ML20205N547

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Summary of 870209 Mgt Meeting W/Util & EPRI at Region II Ofc Re Problems Encountered W/Safe End to Reactor Pressure Vessel Nozzle Welding,Investigation & Course of Action. Attendance List & Viewgraphs Encl
ML20205N547
Person / Time
Site: Browns Ferry Tennessee Valley Authority icon.png
Issue date: 03/17/1987
From: Zech G
NRC OFFICE OF SPECIAL PROJECTS
To: White S
TENNESSEE VALLEY AUTHORITY
References
NUDOCS 8704030050
Download: ML20205N547 (19)


Text

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MAR 171987 Docket Nos. 50-259, 50-260, 50-296 License Nos. DPR-33, DPR-52, DPR-68 Terpiessee Valley Authority TTN: Mr. S. A. White Manager of Nuclear Power 6N 38A Lookout Place 1101 Market Street Chattanooga, TN 37402-2801 Gentlemen:

SUBJECT:

MEETING

SUMMARY

- BROWNS FERRY NUCLEAR PLANT, UNIT 2, DOCKET NO. 50-260 This refers to the management meeting conducted at your request, in the Region II Office on February 9, 1987. This meeting was held to discuss problems encountered with Browns Ferry Unit 2 safe end to reactor pressure vessel (RPV) nozzle welding, problem investigation, and your future course of action. A meeting summary of the topics discussed is provided in Enclosure 1.

Enclosure 2 is the attendance list, and the licensee's handout material is provided in Enclosure 3.

It is our opinion that the meeting was beneficial and has provided a better understanding of the actions taken by TVA in resolving welding concerns.

In accordance with Section 2.790 of NRC's " Rules of Practice," Part 2, Title 10, Code of Federal Regulations, a copy of this letter and its enclosures will be placed in the NRC Public Document Room.

Should you have any questions concerning these matters, we will be pleased to discuss them.

, MIMdl$lGNED BY GARY G. 2ECH Gary G. Zech, Assistant Director, Regional Inspections Division of TVA Projects Office of Special Projects

Enclosures:

1. Meeting Summary
2. Attendance List
3. Licensee Handout Material cc w/encis: (See page 2) 8704030050 870317 PDR ADOCK 05000260 P PDR 1GW

Tennessee Valley Authority 2 MAR 171987 cc w/encis:

LK. P. Pomrehn, Site Director Jrowns Ferry Nuclear. Plant

4. L. Gridley, Director clear Safety and Licensing

. W. Cantrell, Acting Director lear Engineering J. May, Site Licensing Manager be w/encis:

LJ . Keppler, OSP

. Ebneter, OSP

/A.Zwolinski,OSP D. Liaw, OSP R. Connelly, 0IA

. P. Barr, RII IN(C Resident Inspector NRC Document control Desk State of Alabama RII RI 00c(I AIgnatonis:er KB 03//f /87 / 7

ENCLOSURE 1 MEETING

SUMMARY

On February 9,1987, representatives of Tennessee Valley Authority (TVA) met with the NRC, at TVA's request, to discuss Browns Ferry Unit 2 safe end to reactor pressure vessel (RPV) nozzle welding concerns, problem investigation, and the future course of action.

TVA provided an overview of the recirculation piping inlet safe end to RPV weld program starting with a brief information background, commencement of production welding, problems enccuntered and its identification, problem investigation, future work plans, and lessons learned. The presented material is enclosed. Prior to performing any production welding on replacement system piping, the licensee prepared and performed mockup welds. These mockup welds were inspected by radiographic testing (RT) and no rejectable defects were found. On January 4,1987, production welding of the safe end to the nozzle commenced. Nozzles "G", "F", and "J" were welded and RT inspections were performed. For the first nozzle "G" no indications were identified by the Level II inspector. Nozzle "F" and "J" were also RT inspected, but by a Level III inspector who came to the site after production welding commenced.

The Level III inspector identified indications on "F" and "J" nozzle welds, as I well as on the "G" nozzle weld. As a result, TVA stopped production welding on January 7, 1987.

l l The linear indications always appeared in the upper half of the pipe a

circumference and on the nozzle side. The dark line exhibited in the radiograph was interpreted to be as an abrupt density change by TVA. TVA initiated on an informal basis a three prong problem investigation effort. The areas being investigated were mockup work, additional NDE analysis, and additional engineering analysis. TVA was able to reproduce the root condition (i.e. indication) on mockup welding by having a large angle on the chamfer and welding being performed in the upper half of the circumference. The additional NDE analysis included radiograph enhancement and UT analysis of the weld. In the engineering analysis area, TVA planned to review the ASME Code requirements and analyze nozzle repair configurations if needed. TVA was reluctant to repair the nozzle welds because of the potential in creating new problems; however, if the UT, RT enhancement, and boroscope results warranted cutting and repair of nozzle welds, then they would do it.

