ML20207L111
| ML20207L111 | |
| Person / Time | |
|---|---|
| Site: | Sequoyah  |
| Issue date: | 12/23/1986 |
| From: | Sting W TENNESSEE VALLEY AUTHORITY |
| To: | |
| Shared Package | |
| ML20207K584 | List: |
| References | |
| C017304-SQN, C017304-SQN-R03, C17304-SQN, C17304-SQN-R3, NUDOCS 8701090627 | |
| Download: ML20207L111 (8) | |
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. TVA EMPLOYEE CONCERNS REPORT NUMBER: C017304-SQN SPECIAL PROGRAM REPORT TYPE: Sequoyah Nuclear Plant Element REVISION NUMBER: 3 (Final Report) i TITLE: Compression Fittings PAGE 1 0F 7 r
, REASON FOR REVISION:
Incorporate TAS and SRP comments. Revision 1 Changed III. H and IV. H. 3. Revision 2 Added date of evaluation to I.
Incorporate Line Management response, incorporate Revision 3 NRC comments and finalize report.
PREPARATION PREPARED BY:
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- DATE APPROVED BY:
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, DATE MANAGER OF NUCLEAR POWER DATE CONCURRENCE (FINAL REPORT ONLY)
*SRP Secretary's signature denotes SRP concurrences are in files.
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e TVA EMPLOYEE CONCERNS REPORT NUMBER: C017304-SQN SPECIAL PROGRAM REVISION NUMBER: 3 PAGE 2 0F 7 I. INTRODt'CTION Nine concerns involving the installation of compression fittings in instrument and drain lines were evaluated at Sequoyah Nuclear Plant (SQN) from July 7, 1986 to July 10, 1986. A. XX-85-050-001 B. HDE-85-001 C. JAM-85-001 D. IN-85-514-001 E. IN-85-795-001 F .* IN-85-795-N04 G. PH-85-002-027 H. XX-85-050-002 I. XX-85-050-003 II.
SUMMARY
OF PERCEIVED PROBLEMS A. Compression fittings were not installed in accordance with the manufacturers' recommendations. Craft personnel were not trained in how to install compression fittings. B. The installation of compression fittings was not adequately g addressed by the Quality Assurance (QA) program. III. EVALUATION METHODOLOGY A. Interviewed plant personnel in the Instrument Maintenance (IM) Section, Mechanical Maintenance (MM) Section, and the Modifications Section at SQN to determine what problems had been experienced with compression fittings and if these problems had been corrected. B. Reviewed letter from Olson, Modifications Manager, SQM, to Abercrombie, Site Director, SQN, dated January 13, 1986, titled,
" Compression Fitting Evaluation Report," and interviewed modifications personnel involved in survey.
C. Interviewed training personnel at SQN to determine what training for the installs 11on of compression fittings was available. Interviewed IM, MM, Modifications and QA Section Supervisors to determine what training on compression fittings was required. l I' I
TVA EMPLOYEE CONCERNS REPORT NUMBER: C017304-SQN SPECIAL PROGRAR REVISION NUMBER: 3 PAGE 3 0F 7 D. Walked down approximately 50 percent of the instrument panels on elevations 669 and 690 of the Auxiliary Building, and visually examined panels for obvious problems, leaking fittings on instrument and drain lines, and mismatch of fittings. E. Examined storage of compression fittings at SQN Power Stores. F. Reviewed SQN Construction Procedures Index dated November 13, 1985, and SQN Inspection Instructions Index dated */24/86, to determine which procedures might contain installation and inspection requirements. Reviewed procedures on instruments, instrument a lines, and piping to determine if any installation and inspection requirements applied to compression fittings. Interviewed former Construction Instrument Engineer to determine if any procedures specified installation or inspection requirements for compression fittings during construction. Asked NM, IM, and Modifications personnel if any plant procedures now specify installation and inspection requirements.
- Month was unavailable because hole was punched through.
