ML20206D389
| ML20206D389 | |
| Person / Time | |
|---|---|
| Site: | Browns Ferry  |
| Issue date: | 03/13/1987 |
| From: | Blake J, Economos N NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML20206D324 | List: |
| References | |
| 50-259-87-11, 50-260-87-11, 50-296-87-11, NUDOCS 8704130319 | |
| Download: ML20206D389 (8) | |
See also: IR 05000259/1987011
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UNITED STATES
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NUCLEAR REGULATORY COMMISSION
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REGION 11
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101 MARIETTA ST REET, N.W.
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ATL ANTA, GEORGI A 30323
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Report Nos.: 50-259/87-11, 50-260/87-11, and 50-296/87-11
Licensee: Tennessee Valley Authority
6N 38A Lookout Place
1101 Market Street
Chattanooga, TN 37402-2801
Docket Nos.:
50-259, 50-260 and 50-296
and DPR-68
Facility Name:
Browns Ferry 1, 2, and 3
Inspection Conducted:
February 24- ( 1987
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Inspector:
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Approved by:
J. J B14ke~ Chief
Da'te Signed
Mat ri,Is an,d Processes Section
D1 ision of Reactor Safety
SUMMARY
Scope:
This special unannounced inspection was conducted in the area of
recirculation nozzle safe-end welding and previously identified enforcement
matters.
Results: Two violations were identified - Combination Weld Procedure Qualifi-
cation Record Lacking Weld Deposit Thickness Range Information, paragraph 5;
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and Failure to Provide Adequate Measures for the Control and Identification of
Welding Consumables, paragraph 3.a.
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0704130339 07033o
DR
ADOCK 05000259
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REPORT DETAILS
1.
Persons Contacted
Licensee Employees
- R. L. Lewis, Plant Manager
- J. A. Savage, Compliance Engineer
- C. McFall, Compliance Engineer
S. P. Stagnolia, Section Manager, Nozzle Replacement Group
W. R. Bentley, NDE Level III Examiner
R. Latimer, Supervisor, Inservice Inspection
H. S. Dean, QA Evaluator, Quality Surveillance
J. C. Pettitt, Section Supervisor, Nozzle Replacement Group
T. Everitt, Welding Engineer, Nozzle Replacement Group
D. Odom Welding QC Coordinator
Other licensee employees contacted included construction craf tsmen,
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engineers, technicians, office personnel.
NRC Resident Inspectors
- G. L Paulk, Senior Resident Inspector
- C, A. Patterson, Resident Inspector
- Attended exit interview
2.
Exit Interview
The inspection scope and findings were summarized on February 27, 1987,
with those persons indicated in paragraph I above.
The inspector
described the areas inspected and discussed in detail the inspection
findings. No dissenting comments were received from the licensee.
Violation 259, 260, 296/87-11-01,
Combination Weld Procedure Qualifica-
tion Record (PQR) Lacking Weld Deposit Material Thickness Measurement,
paragraph 5.
Violation 259, 260, 296/87-11-02,
Failure to Provide Adequate Measures
for the Control and Identification of Welding Consumables, paragraph 3.
Inspector Followup Item 260/87-11-03, PQRs Used to Qualify Welding
Procedure Lack Adequate Referencing System, paragraph 5 .
The licensee did not identify as proprietary any of the materials provided
to or reviewed by the inspector during this inspection.
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3.
Licensee Action on Previous Enforcement Matters
a.
(Closed) Unresolved Item (50-260/86-34-02):
Documentation and
Traceability of Filler Metal Quality Records
This item was opened because certain weld material quality records
were not available for review at the time of the NRC inspection
between October 6-10, 1986.
At the time, the licensee offered to
retrieve the requested information and forward it to Region II for
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the review. On or about October 14, 1986 the licensee representative
contacted this inspector and stated that certain discrepancies had
been identified in the documents used for issuance, control and
traceability purposes.
Because these discrepancies were considered
significant and involved violations of site implementing documents,
the licensee issued a corrective action report (CAR), No. CAR-86-0201
dated October 14, 1986. The weld materials for which quality records
were requested and discrepancies identified were as follows:
575 Control Number
Type
Size
7386-00585
E7018
1/8" diam.
