ML20210C811

Forwards Repts Addressing Plant Employee Concerns Re Operations,Welding & Matl Control.Listing of Rept Numbers & Related Employee Concerns Encl

ML20210C811
Person / Time
Site:	Sequoyah
Issue date:	09/15/1986
From:	Mcdonald J TENNESSEE VALLEY AUTHORITY
To:	Harold Denton Office of Nuclear Reactor Regulation
References
NUDOCS 8609180434
Download: ML20210C811 (175)

Text

{{#Wiki_filter:- CJ ll} 9[17 TENNESSEE VALLEY ' AUTHORITY Watts Bar Nuclear Plant P. O. Box 800 Spring City, Tennessee 37381 September 15, 1986 Nr. Harold Denton-Director of Nuclear Reactor Regulation U.S. Nuclear Regulatory Commission 7920 Norfolk Avenue Bethesda, Maryland 20814

Dear Mr. Denton:

In the Matter of the Application of ) Docket Nos. 50-327 Tennessee Valley Authority ) 50-328

SUBJECT:

EMPLOYEE CONCERNS TASK GROUP (ECTG) to this letter transmits for NRC's review the following reports addressing Sequoyah Nuclear Plant Employee concerns: 10 reports from operations category 3 reports from welding category 2 reports from material control category { (These reports have been reviewed and approved by the Senior Review Panel). 4 To assist you in your review of these reports, Enclosure 2 provides a comparison between the ECTG Writer's Guide recommended report format and the transmitted reports. Enclosure 3 provides a listing of the report numbers and ~ the related employee concerns. Please feel free to contact Martha Martin at FTS 857-3587 (Watts Bar) if you have any questions. Very truly yours, TENNESSEE VALLEY AUTHORITY N .A. Mcdonald J Site Licensing Nanager Enclosures l 1 0609180434 860915 DR ADOCK 0500 7 f tlt l _. m., ~ ~.. x

2 Nr. Denton September 15, 1986 cc (Enclosures): Dr. B. D. Liaw, Branch Chief U. S. Nuclear Regulatory Commission 7920 Norfolk Ave, Room T-1132 Bethesda, Marlyand 20814 Mr. James H. Taylor, Director Office of Inspection and Enforcement U.S. Nuclear Regulatory Commission Washington, D. C. 20555 Mr. B. J. Youngblood, Project Director PWR Project Directorate #4 Division of PWR Licensing - A U.S. Nuclear Regulatory Commission 7920 Norfolk Avenue Room 440, 5 Story Phillips Bethesda, Maryland 20814 U.S. Nuclear Regulatory Commission Region II Attn: Mr. Gary Zech 101 Marietta Street, NW, Suite 2900 Atlanta, Georgia 30323 )

Exclestro 2 ECTG WRITER'S GUIDE NSRS/ERT* WELD PROJECT (WP) REPORTS NOTES / COMMENTS 1.0 Issue Background Info Issues Addressed Characterization (Section I) By Concerns (Section II) 2.0 List Of Concerns Background Info Scope of Evaluation (Section I) (Section I and Att-1) s 3.0 Evaluators Coversheet Coversheet i l 4.0 Evaluation Scope Not Delineated As Part Process (Section II) Of The WP Reports however it is addressed as part of the Weld Projects Program Manual 1 S.0 Findings Findings Validity or (Section III) Substantiation (Section III) 4 I

• • • Note that recommendations 6.0 Root Cause**

Conclusion and Validity or are not included in element reports under the 4 1 cucrent ECTG program. ) and Conclusion Recommendations Substantiation Overall Root Cause will 1 (Section IV)*** (Section III) not be considered at this-j report' level. 1

• The Weld Project has endorsed a number of ERT Reports and general issue level reports as adequately addressing j

the concerns at this level for SQN. i

MATERIALS CONTROL Enclisure 2 ECTG WRITER'S GUIDE ELEMENT REPORT FORMAT 1.0 Issue I. Introduction Characterization II. Summary of Perceived Problem 2.0 Summary IV. Summary of Findings Conclusions (Portion) 3.0 Evaluators Cover Sheet Information 4.0 Evaluation III. Evaluation Process Methodology

5.0 Findings

IV. Summary of Findings 6.0 Root Cause V. Root Cause

• • Overall Root Cause will (Collective Significance)**

not be considered at this report level. 7.0 Attachments / VIII. Attachments List.of Concerns Other items included VI. Corrective Actions in Construction Element (To be provided by Reports line organizations) VII. Generic Applicability 1905T

OPERATIONS CATEGORY ECTG WRITER'S GUIDE OPERATIONS (OP) ELEMENT REPORTS NOTES /CONNENTS 1.0 Issue I. Title The brief introduction Characterization Very brief introduction touches on the source of the concerns. 2.0 Summary I. Title

1. The Conclusions are Very brief introduction towards the end of the findings.

III. Finding (Conclusions)

2. The Conclusions services as a summary of the findings.

I 3.0 Evaluators Cover Sheet

1. The printed name of the original evaluator (s) appears on the cover sheet.

2. The peer reviewer and CEG-H approval signa-tures are also on the cover sheet.

( 4.0 Evaluation II. Specific Evaluation Process Methodology .5.0 Findings III. Findings 1880T I

Enclestro 2 ECTG WRITER'S GUIDE OPERATIONS (OP) ELMENT REPORTS NOTES /CONMENTS 6.0 Root Cause IV. Root Cause

1. At the element level (Collective Significance) the Root Cause is often not identifible.

2. Collective significance is not addressed at the element report level.

7.0. Attachments / II. Specific Evaluation

1. A list of the concerns List of Concerns Methodology with text are included-within this section.

2. Other reports see sometimes attached, s

e e e e 9

Page 1 of 3 Sequoyah Employee Concern Material Control Number Category Elemet Report MC40206 WI-85-053-Oll NC40510 WI-85-036-002 4

) Page 2 of 3 Sequoyah Empoyee Concern Operations Number Category Element Reports OP30105 NAS-86-002 RCN-85-001 I-86-233-SQN OP30114 IN-86-137-005 OP30204 SQM-6-013-001 OP30501 IN-85-189-001 IN-85-189-002 IN-86-306-001 PH-85-003-006 IN-85-220-001 IN-85-617-001 OP30707 JLH-86-004 XX-85-035-001 OP30801 NAS-85-004 NAS-66-001 TAK-85-002 TAK-85-004 SQP-86-009-004 SQP-86-014-001 OP31001 SQP-5-003-001 SQP-5-003-002 XX-85-067-001 SQM-6-013-002 SQP-6-010-001 XX-85-022-001 IN-85-933-001 ~ 0P31101 XX-85-024-001 XX-85-102-009 XX-85-102-012 j OP31204 XX-85-043-003 OP31302 .RNM-85-001 RNM-85-002 l l l l a l

n 3 Page 3 of 3 Sequoyah Employee Concern Welding Number Reports WP-02-SQN WI-85-013-003 WI-85-041-006 WI-85-041-008 IN-85-458-001 PH-85-040-001 IN-85-767-003 NS-85-001-001 IN-86-019-001 WP-14-SQN IN-86-047-001* IN-86-158-006

• Also considered in WP 01 report WP-20-SQN SQM-6-008-001 l

i 1

~ TVA EMPLOYEE CONCERNS REPORT NUMBER: MC40510-SQN SPECIAL PROGRAM REPORT TYPE: 'Sequoyah Nuclear Plant Element RIVISION N1:.sER:'l PAGE 1 0F 5 TITLE: Requisitions REASON FOR REVISION: Revised to incorporate TAS and SRP comments. PREPARATION . ' PREPARED BY: h M h [.C M 4-r3-86 M GNATURE DATP. REVIEWS PEER: Y 9-l4~86 n on s SIGHATURE DATE TAS: '/. . + - SIGNATURE DATE CONCURRENCES h!/ h CE pg V SRP: SIGNATURE DATE SIGNATURE DATE APPROVED BY: ECSP MANAGER DATE MANAGER OF NUCLEAR POWER DATE CONCURRENCE (FINAL REPORT ONLY) 1261T L ~

TVA EMPLOYEE CONCERNS REPORT NUMBER: MC40510-SQN SPECIAL PROGRAM REVISION NUMBER: 1 PAGE 2 0F 5 I. Introduction This element was extracted from concern WI-85-036-002 and was determined to be generic to Sequoyah Nuclear Plant (SQN) by Watts Bar Nuclear Plant (WBN) Employee Concerns Tast Group (ECTG), Material Control Element Report MC-40510. II. Summary of Perceived Problem Requisitions are being changed and altered later. (Suggesting that changes.were not being properly concurred with.) III. Evaluation Methodology I A. Reviewed expurgated file WI-85-036. B. Determined if any ERT, QTC, NSRS or other reports exist on the IR1 ~ subject concern. C. Reviewed Site Procedure Administrative Instruction AI-ll, Section 8.0, "QA Level Changes and/or Description Changes and/or Substitutions," Revisions 32, 34, 35, and 36. Reviewed sita-initiated requisitions and determined if changes had D. been made according to the procedural requirement. Interviewed knowledgeable personnel associated with the initiation E. of site requisitions and determine if additional information was available regarding the concern. F. Reviewed WBN ECT,G Material.. Control Element Report MC-40510, Requisitions, to determine if'the findings addressed a perceived problem at SQN and if corrective actions were initiated which would address the findings. IV. Summary of Findings A. A review of expurgated file WI-85-036 revealed no additional information regarding this concern. WBN ECTG Element Report MC-40510 stated that QTC files indicated the l B. or IR1 concern was either a Division of Nuclear Construction (DNC) I Office of Nuclear Power (ONP) concern.,

e ~ TVA EMPLOYEE CONCEENS REPORT NUMBER: MC40510-SQN SPECIAL PROGRAM REVISION NUMBER: 1 PAGE 3 0F 5 C. Measures established in SQN Site Procedure AI-ll, Section 8.0, IR1 control the altering and changing of site-initiated requisitions. 1 Section 8.0, "QA Level Changes and/or Description Changes and/or Substitution," required that Attachment 9 to the procedure be completed for QA level changes, QA description char.ges, and substitutions. Subsection 8.1, "QA Level Changes and/or Description Changes Paragraph B," During Procurement Cycle (Up to Receipt)," requires, that during the procurement cycle, changes shall not be mado to approved procuretsnt documents without the review and approval of the originator's organization or designated plant procurement organization (Material Services, SQN) and the designated QA organization (s). This review and approval of changes shall be documented on the affected procurement document, or by signed correspondence of which a copy is filed with the record copy of-the procurement document, or by using Attachment 9 and Attachment 16 (as needed according to paragraph 8.2.1). 6 " Evaluation for Acceptability of Class 1E Substitutions," shall be completed and attached to Attachment 9 for substituted equipment identified for use in a class 1E' application. D. A random' review of site-initiated requisitions from April 8, 1985 lR1 through July 1, 1986 revealed four contracts (362725,.362791, 364203 l and 364239) where changes had been made to approved requisitions. These changes were implemented by the completion of Attachment 9 as required according to Site Procedure AI-11. Note: This review encompassed the time period of which deficiencies IR1 were discovered and identified at WBN-ONP in the corrective I action report initiated by V. L. Patuzzi on January 13, 1986. E. Interviewed personnel from E'legtrical Maintenance, Mechanical Maintenance, Instrumentation, and Materials Unit's Designated Project Procurement Office. (DPPOi, As.a result of these interviews, it was revealed that 'vibfually 'no : instances could be recalled where changes were made to requisitions initiated by the units which would affect the quality of material received or work schedule. An interview with an Electrical Maintenance individual revealed that minor changes had been made to the quality levels of material by the Materials Unit (DPPO) on requisitions 376851 and 377154. In review of the aforementioned requisitions, it was found that the changes had been made by DPPO and technical and QA review had been performed. This review was annotated on the requisition and is an acceptable practice according to paragraph B of Section 8.1 of AI-11. An interview with an instrumentation engineer revealed that requisition 453114 had been changed by the Purchasing Agent without prior notification to the responsible sLte personnel. The initial ^

