ML20078H743
| ML20078H743 | |
| Person / Time | |
|---|---|
| Site: | Bellefonte  |
| Issue date: | 10/05/1983 |
| From: | Mills L TENNESSEE VALLEY AUTHORITY |
| To: | James O'Reilly NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| References | |
| REF-PT21-83 10CFR-050.55E, 10CFR-50.55E, NUDOCS 8310140277 | |
| Download: ML20078H743 (19) | |
Text
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L TENNESSEE VALLEY AUTHORITY CH ATTANOOGA. TENNESSEE 374ol 400 Chestnut Street Tower II g QC)hb0r 3
BLRD-50-438/83-23 U.S. Nuclear Regulatory Commission Region II Attn: Mr. James P. O'Reilly, Regional Administrator 101 Marietta Street, NW, Suite 2900 Atlanta, Georgia 30303
Dear Mr. O'Reilly:
BELLEFONTE NUCLEAR PLANT UNIT 1 - WELDS ON BAFFLE PLATES IN CORE SUPPORT ASSEMBLY BY BABCOCK & WILCOX - BLRD-50-438/83 SECOND INTERIM REPORT The subject deficiency was initially reported to NRC-0IE Inspector P. E.
Fredrickson on March 2, 1983 in accordance with 10 CPR 50.55(e) as NCR 2267 This was followed by our report dated March 30, 1983 Enclosed is our second interim report. We expect to submit our next report by February 21, 1984. We consider 10 CPR Part 21 applicable to this deficiency.
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 Y
L. M. Mills,6 Manager Nuclear Licensing Enclosure oc:
Mr. Richard C. DeYoung, Director (Enclosure)
Office of Inspection and Enforcement U.S. Nuclear Regulatory Commission Washington, D.C.
20555 Mr. R. J. Ansell, Manager (Enclosure)
Bellefonte Project Services Babcock & Wilcox Company P.O. Box 1260 Lynchburg, Virginia 24505 Records Center (Enclosure)
Institute of Nuclear Power Operations 1100 circle 75 Parkway, Suite 1500 DdL Atlanta, Oeorgia 30339 8310140277 831005 COA'gy N
gDRADOCK05000 g
.- J-TVA 5OTH ANNIVERSARY An Equal Opportunity Employer b
ENCLOSUEE BELLEFONTE NUCLEAR PLANT UNIT 1 WELDS ON BAFFLE PLATES IN CORE SUPPORT ASSEMBLY BY B&W 10 CFR 50.55(e)
BLRD-50-438/83-23 NCR 2267 SECOND INTERIM REPORT Description of Deficiency While performing onsite modifications to the unit 1 reactor internals (B&W field change package 194), defects were noticed in 12 of 20 wide baffle plates adjacent to the narrow baffle plates being modified. Former bolts are used to hold the haffle plates together. Nine of the twelve affected baffle plates have 24 bolts each and the other three have 48 bolts each, for a total of 360 bolts. The former bolts are prevented from backing out by the use of locking pins, which are secured by tack welding each end to its baffle plate. At 26 of the 360 locations, tack welds were found to be cracked. One of the 26 locking pins had cracked tack welds at each end.
Additionally, three pins were welded to bolts, there was a lack of fusion indication on one pin, and one pin had a tungsten inclusion. The apparent cause of these defects is poor workmanship during fabrication at B&W.
Corrective Action Preliminary inspection and mapping of the unit 1 baffle plate to former bolt joints were performed shortly after the discovery of cracked locking pin welds. In addition to cracked welds, the inspection revealed defects such as porosity, inclusions, lack of fusion, and undersize welds. B&W's laboratory analysis of three cracked weld samples showed that the cracks were a result of solidification cracking and that the cracked welds were made with Inconel 600 filler metal instead of the required stainless steel 308L. Five 308L welds were analyzed and no evidence of cracks was found.
Shop records show that the Bellefonte unit 1 core basket lock pin welds were made during the same time period and in the same shop bay as that for another job which utilizes 1/16" Inconel 600 weld rod. The 308L weld rod being used for the Bellefonte lock pin welds was also 1/16".
It is hypothesized that several pieces of the inconel rod were inadvertently used on the Bellefonte unit 1 core basket. The unit 2 internals were examined visually and with an alloy separator and no reportable indications were found. B&W also conducted a visual inspection of internal locking pins on other contracts fabricated during the same general period as Bellefonte units 1 and 2.
No inconel welds were found. Thus, B&W believes that i
inadvertent use of inconel filler wire in lieu of stainless steel was an isolated incident affecting only Bellefonte unit 1.