G. Interviewed QA personnel at SQN to determine what the inspection requirements were for the installation of compression fittings. H. Reviewed Quality Technology Company (QTC) expurgated files on the l concerns addressed by this evaluation for additional information l and reviewed Nuclear Safety Review Staff (NSRS) reports I-85-329-SQN, I IN-85-514-001 and Q-85-795-001-02 and SQN Generic Concerns Task lR3 Force (GCTF) Report on concerns 11-85-050-003 and PH-85-002-027 l to determine if this evaluation agreed with the conclusions and l recommendations of these previous reports. l I. Reviewed WBN Instrument Project (IP) Activity 1240 Evaluation-Report and file to determine if incorrect installations were acceptable. IV.
SUMMARY
OF FINDINGS A. Cognizant IM personnel stated that problems had been found with the installation of compression fittings early in the plant life. These problems-had been discovered and repaired during normal maintenance
TVA EMPLOYEE CONCERNS REPORT NUMBER: C017304-SQN SPECIAL PROGRAM REVISION NUMBER: 3 PAGE 4 0F 7 Ih.
SUMMARY
OF FINDINGS (continued) They also stated that they don't have many leaking or bad fittings now. Some incorrect installations have been found on new installations by modifications. MM or Modifications personnel did not report any problems. B. The " Compression Fitting Evaluation Report," (Olson to Abercrombie), stated that 306 fittings were inspected and only 5 defects were found. Personnel involved in the survey stated that all the fittings surveyed had been installed by Modifications. The survey was performed in late 1984, during the unit 2 cycle 2 outage. C. IM training instructor stated that he had written a training class on compression fittings in late 1984. This class became Power Operations Training Center class MMT-28 in August of 1985. The course has been taught to most personnel involved with the use of compression fittings. IM Supervisor stated that all Instrument Mechanics are required to have the training. MM Supervisor required all annual fitters to have the training, but not hourly employees. Modifications stated that most fitters had attended the training, but it was hard to be sure because of changing personnel. D. A personal visual examination of instrument panels on elevations 669 and 690 of the Auxiliary Building was performed and no problems were observed. No signs of leaking fittings on instrument or drain lines were found. E. Three drawers of compression fittings were examined at Power Stores and fittings were not mixed with different sizes, brands, or materials in the same bins. F. The Construction Procedures Index and the Inspection Instructions Index were reviewed and no procedures were found which addressed the installation of compression fittings. The procedures for irstruments, instrument lines, and piping were reviewed and no requirements were found for the installation or inspection of compression fittings. The lack of procedures during construction was confirmed during a telephone interview with a former Construction Instrument Engineer. Personnel of IM, MM, and MOD stated that they had no procedures for the installation or inspection of compression fittings. G. QA personnel stated that they now require inspection on all new installations in the reactor coolant system; however, this requirement is not contained in any plant procedures. QA inspections are not required on any other installations or on remakes of already installed fittings.
. l TVA EMPLOYEE CONCERNS REPORT NUMBER: C017304-SQN SPECIAL PROGRAM REVISION NUMBER: 3 j PAGE 5 0F 7 l
IV.
SUMMARY
OF FINDINGS (continued) H. No additional information was found in the QTC files for the concerns. The findings of the NSRS and GCTF reports are consistent with the results of this evaluation.
- 1. This evaluation concurs with the recommendation of the GCTF report and with NSRS recommendations I-85-329-SQN-02, I-85-329-SQN-03, Q-85-514-001-02, Q-85-795-001-02, and I-85-329-SQN-04, that a formal training program for craft and inspection personnel involved in the installation and maintenance of compression fittings be implemented. The pecgram should ensure and document that only personnel satisfactorily trained should perform compression fitting work. NSRS also recommended that plant procedures include the installation instructions and inspection requirements for compression fitting work.
- 2. NSRS recommendations I-85-329-SQN-01 and Q-85-795-001-01, stated that NCR-6278 be reviewed for generic applicab!11ty.
NCR 6278 Revision 1, was transmitted to the other plants by DNE in Memorandum from J. A. Raulston dated February 25, 1986 (RIMS B45 860225 259). At the time of this evaluation , SQN had not performed the generic condition evaluation of NCR-6278 (Revision 1) as requested by the DNE memorandum.
- 3. NSRS recommendation Q-85-514-001-01 addresses WBN site-specific observations concerning two specific tubes and does not pertain to other plants.