TVA EMPLOYEE CONCERNS REPORT NUMBER: MC40510-SQN SPECIAL PROGRAM REVISION NUMBER: 1 PAGE 4 0F 5 requisition required a source inspection of the material before being shipped to the site. The contract indicated that no source inspection was required. Upon receipt of the material at the site, a Nonconforming Item form (NCI, N2-86-228) was initiated indicating that a quality release source inspection was needed. (As a result of previously mentioned reviews and interviews this was determined to be an isolated occurrence.) F. Through review of WBN ECTG, Material Control Element Report MC-40510 " Requisitions," it was indicated by a Corrective Action Report (CAR) that problems involving the unauthorized changing or altering of requisitions by Purchasing Agents (pas) did exist. The corrective actions taken by the Division of Purchasing regarding this matter were to reduce the number of pas who purchase safety-related material from 75 to 23, to train and continue to periodically train the 23 pas at the division, branch, and section levels as needed, and to develop a checklist for pas and supervisors to'use.in assuring that our QA manual requirement are implemented (Reference TVA memorandum TOO 860304 718 depicting the lR1 corrective actions which have been taken by the Division of Purchasing in regard to the finding of Element Report 40510.) Conclusions Through research of requisitioning documentation and interviews with site personnel, it was determined that very few, if any, problems exist at SQN regarding the improper altering or changing of requisitions by (R1 site or Division of Purchasing personnel. Although one example of an improper change to a contract was identified and was determined to have been made by the Division _of Purchasing, the incident was -identified by site personnel.and cited by the QA Receipt Section at SQN lRl' and did not present a conditions,a,dvepse to qualify. Other incidents of l this kind were not identified. y., % >..[ ~ V. Root Cause None l VI. Corrective Action l None required by line organization. Corrective actions were previously I I implemented as a result of the corrective actions report. These actions IR1 are identified in paragraph F of the summary of findings. l e w- -r-- w --i%.,.----.m--r .mem mp wr .w---

TYA EMPLOYEE CONCERNS REPORT NUMBER: MC40510-SQN SPECIAL PROGRAM REVISION NUMBER: 1 PAGE 5 0F 5 VII. Generic Applicability None: This concern was made generic to SQN, Office of Nuclear Power only, due to the finding indicated in the WBN evaluation MC-40510. However, the corrective actions stated in paragraph F's reference memorandum, TOO 860304 718, involved the. training of all pas in the Division of Purchasing. Therefore, this concern is determined not to be generic to Bellefonte and Browns Ferry Nuclear Plants. VIII. Attachments None 7 ., g 9 a i Q

] TVA EMPLOYEE CONCERNS REPORT NUMBER: MC-40206 SPECIAL PROGRAM REPORT TYPE: Watts Bar Nuclear Plant - Element REVISION NUMBER: 1 TITLE: Materials as it Relates to Purchasing and PAGE 1 0F 5' Requisition REASON FOR REVISION: Revised to incorporate comments from the Technical Assistance Staff (TAS) and the Senior Review Panel (SRP). PREPARATION PREPARED BY: dWW f W Y OS SIGNATURE DATE REVIEWS PEER: CAJL &>.#dL 9- /4 - s c, SitiNATURE DATE TAS: SIGNATURE DATE CONCURRENCES CEG- -&Wl Mb 9hk(3 SRP: SIGNATURE DATE SIGNATURE DATE APPROVED BY: ECSP MANAGER DATE MANAGER OF NUCLEAR POWER DATE CONCURRENCE (FINAL REPORT ONLY) 1427T l

o TVA EMPLOYEE CONCERNS REPORT NUMBER: MC-40206 SPECIAL PROGRAM REVISION NUMBER: 1 PAGE 2 0F 5 I. Introduction This element contains one concern, WI-85-053-011, relating to the material procurenent policy and was not made generic to Sequoyah Nuclear Plant (SQN) during the Watts Bar Nuclear Plant (WBN) evaluation. However, this concern was evaluated by the Generic Concerns Task Force (GCTF) at SQN, and the GCTF report was reviewed for adequacy. II. Summary of Perceived Problems Other TVA sites are not on tho approved vendors list for supplying materials to SQN. III. Evaluation Methodology A. Reviewed Employee Concerns Task Group (ECTG) files, QTC expurgated files, and W3N Element Reports MC-40201 and MC-40206 to determine if applicable infonmation is available to assist in the evaluation. B. Searched for Nonconformance Reports (NCRs), audits, etc., relating to other TVA sites supplying questionable quality materials. C. Interviewed knowledgeable individuals about Quality Assurance (QA) requirements for suppliers of materials to SQN. D. Reviewed SQN GCTF'Reppet WJ-85-053-Oli to determine adequacy of findings dnd 'c'onclusions. . *f jp ' -~. ; ; IV. Summary of Findings A. Reviewed QTC ECTG and QTC expurgated flies and found no l further information. B. Reviewed NCR printout and audit index, also interviewed knowledgeable individuals and found no NCRs or audit findings relative to inferior or unacceptable items j received from other TVA sites. 4

e T7A EMPLOYEE CONCERNS REPORT NUMBER: MC-40206 SPECIAL PROGRAM REVISION NUMBER: 1 PAGE 3 0F 5 IV. Summary of Findings (Continued) C. Interviews with knowledgeable QA individuals indicated that the policy is to designate the material and documentation requirements on the requisition and verify upon receipt that the requirements are met. Knowledgeable QA individuals also stated the site procedures (Administrative Instructions AI-11 Standard Practice SQA45, etc.) are being implemented. D. A review of the (GCTF) report revealed the following: 10 CFR 50, Appendix B, criteria II, IV, and VII require i establishment of a QA program that covers procurement of IR1 material, parts, and services. NRC Regulatory Guide (RG) l 1.123, QA Requirements for Control of Procurement of Equipment, l Materials and Services, establishes acceptable standards for procurement programs. RG 1.123 (Revision 1) endorses American National Standards Institute (ANSI) Standard l N45.2.13, QA Requirements for Control of Procurement of IR1 Items and Services for Nuclear Power Plants. The TVA l Topical Report includes these regulatory guides with no I I exceptions taken. ANSI N45.2-1971, " Quality Assurance Program Requirements lR1 for Nuclear Power Plants" sets up the general guidelines for a QA program. Section 8 requires measures to assure that material ordered and documentation agree. It also requires a purchasing entity make provisions for source evaluation / selection, obtaining objective evidence of quality, source verifications, and receipt inspections. ~ ANSIN45'.2.13-1975,"Qua1gyAssuranceRequirementsfor Control of Procurementc..of Items and Service for Nuclear Power' Plants,"I/ciidesm6eespecificdetailsforaQA program for procurement.' Section 7 gives broad guidelines for ascertaining quality of parts. Sections 10.2 and 10.3 .give specific details on parts documentation. Section 10.3 states that verifications can be performed by source inspections, receipt inspections, certificate of conformance, or post-installation testing. Each of these is lR1 neceptable under certain criteria which are provided in Sections 10.2 and 10.3. Nuclear Quality Assurance Manual (NQAM) Part III Section IR1 2.1 requires that only QA sources (i.e., acceptable suppliers) be used for QA Level I,,II, and IS items.

~ TVA EMPLOYEE CONCERNS REPORT NUMBER: MC-40206 SPECIAL PROGRAM REVISION NUMBER: 1 PAGE 4 0F 5 IV. Summary of Findings (continued) Step 2.1.2 assigns the DQA Procurement Evaluation Branch (PEB) with responsibility for establishing and maintaining an Acceptable Suppliers List (ASL). The ASL is on TVAs computer system and accessible by all plants, not all TVA facilities are listed. However, other TVA facilities transfer material and equipment on a routine basis within the constraints and guidelines as outlined in the procedures and instructions lR1 listed in this Element Report. A cover memorandum to the ASL restates that before a contract is signed, the supplier must be approved by PEB. Other TVA facilities that fully meet the requirements, as previously stated, are acceptable suppliers and are approved by PEB. IR1 Sequoyah Standard Practice SQA45, " Quality Control of Material, Parts and Services," provides guidance.on responsibilities for the procurement process for SQN. SQA45 Section 5 provides a list of 26 items to be considered during preparation of a purchase requisition. Item 10 requires designation of a supplier and that the ASL shall be used for source selection, except for material and equipment transferred from other approved TVA facilities as stated above. Item 15 provides for source inspection access. Item 16 requires consideration of the need for a Certificate of Conformance. SQN45 Section 6 discusses the SQN procurement process and responsibilities in detail. It defines the QA Levels and details review responsibilities. Both QA and Power Stores are assigned responsibility,for caview of Purchase Requisitions / purchase documents before fjnal, approval. This includes administra,tive and t.echq,ical. reviews., Section 6.10 provides guidance on when t7 ds'tiesch of'the request form types. Section 6.12 provides guidance'on specifying QA requirements that meet 10 CFR 50, Appendix B, ANSI, and ASME standards, by paraphrasing ANSI N45.2.13 Section 10.3. SQN45, Section 11 provides guidance for specifying a source I inspection on the purchase documents. The criteria cited are taken from ANSI N45.2.13. SQN45, Secticn 17 assigns QA and Power Stores the responsibility for performance of receipt inspections in i accordance with Administrative Instruction AI-ll.

s' ~_ TVA EMPLOYEE CONCERNS REPORT NUMBER: MC-40706 SPECIAL PROGRAM REVISION h"JMBER: 1 PAGE 5 UF 5 t IV. Summary of Findings (continued) 1 AI-ll, " Receipt Inspection, Nonconforming Items,-QA Level / Description Changes and Substitutions " Section 5.1, designates responsibility for receipt inspections to Power Stores. A receipt inspection is required for a*.1 CSSC parts and services. QA must also review receipt of shy item designated QA Level I, IS, II, IIS, III (requiring a COC). Engineering Change Notice (ECN) QA Part 21, or EIN QA Part 21 indeterminate. These reviews must include verification that the material or service conforms to the purchase requisition. Step 6.5.4 specifically addresses transfers,.and step 6.5.8 specifically calls for a review of the vendor QA program requirements. Note: This evaluation found the GCTF report findings'above to be adequate and-the conclusion that no problem existed to be correct. Conclusions TVA sites are not on the Acceptable Suppliers List (ASL). TVA sites l are not considered vendors in the normal sense. A program is in place l r.1 to ensure that adequate technical and QA requirements are met or. f items transferred from other TVA sites. Not all TVA sites are on ( the ASL, and it is not a requirement because other TVA sites must i fully meet all the requirements described in procedures discassed l in this element report. Therefore, no problem exists relative to lR1 the perceived problem and the perceived problem is not valid. I V. Root Cause 9, - No problem'*1dentified$.,T 'q.. ) t% 2 VI. Corrective Action .Ncne required. IR1 VII. Generic Applicability It has been determined to be generically applicable to Browns Ferry Evalear Plant (BFN) and to Bellefonte Nuclsar Plant (BLN) lR1 sitco both plants received material from other TVA sites. VIII. Attachments None n

t s. t 4 1 TENNESSEE VALLEY AUTHORITY SEQUOYAH NUCLEAR PLANT EMPLOYEE CONCERNS TASK GROUP OPERATIONS CEG Mechanical Equipment Reliability / Design Subcategory: Questionable Design and Construction Practices Elwent: 201.05-SQN Report Number: MAS-86-OO2 RCM-85-001 I-86-233-SQN I b2028[ Evaluator: s Date I Scott McComb

4. 2 2, /

( Revicwed by: ~ OPS CE Member []) ate i[7-Ib 4% ' e Approved by: bate' / W. R. Lage3 -e n i I ( 1586T ( ~

~ Questionable Design and Construction Practices at Sequoyah Nuclear Plant 'I. This report specifically addresses three employee concerns about theAll design and construction practices at Sequoyah Nuclear Plant (SQN). Two of these concerns were three of the concerns are specific to SQN. determined to be nuclear safety related by the NSRS. Specific Evaluation Methodology II. Three specific concerns were evaluated in this report. " Improper mounting of limit switches on 2-FCV-30-15." MAS-86-002: " Failed bladder on B-CST allowed water on top of RCM-85-001: Bladder could get into ERCW suction." bladder. "An anonymous individual mailed in a potential safety I-86-233-SQN: hazard associated with the condensate domineralizer waste evaporator (CDWE) on elevation 706 of the-The Auxiliary Building at Sequoyah Nuclear Plant (SQN). original stainless steel piping for pumping " Bottoms" from the CCWE was removed and replaced by a temporary Extensive modifications are being rubber hose. Welding hot chips have performed over the rubber hose. Damage to or been observed falling on the rubber hose. rupture in the hose would result in possible personnel exposure of a high amount." Concerns MAS-86-OO2 and RCM-85-001 were expressed through the concerned Concern I-86-233-SQN was mailed in by an individuals' supervisor. anonymous individual. ~The three concerns are specific _in nature and will be addressed separately. Items reviewed are A review of previous evaluations was performed. Interviews with listed in the Reference Section df'this report. cognizant personnel wera perfdrmed; when needed, to address these ~ 't.( ~ ~' concerns. Due to the specific nature of these concerns, no review of regulatory 1 requirements or plant procedures was performed. l III. Findings i f NAS-86-002: A memorandum from B. M. Patterren to R. W. Olson da 1. "During field verification and af ter cycling of zone switches following maintenance, a mounting problem of zone switches on butterfly valves with circular movement of the actuator wasThe m identified." Page 1 of 4 i l