An inipection of all locking d vica v' =.d cpplicctions in the unit 1 core.
b skst, co listcd in Tcbla 3, h s brtn complet;d to assura that all defects have been discovered. Table 1 identifies the results of the detailed visual inspection c.ad inspection for inconel filler metal performed for the baffle plate to former bolt joints. Table 1 categorizes the defects based on the repair method for each specific defect. Figures 1 and 2 define the plate locations and bolt numbers shown in Table 1.
All inconel welds in the baffle plate to former bolt joints have been identified using an alloy separator. All baffle plates to former bolt locking pin weld defects identified in Table 1 have been repaired in accordance with the recommended repair methods identified in Table 2.
Inspection results for the other joints in Table 3 will be provided in the next report.,
TVA's Quality Engineering Branch has alerted the appropriate regional quality control inspection office of the nonconforming condition and has instructed inspectors to perform closer surveillance of any locking pin welding in the future. Corrective action taken by B&W to preclude the possibility of future incidents of this nature is to increase emphasis c already established quality assurance (QA) and quality control procedures.
The procedures in use in B&W's shop today are adequate to preclude such an occurrence. and are reviewed periodically by B&W internal audits as well as by customer QA audits.
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.o y FIGURE 1: IDENTIFICATION OF PLATE LOCATIONS VIEWING FROM TOP 0F CORE BASKET.
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_ _N FIGURE 2: IDENTIFICATION OF BOLT NUMBERS VIEWING FROM INSID,E THE CORE BASKET AND FACING THE PLATE.
Document No. 51-1142200-01 I..
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TABLE 1 NSS-IS INSPECTION RESULTS BAFFLE TO FORMER. BOLT LOCXING PIN WELDS
- CATEGORY 1: WELD CRACED TiiRU OR PARTIALLY THRU OR INCCMEL FILLER METAL PLATE LOCATION BOLT NUMBER DESCRIPTION OF DEFECT 44/1 24 Cracked One End Thru
- 18/19 10 Cracked One End Thru - Inconel
- 26/27 15 Cracked One End Thru - Inconel 29/30 1
Cracked One End Thru - Incenel 33/34 21 Cracked One End Th'ru - Inconel 33/34 '
22 Cracked One End Thru - Inconel 3'7/33 6
Cracked One End Thru - Inconel 40/41 4
Cracke<t One End Thru - Inconel 44/1 17 Cracked Both Ends - One End Thru - Inconel
. 26/27 3
Cracked Both Ends - One End Thru - Incenel 29/30 4
Cracked Both Ends - One End Th'ru - Inconel
- 40/41 10 Cracked Both Ends - One End Thru - Inconel 22/23 21 Partial Crack One End - Incenel 26/27 6
Partial Crack One End - Inconel
~~
'f/38 3
Partial Crack One End - !nconal 3
40/41 1
Partial Crack One End - Inconel 44/1 14 Partial Crack Both Ends 4/1 15 Partial Crack Both Ends - Inconel 4/5 6
Partial Crack "oth Ends,- Inconel 15/16 3
Partial Crack both Ends - Inconel 15/16 6
Partial Crack Both Ends - Inconel 18/19 4
Partial Crack Both Ends - Inconel l
- Pin 'has been removed from this location and sent to lab for analysis.
1 Document No. 51-1142200-01
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TABLE 1 CONTINUED NSS-15 INSPECTION RESULTS BAFFLE TO FORMER BOLT LOCXING PIN WELDS CATEGORY 1: UELD CRACXED THRU OR PARTIALLY THRU OR INCONEL FILLER METAL
=
PLATE LOCATION BOLT NUM3ER DESCRIPTIO!! 0F' DEFECT I
i 44/1.
