ML20037D186
| ML20037D186 | |
| Person / Time | |
|---|---|
| Site: | Phipps Bend  |
| Issue date: | 05/15/1981 |
| 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-PBN-160, NUDOCS 8105220185 | |
| Download: ML20037D186 (3) | |
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TENNESSEE VALLEY AUTHORITY CHATTANOOGA. TENNESSEE 374ot 400 Chestnut Street Tower II f.o spg-- ', k i
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'<./ l May 15, 1981 S
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5 Mr. James P. O'Reilly, Director Office of Inspection and Enforcement
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lj[j 7N U.S. Nuclear Regulatory Commission Region II - Suite 3100 vs 101 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 AND 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.
Th* first and second interim reports were submitted on November 24, 1980 and February 20, 1981, respectively. In compliance with paragraph 50.55(e) of 10 CFR Part 50. we are enclosing the third interim report on the subject deficiency. TVA anticipates transmitting the final report on or before September 18, 1981. If you have any questions regarding this subject, please call Jim Domer at FTS 857-2014.
Very truly yours, TENNESSEE VALLEY AUTHORITY l
L. M. Mills, Manager Nuclear Regulation and Safety Enclosure cc:
Mr. Victor Stello, Director (Enclosure)g/
Office of Inspection and Enforcement V
U.S. Nuclear Regulatory Commission Washington, DC 20555 Qoli S
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siescao # f An Equal Opportunity Employer
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f-ENCLOSURE PHIPPS BEND NUCLEAR PLANT INADEQUATE WELDS ON EMBEDDED PIPE SLEEVES TO PLATES STRUCTURAL WELDING DEFICIENCIES 10CFR50.55(e) REPORT NUMBER 3 (INTERIM)
NCR PBN-160 AND AUDIT PB-G-80-14 DEFICIENCY NUMBER 2 On October 24, 1980, TVA informed NRC-0IE 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. He was also informed on December 2,1980, of the addition of. concerns about documentation of welds made on structural frames. This is the third interim report on the subject reportable condition under 10CFR50.55(e). An interim report is being filed because of additional work to be performed by the Technical Engineer (GE) on items associated with Concern II below. The final report will be filed on or before September 18, 1981.
Description of Deficiency Investigations have disclosed deficiencies in the AWS structural welding program at Phipps Bend N" clear Plant. The structural welding deficiencies are grouped into two main concerns as follows:
(I) A major portion of pipe sleeves which had a complete penetration weld specified between the end plate and pipe and which were fabricated.before October 24, 1980, for the auxiliary, fuel, and reactor buildings were welded using a partial penetration joint detail. Sleeve types are 2, 3, 5, 12, 13, 14, 15, 16, and 17; and, (II) For embedded structure.1 frames, plates, and sleeves fabricated before October 24, 1980, weld inspection documentation was j
incomplete. This condition is applicable to a major portion of these items.
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 i
shop fabrication sketches and process documents.
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2.
Acceptance by QC-Welding inspectors of welds made under cause 1.
3 In some cases, a complete engineering review was not given to i
the process documents.
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.
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- 5. Failure of QC-Welding personnel to complete and review welding documentation for those items under concern (II).
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Corrective Action For concern (I), the subject sleeves have been or are being reworked to effect compliance with design reouirements. Alternate joint geometries resulting in complete penetration welds were submitted to and approved by the technical engineer. To date, 75 percent of the required rework has been accomp1'ished. This work is scheduled to be completed by the time of the final report and will be discussed therein.
For concern (II), acceptable documentation is being generated by (a) verification of previous inspections, and (b) physical reinspection. Items which are not accessible for verification or complete reinspection will be handled on a case-by-case basis with the technical engineer.
The actions taken to prevent recurrence address the causes identified under Description of Deficiency above and are as follows:
1.
The major cause was identified as an inadequate number of personnel to accomplish the required inspections. Since November 1980, six additional inspectors have been acquired and five more are to be added in the near future.
2.
QC-Welding inspectors, regardless of qualifications, are now required to have a minimum of six months experience before they can be certified for visual inspections. This was effective as of May 1981. Additionally, inspections are now specified by ths Automated Process Control (APC) Card.
3 & 4.
All AWS welding is now being accomplished by use of the APC system. This requires a complete engineering review and grastly reduces the possibility of improper weld procedure assignment.
5.
Classes were conducted and documented to delineate the j
responsibilities to Welding QC personnel for the initiation, l
completion, and review of quality assurance records. To ensure that completed documentation is reviewed, encoded, and j
forwarded to the Document Control Unit for storage in a timely manner, a limit of five days has been imposed for the accomplishment of the activities listed above on completion of the document. Lead inspectors are performing random reviews to verify that the required documentation is generated and completed.
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