1-ZS-30-7 1-A 1-ZS-30-14 1-A 1-ZS-30-16 1-B 2-ZS-30-14 1-A, 2-ZS-30-15 1-B 2-ZS-30-16 1-B The memorandum suggests straightening the zone switch on existing mounting so that the actuation level arm lever is tangent to the strike plate's circular plate (Reference 1). A memorandum from R. W. 'Olson to B. M. Patterson on April 11, 1986, 2. "Sequoyah Nuclear Plant - Zone Switch Mountings," states that, "The zone switches referenced in the March 7, 1986 memorandum (SS3 860124 910) were investigated, and it was found that a mounting problem existed on 2-ZS-30-15 only. It also states that the problem with 2-ZS-30-15 was corrected by work request B-110369 (Reference 2). A memorandum from M. A. Skarzinski to F. C. Mashburn dated April 28, 3. 1986, " MAS-86-002," states that, "2-ZS-30-15 has been repaired, and concern MAS-86-002 is closed." The memorandum also states, "We will continue to evaluate these conditions as they are identified and will push Modifications for a' resolution of the previously identified ZSs they claim require no fine tuning" (Reference 3). Informa? telephone interview with a modification RCM-85-001: engineer at SQN revealed: The CST check valve problem was the result of five styrofoam float. 1. These five styrofoam va,1ves at the top of the bladder decaying. discs were supposed to seal off five holes in the top of the bladder when the water reaches the top of the bladder. These styrofoam discs shrank in size until they passed through the holes they were to seal against. The check valve problem was fixed by replacing the styrofoam discs 2. with plastic discs, under WP 11844 initiated by ECN L6515 and Category D, FCR 3317. No further problems with the check valves have been reported since this modification. .,. g. There was a concern 'wlth the[11'ner being drawn into the auxiliary 3. feedwater vacuum dragline. The cage around the suction inlet was This work was also enlarged to prevent this potential occurrence. initiated by ECN-L 6515. I-86-233-SQN: Informal interview with a site services engineer revealed the following: The bottoms piping is stainless steel and has not been replaced by a 1. temporary rubber hose. The piping for offgrade (non-radioactive but higher conductivity than normal distillates flow path) distillateThe from the CCWE system was replaced with a temporary rubber hose. This old piping routed the offgrade distillate to the floor drains. Page 2 of 4

[ ~ g a resulted in the floor drain getting clogged because of boric acid perceptitates. To ensure that this did not happen again, a temporary hose for offgrade, distillate was run directly to the floor drain collector tank. This 2-inch hose is about 400 feet long and drops about 80 feet from the CDWE to the floor drain collector tank. 2. The pressure in the hose is very low. In fact, the 80-foot drop between the CDWE system and the floor drain collector tank (FDCT) results in a vacuum on the line. 3. An informal interview with a design engineer in Knoxville revealed that ECN-6326 was written to install permanent piping from the CDWE system to the FDCT. This ECN was the result of.DCR 2152. This ECN has not yet been worked, i Conclusions 1. Concern MAS-86-002 on zone switch 2-ZS-30-15 was valid; the problem was corrected by work performed under work request B-110369. The zone switch was straightened on its existing mounting so that the actuation lever arm travel is tangent to the strike plate's' circular path. 2. There was a problem with the check valves on the CST bladder. These valves have been replaced, and a larger inlet grate has been installed over the auxiliary feedwater vacuum dragline inlet in the CST. Concern RCM-85-001 was valid, but all repairs at SQN have been made. 3. There is a temporary rubber hose installed between the CDWE system and the FDCT. This hose carries offgrade distillate from CCWE to FDCT. This hose is not under high pressure and does not carry CCWE " Bottoms." A rupture of this hose would not expose personnel to a high amount of radiation. Concern I-86-233-SQN is not valid. Based on the findings presen'te'd above there were no outstanding 4. nuclear safety-related iss'ues'Found

• ?.f IV.

Root Causes The results of this evaluation have determined these concerns to be specific and isolated problems. The original design may be a potential root cause for all three concerns. V. Generic Applicability Since WBN and SQN's are similiar plants, these three concerns need to be evaluated at WBN. Also, the zone switch problem and CST bladder problem need to be evaluated for applicability to' Browns Ferry and Bellefonte Nuclear Plants. Page 3 of 4 ^ ~

. v VI. References 1. Memorandum from B. M. Patterson to R. W. Olson dated March 1986, "Sequoyah Nuclear Plant - Zone Switch Mountings" 2. Memorandum from R. W. Olson to B. M. Patterson dated April 11, 1986, "Sequoyah Nuclear Plant - Zone Switch Mountings. 3. Memorandum ttom M. A. Skarzinski to F. C. Mashburn dated April 28, 7 1986, " MAS-86-OO2" t VII. Immediate or Long-term Corrective Action None . L. y,,, I \\ 4 m -I ( \\ t )

s. '

c e Page 4 of 4 I ~

'n h.... c s., ef, a 3 ~. i +- u 9 A g TENNESSEE VALLEY AUTHORITY o 7' SEQUOYAH NUCLEAR PLANT EMPLOYEE CONCERNS TASK GROUP 4 OPERATIONS CEG f' ,m Subcategoryi Mechanical Equipment Reliability / Design Element: Malfunction of Doors Report Number: 301.14 - SQN ). -+

1. [Ohh b

Uf[ c&r/ Evaluator: ~ Dage C. W. Touchstone k /M/ [ Reviewed by: ~ / D&te t'S OPS CEG)fembfr p b Approved by: W.R.Lapt,gren Dhte 01442T o-

p: I. Malfunction-of Doors This report expands on findings of the Sequoyah Nuclear Plant (SQN) Generic Concerns Task Force (GCTF) Report--IN-86-137-005 (Reference 1), which evaluated the issues concerning air lock doors A56 and A57 at SQN. II. Specific Evaluation Methodology A review of the K-forms (Reference 2) was conducted to evaluate the scope of this element. SQN GCTF Report IN-86-137-005 was reviewed to determine adequacy of evaluation. Historical information such as engineering change notices (ECNs) reviewed are listed in section VI. Interviews included personnel in Mechanical Modifications, Industrial Safety, and Design Services. The following concern was evaluated: IN-85-137-005 . Doors A56 and A57 between the control room and Auxiliary Building malfunction every three or four days. CI was told that several individuals at Sequoyah (names not given) had been injured as a result of these same doors malfunctioning. CI questioned actions (or lack thereof) to prevent this-from occurring at WBN. Note: A determination was made in Reference 1, that .the above concern should be read " service building" instead of " control room." III. Findings SQN GCTF Report IN-86-137-005, (Reference 1) evaluated the issues concerning doors A56 and A57. The report's conclusions were: Injuries associated with doors A56 and A57 have occurred at 1. SQN. 2. Doors A56 and A57'are high maintenance doors at SQN. .3- .,,7 'The report also gave the'following recommendations: TVA Design Organization, SQN, and Watts Bar Nuclear Plant 1. (WBN) need to jointly evaluate the access problem (s). Future modifications to the doors should not be made until 2. the joint evaluation has been performed. i l The report roted that WBN has airlock doors which are operated using a l l mechanical cperator; however, SQN requires manual operation but has plans to modify their system with a mechanical operator in the future. I ECN-5855 is pending for these modifications. Page 1 of 5 m

a A followup evaluation by this evaluator included a review of ECN-5855 status, and-interviews with SQN individuals in Safety Mechanical Modifications, and Design Serv, ices. ECN-5855 " Modify Doors A56, A57, and A58 as required to withstand 1. High Frequency Use," (Reference 3). There were five (5).workplans (WPs) found against this ECN, two of which are complete: I WP-10628 ~ Complete. October 1983 - Addition of a dp light to warn personnel of high differential pressure between Auxiliary and Service Buildings. WP-11577 Complete, April 1985 - Remove plaster in Auxiliary Building airlock to allow installation of door operator. WP-11586 Install door A56 and associated equipment. WP-11587 Install. door A57 and associated equipment. WP-11654 Install electrical part of doors A56 and A57. 2. Interviews Mechanical Modifications a. Discussed the door situation with cognizant engineer-responsible for ensuing modifications and author of WPs 11586 and 11587. He noted these workplans are in the approval cycle but are basically awaiting scheduling of the work. He agreed with recommendation number one in section III; however, with respect to recommendation number 2, he noted that some work has -already started such as previously mentioned WP-11577. The engineer noted that an informal coordination effort with WBN is presently underway to assess problems with doors A56 and-A57"op.eration. He mentioned that SQN individuals from Safety, Design Services, and Nechanical Modifications (including himself), observed problems with WBN doors during a "walkthrough" in July 1986. He commented that the vendor. OVERLY, has not yet been awarded the contract to fix WBN doors though it is expected. The doors delivered at SQN are also by OVERLY and thus SQN would likely need assistance from vendor with modification. Page 2 of 5 _ -.-.- _ m, _ - -. _

1 i b. Industrial Safety. Discussion verified coordination of SQN with WBN. Individual mentioned the July 1986 "walkthrough" discussed ~ above. Several problems were observed with WBN doors such doors would not close, door-dogs came out, parts of as: the emergency stops safety-switch f ailed-to stop doors while in travel. and the air cylinders cycled with violent surges until the door had to be stopped for fear of damage to the' system. The safety individual commented that when these doors function as designed, they are safe.. Asked what SQN should do, he said that it would be to SQNs advantage to install the new doors and resolve problems learned from WBN during the present outage. The safety individual made a list of recommendations (Reference 4) for SQN based on observation of the WBN doors. c. Design Services This individual was also involved in the July 1986 "walkthrough" at WBN and emphasized that SQN must continue to coordinate with WBN in order to gain from experiences there. He noted that the frame alignment for door A57 was a major problem at WBN as observed by SQN and WBN personnel and identified by OVERLY and that SQN should definitely keep this-fact in mind. The design individual suggested the door modifications be done for SQN during the present outage. Conclusions Concern IN-86-137-005 is valid as summarized in Reference 1 due to the safety and maintenance aspects of the airlock door operation. Presently, SQN Mechanical Modifications Safety, and Design Services personnel are coordinating with WBN to identify operational problems with the doors. This effort will be of value to SQN as they prepare to 1nstall their mechanically operated systemn f,p' A" IV. Root Cause None 'l V. Generic Applicability Element Report 301.14 evaluates problem with door lock operation at WBN. i s i Page 3 of 5 i i

t VI. References TVA - SQN Generic Concern Task Force (GCTF) Report IN-86-137-005, 1. " Auxiliary Building Door's A56 and A57," Revision 1. May 19, 1986 2. .K-form, IN-8'6-137-005 SQN - Engineering Change Notice (ECN) - 5855, " Modify Doors A56, 3. A57, and A58 as Required to Withstand High Frequency Usage," July 25, 1983 i Meeting Notes - SQN Observation of WBN Door A56/A57 Operation, 4 July 1986 J. .J i t i f Page 4 of 5 ,-_,,,nn a.n.. ,___r._-,.,n

I VII. Corrective Actions Later J I I l 8 Page 5 of 5 1 m

a,. -4 i TENNESSEE VALLEY AUTHORITY SEQUOYAH NUCLEAR PLANT EMPLOYEE CONCERNS TASK GROUP OPERATIONS CEG k Subcategory: Cable & Conduit Element: Ground Detector Problem Report Number: 302.04 - SQN SQM-6-013-001 8 og ~ ~ Evaluator: B. Meers Date Reviewed by: / ((ik I"/M-[I ' OPS CEG ember Date Approved by: I W. R. Lagergren Date 1466T

? I '. Ground 0 trette Probita ~ This element report evaluates the concern of replacement bulbs in various ground fault detectors giving false indications. The scope of this report is limited to evaluation of replacement of bulbs in the ground fault detectors found on the various power distribution boards at Sequoyah Nuclear Plant. II. Specific Evaluation Methodology This element is made up of one K-form: "SQM-013-001 - Changing out the Sylvannia bulbs in various ground detectors causes a resistance change which shows a ground between all-three phases on the board when the test button is pushed. This false ground signal overshadows an actual ground on the board, since the bulb lights up brighter than the other bulbs indicating a ground although an actual ground may be on one of the other phases. Nuclear Power Department concern. Anonymous concern." .The K-form was reviewed to determine the area of concern, requirements were researched, and cognizant individuals in Operations and Electrical Maintenance were interviewed. TVA schematic diagrams were reviewed to determine the wiring connections of the ground detectors. No procedures or requirements for changing ground detector bulbs were found. The contract for the 480-volt Shutdown Boards was reviewed for the equipment requirements (Reference 1). Operations instruction letter OSLA99 was reviewed for the operations requirements (Reference 2). III. Findings The contract files were reviewed to oetermine the required equipment ..and TVA drawings were reviewed to determine the circuit configuration (References 1 and 3). The contract specifies 3 clear lights to indicate grounds when a test button is pressed. The TVA schematic diagra.s agree with this configuration. A contract drawing specifies the bulb and clear lens. combination (Reference 4). h Cognizant individuals in operations (Assistant Operations Supervisor, and ASE and a SRO) were interviewed to determine the action taken to detect grounds. Cognizant individuals in Electrical Maintenance (an Electrical Engineer, and Electrician-Foreman, and an Electrician) were interviewed to determine the action taken in response to a Work Request stating that operations personnel had found indications of a ground on the 400-volt Shutdown Boards. The following is a summary of the findings from these interviews: Page 1 of 4 4

