ML20041F989
| ML20041F989 | |
| Person / Time | |
|---|---|
| Site: | Bellefonte  |
| Issue date: | 03/05/1982 |
| 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, NUDOCS 8203170627 | |
| Download: ML20041F989 (3) | |
Text
s TENNESSEE VALLEY AUTHORITY
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U.S. Nuclear Regulatory Commission ro Region II g>
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Mr. James P. O'Reilly, Regional Administrator 101 Marietta Street, Suite 3100 2
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Dear Mr. O'Reilly:
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BELLEFONTE NUCLEAR PLANT UNITS 1 AND 2 - QA BREAKDOWN - DEFICIENT FILL
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WELDS - NCR'S 1188,1203, AND 1563 - EIGHTH INTERIM REPORT On May 7, 1980, R. W. Wright, NRC-0IE Region II, was informed that nonconformance report (NCR) 1188 was determined to be reportable in accordance with 10 CFR 50.55(e). Since that time, related NCR 1203 has been determined to be reportable in accordance with 10 CFR 50.55(e). This was followed by our interim reports dated June 6, September 19, and December 15, 1980 and March 6 and June 10, 1981. Some of the affected welds are inaccessible for inspection; therefore, NCR 1563 has been written to disposition these welds. This was followed by our interim reports dated August 27 and December 11, 1981. Enclosed is our eighth interim report.
We expect to submit our next report by May 20, 1982.
If you have any questions concerning this matter, please get in touch with R. H. Shell at FTS 858-2688.
Very truly yours, TENNESSEE VALLEY AUTHORITY N. $b L. M. Mills, Manager Nuclear Regulation and Safety Enclosure cc:
Mr. Richard C. DeYoung, Director (Enclosure)
Office of Inspection and Enforcement U.S. Nuclear Regulatory Commission Washington, DC 20555 8@%L COPY 8203170627 820305 PDR ADOCK 05000430 "7b, d PDR S
An Equal Opportunity Employer 4
h ENCLOSURE BELLEFONTE NUCLEAR PLANT UNITS 1 AND 2 QA BREAKDOWN - DEFICIENT FILLET WELDS NCR'S 1188, 1203, AND 1563 10 CFR 50.55(e)-
EIGHTH INTERIM REPORT Description cf Deficiency Numerous fillet welds located in various safety-related systems do not meet ASME Code and/or TVA Construction Specification G-29 requirements because of inadequate fillet leg size or theoretical throat dicensions. Deficient welds have been found in socket weld fittings and socket weld flanges
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(NCR's 1188 and 1563) and in component support welds (NCR 1203). This quality assurance problem is attributable in part to the procedure for fillet weld inspection because it did not accurately reflect the applicable ASME Code requirements. Additional problems with socket weld flanges arose because, at the time the procedures were. written, G-29M requirements did not specify socket weld flange requirements. G-29M was revised on March 21, 1979 to include socket weld flange requirements. However, TVA failed to incorporate this change into its site quality control procedure.
Fillet weld gauges not being available to assist the inspectors in determining the adequacy of welds also contributed to the problem.
Interim Progress NCR 1188 A total of 10,140 socket welds in 43 plant systems under the scope of NCR 1188 were identified. Of this amount, 9,451 were reinspected, 673 were embedded, and 16 more are inaccessible for inspection. NCR 1563 was written to disposition these embedded and inaccessible welds.
The total rejectable of those inspected was 668 welds equating to a total reject rate of 7.1 percent. Only 66 welds (0.7 percent) were undersized by more than 1/16". A breakdown on those welds found rejectable follows:
Undersized Throat Undersized Le3 Undersized Leg & Throat Together 318 271 79 I
All rework on accessible welds has been completed.* To prevent recurrence, guidelines for accepting various welds have been added to quality control procedures and inspectors have incorporated use of weld gauges. TVA has inspected 540 socket welds that were made sometime after completion of inspector training and implementation of the use of fillet weld gauges, and no rejectable welds were found.
O Page 2 NCR 1203 Two hundred randomly selected supports of the approximately 8,500 supports identified under the scope of this NCR have.been reinspected and data submitted for evaluation. TVA has determined all welds under the scope of this NCR will have to be reinspected. All rejected welds will have to be reworked or evaluated on a case-by-case basis to qualify existing welds. A total of 2,428 hangers have been reinspected as of January 27, 1982. This.
constitutes a total of 9,592 welds. Of the 9,592 welds reinspected, 3,637 have been rejected. This indicates a rejection rate of approximately 38 percent.
Reinspection of the hangers will continue with additional information to be supplied in our next report.
NCR 1563 Honconformance report 1563, resulting from NCR 1188, addresses a total of
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689 socket welds categorized as " inaccessible." TVA is gathering the available information on these welds and,will evaluate this information to determine any action that needs to be taken. Further information regarding NCR 1563 will be supplied pending completion of the evaluation.
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