TVA also researched similar work performed at the Peach Bottom and Vermont

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Yankee facilities. The Vermont Yankee radiographs of the safe end to nozzle welds also exhibited dark lines, but the indications were not attributed by the chamfer angle effect. Their problem was different and the repairs were made as j needed.

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Enclosure 1 2 i

For the lessons learned, TVA concluded that they should have had Level III inspector involvement early in the project and should have had better project control. However, once the problems surfaced TVA has stated that they quickly responded to them, although no formal (written) plans were made for the recovery effort. The Site Director was fully involved in the problem investigation. TVA committed to document their work and inform the NRC prior to restart of production welding.

I i On February 27, 1987, TVA informed the NRC of their intent to resume production

. welding. Production welding on the "B" nozzle was completed and radiographed

} as satisfactory. The large angle on the chamfer was verified to be the principle contributor of the safe end to nozzle welding problem.

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1 ENCLOSURE 2 MEETING ATTENDEES U.S. Nuclear Regulatory Commission G. G. Zech, Assistant Director, Regional Inspection, DTVA, OSP K. P. Barr, Deputy, Assistant Director, Regional Inspections, DTVA, OSP A. J. Ignatonis, Chief, Projects Section 2, DTVAP, OSP A. R. Herdt, Chief, Engineering Branch, Division of Reactor Safety (DRS)

J. J. Blake, Chief, Materials and Processes Section, DRS J. L. Coley, Reactor Inspector, i RS E. H. Girard, Reactor Inspector, DRS R. W. Newsome, Reactor Inspector, DRS Tennessee Valley Authority l H. P. Pomrehn, Site Director, Browns Ferry j M. J. May, Manager of Licensing, Browns Ferry

E. Hartwig, Project Manager, Browns Ferry Project Management.

4 S. P. Stagnolia, Section Manager, Nozzle Replacement Group

A. J. Everitt, Welding Engineer, Nozzle Replacement Group
R. McKenna, Project Management, Browns Ferry l N. R. Bentley, BDE Engineer M. Turnbow, ISI/QA Engineer J. H. Fox, Senior Metallurgical Engineer Electric Power _Research Institute (EPRI) NDE Center J. A. Disney i-f 4

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ENCLOSURE 3 LICENSEE HAND 0UT MATERIAL

'. ? V A BROWNS FERRY - UNIT 11 SAFE END TO RPV NOZZLE WELO PROGRAM

FEBRUARY 9,1987 MEETING IN NRC OFFICES ATLANTA, GA.

OUTLINE OF DISCUSSION

= PREFIELD WELDING

= WELDING ON RPV COMMENCES

= PROBLEM IDENTIFICATION

= PROBLEM INVESTIGATION

= ADDITIONAL MOCK UP PROGRAM INITIATED

= ADDITIONAL NDE ANALYSIS INITIATED -~

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= ADDITIONAL ENGINEERING ANALYSIS INITIATED a CONSULTATION WITH EXPERTS

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= CURRENT STATUS '

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= FINAL VERIFICATION ON MOCKUP WITH -

REVISED WELDING PARAMETERS

= FUTURE WORK PLANS

= LESSONS LEARNED

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SAFE END TO RPV NOZZLE WELD PROGRAM PRE FIELO WELOING KICK OFF MEETING WITH NRC NOVEL BER 4,1986

= EQUIPMENT AVAILABLE AND OPERATIONAL

= WELDING PROCEDURES OUALIFIED

= MOCK UPS OF WELO MADE

-RT INSPECTION OF WELDS PERFORMED TESTING OF WELDERS 1

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l SAFE END TO RPV NOZZLE WELD PROGRAM WELDING ON RPV COMMENCES

= STARTING DATE JANUARY 4,1987 ON SAFE END TO NOZZLE

= FIRST NOZZLE (G) INSPECTED BY RT 4

- IN PROCESS ROOT CONSUMED PLUS FOUR HOT PASSES

- INDICATION NOT IDENTIFIED BY LEVEL ll INSPECTOR SECOND AND THIRD NOZZLES (F AND J) INSPECTED BY RT l

l - IN PROCESS (ROOT CONSUMED PLUS FOUR HOT PASSES)

- LACK OF FUSION IDENTIFIED IN NOZZLE (F).

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- LACK OF FUSION REMOVED BY EXCAVATION .

- (F) AND (J) REVIEWED AND INDICATION IDENTIFIED BY LEVEL lli ~ '

-(G) NOZZLE REVIEWED AND INDICATION IDENTIFIED BY LEVEL 111

= TVA STOPPED PRODUCTION WORK ON JANUARY 7,1987 .