I 1) Operations AV0s are required by 0SLA99 to check the condition of the 480-volt Shutdown Boards once per shift and document the check on Attachment F of OSLA99. Based on interviews with cognizant individuals in operations, part of this check is to press the test buttons of the ground detectors in order to identify any possible grounds. This checking process. is not in procedure form but is part of the AUOs.past training experience. If problems are identified, an ASE or SRO is called for assistance in evaluating the problem. 2) If a ground fault is identified,,a work request is initiated to allow the electricians to determine and repair the cause of the ground fault. Electricians are requested to check all three phases in evaluation of the problem. Based on interviews with cognizant individuals in Electrical Maintenance, a Work Request to troubleshoot and repair a ground on the 480-volt Shutdown Board is handled as follows: The electrician requests the help of an ASE to isolate the circuit causing the ground. This is done by opening circuit breakers and observing the ground detector when the test button it depressed. Absence of a ground indication when a breaker is oraned identifies the associated circuit as the circuit causing the ground problem. The circuit breaker is left open and the electrician measures the resistance of each phase to ground with a calibrated ohm meter. A low resistance measurement on a phase indicates that phase is grounded. The electrician proceeds to locate and repair the ground condition. 3) Operations personnel change the ground detector bulbs when they are broken or show unequal brightness with the other detector bulbs in a set of three. 4) There are two types of bulbs that can be used as replacements in the ground detector circuit. 5) If bulbs of different types are mixed in the same ground j detector, falso partia,1.g'round fault indications will occur when the test button is pushedi* ~ - 6) No procedure for changing the ground detector bulbs could be identified. 7) No operations night order" was identified that specifies ground ~ detector bulb changing procedure. 8) The bulb type to use as replacement is not identified. The bulbs are replaced by bulbs of the same type number verified by I inspection of the old and new bulbs. Page 2 of 4

9) The 480-volt boards that are equipped with ground detectors are also equipped with overcurrent protection relays. Conclusions 4 1) Problems of false ground faults, partial and full, indications on the ground detectors have occurred in the past. 2) Operations personnel replace ground detector bulbs as necessary based on training and previous experience. No procedure was found that identifies the correct bulb type. 3) If a ground is identified on one of the phases, operations personnel write a work request to have the problem evaluated by the electricians. No procedure was found that describes the corrective maintenance. 4) Bulbs of different types could overshadow a partial ground problem on one of the phases. ~ .5) The ground detector problem will not degrade equipment reliability because the 480-volt boards are equipped with overcurrent protective relays on all phases. The overcu'rrent relays will trip the breaker if a ground fault exists on two or more phases. A ground on one phase only will cause no equipment degradation, but should be identified and repaired. Based on the findings, employee concern SQP--013-001 is determined to be valid. IV. Root Cause Based on the findings, no procedure exists for ground detector bulb replacement and trouble shooting. V. Generic Applicability Based on the findings, this doncern has been determined to be ~ applicable to other TVA;qyclear plants / VI. References 1. TVA Contract Number 71C2-54523 2. Operations Instruction Letter OSLA99, page 5, dated January 10, l 1986 and page 61 (Attachment f) dated April 10, 1986. 3. TVA Schematic Diagrams 45W760-212-1, 45W760-212-2, and ) 45W760-212-3. (All revisions show the ground detectors) ( I 4. Contract Number 71C2-54523 Drawing Number 6846035 R9 l f i Page 3 of 4

a s. Immediate or Long-term Corrective Action VII. Sequoyah Nuclear Plant Line Management has been briefed concerning the findings of this report and has initiated an investigation which will result in appropriate corrective action. l ( I i 1 I Ii 't 1 I i, .,., *g., 9-t I i i 8 Page 4 of 4 L

I 1 ~ .m A' S i i r! TENNESSEE VALLEY AUTHORITY SEQUOYAH NUCLE 6R PLANT EMPLOYEE CONCERNS TASK GROUP OPERATIONS CEG Subcategory: Accessibility Element: Accessibility Problems' Report Number: 305,01-SQN J' VO h. _h Evaluator: /~ Duto C. W. Tou hstono i

• 7 fl' 'M 7/so/F4 Reviewed by:

OPS CEG Mom F / Dato ~ ~[/*M/$ b '.) - %v i Approved by: W.R.Lagerbryn ' Dato i i I 1266T I L.

I. Accessibility Problems This report examines the program for identifying accessibility problems at Sequoyah Nuclear Plant (SQN) which may affect normal plant operation, The six evaluated employee maintenance, testing, or inspection. concerns are Watts Bar Nuclear Plant (WBN) specific, but have generic applicability to SQN.. Examples of previous corrective actions proposed ~ a ,, r and/or implemented are included. The scope of this evaluation does not consider safety and health physics aspects of access problems, though mention of these aspects may at times be necessary for clarification. II. Specific Evaluation Methodology A thorough review of the K-Forms (Reference 1) was conducted to evaluate Historical information such as engineering the scope of this element. change notices (ECNs), workplans, and surveys are listed in section Interviews with SQN personnel were conducted to address items VII. Among those contacted were an engineer and related to accessibility. supervisors in the Industrial Safety Section, two engineers in the Mechanical Engineering Test Section, an assistant shift engineer (ASE) in Operations, and a Plant Operations Roview Committee (PORC) representative. Following is a list of the concerns evaluated for generic applicability to SQN: Concern IN-85-189-001 WBNP Unit #2, once scaffolding is removed, some valves would be hard to get'to, og: 15 feet off floor, to manually open or close valve. CI could not provide specific valve #'s, systems, buildings or clovations. CI stated this condition exist throughout the plant. Concern IN-85-189-002 Valves located in WBNP #2 South Valve Room aro very congested and inaccessible. Only a small CI stated person would be able to get to them. .ona example is Drain Valve on Main Steam System (E South Vaive Room Unit #2. CI could not provide any additional details. Various equipment that.could be needed during an '] Concern IN-86-306-001 emergency is not readily accessible to applicable personnel. Example: Aux Building 713' Elev (also Containement Building) the instrument panels and the aux feedwater pumps are so'congosted it is very time consuming to Nuclear get in there to read the instruments. CI has no further information. Power Concern. Concern PH-85-003-006 Watts Bar Instrumentation is not properly designed f or accessibility. CI has no more additional information available. 2 Page 1 of 7 (

a Concern IN-85-220-001 Due to excessive number of hangers and overcrowding in Unit 2 Keactor Building, especially accumulator room #4, Health Physics l problems (ALARA concerns) during plant-operations are anticipated..CI feels that not I enough concern was shown'regarding the number of hangers being used. Qonstr. Dept. concern. CI "/

e. :

could not provide any additional details / specifics. Concern IN-85-617-001 The building of hangers & pipe support systems to.the point of accessability being made impossible. This concern involves both unit 1&2. The primary places of intorest are: roof, Aux Bldg. elv. 737, the ERCW vont valves, CCS valves to heat exchangers, #4 accumulator room, north & south steam valve rooms & elv. 713, BIT tank room. Accessability is nonexistar.t due to potentially hot pipes & congested areas. Presently there are scaffolds to some inaccessable areas, when scaffolds are removed, no access will be available. Note: SQN elevations are 23 feet below those at WBN. SQN main steam valves rooms are situated east and west. III. Findings SQN, like all nuclear plants, has areas that tend to be less accessible than other areas. The primary areas of concern are the main steam valve rooms, the accunalator rocms, and valve and instrumentation accessibility in general. This report examines first the SQN accessibility program in general and then the specifics of the program including problem identifiestion and resolution. 1.- SQN Accessibility Gener.1 '- +. .e s t The accessibility progr'at at SQN basically consists of the Platform and Valve Accessibility t'rogram (Reference 2) initiated several years ago to identify anc propose correct {ve action for specific access problems.' Industr ial Safety was unsure of the program's "1 prosent status bu't felt t hat many of the items were either cancoled or slow to be implementec. They felt the level of priority given to some of the items was per1aps lower than what personnel safoty dictated. Investigation of the atove revealed that although some of the items have yet to be worked, many are presently scheduled and some are totally complete. Fo*J of the items have been cancolod and those which have are mostl.' minor. Upon hearing this, one Safety Section individual acknowled6ed that until workplans to correct problems actually "come acro ss the desk" for review, status of propcsod items is generally in question. Page 2 of 7 L-

III. Findings (Continued) Although the accessibility program is presently less defined than in access problems are brought to the attention of cognizant the past, plant personnel. I A Safety Section supervisor noted that accessibility items of any nature are of definite interest to Industrial Safety and felt that r* ! He noted that plant coordination through them has been fairly good. sections' safety meetings are one example of how access concerns may Reference 3 documents a few accessibility concerns be expressed. identified in Electrical Maintenance Section safety meetings. Furthermore, employee suggestions, employee concerns, and plant section informal and formal notification are also methodc by which access problems may be identified. An assistant shift engineer agreed that coordination with plant "line" organizations was generally not a problem and that Industrial Safety would likely be However, he added that the Operations consulted if the need arose. Section does have frequent difficulty in coordinating activities in general with design organizations. 2. SQN Accessibility - Specific SQN Generic Concern Report (Reference 4) discusses particular accessibility facets at SQN and additional comments on hou SQN solvoc access problems. The report states that a walkdoun was conducted to evaluate access in the BIT tank room, the east and west main steam valve rooms, and the number 4 accumulator room (most congested of all accumulator rooms). Access was found to be difficult; however, Operations personnel are able to access and The walkdown also considered operate all valves within these areas. the ERCU vent valves, and the auxiliary building (elevation 714'), the CCS Hx valves.and found these areas were accessible but cumbersome in some cases. The report further notes that remote operators have been. installed for valves that are not read'ily accessible during normal operation. AnASEatSQNalsonoted%hatemergencyequipmentcouldbeaccessed in a timely manner'.' Exkmples of such equipment are the flood-modd The ASE spool pieces, some of which are located in congested areas. said that despite the congestion, spool pieces could be installed within time limits.. 3 The SQN Platform and Valve Accessibility Program (Reference 2) identified numerous access deficiencies which if uncorrected could result in operational, maintenance, testing, and safety problems for plant personnel. Fifty-three items were tabulated and their present status is doscribed in References 2 and 5. Of the 53 items identified, 47 have either been completed, partially worked, scheduled, or ECNs written. Examples of these items and other items mentioned in Reference 4 follow: Page' 3 of 7 k

-.? ' ~ ' f III. Findings (Continued) Main Steam Yalve Room (MSVR) Access to U-1 and U-2 west MSVR S/G Blowdown throttle valves I Access from north to south walls d '8 l

p. g Access to west MSVR feedwater isolation. valves Access problems in vicinity of main steam relief valves