3 Inconel 2
44/1 4
Inconel 44/1-13 Inconel
~
44/1 16 Irenel 44/1 18 Inconel 44/1 20
-Inconel 44/1 21 Inconel 44/1 22 Inconel 4/5 3,
Inconel 4/5 12 Inconel 7/8 1
Inconel 7/8 4
Inconel 11/12 1
Inconel 11/12 2
Inconel 11/12 3
Inconel
~
11/12 4
Inconel 11/12 5
.Inconel 11/12 6
Inconel 11/12 21 Inconel i
j 11/12 22 Inconel 18/19 1
Inconel 18/19 3
Inconel 22/23 3
Inconel o
22/23 4
Inconel 22/23 22 Inconel
. 26/27 12 Inconel 29/30 10 Inconel Document No. 51-1142200-01 I
~
TABLE 1 CONTINUED NSS-IS INSPECTION RESULTS BAFFLE TO FORMER BOLT LOCXING PIN WELDS
~
CATEGORY 1: WELD CRACXED THRU OR PARTIALLY THRU OR INCONEL Fill'ER METAL
~
~ ~ ' ~ ~ ' ' ' ' ~
PLATE LOCATION BOLT nut 1SER DESCRIPTION OF DEFECT
~
29/30 13 Inconel 33/34 3
Inconel 33/34 4
Inconel 33/34 31 Inconel' 35/36 23
,Incenel 35/36 24 Incenel 37/38 12 Inconel 37/38 15 Inconel 40/41 13 Inconel i
9 l
l Document No. 51-1142200-01 lh;::
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.e TABLE 1-CORTINUED NSS-15 INSPECTION RESULTS
~
BAFFLE TO FORf!ER SOLT LOCXING PIN WELDS '
CATEGORY 2: PARTIAL CRACKS PLATE LOCATION BOLT NUMBER POSITION OF DEFEGT (O'CLC X) 4
- - 44/1 28 5:00 44/1 38 11:00 44/1 48 4:00 2/3 1
4:00 2/3 9
10:00 4/5 23 10:00 7/8 6
'1:00
,7/8, 11 7:00 9/10 24 2:00 11/12 27 10:00
~
11/12 28 2:00 11/12 42 10:00 13/14 4
1:00 13/14 15 2:00 15/16 2
5:00 15/16 13 5:00 15/16 15 7:00 18/19 7
8:00 i8/19 13 10:00 18/19 21 4:00 20/21
, 14 9:00 20/21 15 7:00 24/25 24 4:00 29/30 3
4:00 33/34 12 4:00 40/41 1
4:00 40/41 24 5:00 Document No. 51-1142200-01
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TABLE 1 - CONTINUED NSS-15 INSPECTION RESULTS BAFFLE TO FORMER BOLT LOCXING PIN WELDS.
' CATEGORY 3: MISCELLANEOUS DEFECTS PLATE LOCATION BOLT NUMBER POSITIONOFDEFECT(O'CLOCX) 44/1 9
Crator 9 5:00 & 11:00 15/16 5
Crator 9 3:00 44/1 38 Porosity 9 5:00 44/1 39 Torosity 9 5:00 22/23 36 Porosity ' '0:00 '
29/30 20 Porosity 0 7:00 4/5 10 Tungsten Inclusion 0 8:00 7/8 7
Tt.ngsten Inclus' ion 9 5:00 20/21 13 Tungsten Inclusion 9 4:00 l
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l Document No. 51-1142200-01 t
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TABLE'1 - CONTINUED NSS-15 INSPECTION RESULTS BAFR.E TO FORMER BOLT LOCXING PIN WELDS 0
CATEGORY 4: INSUFFICIENTWELD(NOT180 OR NOT 1/16" FILLET)
PLATE LOCATION BOLT NUMBER POSITION (O'CLCCK) 44/1 i
25 6:00
- 44/1 27 5:00 44/1 29 11:00 44/'.
30 a:og 44/1 33 8:00 44/1 35
-8:00 44/1,
37 8:00.