5685-06945
E7018
3/32" diam.
5686-1190
E7018
3/32" diam.
Specifically the discrepancies noted on the aforementioned CAR were
as follows:
(1)
Form 575 No. 5686-11900 contained no heat number.
(2) Form 575 number 5686-011473 was first issued as 575 control
number 7386-00585.
When the warehouse changed the 575 control
number on its copy, it did not send copies of the 575 form with
the change control number to the tool rooms.
Therefore, the
voided 575 control number was referenced in work plans (WPs) and
modification requests (MRs) instead of the new number. Control
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575 number 5685-06945 specifies that 921210 is the heat number
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for E7018, 3/32 diameter welding electrodes, 921210 is the lot
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number and not the heat number.
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Discussions with licensee representatives disclosed the above
discrepancies reflected violations of site implementing procedures
BF6.2 and BF16.4 which require that, the correct heat number be
recorded on the TVA 575 Form and that welding material in tool room
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be identified by the correct 575 control number including heat
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number.
Further discussions with cognizant licensee personnel
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disclosed that upon further investigation other discrepancies of a
similar nature were found. Also, it was disclosed that until recently
each site organization, i.e. plant maintenance and modifications
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etc., maintained and distributed weld materials from their own
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separate inventories.
In other words, the same material was being
issued by several site organizations conceivably under different
575 control numbers.
Apparently this system has the potential for
creating documentation and material control problems as evidenced
by the aforementioned CAR.
This situation was corroborated by the
licensee's root cause analysis statement on the subject CAR.
It
stated that, identical welding materials are presently maintained in
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maintenance, modification and direct charge status at BFN.
This
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creates the potential for (material) issuing errors and therefore
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subsequent changes to 575 control number.
The licensee's stated
actions to prevent recurrence of this problem were as follows:
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In the future, all weld electrodes will be placed in modifica-
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tions inventory.
This will resolve the inadvertent issue of
like uaterials from the incorrect inventory and therefore
eliminate the need to change 575 control numbers.
Power Stores issuing personnel have been retrained in the
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importance of proper weld rod issues.
Because the licensee eventually retrieved the information requested,
the inspector closed the subject unresolved item.
However, the
inspector stated that because the documentation discrepancies in the
issuance and control of weld material had gone undetected and therefore
uncorrected prior to the request for information on October 10, 1986,
a violation was being issued to underscore the fact that the weld
material control program at this site was inadequate.
This failure
to provide adequate measures for the control and identification
of materials (welding consumables) was a violation of 10 CFR 50,
Appendix B, Criterion VIII and was identified as violation 259, 260,
296/87-11-02, Failure to Provide Adequate Measures for the Control and
Identification of Welding Consumables.
b.
(Closed) Violation 259, 260, 296/86-34-01, Welder Performance
Qualification Records Lacking Thickness Range Information.
The licensee's letter of response dated December 30, 1986, has been
reviewed and determined acceptable by Region II.
The inspector
held discussions with the cognizant licensee personnel and examined
the corrective actions as stated in the letter of response.
The
inspector concluded that the licensee had determined the full extent
of the subject noncompliance, performed the necessary followup
actions to correct the present conditions, and developed the
necessary corrective conditions.
The corrective actions identified
in the letter of response have been implemented.
4.
Unresolved Items
Unresolved Items were not identified during this inspection.
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5.
Inspection of Replacement of Recirculation Piping (Unit 2) (TI2512/13)
The inspection effort in this area was a followup to previous inspections
conducted by Region II staff and subsequently documented in inspection
reports 50-260/87-01 and 50-260/87-04. Selected aspects of ,the licensee'.s-
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welding activities and related QA/QC records were reviewed to ascertain
whether they were consistent with applicable code and regulatory require-
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ments. The recirculation nozzle safe-ends and associated piping are being
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installed in accordance with ASME, Code Section(s) XI/III (80W81); fabri-
cation and nondestructive examination are performed to the requirement of
ASME Section III, (S83) addenda.
The original code of record for this
system was USAS B31.1 Power Piping Code 1967 Edition.
The inspector
observed safe-end to nozzle welds both those that had been welded out and
others in process. Weld fabrication was being performed with a consumable
insert welding procedure GTA-88-C-5 Revision 3, using the automatic gas
tungsten arc (TIG) process.
