ML20151Z067
| ML20151Z067 | |
| Person / Time | |
|---|---|
| Site: | Browns Ferry  |
| Issue date: | 04/16/1987 |
| From: | Lewis J, Pate B, Rose J TENNESSEE VALLEY AUTHORITY |
| To: | |
| Shared Package | |
| ML20151Z000 | List: |
| References | |
| WP-24-BFN, WP-24-BFN-R, WP-24-BFN-R00, NUDOCS 8808290153 | |
| Download: ML20151Z067 (8) | |
Text
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WELDING PROJECT EMPLOYEE CONCERN EVALUATION REPORT WELDER QUALIFICATION AT_
BROWNS FERRY NUCLSAR PLANT PREPARED BY i
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Report Number WP-24-hFN Revision 0 Date Y-/ 6 -87 8808290153 880822 DR ADOCK 050002 9 i
12250
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WP-24-BFW Revision 0 EMPLOYEE CONCERN SUMl'ARY SHEET WELDER OUAL17! CATION AT BROWNS FERRY NUCtEAR PLANT I.
SCOPE OF EVALUATION This report addresses one employee concern dealing with welder qualification at Watts Bar Nuclear Plant (WBN). This concern involved one issue.
A.
Welders from Muscle Shoals may not have received the appropriate number of bend tests when taking welder qualification test.
Text of the one concern is provided in the technical report (WP-24-BFN) under Attachment 1.
II.
ANALYSIS OF ISSUES ADDRESSED BY CONCERNS A.
Personnel at Muscle Shoals have indicated that four bend tests were conducted for each wolder qualification test, but only two bend
- tests were being entered on the qualification record. The omission of Suberticle QW-302.3, paragraph QW-302 from the 1974 edition of ASME Section IX could lead one to interpret the qualification requirement to require only two bend tests. TVA at Browns Ferry identified the problem and took corrective action by reviewing welder certification records and rotesting all affected welders.
A detailed discuscion of this issue is presented in WP-24-BFN, Paragraph III A.
III. COLLECTIVE SIGNIFICANCE A.
All affected welds have, received Quality Control acceptance and generic evaluation of a portion of the welds concluded the welds to be acceptable "as is."
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B.
The basic criterion established for welder qualification is to determine the wolder's ability to deposit sound weld metal.
C.
The TVA Welder Qualification Program at Browns Ferry is in compliance with ASME IX.
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IV.
ROOT CAUSE(S)
The omission of Subarticle QW-302.3, paragraph QW-302 ASME Section IX i
led to a misinterpretation of the testing requirements.
12250 Page 1 of 2 I
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WP-24-BFW Revision 0 V.
CORRECTIVE ACTION TVA has effected the necessary corrective action by requalifying all affected welders under the rules of the governing code. No further corrective action is indicated.
I VI.
REINSPECTION REQUIRED No.
VII.
ISSUE CLOSURE closed.
VIII. ATTACHMENTS 1.
Evaluation Report WP-24-BFN, Revision O.
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1 I
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WP-24-BFW Revision 0 WELDING PROJECT EMPLOYEE CONCERN EVALUATION REPORT WELDER OUALIFICATION AT BROWNS FERRY NUCLEAR PLANT I.
SCOPE OF EVALUATION A.
One employee concern.
Text of concern is provided under.
The subject concern originated at Sequoyah Nuclear Plant and was generically applied to Browns Ferry Nuclear Plant (BFN). This evaluation is based on review of the BFN Welding Phase 1 Report, current and superseded process specifications, and implementing Procedures, and the Weld Project Report WP-24-SQN.
Also reviewed were the BFN Corrective Action Reports, Discrepancy Reports, and Nonconformance Reports. The American Society of Mechanical Engineers (ASME) Welding and Brazing QualificationsSection II was reviewed and compared with the text of the concern.
The findings
. Pr?sented herein are based upon review of the above noted documents and interviews with cognizant TVA personnel.
II.
ISSUES ADDRESSED BY CONCERN Welders from Muscle Shoals may not have received the appropriate number of bend tests when taking weld qualification test.
III.
ANALYSIS OF ISSUES ADDRESSED BY CONCERNS A.
The one concern stated that welders at Muscle Shoals may not have received the appropriate bend tests.
The ASME Code, Section IX-1974 Edition. Article III, "Welding Performance Qualification " requirea that the type and number of test specimens required for mechanical testing shall be in accordance with QW-302.3 for guided bend tests. Paragraph QW-302.3 was not printed in the 1974 Edition. Table QW-452 specified one root and one face bend and allowed that two side bonds could be substituted for the root and face bend for thicknesses over 3/8 inch but less than 3/4 inch.