~ ~
44/1 39 11:00 44/1 40 5:00 44/1 43 7:00 44/1 44 10:00 44/1 45 5:00 l
44/1 46 8:00 2/3 5
4:00 & 10:00 2/3 6
4:00 2/3 7
4:00 2/3 23 2:00
.7/8 6
7:00 7/8 9
10:00 7/8 10 2:00 7/8 14 8:00 7/8 16 3:00 & 9:00 7/8 19 10:00 7/8 22 1:00 & 7:00 7/8 23 2:00 & 8:00 7/8 24 2:00 Document No. 51-1142200-01
' ' " ~
l TABLE 1 - CONTINUED NSS-15 INSPECTION RESULTS BAFFLE TO FORMER BOLT LOCXING PIN WELDS-0 CATEGORY 4:
INSUFFICIENT WELD (NOT 180 OR NOT 1/16" FILLET)
~
~ ~
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PLATE LOCATION BOLT NUMBER POSITION (O'CLOCX)
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9/10 13 11:00 9/10 14 2:00 9/10 15 3:00 & 9:00
'9/10 16 3 00 9/10 17 12:00 9/10 19
.2:00 9/10 20 3:00 9/10 22 4:00
, 11/12 7
5:00 ' " "
11/12 8
11:00 11/12 15 5:00 11/12 16 3:00
.11/12 17 2:00 11/12 20 3:00 11/12 28 5:00 & 11:00 11/12 29 I:00 11/12 30 6:00 & 12:00 11/12 31 7:00 11/12 32 1:00 11/12' 33 2:00 11/12 34 2:00 & 8:00 11/12 35 1:00 & 7:00 11/12 36 4:00 11/12 37 6:00 11/12 38 2:00 & 8:00 11/12 39 1:00
'11/12 40 4:00 11/12 41 6:00 & 12:00 Document No. 51-1142200-01
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TABLE 1
. CONTINUED NSS-15 INSPECTION RESULTS BAFFLE TO FORMER BOLT LOCXING PIN WELDS '
0 CATEGORY 4: INSUFFICIENT WELD (NOT 180 OR NOT 1/16" FILLET) -
PLATE LOCATION BOLT NUMBER POSITION (O'CLOCX) 11/12 43 8:00 11/12 44 5:00 11/12 46 4:00 & 10:00 11/12 48 2:00 13/14 3
6:00 & 12:00 13/14 4
7:00 13/14 5
'3:00 & 9:00 13/14 8
6:00 13/14 10 11:00 13/14 11 11:00 13/14 13 9:00 13/14 16 9:00 13/14 17 11:00
~
13/14 18 5:00 l
13/14 21 7:00 13/14 22 1:00 & 7:00 13/14 23 9:00 13/14 24 8:00 15/16 4
11:00 15/15 5
9:00 15/16 13 11:00 15/16
' 17 8:00 15/16 18 5:00 & 11:00 15/16 21 4:00 i
15/16 22 10:00 15/16 23 5:00 & 11:00 l
15/16 24 2:00 Document No. 51-1142200-01
.m..
TABLE 1 - CONTINUED NSS-15 INSPECTION RESULTS BAFFLE TO FORMER TOLT LOCKING PIN WELDS 0
CATEGORY 4: INSUFFICIENT WELD (NOT 180 OR NOT 1/16" FILLET) '
PLATE LOCATION BOLT NUMBER POSITION (O' CLOCK)
^ * ~ ~~
18/19 3
8:00 18/19 '
6 2:00 18/19 8
1:00 18/19 11 7:00 lb/19 13 4:00 18/19 14 2:00 18/19 16
'5:00 & 11:00
~
18/19 19 2:00 & 8 4
~
18/19 22 1:00 18/19 24 2:00 20/21 2
1:00 & 7:00 20/21
~
3 3:00 20/21 6
' 3:00
'20/21 9
3:00 20/21 10 6:00 20/21 12 7:00 20/21 15 1:00 20/21 18 4:00 20/21 19 5:00 & 11:00 20/21 2?
4:00 20/21 22 7:00 20/21
~ 23 6:00 & 12:00 20/21 24 1:00 & 7:00 22/23 6
12:00 22/23 24 12:00 22/23 39 1:00 22/23 44 3:00
- ~
Docue nt No. 51-1142200-01 6,
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3 TABLE I -C0tlTINUED NSS-15 INSPECTION RESULTS BAFFLE TO FORMER BOLT LOCXING PIN WELOS' 0
CATEGORY 4: INSUFFICIENT WELD (NOT 180 OR NOT 1/16" FILLET)'
PLATE LOCATION BOLT NUM8ER POSITION (O'CLOCX) 24/25 2
5:00 24/25 ~
14 9:00 24/25 23 5:00 26/27 8
5:00 26/27 13 2:00 25/27 17 7:00
~
25/27 18 3:00 25/27 24 143-
~ ' '
33/34 10 4:00 33/34 18 12:00 33/34 26 7:00 33/34 29 1:00 33/34 30 1:00 33/34 32 3:00 33/34 36 3:00 33/34 37 5:00 33/34 39 11:00 33/34 44 4:00 33/34 45 5:00 & 11:00 33/34 46 1:00 35/36 7
7:00 s
35/36 13 6:00 & 12:00 35/36 20 7:00 37/38 7
5:00
~
37/38 8
6:00 37/33 11 1:00 & 7:00 37/38 13 11:00 Document No. 51-1142200-01
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i TABLE 1 - 40ftTINUED NSS-15 INSPECTION RESULTS BAFFLE TO FORMER SOLT LOCXING PIN WELDS '
0 CATEGORY 4: INSUFFICIENT WELD (NOT 180 or NOT 1/16" FILLET)
PALTE L MTION BOLT NUMBER.