Automatic TIG welding machines were used to
control welding parameters and fabricate the weldment. Qualified welding
operators using remote control devices assisted by TV monitors maintained
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control of the fabrication.
At the time of this inspection, the safe-end
to nozzle welds on nozzles B, D, F and G had been completed. Consumption,
of.the insert and deposition of the hot passes was in progress on nozzles
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C & J. Areas of interest included weld bead appearance, configuration,
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fusion and width, arc behavior, weld pool turbulences or lack thereof,
wire feed, travel, and oscillation.
These conditions / parameters were
observed to ascertain compliance with the aforementioned welding procedure
and code requirements.
Fabrication history and QA/QC inspections performed on each nozzle is
maintained through the use of a workplan and inspection record (WP&IR),
document which appears as attachment 2 to BF-SDSP-8.4 Rev.1.
The
inspector reviewed WP&IR No. 2174-86, Nozzle C and No. 2177-86,_ Nozzle F
for completeness and accuracy; hold points designated by the authorized
nuclear inspector were identified as line items in the plar,s.
In addi-
tion, the inspector reviewed the following documents:
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1.M.1.2 Rev. 4
TVA General Welding Procedures Specification
BF6.2-05
Quality Control of Welding Activities
BF16.4 Rev. 4
Material, Components and Spare Parts Receipts,
Handling, Storage Issuing, Return to Storeroom
and transfer
BF-SDSP-13.2 Rev. 1
Welding and Brazing Filler Material
Control. . .
MAI-49 Rev. 3
N2 Nozzle Safe-End and Riser Elbow Assembly
Replacement.
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Weld Procedures and Associated P M
Thickness
Weld Procedures
Date.
Range
GT-88-0-1A Rev. 1, 11-6-78
GT-88-0-1
03-06-78
3/16" - 1.00"
GT-88-0-6 Rev. O, 11-6-86
GT-88-0-1
05-28-74
1/16" - 11/16"
GT-88-0-1
05-14-70
1/16" - 1/2"
GTA-88-C-5 Rev. 3, 1/21/87
GTA-88-C-1
09-26-72
3/16" - 1.436"
GT-SM88-0-1B Rev. 2, 4/4/85
GT-SM88-01
09/18/70
3/16" - 1 7/16"
GT-SM88-0-2
06/24/74
3/16" - 4 1/2"
Performance Qualification Test
Thickness
Test No.
Weld Procedure
Range
GTA-7-C-3-H(a)Rev.O,11-5-86
GTA-88-C-5
3/16" - 1.436
Within these areas the inspector noted the following:
Weld procedure GT-SM88-0-1B above was qualified as a combination procedure
using both the gas tungsten arc process and the shielded metal arc process
as permitted by the code.
To do this, the licensee used PQRs, GT-SM-0-1
and GT-SM-0-2 which were qualified using the gas tungsten arc process
(GTA) for the root portion of the weldment and the shielded metal arc
process (SMAW) to weld out the remainder of the weld joint. The aforemen-
tioned weld procedure references General Welding Procedure Specification
1.M.1.2 (R4) which in turn reference ASME Code Section IX as the governing
code for welding procedure qualifications. The weld procedure and associ-
ated PQRs are contained in TVA's specification G-29M, DPM.N73.M.2.
In
reference to the use of combination welding procedures on production
welds paragraph QW-200.4 of ASME Section IX, requires that these proce-
dures be qualified for the deposited weld metal thickness range for each
of the processes to be used in the production joint.
Also, the code
states that-the qualified thickness of each process shall not be additive
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in determining the maximum thickness of the production joint welded.
Contrary to this requirement the inspector noted that neither of these
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two PQRs provided the thickness of the metal deposited by each process
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as required by the aforementioned code.
This failure to comply with
applicable ASME Section IX requirements is in violation of paragraph
(a)(1) of the 10 CFR 50.55a and is identified as violation 50-259, -260,
-296/87-11-01, Combination Weld Procedure Qualification Record Lacking
Weld Deposit Material Thickness Measurements.
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Also, during this review the inspector noted that, weld procedure
GT88-0-1A Rev. 1, 11/6/78 referenced PQR GT88-0-1 as that used to qualify
the procedure.