12260 Page 1 of 3
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Wp-24-BFN Revision 0 Due to the omission of paragraph QW-302.3, paragraph QW-302) could lead one to interpret the qualification requirement to regtrire only two bend tests. The Errata to the 1974 Edition of Section II published in the Summer 1974 addenda to Section IX added paragraph QW-302.3 which requires that four specimens, for the SG an6 60 positions, pass the guided bend test. The Summer Addends' to the 1978 Edition of Section II added a footnote to Table QW-451 which stated "a total of four specimens is required to qualify 4or positions 50 and 60 as prescribed by QW-302.3."
personnel at Muscle Shoals have indicated that four specilmens were tested for each welder qualification test'in the SG and 6G
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positions, but only two 'uend specimens were rtcorded on the welders 3
qualification record.
The time period that this practieet was conducted can be bounded to 1975 to 1977.
It was not established as to how many, if any, welders q'dafified at Muscle Shoals have performed welding activities at Browns F6rry.
However, as corrective action to DR 84-0185, all Mechanical Maintenance Welder Certifications were reviewed and all tests administered af ter 1 75 with only two bend test sampleetwere voided. The welders were retested and all requalified.
Modifications and Additions Welder Certifications were also reviewed and those tests with only two bend samples wora rescinded and the welders were retested to ASME Section IX requirements.
This was, however, done administrative 1y rather than by processing a Deficiency Report.
A generic engineering evaluation was conducted of the welds made at Browns Ferry by welders who had their certifications rescinded because of only having two teot bend samples. Additionally, all welds have been inspected and accepted under the provision'of the Quality Assurance program for CSSC items.
IV.
COLLECTIVE SIGNIFICANCE TVA at Browns Ferry, through the Quality Assurance program,Mdentified the problem and took corrective action by rethsting the affected welders to ASME Section IX requirements. Also, a generic e'vatbation of welds made by Mechanical Maintenance Welders was conducted bytsite Maintenance Engineering and the welds were determined accepthble "as is."
The Mechanical Maintenance Welders were addressed on a discrepancy report and it would have been more appropriate to have addrosted the Modifications and Additions Welders in the same manner.
TVAbald however demonstrate these welders' competence through testinginder the rules of ASME Section IX, 12260 dage 2 of 3
l WP-24 BFW Hevicion 0 The basic criterion estabilshed for welder qualification t determine the welder's ability to deposit sound weld mets'.,
V.
ROOT CAUSE(S)
The omission of Subarticle QW-302.3. ASME Section II letkis c misinterpretation of the testing requirements.
VI.
CORRECTIVE ACTION TVA requalified all potentially affected welders under bae ruler of ASME Section 11.
No further corrective action is indictied.
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VII. ATTACHMENTS 1.
Employee concern.
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12260 Pago 3 of 3 I
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WP-24-BFW Revision 0 WELDING PROJECT EMPLOYEE CONCERN EVALUATION REPORT, ATTACHMENT 1 TEXT OF EMPLOYE2 CONCERNS Evaluation Report WP-24-BFN addresses one employee concern. The text of the concern is shown on the following page.
JLH-85-002 d
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TEFERECCE
- ECPS132J-ECPS132C TENNESSEE VALLEY AUTHORITY
~CEQUENCY
- RECUEST PAGE 1
)MP - ISSS - Run OFFICE OF NUCLEAR PDHER s
EMPLOYEE CONCERN PROGRAM SYSTEM (ECPS)
RUN TIME - II 54:4a EMPLOYEE CONCERN INFORMATION BY CATEGORY / SUBCATEGORY RUN DATE - 03/16/8'
\\TEGORY: HE NON 4A/4C HELDING HP - 24 WELDER PERFOR!!ANCE QUALIFICATION CONTINUITY-SQN 3
H I REPORT APPL REF. SECTIor SUB R PLT 2 SAF RELATED HISTORICAL CONCERN C0f4CER3 NUMBER CAT CAT D LOC CAT
- HE BF BL SQ HB REPORT ORIGIN CONCERN DESCRIPTION SUBCAT - 24
'!LH-55-CO2 01 HE S0124 N SQN 1Y Y Y Y DECP THIS CONCERN HAS NOT DOCUMENTED PER 2 SS SS SS SS SQAI66 BUT HAS BEEN INCLUDED IN THE EMPLOYEE CONCERN LOG.
HELDERS FROM MUSCLE SHOALS MAY NOT HAVE RECEIVED THE APPROPRIATE NUMBER OF. BEND TESTS WHEN TAKING HELD QUALIFICATION TEST S. (SQN ISSUES ADDRESSED IN RPT HP-2 4-SQN RO) 1 CONCERNS FOR CATEGORY HE HP - 24 CONCERNS ARE GROUPED BY LAST 2 DIGITS OF SUBCATEGORY HUMBER.
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