I. The IP Activity 1240 was assigned responsibility for investigating l and resolving all the problems associated with the use of I compression fittings. To determine if the incorrect installations IR3 identified at WBN on NCR 6278, revision 0 and 1 were acceptable I for use as installed, DNE established a testing program at TVA's l Singleton Materials Laboratory (SME) beginning September 11, 1985. l Testing of compression fittings assembled both correctly and with l the problems identified in NCR 6278, revision 0, and NCR 6278, I revision 1 was performed at SME. The fittings were subjected to I axial tension test (pullout test), low-amplitude vibration test lR3 simulating extended plant operation, and high-amplitude cyclic test l simulating a seismic event. The results of test for correctly and l incorrectly assembled fittings were compared, and although some l
TVA EMPLOYEE CONCERNS REPORT NURSER: C017304-SQN SPECIAL PROGRAN REVISION NUMBER: 3 l PAGE 6 0F 7 i decrease in strength was noted, the incorrect assemblies were l 1eaktight. Flow tests were also performed on tubing that was not lR3 deburred, and results were iound to be acceptable. [ IP reviewed One test results from SME and agreed that the incorrectly 1 installed compression fittings were acceptable, if proven not to leak lR3 by pressure testing or plant operation. I Conclusion A. Compression fittings may not be installed in accordance with the manufacturers' recommendations; however, these installations are acceptable if the joints do not leak. This evaluation and past operating history at SQN showed that the fittings were not leaking, and therefore acceptable. This concern was not conclusively factual. No formal training program on compression fittings existed during construction, therefore, this concern was factual. A training class on compression fittings has been taught since January, 1985. However, a formal program with personnel training requirements has not beer established. B. SQN has never had any procedures documenting the QA requirements for the installation of compression fittings, therefore, this concern was factual. No procedures have been written to implement recently issued requirements in General Construction Specification G-29, Part 3.M.13.1, for the installation and inspection of compression fittings. (Note: WBN has committed to have instructions controlling compression fitting work.) l V. ROOT CAUSE TVA did not recognize the need for ensuring that compression fittings were correctly installed. No TVA documents outlined the requirements for installation and inspection, and no site quality control program existed. Craftsmen, foremen, engineers, or inspectors were not trained to correctly install compression fittings in accordance with vendors' recommendations.
TVA EMPLOYEE CONCERNS REPORT NUMBER: C017304-SQN SPECIAL PROGRAM l i REVISION NUMBER: 3 i PAGE 7 0F 7 1 VI. CORRECTIVE ACTION The following is the Line Management's response to corrective actions. l These corrective actions are not restart items. IR3 CATD 17304-SQN-01 lR3 A procedure will be written defining requirements for installation of l tube fittings at SQN. lR3 Retraining requirements will be established on a frequency of one year l for Modifications personnel and two years for Maintenance personnel. lR3 CATD 17304-SQN-02 lR3 A memorandum (S02 861202 827) was transmitted to DNE requesting their l evaluation of NCR/SCR 6278 for generic applicability to SQN. lR3 VII. GENERIC APPLICABILITY These concerns are potentially generic to TVA's other nuclear plants as determined by WBN Element Report C017?O4 (Revision 1). VIII. ATTACHMENTS Attachment A - Listing of concerns indicating safety relationship and I generic applicability. lR3 l t l l l l l l l l i l
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- ' , h\ t t FA(.1-u VILL IN l ts TENNESSEE VALLEY AUTHORITY PA!E -
122 1kFERENCE - ECPS120J-ECPS121C RUN TIME - 12:49 31
- REQUEST OFFICE OF NUCLEAR P0HER FREQUENCY EMPLOYEE CONCERN PROGRAM SYSTEM (ECPS) RUN DATE - 12/02/86 ONP - IS$3 - RHN LIST OF EMPLOYEE CONCERN INFORMATION
%IEGORY: CO CONSTRUCTION-PROCESS SUBCATEGORYs 17300 INSTRUMENT LINE INSTALLATION
$ GENERIC KEYHORD A H APPL QT C/NSR$ P KEYHORD B BBSH CONCERN KEYHORD C CONCERN SUB R PLT INVESTIGATION S KEYHORD D NUMBER CAT CAT D LOC FLQB REPORT R DESCRIPTION 17300 $ SQN YYYY 1 I-85 329-SQN SS INADEQUATE QUALITY ASSURANCE CONTROL INSPECTION XX .85-050-001
- CO S HERE APPLIED.TO THE INSTALLATION O INSTALLATION T50096 QA 80202 K-FORM INSTRUMENTATION F INSTRUMENT TUBING COMPRESSION FITT INGS AT SEQUOYAH. NO FURTHER INFORM FITTINGS j ATION AVAILABLE. No FOLLOH UP REQUI RED.