-Accumulator Rooms Platform and ladder for access to SIS cold leg accumulator tank's level transmitter sensor bellows o Fixed ladder access from Reactor Building raceway to accumulator number 4 l Poor access to vent valv6s, check valves,.and isolation valves for leak testing. This item (ECN 5531, item 44) was cancelod; however, plans are for Mechanical Test Section to considor alternative corrective action after plant startup. Instrumentation Accessibility Installation of piping and valves to allow neutralization of makeup water treatment regeneration waste water; relocation of i instruments to local panel-FLxed ladders to top of cooling tower lift pump motors for reading f gages once per shift Four portable platforms for the condensate demineralizer polishers inspection view ports Installation of larger > gages for diesel generator lube oli to allowreadingfrom,{loor-Platform installation to a'11ow access to steam generator inspection ports ,7 Many other efforts including chain operators for inaccessible valves, steel scaffold, portable Inddors, grating, hoists, and guardrails have been implemented to aid access to various ,j-equipment at SQN e Page'4 of 7 s:

o III. Findings (Continued) 4 Conclusion Accessibility to.certain areas is a recognized problem at SQN. SQN has identified many areas in which access is a problem and has taken measures to rectify same. Consideration of sqfety, operational, and a

p. :

maintenance aspects of access problems has been used in addressing the issues. Reference 6 notes that experience at SQN indicates that although difficult, adequate and proper maintenance can be accomplished. The concerns below are all valid to certain extents; however, actions as described above and more thoroughly in the report have been taken to minimize the difficulties encountered. IN-85-189-001 Valve accessibility has been a continual effort at SQN with many corrective actions already implomented. IN-85-189-002 MSVRs are high on the " safety list." Efforts by safety to monitor these areas has been very safety conscious and several modifications have boon planned or implemented. IN-86-306-001 The Auxiliary Building is indeed congested; however, Operations personnel do not consider the turbine or motor-driven auxiliary foodwater pumps excessively congested at SQN. l PH-85-003-006 Problems with access to instrumentation have not gone unnoticed and various actions have been taken to l identify / correct these problems. IN-85-220-001 The accumulator #4 is indeed congested; hence, it has received paramount attention. Health Physics specific concerns are beyond the scope of this report. IN-85-617-001 Accessibillt,y to,these areas is congested; however, SQN has taken actions.to minimize its effect. Operations personnel are able to access those areas and operato equipment. IV. Root Cause The original plant layout was based on data from Westinghouse and on similar designs by other utilitios in the late 1960s. Docause the internal building design could not be modified to accommodate modifications and additions, certain areas have proven to be insufficient to prevent tight and crowded conditions. (Referenco 7) Page.5 of 7 s m

a V. Generic Applicability a Accessibility concerns for WBN'have been evaluated in subcategory report 305.01. I pVI. References s 1. K-Forms: IN-85-189-001 IN-86-306-001 IN-85-189-002 PH-85-003-006 IN-85-220-001 IN-85-617-001 2. Memorandum and status report to Those listed from James Doty, " Platform and Valve Accessibility Program," June 6, 1984, RIHS LS1 840606 843 3. SQN " Electrical Maintenance January Safety Concerns," January, 1986 4. TVA SQN Generic Concerns Task Force (GCTF) Report on Employee Concern: IN-85-617-001, " Accessibility Impossible Due to Hangers and Pipe Supports," by T. H. Huth, June 6, 1986 (Rl) and February 18, 1986 (RO) 5. Status report for platform and valve accessibility as of July 1986 - data obtained fro'm SQN Planning and Scheduling Section (this information pertains to Reference 2) 6. Memorandum to W. H. Thompson from W. T. Cottle, "QTC Concern IN-85-430-001," August 13, 1985, reported by R. Goode 7. Memorandum to K. W. Whitt from R. V. Pierce. " Employee Concern Evaluation for IN-85-286-002," July 19, 1985 8. SQN Engineering change Notice (ECN)-5889 and SQN workplan (WP)-10954, " East Main Steam Valve Room Access Platform Addition," April 19, 1984 9. SQN ECN-6170 and SQN WP-11618,'R1, "Mainsteam Valve Rooms - Emergency Descent Dev,1ce..and Hi*nged Gate," June 28, 1985

• :(

w :

10. SQN ECN 5635 and SQN WPs 9936 and 11648, "RB Accumulator Room

+ Ladder," May 30, 1985 ..s c.3 Page 6 of 7 s.

o a, VII. Inunediate or Long-tenn Correctlye Action i I P. ! f I i 2 +- .og 9 ~ 1 Page 7 of 7 w.

} TENNESSEE VALLEY AUTHORITY SE7)CY AH rsuCLEAR PLANT EMPLOYEE f.ONCERNS TASK GROUP OPERATICNS CEG Nuclear Power / Site Program / Procedure Subcategory

• Element: Radiological Emergency Preparedness Report Nunber:

107.07 - SQN JLH-86-004 XX-85-035-001 1 f h/ /d Yf Evaluator: Date )Q f M. Str9d1)7' ^ _[d//h [9 [ Reviewed by: Dat'e [0PS C(d M' ember f' W Approved by~. / Ddte W. R., Lagergren 1534T

6 r b .4 + i I'. Title Radiolcgical Emergency Plan Two Sequoyah Nuclear Plant (SQN)' specific concerns are addressed in this j, One concern questions the adequacy of evacuation routes, the report. other concern questions the prudence of issuing potassium iodide (KI) to l Sequoyah site employees and the general public. i i II. Specific Evaluation Methodolqgg ^ Concern JLH-86-004 states: "The evacuation route away from Sequoyah Nuclear Plant for areaA f I residents on both sidos of the Tennessee Rivpr is inadoquato. four-lane highway frma the new Highway 27 to SQN and across the Tennessen River to connect with I-75 would provide for a safe evacuation in case of a nuclear related accident." 1 1 Concern XX-85-035-001 states: f " Iodine tablets have been issued to Sequoyah site employees and the j general public in the Sequoyah area, before the occurrence of a [ The result is that these tablets may be used in an l radiation incident. unsupervised and possible hazardous manner." t The evaluation of these concerns included a review of aoplicable NRC and FEMA emergency preparedness criteria. This iticluded 10 CFR 50, Appendix i E and NUREG 0654/ FEMA Rep 1. TVA, State of Tennessee, Bradley and Hamilton County emergency j preparedness documents were reviewed. Cegnizant emergency preparedness personnel at SQN and Chattanoo interviewed. Recent FEMA evaluations of SQN emergency agercise$ were also contacted. l reviewed. i 4 1 + i III. Findings

2. '

Evaluatinn Results. . cy, A-i 3LH-84-004 NRC requires nuclear power plants to develop and implement emergency i. These pians must a:idress protective measures, incluctng 6 l response pir.ns. However, TVA has no legal evacuation, to protect the general public. 1 t implement protective measures outside the plant authorit'j t2 The Tennessed Emergency Management Agency (TEMA), Hamilton and Gradley Counties have developed a " Multi-Jurisdictional Radiological boundaries. Emergency Responso Plan," which provides for the evacuation of a lO-mile i aroa around SQN. 6 ? I i i t t i f Page 1 of 4 1 + w me e.-r - w e r,- n,-- - - --~, -n, -,,,.- e r mw w.? ww-e n, w, e., rm, rw.. m .,n m e- ,,,, ww ww wm m m - w w. -en-ee ame,--r.----,sww,

j J The multi-jurisdictional respanse plan includes the emergency response plans fer Hanilton and Bradley Counties (counties within the 10-mile emergency planning zone). The plan identifies the evacuation routes for area residents, gives popul:Atton and vehicle estimates for both the / permanent and transient populaticns, oescribes the roadwaycharac required to evacuate the population, s The plan also includes tha responsibilities and means for alerting end warning the p;blic, traf fic control point-s for rerooting or diverting i traffic from crosded routes, and traffic assistance teams to assist vehicles that have broken down or run out of gas. Management egency (FEMA) has reviewed the The raderal Emergenc3 multi-jurisdictional plan and has evaluated the annual emergency l preparedness exercises conducted jointly by TVA, the State of Tennessee, FEMA has found that the ( and Hamtitcn and Bradley Counties. multi-jurisdictional response plan provides adequate protection for the i The FEM 4 Evaluation Report on the 1935 emergency population arcund SQN. excretse for SQN stated: "Bradley and Hanilton counties demonttrated an adequate capability to 4 evacuate the populace of an endangered area." Residents living within 10 miles of SON have received an information ^ brochura on alerg ncy.2ctic.1s in case of a radiological emergency at CQFJ. The brochure include-s information on: Emergency classifications I o Sirens Potassium Icdido pills I t Evacuation and evacuation routes I SQN - Radiological Emargency plan (REP) S7N REP - Implementing Procedur.es (IPs) 8 .~ ' Tennessee Nulit-7urtid*letiona) RLdiological Emergency Rasponse Plan j for SQN i SQN Emergency Information Brochure I l XX - A S-035-001 Potassium iodido (RI) tablets are uses to reduce the uptake of f radicactive iodine by individuals exposed to airborne radioactive The issuance of KI to site emplovees is controlled by 1 l material. During an KI has got been distributed to emoloyees at SQN. actual radiological amorgency, NI may be issued to individuals suspected SQN-IPs. i i Page 2 of 4 I -~

- ~ Currently, EI is stored of receiving thyroid doses greater than 10 res.The' supply of KL is maintain Information on KI, including who should and should not onsite. is provided by the manu*acturer. plant nurse. take it and possible side effects, This literature is contained in the KI packages and SQN-Ip-14. The State of Tennessee has distributed KI to each household within a In addition, KI is stored at each school within 5-nile radius of SQY.This decision was made by the State of Tennessee not the 5-mile radius. TVA has no authority or control over decisions made by the State. Tha decision to actually use XI would be made by the State Division of TVA. The Emergency Radiological Hoalth and the Gtate Medical Officor. Information Orochure informs residents that "you should not take the pills unless you have been specifically told to do so by State llealth Of'f ic ials. " Conclusions FEMA has stated that the counties within Neither concern was validated. 10 miles have " demonstrated an adoquate capability to evacuate the The distribution of KI to site personnel is controlled by populace." The KI has not been given to site parsonnel. distribution cf HI to area residents is a function of state and local plant procedures. TVA has no authority or control over decisons made by the scwornment. State of Tennessee. IV. Root Causo N/A V. Generic Applicability Cencern JLH-86-004 is Sequoyah specific and is not applicable to other The distribution of KI to site parsonnel, Concern i TVA sites. XX-85-035-001, is applicable to other TV6 sites. a VI. References . *f,,.

1. 10 CFR 50, Appendix E*

2. NUREG 0654/ FEMA Rep 1

3. Gequoyah Nuclour Plant - Radiological Emergency Plan (RCP)

4. CQN-IP-14, " Health Physics Procedure," Revision 9. Cecemter 2/,1964 l

Page 3 of 4 O

1 j f

5. SQN-IP-17, "Crergency Equipment and Supplies," Revision 10, October 16, 1985

6. " Tennessee Multi-Jurisdictional Padiological Emergency Response Plan for Sequoyah Nuclear Plant," March 1986

7. Sequcyah Emergency Information Booklet, Spring 1986

8. Sequoyah Nuclear Power Plant Exercise Report, FEMA, March 5, 1986

9. NUREG/CR-1856, "An Analysis of Evacuation Time Estimates Around 52 Nuclear power Plant Sites," USNRC, May 1981

10. " Employee Response Team Investigation Report For Concern IN-85-170-002," J. W. Hufham to K. W. Whitt, June 19, 1985 (L63 850612 810)

11. Employee Concern Disposition Report, Concern No. XX-85-035-001, July 12, 1985

12. Response to Employee Concern JLH-86-004, W. S._Wilburn to J. L Hamilton, March 5, 1986 (S01 860305 995)

VII. Immediate or Long-Term Corrective Action None J.

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2 a TENNESSEE VALLEY AUTHORITY ~ SEQUOYAH BAR NUCLEAR PLANT EMPLOYEE CONCERNS TASK GROUP OPERATIONS CEG r Subcategory: Maintenance J Element: Adequacy of Procedures Report Number: 308.01 - SQN ) SQP-6--009-004 SQP-6-014-001 MAS-86-001 l MAS-85-004 l TAK-85-002 I TAK-85-004 ~/...