However, the inspector noted that there were three PQRs
having. number GT88-0-1, see above, each qualified on a different date, a
different pipe diameter and thickness range,
Also, the one qualified on
3/6/78 showed the weld joint configuration sketch with a backing strip
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instead of the open butt as indicated by the procedure and PQR number
designation.
The inspector discussed this discrepancy with cognizant
licensee personnel who agreed that the PQRs should be numbered in a manner
that would show that all three were interrelated with the applicable weld ~
procedure and therefore help minimize the existing confusion factor.
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Also, the inspector suggested that the joint configuration sketch be
revised to be consistent with the designated PQR number. This matter was
identified as an inspector followup item until the appropriate corrective
action has been taken by the licensee.
IFI 259, 260, 296/87-11-03, PQRs,
used to Qualify Weld Procedure Lack Adequately Referencing Information.
a.
Review of Material Quality Records
The inspector reviewed quality records for equipment, replacement
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materials and welding consumables listed below.
Welding Machine
Machine S/N, 1231, 1239, 1544, 1196
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Calibration
Records
Grade SA-182, F316NG, 12" diameter heat
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Replacements
No. 131BN
RT Plugs
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Grade SA-182 F316NG Threaded
Replacement Pipe,
12" diameter
Grade SA403, WP316NG, Ht #D440904, D442604,
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D45A704, D442004, D451004, D441104
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Weld Consumables
Insert - 1/8"x5/32" IN308L Ht #5493T308L
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Wire - 0.045" 9 ER308L Ht #SE0591
These records were retrievable complete and accurate.
Within the
areas inspected no violations or deviation were identified.
b.
Radiography (57090)
As part of the current inspection effort, the inspector reviewed
radiographs of two completed safe-end and nozzle welds identified as
"B" and "G".
TVA Radiographic Procedure N-RT-1, Revision 5, written
to comply with ASME Section III, Edition (80W81), was used to produce
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the radiographs. Radiographic film associated with subject welds was
reviewed to ascertain whether radiographic quality was in accordance
with the above code and procedural requirements in the following
areas:
(1) Penetrameter type, size, placement
(2) Penetrameter sensitivity
(3)
Film density, density variation
(4) Film identification
(5) Film quality
(6) Weld coverage (overlap)
Within these areas the inspector noted that the linear indication at
the root of the nozzle
"G"
weld safe-end, discussed earlier in
Reports 50-260/87-01 and -04, had been interpreted by TVA's Level III
NDE examiner as a root condition associated with weld joint geometry,
12 chamfer, and the shape of the consumed insert.
To support this
position, the licensee presented a sequence of radiographs from
mock-up weld specimen
"T", and nozzle
"G" taken with different
techniques including parallax.
The inspector agreed with the
licensee's interpretation but stated that because this matter was a
part of a broader concern which was documented in Report., 50-260/
87-01 and 50-260/87-04 it was preferable to let the matter be
resolved by those individuals more familiar with the concern.
In
response to the inspector's request, the licensee provided duplicate
radiographs from the mock-up welds and the "G" nozzle.
The radio-
graphs, along with a 31 inch long sample segment of weld removed from
mock-up weldment "T" were brought to the Region for further review
and evaluation by the staff.
Within the areas inspected, no violations or deviations were identified.
6.
(Closed) Inspector Followup Item 86-34-03, Weld Gap in Gusset Plate
This item was identified when the inspector noted that a plate in ring-
girder #2, on the side of Bay-2 exhibited a gap about 3/16 inches wide in
the fillet weld area.
The associated work plan was WP2067-86 and
applicable drawing was 48W1218-7R10.
The inspectors requested that the
weldment in question be reinspected, evaluated by design engineering and
the results presented to the inspectors for review on a future inspection.
During the current inspection the inspector reviewed the licensee's
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corrective actions which were documented under action item no. SLT-86-
1086-002 generated by Design Engineering.
Other documents reviewed
included:
a.
Calculation - BFEC10367, sheet 40.10A and .10B
b.
Design Drawing - 48W128-7, Rev. 13
c.
Work Plan - WP 2067-86
Corrective action on the subject weld has been completed and the work plan
is in the final closecut cycle.
Therefore, this item is considered
closed.
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