I I-85-330-BFN SR INADEQUATE QUALITY ASSURANCE CONTROL INSPECTION XX 050-002 CD 17300 N BFN YYYY S HERE APPLIED TO THE INSTALLATION O INSTALLATION T50096 REPORT F INSTRUMENT TUBING COMPRESSION FITT INSTRUMENTATION
' INGS AT BROWNS FERRY. NO FURTHER DE FITTINGS TAILS AVAILABLE. NO FOLLOH UP REQUI RED.
I-85-331-BLN SR INADEQUATE QUALITY ASSURANCE CONTROL INSPECTION XX 050-003 CD 17300 $ BLN YYYY $ ARE APPLIED TO THE INSTALLATION OF INSTALLATION T50096 QA 80202 REPORT INSTRUMENTATION INSTRUMENT TUBING COMPRESSION FITTI NGS AT BELLAFONTE. NO FURTHER DETAI FITTINGS LS AVAILABLE. NO FOLLOH UP REQUIRED SR INSTRUMENTATION TUBING HHICH AHD BEE INSPECTION
.PN 002-027 CO 17300 N HBN YYYY H CUT SHORT HAS NOT RECUT, BUT HAS I INSTALLATION i' T50164 REPORT MPROPERLY INSTALLED IN THE FERRULE C INSTRUMENTATION ONNECTION TO COMPENSATE FOR THE IMPR FITTINGS OPER LENGTH. DETAILS KNOHN TO QTC, HITHELD DUE TO CONFIDENTIALITY. CON STRUCTION DEPT CONCERN. CI HAS NO F URTHER INFORMATION. NO FOLLOHUP REQ UIRED. . 3 -
9 JAM-85-001 CD 17300 N SQN YYYY $$ COMPRESSION, FITTINGS - EMPLOYEE FOUN K-FORN D 2 OUT OF 4 IMPERIAL EASTMAN FITTIN GS INSTALLED IMPROPERLY (FERRULE IN STALLED BACKHARDS). WILL THIS AFFEC T BOTH NUCLEAR AND/OR PERSONNEL SAFE TY. IN 795-N04 CO 17300 N HEN YYYY SR HRC IDENTIFIED THE FOLL0HING CONCERN REPORT FOR REVIEW OF QTC FILE. "NO FORMAL TRAINING GIVEN TO CRAFT ON COMPRESS ION FITTINGS INSTALLATION." REVIEH OF FILE INDICATES THAT THIS CONCERN
- APPLIES PRIOR TO UNIT 2.
IN 795-001 CO 17330 N HBN YYYY IN-85-795-001 $$ COMPRESSION FITTINGS ON INSTRUMENT T NONCONFORMANCE T50078 REPORT UBING ARE NOT INSTALLED PER VENDOR I INSTALLATION NSTRUCTIONS. INSTRUMENTATION FITTINGS IN 514-001 CD 17300 N HBN YYYY IN-85-514-001 SR 1/4" 0 TUBING FROM DRN 150 VLV TO DR INSPECTION T50043 REPORT N HDR ON SYSTEM 276 CLOSED DRAIN SYS INSTALLATION REQUIRES REAMING HHEN CUT HITH A TU INSTRUMENTATION BE CUTTER. THIS IS NOT ALHAYS DONE. FITTINGS NOR IS THERE AN INSPECTION HOLD POI NT. IT IS POSSIBLE. BECAUSE OF TUBI NG DEFORMATION DURING CUTTING PROCES S, THAT DRAIN SYS HILL NOT FUNCTION AS DESIGNED AND AN INDIVIDUAL CUTTIN GINTO A SYSTEM COULD BECOME CONTAMIN ATED. BOTH UNITS 8182. HDE-85-001 CO 17300 N SQN YYYY SR 2-FSV-43-319 HAS PARKER TUBING REDUC REPORT ERS HITH IMPERIAL EASTMAN NUTS. THIS IS AN AIR SAMPLE LINE. lI}}