office of Inspection and Enforcement U.S. Nuclear Regulstory Commission Washington, DC 20555 Bo/9 s

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I ENCLOSURE ,

PHIPPS BEND NUCLEAR PLANT INADEQUATE WELDS ON EMBEDDED PIPE SLEEVES TO PLATES 10CFR 50.55(e) REPORT NO.1 (INTERIM)

NCR PBNP-160 AND AUDIT PB-0-80-14 DEF. #2 On October 24, 1980, TVA' informed NRC-01E Region II, Inspector R. W.

Wright, of a potentially reportable condition regarding welds joining embedded pipe sleeves and end plates (at penetration surface) at the Phipps Bend Nuclear Plant. This is the first interim report on the subject reportable condition under 10CFR 50.55(e). The Final Report will be filed on or before February 23, 1981.

Description of Deficiency Investigations disclosed that all pipe sleeve to end plate welds made at Phipps Bend Nuclear Plant on or before October 24', 1980, may have been partial penetration fillet welds instead of full penetration welds as required.- Full penetration welds were specified for these joints because a number of the end plates are employed by C. F. Braun design as points for pipe restraint. This condition exists for pipe sleeves installed in the auxiliary, fuel, radwaste and reactor ,

buildings.

This breakdown of the structural welding program is attributed to the following causes:

(1) Failure to adhere to the weld requirements as specified in the shop fabrication sketches and process documents; (2) Acceptance by QC-Welding inspectors of welds made under' item (1). ---

(3) In some cases, a complete engineering review was not given to the process dccuments; and (4) In some cases, partial penetration welding procedures were specified in error although the correct weld joint geometry was '

specified on the shop fabrication sketches.

Corrective Actions

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All sleeves having end plates installed before October 24, 1980, have teen placed on " HOLD". These sleeves have been grouped into three priorities:

Priority 1 - Sleeves installed in talls being prepared for concrete pours.

Priority 2 - ~4r ves (with end plates attachSJ) not installed.

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Priority 3 - Sleeves -installed in walls which have had concrete placed.

TVA is proceeding to rework all accessible sleeves which have end plates serving as points of pipe system restraint. Sleeves not in the above category will be-submitted to C. F. Braun for approval of use as is.

Rework on accessible sleeves will be accomplished in two ways as follows:

Priority 1 and 3 Sleeves - Use alternate weld procedure (from inside of pipe diameter) to effect a full penetration weld.

Priority 2 Sleeves - Remove fillet weld and rework to original design requirement or handle in accordance with the strategy used for priority 1 and 3 sleeves.

As a result of this problem, all structural welding activities have been placed on hold and are beir,3 individually reviewed for adherence to specified requirements. A policy statement on adherence to procedures has been issued by the Construction Engineer to all construction engineering personnel. Also, plans are being developed for additional craft training.

To prevent recurrence of this problem a management assessment has been made and documented. A summary of the recommendations are as fo'. lows :

(1) Increase manpower in the weld inspection area; (2) Improve the overall caliber of welding-inspectors by placing requirements relative to minimum experience and education. ,

(3) Establish an ;aternal weld documentation training program; (4) Utilize c',aputerized weld documentation control on all future safety r . lated structural welding; and .

(5) Clearly delineate record review guidelines for weld documentation (specifically, the review of weld inspection records by the group leaders within five working days of their generation).

In addition, our welding inspector and welding engineering functions have been separated to create a more dedicated effort in the review of design information and subsequent assignment of weld procedures.

E30324.07

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