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I. Title - Adequacy of Procedures, This report evaluates six covicorns involving the adequacy of maintenance instructions at Sequoyah Nuclear Plant. II. Specific Evaluation Methodology " Adequacy of MI 10.48 (Motor Lubs)" Concern NAS-85-004 states: Concern MAS-86-001 states: " Adequacy of MI 6.20" "M&AI-9 does not specify torque -for screws Concern TAK-85-002 states: less than #10" " Lubrication of geared limit switches on Concern TAK-85-004 states: MOVs not properly inspected." " Maintenance instructions are unclear l Concern SQP-86-009-004 states: and do not provide adequate instruction. Details known to QTC,' withheld No further information may be released. due to confidentiality. Nuclear Power department concern." " Foreman do not always support the craft states: Concern SQP-86-014-001 in providing them with everything they need to do the job, E. G. CI has no further information." required prints. Nuclear Power concern. These concerns were evaluated by reviewing appropria'te TVA documents and procedures, regulatory requirements, industry standards, and From the electrical maintenance section, one manufacturer instructions. supervisor, two engineers, and two craftsman were interviewed. One - mechanical maintenance engineer was interviewed. This report was conducted in accordance with the Evaluation Plan for the Operations concern Evaluation Group and the Operations / Operational Subcategory Evaluation Plan. .f'; ..q n. III. Findings Evaluation Results A. MAS-85-004 The procedures for lubrication of motors at Sequoyah are basically Electrical Maintenance was made aware taken from vendor manuals. that NI 10.48 was inadequate in that the procedure was generic and did not specifically address each motor manufacturers requirements The DR and a Deficiency Report (DR) was written on the procedure. has been dispositioned in that the MI has been rewritten and motor 15.2.1, 15.4.1, and lubrication instructions are provided 'in MIsThe procedures now address 15.6.1 which were approved June 30, 1986. the requirements of different motor manufacturers specifically. Page 1 of 6

MI 10.48 will be cancelled when it is determined that all motor This vendor requirements have bee'n addressed in other procedures. should be followed to ensure it is cancelled. B. MAS-86-001 NQAM, Part II, Section 2.1 requires a means to control changes in MI 6.20 contains a dasign configuration during trouble shooting. data sheet for logging changes in design configur for removal and return to normal.The NI contains ins'cructions for to the MR initiating the work. filling out the data sheet and gives exam which require entry into this data sheet. C. TAK-85-002 17, 1985) to M&AI-9 was completely rewritten in revision 5 (Decemb Section 3.5.6 of G-38 states that screws ll be with G-38 requirements. size #10 or smaller used in cable splices and termina No tightened to the point at which the lockwasher is flattened. NQAM,'part torquing valves are given for screws in this category. II, section 2.1 states that the plant maintenance program obj(ctive least shall be to maintain each item of the CSSC to ensure quality at l equivalent to that specified in the original design, materia specifications, and inspection requirements. Craft personnel interviewed did not express any problems with this section of the M&AI. D. T,AK-85-004 Limitorque Corporation has experienced problems with the lubricant t (Beacon 325) originally furnished in the geared limit switches of Sequoyah has their valve operators in hlgh bemperature environments. encountered hardenihg pf"this,lu,bricant in a few safety-related in the operators and has initiated a.WR/NR to change out the grease to geared limit switches of all safety-related Limitorque operators t Mobil Grease 28, which is recommended by Limitorque unit 2 is complete and only a few operators remain on unit 1. lubricant. f The Sequoyah preventive maintenance program c d consistency at 36-month intervals as recommended by Limitorque. Engineering personnel can be called in for evalua Although the grease in the limit switch gears of the i nonsafety-related operators are not being changed out at this t me, i they are included in the PM program and have th same inspect on If hardening is requirements as the safety-related operators. discovered during the inspection, the grease in that particular operator will be changed. Page 2 of 6

t E.-SQP-86-OO9-004 This concern was evaluated based on maintenance instructions reviewed Craft and the resultant findings in the four previous concerns. personnel were also interviewed. The findings are summarized below. Detailed findings are in each individual concern. MI 10.48 was evaluated in concern MAS-85-004 and was determined by This instruction has been the cognizant section to be inadequate. rewritten to conform to vendor maintenance instructions. h?. 6.20 was evalcated in concern NAS-86-001 and appear 4d to meet all the requirements of the NQAM. N&AI-9 was evaluated in concern TAK-85-002 and appeared to meet all the requirements of G-38. NI 11.2 was evaluated eecause it was associated with concern This MI war very detailed (more so than the\\ vendor ~ TAK-85-004. instruction manual)vand included detailed sketches throughout the in1truction to aid the craftsman in performing maintenance on the operator. Craf t personneh interviewed did not express any problems with these n.aintenance instructions. If problems do arise with a particular instruction, they felt the necessary changes would be cadai ^ Craf tsmen are provided a place on the Instruction Review shoet, Appendix E of SQM-2, to recommend changes to the instruction used to perform the work. the NQAM, Part III, Section 1.1 requires plant instructions be ~ Alsoi reviewed no less frequently than every two years to determine if. The instructions evaluated had changes are necessary or desirable.s all been revised within the last six' months. F. SQp-86-014-001 t ). Sequoyah SQM-2 controls the Wor,p Requegt;(WR)' process at Sequoyah. utilizes planners (forMerly cfaft personnel) to plan out the work The requested by th'e WR/NR, which includes making up the WR package. responsible foreman ensures the WR package is complete and all l The foreman and the responsible \\ i necessary instructions are included. i craftsmei sign the Instruction Review Sheet verifying the The instructions included are adequate for performing the work. is not addressed in inclusion of necus?ary drawings in the WR package SQM-2. t On occasion the planners include the necessary drawings in the WR l package and sometimes only a drawing number is provided, either by Craftsmen in the planners or listed in the applicable instruction. ^ the past have always been responsible.for acquiring the drawings necessary to perform the work. Page 3 of 6 'g s q

According to craf t personnel interviewed, there were some problems with WR packages being incomplete when the planner concept was first initiated, but they felt WR packages now contain the correct material. No problems with foremen providing correct work material were expressed. Conclusions A. MAS-85-004 The concern that MI 10.48 was inadequate was validated. However, the MI 10.48 has been problem has been corrected before this evaluation. rewritten and is now MI 15.2.1, 15.4.1, and 15.6.1 which addresses vendor requirements specifically. MI 10.48 will be cancelled. Since this problem has been corrected, the concern is not nuclear safety-significant. B,. MAS-86-001 The concern that MI 6.20 is inadequate was not validated. This MI meets the requirements of the NQAM. A data sheet is provided in the instruction for entering configuration changes during trouble shooting and detailed instructions of how and when to fill our the data sheet are provided. C. TAK-85-002 The concern that M&AI-9 does not specify torque for screws less than

1. 10 was not ' validated. M&AI-9 does not specify torqueing values for screws #10 or smaller, but this is in agreement with General Ccnstruction Specification G-38, and being in line with G-38 meets The craft the requirements of a maintenance program in the NQAM.

personnel interviewed did not express any problem with this item. D. TAK-85-004 i The concern that the lubrfcht' ion of geared limit switches on MOV's is not being properly inspected was, not' validated. Sequoyah is in the process of changing out the lubricant in the geared limit switches of 5 g all safety-related Limitorque operators because of problems with the original lubricant furnished. This is a required restart item and presently, unit 2 is' complete and only a few operators are remaining l on unit 1. The Sequoyah preventive maintenance program for l Limitorque operators is in line with manufacturer's recommendations. E. SQP-86-009-004 l The concarn that maintenance instructions are unclear and do not [ provide adequate instruction was not validated based on the i i instructions reviewed. If there are cases of maintenance instructions being unclear or inadequate, the craftsmen have a means of recommending changes to these instructions. i l Page 4 of 6 L ~- g

h F. SQP-86-014-001 The concern that foremen do not always support the craft in providing them with everything they need to do the job, e.g., required prints, was not validated. SQM-2 requires the planners to provide the needed material in the work package. SQM-2 specifically requires the needed instructions be included in the work package but does not address The planners are providing the correct material, required prints. for the craftsmen to perform the job specifically in in the case of drawings, either the correct drawing or the drawing number is supplied. IV. Root Cause The root cause of concern NAS-85-004 is that the procedure was written for the. generic lubrication of motors and did not specifically address - the lubrication requirements of each Sequoyah motor vendcr. V. Generic Applicability Concern NAS-85-004 is'not applicable to the other plants. MI 10.48 has been rewritten from a generic lubrication procedure to one that addresses specific motors at SQN. MI 6.20 Concern MAS-86-001 is not applicable to the other plants. l specifically addresses configuration control procedures at SQN. Concern TAK-85-002 is not applicable to the other plants. M&AI-9 specifically addresses torquing requirements at SQN. Concern TAK-85-004 is applicable to BFN, WBN, and BLN. These plants all have Limitorque operators and are subject to the same inspection requirements. J. ' This Concern SQP-86-009-004,is,not applicable.to the other plants. concern addresses the ade'quacy of procedures written at SQN. Concern.SQP-86-014-001 is not applicable to the other plants. The procedures for handling work packages at SQN are specific to this plant. Page 5 of 6

1 a; VII. References 1. NQAM, Part II, Sec. 2.1 RO 2. NQAM, Part III, Sec. 1.1 RO 3. 110 CFR 50.49 Code of Federal Regulations - Environmental Qualification Revised January 1, 1985 4. ANSI B31.7 1971 Addenda to Nuclear Power Piping 5. General Construction Specification G-38 Installing Insulated Cables Rated Up to 15,000 Volts R8 6. SQM-2 Maintenance Management System R18 7. UL 486A Standard For Wire Connectors And Soldering Lugs For Use With Copper Conductors Seventh Edition 8. UL 486B Standard For Wire Connectors For Use With Aluminum' Conductors First Editicn 9. M&AI-9 Inspection of Bolted Connections R7 10. MI 11.2 Motor Operated Valve Adjustment Guidelines R18 11. MI 10.48 Relubrication Of Motors R1 12. MI 6.20 Configuration Centrol During Maintenance Activities R8 13. MI 15.2.1 Lubrication Of Reliance Motors RO ~MIr15.'4.1' Lubrication Of Allis Chalmers/Siemens-Allis Motors R) 14. 15. .MI 15.6.1 Lubrication of Westinghouse Motors RO 16. Limitorque Type SMB InstAuction And Maintenance Manual ' * ;l "'"? _w, VII. Immediate and Long-Term Cor'rective Actions Based on the findings and conclusions no corrective actions are required. [ l f i Page 6 of 6 l

} I., 4 't .I-TENNESSEE VALLEY AUTHORITY SEQUOYAH NUCLEAR PLANT EMPLOYEE CONCERNS TASK GROUP OPERATIONS CEG Subcategory: Operations / Operational Element: Operators Programs / Procedures Inadequate Report Number: 310.01-SQN SQP-5-003-OO1 SQP-5-OO3-002 XX-85-067-OO1 SQM-6-013-002 SQP-6-010-OO1 XX-85-022-001' IN-85-933-001 .u - ,p d I Cut Evaluator: ' Date V J. uf ////Y [//6!8'd Reviewed by: ' Date OPSCE4Mger Approved by: Date W. R. Lagergren i 1614T r .___..m_

I ~ I. Operators Programs / Procedures Inadequate This report primarily addresses concerns describing past or potential incidents involving operations personnel directly relating to a lack of experience or training. The scope of this investigation will be directed toward: (A) Evaluating each individual concern and, (B) Establishing whether the stated incident was a result of: (1) Operator error (2) A failure of other involved personnel to adequately comprehend all circumstances of an incident, (3) Inadequate procedures or, (4) A combination of the above II. Soecific Evaluaticn Methodology This report was ccnducted in accordance with the Evaluation Plan for the Operations Concern Evaluation Group and the Operations / Operational Subcategory Evaluation Plan. The following concerns were reviewed during this report: SQP-5-003-OO1 Sequoyah - On the evening of 12/9/85, an electrician operated Concern: a valve in the unit 2 RHR heat exchanger room without a unit operator Thi's caused a spill-(unknown amount) of what the CI described present. as " reactor grade" (highly radioactive) water into the room. The spill was secured by a health physics technician who happened to be in the CI stated that it was alleged that a unit operator had told the area. electrician to go and separate the valve, and that unit operators are not authorized to give such directions. CI could provide no estimate of amount of radioactivity released, and stated that "everyone is being real closed mouthed about this thing". CI has no further information, and is anonymous. +- SQP-5-003-002 Sequoyah - CI expressed that management / supervision have an Concern: attitude of "' Hurry up and get the job done" in an effort to get the CI feels that procedures are not being followed in an plant on line. effort to accomplish work as quickly as possible, and evidenced this by the radioactive water spill which occurred on 12-9-85, and addressed in this file, concern 001. CI has no further information, and is anonymous. I XX-85-067-001 Sequoyah - Small problems in plant operation were disregarded. Concern: (1983), and the plant (unit 1) was kept operating as if in a race, which resulted in bigger problems. Nuc. Power Dept, concern. CI has no further information and has expressed this as a generic concern. Page 1 of 7 i 1