POSITION (O'CLOCX) 37/38 16 5:00 & 11:00 37/38 '
17 1:00 & 7:00 37/38 18 5:00 37/38 22 1:00 & 7:00 37/38 23 6:00 18 9:00 40/41 40/41 23
'2:00 & 8:00 42/43
- All 24 Both Ende a# Pin Bolts
- Repair 42/43-10, 11, 14, & 15 in Accordance with Instructions Given for Category #5.
Document No. 51-1142200-01 g.,.
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b TABLE - 1 CONTINUED NSS-15 INSPECIT0!! RESULTS BAFFLE TO FORMER. BOLT LOCXING PIN WELDS '
CATEGORY 5: LACX OF FUSION
~
PLATE LOCATION BOLT NUMBER POSITION (di~LOCX)
~
~
~ ^
C 4/5 16 2:00
- - - - - - ~ - ~
--~
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13/14 -
2 2:00 & 8:00 13/14 '
6 1:00 13/14 9
2:00 15/,16 7
4:00 15/16 16 2:00 15/ 19 7
2:00
~
20/21 5
8:00 20/21 6
9:00 20/21 7
5:00 20/21 9
9:00
~
i 20/21 11 4:00 22/23 5
7:00 22/23 27 11:00 22/23 35 1:00 24/25 7
4:00 24/25 20 11:00 24/25 23 11:00 26/27 17 1:00 33/34 38 8:00 33/34 39 4:00 35/35 5
7:00 37/38 4
1:00 42/43 10 5:00 1 11:00 42/43 11 7:00 42/43 14 3:00 & 9:00 42/43 15 11:00 Document No. 51-1142200-01 L
~
TABLE l' - CONTINUED NSS-15 INSPECTION RESULTS
~
BAFFLE TO FORMER BOLT LOCXING PIN WELDS-CATEGORY 6: MISCELLANEOUS ABNORMALITIES CATEGORY 6 INCLUDES ALL WELDS CATEGORIZED AS FOLLOWS:
. WELD METAL ON BOLT 7-
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2 --
WELD SPANS BOLT - SPAN CRACKED MINOR. MELTING OF BOLT CONCIVECONDITIONDUETOSLOPINGOUT OVERLAP ARC STRIKE CORROSION SPLATTER
~
- UNDERCUT UNACCEPTABLE CONTCUR l
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i Document No. 51-1142200-01 I
4 i
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1 4
TABLE 2 CATEGORY OF DEFECTS AND RECOINENilED REPAIR, l
4 i
CATEGORY #1 CATEGORY #2 CATEGORY #3 CATEGORY #4 CATEGORY #5 CATEGORY #6 IliRU CRACKS PARTIAL HISC.
INSuff!CIENT LACK OF MISCELLANEOUS REC 0tfiENDED REPAIR H.Elll0D OR INCONEL l.
Remove Pin and Replace with New Pin and New c,
8 Weld
.X c
2 l
N 2.
Grind out Defect and if Add Additional filler 1
Metal X
1 X
e i
S I
i
.L i
3.. Add Additional filler-R!
Hotal I
8 X
0 l
4.
Accept As is X
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TABLE 3
JOINT IDENTIFICATION AND LOCKING MECHAt1 ISM WELDS TO BE INSPECTED ON NSS-15 CSA
'~
Joint Identificaticn Quantity of Bolt
- Bol t P/N Locking' Mechanism
- Upper Grid Pad Mtg.
444 18-335 Weld to Head Screws
- Lower Grid Pad Mtg.
444 21-323 Weld to Head
. _. _...... Screws
- Upper Grid to Plenum 56 16-322 Locking Pin Cylinder
~~~
- Plenum Cylinder to 70 16-320 Locking Clip-
'~~
Plenum Cover
- Rod Guide Caps to L
162 16-344 Locking Cup Plenum Cover 1
- Vent Ass'y. Mounting l 64 12-347 Locking Cup
- -Screws
- 8affle to Former 576 11-324 Lacking Pin Bolts
- Support Post to 52 21-334 Locking Pin Lower Grid I-
- Flow Distributor to 134 22-346 Locking Pin Lower Grid f
i Former to Core Barrel 992 11-325 Locking Pin I
Brazement Set Screws 81 of the 243 to be 23-330 Locking Cup i
(Inspect Lower Inspected ElevationOnly) i s
- 100% inspection req'd. for Hot Functional Testing l
- 5% inspection req'd. for Hot Functional Testing i
51-1142172-00
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