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1 PROBLEM IDENTIFICATION

= ABRUPT DENSITY CHANGE

= LINEAR INDICATION CHARACTERISTICS

- ALWAYS ON NOZZLE SIDE

- PARALLEL TO ROOT PASS

- OUTSIDE OF ROOT AREA

- ALWAYS IN THE UPPER HALF OF THE PIPE CIRCUMFERENCE

= LACK OF FUSION

- ONE TWO INCH LACK OF FUSION FOUND AND -

REMOVED SUCCESSFULLY ON NOZZLE (F) i i

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SAFE END TO RPV NOZZLE WELD PROGRAM PROBLEM INVESTIGATION GRINDING ON (F) AND (J) NOZZLES IN AREAS OF INDICATION - JANUARY 9,1987

- HOT PASSES REMOVED (ROOT PASS REMAINS)

- NO IRREGULARITIES FOUND

- INDICATION REMAINS

= (G) NOZZLE WELDED OUT AND RT TAKEN. INDICATION REMAINS - JANUARY 14,1987 i

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SAFE END TO RPV NOZZLE WELD PROGRAM i

ADDITIONAL MOCK UP PROGRAM INITIATED

= PHIPPS BEND RPV NOZZLE

- USE SAME PARAMETERS AS PRODUCTION WELDS

- RT TAKEN IN PROCESS SET UP BEFORE WELDING AFTER INSERT CONSUMED FIRST HOT LAYER - TWO PASSES SECOND HOT LAYER - TWO PASSES THIRD HOT LAYER -

FULL WELD OUT

- NONE OF THE RT EXAMINATIONS SHOWS THE SUBJECT INDICATION CONSTRUCT ADDITIONAL PIPE TO PIPE MOCK UPS

- MATRIX DETAILING MOCK UPS

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= ROOT CONDITION REPRODUCED ON PIPE TO PIPE MOCKUP -

ONLY WHEN: I

- LARGE ANGLE ON CHAMFER

- CHAMFER SIDE ONLY

- UPPER HALF OF THE WELD

SAFE END TO RPV NOZZLE WELD PROGRAM ADDITIONAL NDE ANALYSIS INITIATEO

= PARALLAX RT ON NOZZLE G

- RADIOGRAPHS SENT TO APTECH FOR STUDY

- RESULTS OF STUDY

= DIGITAL ENHANCEMENT OF RADIOGRAPHS

- BY APTECH

- RESULTS OF STUDY

= UT ANALYSIS OF WELD.

- QUALIFY PROGRAM

- APPLICATION OF l-98 PROGRAM

- EXAMINATION OF PHIPPS BEND MOCKUP AND NOZZLE G

- RESULTS OF EXAMINATION

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SAFE END TO RPV NOZZLE WELD PROGRAM LESSONS LEARNED

= USE UT TO COMPLEMENT RT BETTER SIMULATION OF PLANT CONDITIONS EARLY LEVEL lli INVOLVEMENT e

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SAFE END TO RPV NOZZLE WELD PROGRAM i

ADDITIONAL ENGINEERING ANALYSIS INITIATED REVIEW OF CODE INTERPRETATION 2'

- INTERPRETATION FOUND CONCERNING DRESDEN

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CONCERNS CENTER ON ROOT CONDITION - DOES NOT APPLY TO BF ., -

= OESIGN ANALYSIS OF WELO JOINT CONFIGURATION

- NOZZLE DESIGN REPORT REVIEW

- STUDY OF HEAT INPUT VS SHRINKAGE -

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= ANALYSE NOZZLE REPAIR CONFIGURATIONS.

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SAFE END TO RPV NOZZLE WELD PROGRAM CONSULTATION WITH EXPERTS TVA

= OTHER BWR PLANTS

= DESIGN ENGINEERING FIRMS

= EPRI e

9 CONTRACTORS

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SAFE END TO RPV NOZZLE WELD PROGRAM CURRENT STATUS

= EVALUATING UT REPORT ON PHIPPS BEND NOZZLE

= EVALUATING UT REPORT ON G NOZZLE

= OlGITAL ENHANCEMENT OF RT -

= VERIFICATION MOCKUPS IN FABRICATION

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SAFE END TO RPV NOZZLE WELD PROGRAM FINAL VERIFICATION ON MOCK UP WITH REVISED WELDING PARAMETERS

= RETAIN CONFIGURATION OF FIELD W5LD

= ADD CHAMFER DETAIL TO DUPLICATE FIELD AS BUILT.

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= INSERT PLACEMENT NO CHANGE

= CONSUME INSERT USING EXISTING PARAMETERS

= HOT PASSES (ONE LAYER OVER ROOT) USING EXISTING '

PARAMETERS

= FILL PASSES TO RECEIVE LESS HEAT INPUT

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SAFE END TO RPV NOZZLE WELD PROGRAM c

FUTURE WORK PLAN:

j = RESUME PRODUCTION WELDING USING:

- MODIFIED IN PROCESS INSPECTION PROGRAM

- REVISED WELDING PARAMETERS a NOZZLE G  !

= NOZZLES F & J

- PROGRAM FOR WELD DISPOSITION r

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