SQM-6-013-002 An itemized list for the proper size voltage, amperage, and Concern: type of bulbs and fuses needs to be available to operations for all equipment under their control. ' Nuclear Power concern. Anonymous concern. SQP-6-010-OO1 While working at Sequoyah in 1973 on electrical lines, switch Concern: box controlling these lines was only tagged. To ensure personnel safety, CI feels that the switch boxes should have been locked and the electrician working on the electrical lines should have the key to the lock on the switch box. CI has no additional information. Construction department concern. XX-85-022-OO1 Operators at Sequoyah should show more concern and exercise Concern: While removing test Conn and more caution when tagging out valves. installing blind flg at RC Pmp #2, operators started filling sys while craft was still working. This occurred in September 1984. Names are known. IN-85-933-OO1 TVA's program of placing degreed. engineers as Senior Reactor Concern: Operators with only 20 months of plant experience will reduce the level of reactor operating safety by having individuals in charge who do not know how to react to and resolve the practical problems that will be encountered during operations. Operaticns concern. CI has no further information. Informal interviews with cognizant individuals and reviews of applicable procedures and documents were conducted during the investigation of each concern. i i III. Findings The findings of this investigation, are listed below in the same order Refer to the individual concerns are' listed in the previous section. the previous section for the wording of each section. Concern SQP-5-OO3-001 and SQP-5-005-002 were satisfactorily addressed in This NSRS report Nuclear Safety Review Staff report I-85-137-SQN. substantiated that a contaminated water spill did occur as described, i but did not substantiate that any effort had been made to cover up the Administration Instructions AI-30, AI-3 and Maintenance incident. Instruction MI-10.46, procedures applicable to the incident, were found The concern did to be sufficient and warranted no necessary revisions. identify a questionable practice utilized by shift operations personnel of allowing maintenance workers to manipulate valves without proper supervision or the issuance of an operating permit while performing While this practice in no way caused the certain test procedures. incident, plant management did issue verbal instructions to all shift engineers to insure the practice was discontinued for all future related w rk. Page 2 of 7

a Unit operator and health physics daily journals documented the incidsnt in a manner sufficient to preclude any question of a plant cover up attempt. was adequately addressed by the Nuclear Safety Concern XX-85-067-001 Because the concern was so Review Staff report I-85-862-SQN. generalized in nature, containing no specifics relating to the alleged the NSRS committee utilized a wide range of reports to

problem, accurately document unit 1 performance during 1983, consisting of:

NRC Systematic Assessment on Licensee Performance (SALP reports) I (1) from July 1, 1981 to May 31, 1985. NRC Regulatory violations as documented in I&E inspection (2) reports. (3) License Event Reports (LER's) Monthly operating reports submitted by Sequoyah Nuclear Plant to (4) NRC and, Interviews with individuals cognizant of unit 1 operations during (5) the time period stated. Section III of the NSRS report meticulously details the committees The investigation findings relating to each category listed above. revealed: No specific problems associated with the operation of unit 1 that (1) were disregarded by plant management. No individuals who had any knowledge of ruch problems. (2) Several instances of the unit being taken off line or dropped to a (3) reduced power level for maintenance to be performed. A reduction of LER's for 1983 relative to 1982. (4) SALP appraisals reflecting an overall improvement in plant (See NSRS rdport. references). The NSRS investigating (5) operation. committee could find,,-no' instances in the covered data to substantiate the concern. appears to be-more a matter of convenience than a Concern SQM-6-013-002 l All interviewed Assistant Shift Engineers indicated that an itemized list of fuse and light bulb sizes would be helpful, but safety concern. l The plant was not absolutely necessary for continued unit operations. operations superintendent affirmed that work plans are currently being written to add updated fuse descriptions to each fuse location throughout the plant, as well as to have fuse descriptions added to the These requirements Operating Instruction Power Availability Checklists. A should alleviate the need for a separate itemized checklist. computerized list of fuses for plant equipment is presently available in Interviews with Assistant Shift Engineers have the Main Control Room. indicated that enough information is presently available to allow for i Page 3 of 7 i I ~

correct fuse identification, although several different references frequently need to be utilized to make this determination. When work plans 120-20, 120-52, 120-57, 120-58, 120-65 and 121-52 involving fuse identification and replacement are completed and precise fuse descriptions are included in op'eration instructions, fuse identification should then prove to be a relatively simple procedure for operations personnel. Concern SQP-6-010-001 references an alleged tagging incident which occurred during the early construction phase of Sequoyah Nuclear Plant. The main point of concern appears to be a dissatisfaction with the method utilized to clear high voltage lines for work. A review of the Clearance Procedure Administrative Instruction AI-3 was conducted to determine current clearance methods covering such work. In particular, AI-3 part 5.2.1.2 specifically applies to conditions referred to in the concern. All Motor Operated Disconnects (MOD's) and Airbreak Switches are required to be mechanically locked in the open position and visually checked to insure a positive opening in the circuit before a clearance is issued. AI-3 section 10 gives guidance for placing safety grounds to further insure safe working conditions during such conditions. Part 5.3.4 includes a note requiring the individual receiving the clearance to insure himself all equipment is - properly isolated and tagged before allowing work to proceed. While the evaluation was unable to reveal any facts directly related to the described 1973 incident, it did conclude that present instructions . covering the clearance procedure are extremely effective in insuring safe working conditions on equipment. All assistant shift engineers, shift engineers, and plant maintenance personnel interviewed demonstrated complete familiarity with AI-3. Sufficient safeguards are presently required by AI-3 so as to invalidate any necessity to allow a maintenance worker to personally retain a key to ensure his safety. Concern XX-85-022-001 describes an alleged incident where operators began to fill system piping before test work was completed. The concern implies that the system was tagged for the test work. A review of the September 1984 Unit Operator and Assistant Shift Engineers daily journals for both' units revealed no such incident as having occurred. On September'11;*1984, Surveillance Instruction SI 166.10 was performed on' a< gn'it"." This in'struction requires the removal of blind flanges and installation.of test flanges to test check valve leak rates in system 63 (Safety Injection System). The SI requires that an isolation valve be closed during flange replacement. This work is very similar to that described in the concern. Interviews with a j mechanical maintenance foreman and assistant shift engincors revealed that the flange removal work is conducted via a maintenance request. No l tagging is involved. The cognizant ASE/UO is made aware of the work in progrers by being required to sign and authorize the SI and.MR for work l to begin. During the September 1984 performance of this SI, the isolation valve leaked through before the test flange was replaced. This apparently led maintenance personnel to conclude some inappropriate actions were l conducted by operations. During interviews, individuals knowledgeable l Page 4 of 7 l l

with the incident, both in operations and maintenance, recognized this No as an isolated incident caused by a faulty isolation valve. documented evidence could be found implicating operations personne1' in a During this particular work, no tagging is tagging discrepancy. All maintenance required due to the SI and MR s'ign off requirements. individuals interviewed expressed complete confidence in operators ability to correctly and safely clear systems when required. Concern IN-85-933-001 was investigated adequately by a Generic Concern Task Force report dated April 26, 1986 entitled SRO/ Engineers Lack plant This committee conducted interviews with knowledgeable Experience. individuals and reviewed the following documents: Manager Licensing and Development Program, June 1985. 1. 2. NUREG 0737 Enclosure 1, Item A. 3. TVA Program Manual, PM 0202.05, Nuclear Plant Operator Training Program, March 1985. An indepth analysis of the above training documents in conjunction with the personnel interviews led the committee to conclude the following regarding the concern: TVA's program to license degreed engineers meets or exceeds 1. federal licensing requirements. The degreed engineers are required to pass the same NRC 2. administered exam as non-degreed personnel, and Plant management would not jeopardize plant safety by placing an 3. SRO in a line supervisory function if' their capabilities were in question. As a result of these findings, the committee did not validate the Should the training program be adhered to properly, concern. unqualified candidates would be eliminated through the various stages There presently exists'no verifiable reason to suspect when necessary. reactor safety will ever be jeopardized as a result of this program. Coaclusions:

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The portion of concern SQP-5-003-001 describing a contaminated water spill caused by an electrician operating a valve was substantiated. This incident revealed circumstances where involved operations personnel failed to follow established practices, although this failure did not Plant management has issued verbal directly cause the incident. instructions to operations directing them to discontinue the practice. The incident was properly documented and no indication of a plant cover up attempt was substantiated. No further actions are necessary regarding this incident. was not substantiated. The specific example Concern SQP-5-003-002 stated in the concern was not found to be. caused by a failure to follow specific procedures in the workplan. No evidence was found that management supervision directed work to be performed in violation of procedures. Page 5 of 7 N

1 l.*. ' :. Concern XX-85-067-001 was not substantiated by the NSRS investigation. J An indepth analysis of unit 1 operations date for 1983 failed to identify any specific problems which could have prompted the concern. The investigation concluded tha.t no action was necessary regarding the Concern. Interviews with knowledgeable individuals involved with concern SQM-6-013-002 revealed that a fuse / bulb list was more of a convenience item rather than a necessity. Plant management indicated that sufficient modifications and procedure revisions were currently in progress to insure the correction of any fuse problems presently identified at Sequoyah. No additional actions are necessary regarding this concern. An investigation of concern SQP-6-010-001 could not substantiate the Present procedures provide adequate safety for work involving concern. high voltage lines. The procedure was reviewed and found to be fully The procedure does require disconnects and air break switches adequate. to be both locked and tagged in the open position. No further action is necessary regarding this concern. Investigation of concern XX-85-022-001. failed to reveal any definite incident involving operational tagging inadequacies during September An incident similiar to that described did occur during a 1984. surveillance Instruction performance, but no tagging was involved during this work. The investigation failed to reveal any tagging discrepancies by operations during this time period and could neither confirm or This particular disprove the allegation with the information available. concern seems to have resulted from a maintenance workers failure to properly comprehend the circumstances involved in the incident rather than a tagging discrepancy. Concern IN-85-933-001 deals with conditions that could result from an ineffective degreed engineer operator training program. The SQN Generic Concerns Task Group (GCTG) adequately investigated the new training program, compared it to the current operator training program, and concluded that the requirements for successful completion exceeded the minimum requirements established by NRC. Based on the apparent quality of the training program and the multiple examination process, the GCTG determined the concern to not' be valid. ' c - A" This evaluation concurs with all.of the above listed conclusions of the All of the concerns addressed in this report, NSRS and GCTG reports. based on the findings, are not safety-related. 1-IV. Root Cause of the seven concerns included in this evaluation, one was On substantiated. The one incident appears to be an isolated case. this basis, root cause was not determined. V. Generic Applicability i is restricted to a specific operational event that Concern SQP-5-003-001 i allegedly occurred at SQN. No generic applicability. Page 6 of 7 na, - - - -,.

Concern XX-85-067-001 described. specific management decisions at SQN. No generic applicability. Concern SQM-6-013-002 appears mo,re of a convenience item for operations personnel than a concern. Could be helpful at all plant sites. Concern.SQP-6-010-001 deals with alleged clearance procedure inadequacies. TVA clearance procedures are standardized system wide. This conc'ern was not substantiated and should have no effect on other sites. Concern XX-85-022-001 refers to a specific event at SQN. No generic applicability. Concern IN-85-933-001 eddresses programs that could impact SRO experience levels at all nuclear plant sites. VI. References 1. Nuclear Safety Review Staff Report I-85-137-SQN. SQN Administrative Instruction AI-30, A7, " Nuclear Plant Method of 2. Operation," dated July 18, 1984. SQN Administrative Instruction AI-3, R 31, " Clearance Procedure," 3. dated June 27, 1986. 4. Nuclear Safety Review Staff Report I-85-826-SQN. 5. SQN Surveillance Instruction SI-166.10, R20, " Accumulator / Injection Primary and Secondary Check Valve Integrity," dated October 23, 1985. Generic Task Force Report SRO/ Engineers Lack plant Experience 6. dated April 26, 1986. 7. Unit Operator Daily Journal, unit 2, September 11, 1984. VII. Immediate or Long-term Corrective Action-Workplans 120-20, 120-52, 120-57,'120-58, 120-65, 121-52 are still outstanding. l l l Page 7 of 7 l ~

f... ~ tv A C4 (SS 9 45) (OP wp S 85) UNITED STATES GOVERNMENT TENNESSEE VALLEY AUTHORITY Memorandum Employee Concerns Task Group Files TO W. R. Lagergren, Jr., CEG Head, Operations, Employee Concerns Tast l FROM Grou, Watts Bar Nuclear Plant ONP 73$ WATTS B R NUCLEAR PLANT - SEQUOYAH SPECIFIC EMPLOYEE CONCE AND A CONCERN MADE GENERIC TO SEQUOYAH IN-85-933-010 -

SUBJECT:

XX-85-007-002 INVESTIGATION W r.01 SQN /0"O 9/pg were received after Employee concerns XX-85-007-002 and IN-85-933-010the investiga The Element Report addressed the issues raised by the two concerns The but will not be revised or reissued to include them specifically. SQN. TVA Element Report will include the two concerns and if-the need arises to reissue the SQN Element Report, for some ot.her reason, the concern will be included. i l' sJ W. R. Lageygren WRL:NC cc: RIMS, MR AN 72A-C l ,, g ( t l p 24 a 1; w-

s. I a 1 I ~ l TENNESSEE VALLEY AUTHORITY-SEQUOYAH NUCLEAR PLANT EMPLOYEE CONCERNS TASK GROUP OPERATIONS CEG ] Health Physics l Subcategory: Health Physics Staff Training Element: Report Number: 311.01 SQN XX-85-024-OO1 XX-85-102-009 XX-85-102-012 i J. ~ ~. s Yl[f$h h.: Evaluator: _ Day (ov tt Date [I '!! f!/ ((_ Reviewed by: Date ' OPS CgMeniber /4 Approved by: Date W. R. Lagergren 1312T i Y 3

~ Health Physics Staff Training I. This report evaluates three concerns identified to QTC regarding Health Physics technician training and awareness of protective clothing requirements. Specific Evaluation Methodology II. Three concerns were included in this Element Evaluation Report Conc'ern XX-85-024-001 Health Physics personnel are not aware of protective Example: HP at Sequoyah: equipment required for work area. entrance to radiation area informed craft that While working, HP particulate masks were not required. told craft to stop wor This happened in 1983 and not have particulate masks. Nuclear Power Concern units 1 and 2. 1984. Concern XX-85-102-009 The permanent plant Health Physics people are poorly CI does not feel-the present HP. staff has an Browns Ferry: trained. adequate knowledge of working in radiated areas. XX-85-102-012 Concern The permanent plant Health Physics people are poorly CI does not feel the present HP staff has an Sequoyah: trained. adequate knowledge of working in radiated areas. is a specific concern for Browns Ferry (BFN) The concern XX-85-102-009 Concern XX-85-102-012 is a but has generic applicability to SQN. Concerns XX-85-102-009 and specific concern written to SQN.are the exact same concern affecting SQN. XX-85-102-012 (Ref was investigated by.NSRS under report I-85-734-SQN. Therefore,- this evaluatfon.pf the concerns, XX-85-102-009 and XX-85-102-012 focusedon,determinpngtheadequacyoftheNSRSreport. 11.) XX-85-102-012, ~y v is a specific concern evaluated for the SQN site. Concern XX-85-024-001 The concern as written references a specific incident where the f concerned individual questioned Health Physics (HP) awareness oHowever, d protective equipment requirements. evaluated from a general programmatic standpoint w llowing areas: Training of Health Physics Technicians in establishing protective 1. clothing requirements Page 1 of 10

Health Physics Technician stop work authority 2. Health Physics Technician error l 3. Establishing and Revising'RWP requirements 4. A review of regulatory requirements, procedural requirements,.and past Items reviewed are listed in the report and in the audits was done. reference section of this report. Interviews with cognizant personnel were also conduct'ed to address the In addition, similar concerns having already been above listed areas. investigated were reviewed for applicability to this concern. III. Summary of Findings were evaluated by validating Concerns XX-85-102-009 and XX-85-102-012 This was done by reviewing the results of NSRS Report, I-85-734-SQN. 'in detail, references 9 and 13 and other support documentation of the Training individual ,eport and' interviewing a cognizant Health Physics. at the Power Operations Training Center (POTC). r The results of the evaluation by area are as follows: Training of Hea.lth Physics Technicians 1. A review of Nuclear Regulatory Commission (NRC), Institute of Nuclear Power Operations (INPO) accreditation, and Quality Auditing Branch (QAB) audits for the HP training section was done with no pertinent concerns, violations, or deviations found. An interview was conducted to determine if the identified areas for improvement of NSRS Report I-85-734-SQN were ' implemented. (1) Airborne radionuclide origin and These items are as follows: behavior; (2) Maximum Permissible Concentrations (MPC's); (3) (4) Ap,11 cation of radiation limits to 7 Familiarity w/10 CFR 20; real life situations; and (5) Operational theory ofAccording fo this e instrumentation. individual J, items 1, 3; ahd 5 of the Nuclear Safety Review Staff (NSRS) repory,,were either revised in training documents HPT-LP14, Revision' 0, HPT 002'.013, Revision 2, and HPT 002L.002, [ Revision 2, respectively, or were being further stressed in Item 4 is Item 2 is emphasized in HPT-LP16. classroom lectures. emphasized in all four of these training formats. Based upon this evaluator's review of 1985 HP technician feedback has questionnaires and interview with individual J, the HP staff an ongoing program to identify deficiencies in the training These questionnaires are reviewed by individual J to When a trend toward a deficiency is identified. program. then a review of the particular training format is performed and find trends. revised as necessary. Page 2 of 10 i I o

~ As outlined in SQN ASIL-3, the HP Technician Training is dividad The classroom phase into classroom phase and in-plant phase. introduces the technician to Health Physics Fundamentals, 10 CFR,20, and other disciplines as necessary l Regulatory Guides, to provide the technician with the background to' complete the 1 in-plant phase. 4 The in-plant phase of the Technician Training Program is designed to ensure that the trainee is competent in the applications of HP During this 20-month period, the in real life circumstances. technician is observed and evaluated by ANSI-qualified Senior HP This_ technicians and the HP supervisor of in-plant training. phase of the technicians training includes oral examinations which must be successfully completed for advancement.to the senior technician level. A review of the 1985 SQN supervisor feedback' questionnaire and response revealed several deficiencies in th'e in-plant phaseThe deficiencies not which were noted by the SQN supervisors.

However, pertained only to in-plant situations and practices.the resolu I

did not address the in-plant phase. According to the interview with individual E. the in-plant phase gives the technician the opportunity to develop independent evaluation and. judgment in establishing protective clothing j requirements as well as general HP practices. i ? An interview was conducted with eight randomly selected HP This sample represented 45 technicians, individuals K through R. percent of the HP technicians on shift and was composed of SE-4 Two of the technicians, and SE-5 level HP technicians. 1983-1984 individuals O and P, were onsite as SE-4s during the l timeframe but had no knowledge of the concern in question. The interview was directed towards determining if these - technicians were aware of protective clothing requirements and Every how they are established in a given real-life. scenario. technician interviewed demonstrated an ability to use independent judgment and professional opinion in determining Each clothing / respiratory.'-requirements in a given situation. technician referenc'ed to.the' guidelines established for' RCI-14, protective equipment requfrements outlined in SQN HPSIL-3 Appendix 1, Revision 5, Attachment 3, and SQN Each technician also stressed that these recommendations are designed to help HP in deciding protective Revision 11. clothing and equipment but that protective clothing / respirator requirements are assigned on a case-by-case basis with factors such as type of work to be performed, radiation levels, In contamination levels and air quality taken into account. addition each technician draws upon previous RWP data and/or personal experience for jobs that are repetitious, in determining Page 3 of 10

protective equipment requirements. As a result of the interview, it was determined that HP technicians.are aware of protective clothing / equipment requirements, how they ar'e established and documented on RWPs. It was also found that they demonstrated good judgment and an ability to make decisions within the bounds of Federal'.and plant requirements. Health Physics Technician Stop Work Authority 2. The following documents allow HP personnel to issue.a stop work order when in the judgment of the HP representative'such an ' action is prudent to protect craf t workers from unnecessary or dangerous exposure conditions: SQN RCI-1 Section VII, Revision ROI-4 Section VI-A, Revision 20, and HPSIL-3 29, SQN Section III-E, Revision 11. which sets guidelines by which respirators NUREG 0041, 2.1.4 should be utilized, states, " Personnel who are responsible for .and maintaining respiratory protection programs establishing. must exercise sound judgment _ by providing and using engineering controls, where feasible, and by avoiding unwarra'nted use of Section 2.1.1, states that "when such controls are respirators." not feasible or cannot be applied, the use of respiratory protective devices may be appropriate." The above supportive documents allow HP discretion in the assignment of particulate masks and other protective clothing as well as giving the HP personnel the authority, based upon their professional judgment and training background, to alter those requi ements in a conservative direction and to stop work when, in the professional opinion of the HP, the health and safety of the craft workers will be compromised. 3. Health Physics Technician Error Interviews were conducted to determine what, if any, corrective According action mechanism exists in regard to technician error. B, and E.,, judgment made in establishing to individuals A, protective clothing, requirements.or enforcing work practices that are in a conservative mann'er are' supported through HP t Other errors'that might result in violation of management. radiological control instructions result in the generation of a Radiological Incident Report (RIR) being written against the A review of RIRs for the period of 1983 and technician involved. 1984 failed to reveal any situation where a technician was disciplined for failing to follow good radiological practices. l Page 4 of 10 L e

Establishing and revising Radiological Work Permit (RWP) e 4. requirements Prior to craft entry into an RWP area, HP personnel are responsible for surveying the work area and establishing the protective According to SQN RCI-14, Section IV 88, clothing requirements. Revision 5, the individual performing the survey (radiation, contamination, airborne) is responsible for. ensuring that the RWP Also, as stated in is updated with the appropriate information. RCI-14 IV B.12, Revision 5, " changes in protective clothing .may be necessary because of changing work requirements. conditions." Specific responsibilities of the work supervisor. HP representative, and the individual employee are outlined in sections VI A, B, and E of RCI-14, Revision 5. As stated in it is the employee's section VI E.1 and E.5. of RCI-14, responsibility to " read and adhere to all requirements of the RWP. Since . associated with the area entered and the work performed." it cannot be specific details of the concern were not available, determined whether the HP technicians or the craft workers involved section VI-A, VI-B, failed to adhere to the requirements of RCI-14, and VI-Ef Several RIRs investigated during'this timeframe.did provide documentation of failure to follow RWP instructions byNo various crafts. to the concern. XX-85-024-001 The information provided by this employee concern was not specific However, several scenarios enough to, allow a direct investigation. were evaluated to ascertain whether the concern was valid and whether deficiencies in regulatory or procedural noncompliance existed. These are as follows: Are HP personnel fully knowledgeable of protective clothing Interviews with HP personnel, individuals A, 1. requirements? B, E, K - R, reviews of past audits of HP training, and regulatory and sites procedures indicate that HP personnel are aware of basit' requirements for protective clothing. + Was the HP dh'd stopp,e'd 'the craf ts from working justified? According to SQN procedures, the technician was justified in 2. stopping work when in his judgment it was necessary for It protecting the health and safety of the craft workers. i is possible that, although none of the work that the craf ts l wera performing required respirators, some concurrent work in the same area may have had the RWP requirement for respiratory protection and the proximity of this other work in the HP's judgment, a valid was close enough that, In this case, neither HP was radiological concern existed. wrong. Page 5 of 10

Were both HP's inbolved in the incident Et fKult dus to 4 There is insufficient knowledge of the work in the area? 3. not enough information available to make an adequate However, none of the determination of this circumstance. RIRs investigated du' ring the 1983 and 1984 timeframe revealed a situation where HP's failed to follow good radiological practices. Were respiratory requirements specified on the RWP and, if Oue to the so, did the craft workers read and sign the'RWP7 4. lack of specifics surrounding this incident, this scenario However, a review of RIRs for cou'Id not be substantiated. this period revealed in 16 of 62 cases that failure to follow instructions on the RWP was the cause of RIR being generated. people that respirators were If the HP who told the craf ts' not-required violated the requirements of the RWP, an RIR None were should have been written against the violation. found. Was the concern a result of poor communication between HP's 5. All of the personnel interviewed stated and the crafts? that communication between HP and other departments and crafts has been a problem but that it has shown improvement in recent years. Conclusions XX-85-102-009 and XX-85-102-012 The evaluation and review of NSRS Report I-85-734-SQN resulted in agreement between this evaluator and the conclusions o i.e., INPO accreditations and various audit materials, no major programmatic deficiencies report. found. h POTC addressed and where appropriate have resulted in revisions to t e There were however, some minor ~ basic phase training format. deficiencies identified in thh'acea of response to supervisor feedback These. deficiencies have not been corrected, but based it is not questionnaire. on the results of interviews wi,th ' individuals K through R, felt that these deficiencies have had significant impact to the Therefore, the evaluator awareness of Health Physics technicians. agrees with and supports the NSRS conclusions that the concernsas stated XX-85-102-012 and XX-85-102-009, Page 6 of 10

i XX-85-024-001 Based upon the results of this evaluation of concern XX-85-024-OO1 and j the questions formatted and resolved, it was determined that the concern is not substantiated and in need of no corrective action. 1 IV. Root Cause No root cause could be determined during the course of this [ evaluation. 4 i l V. Generic Applicability The findings of this report regarding the basic phase of Health Physics Technician training are considered generic to ali TVA sites as the training is conducted at the POTC alone. . The findings regarding the site specific training cannot be considered generic as each site's program differs. Therefore, further evaluation lof these concerns should be conducted. 4 1 ), ., _;.+ .t + 4 P Page 7 of 10 \\

e 1 1 -VI. References i. 1. SQN RCI-1, Revision 29 '2. $QN RCI-4, Revision 20 I 3, SQN ROI-11, Revision 5 A. SQN RCI-14 Revisien 5 6. SQN HPSIL-3, Revision 11 6. SQt! HPSIL-31, Revision C

7..SQfJ ASIL-3, Revision 10 8.

SQfJ HPSIL-5, Revision 19 SQN FSAR Scction 12.3 "' Health Physics Frogram" 9. 10. SQN HFGIL-7, Revision 12 i 11. N3R'S Report Mamber 1-05-734-3QN "Trainirg of Health Physict Techn.icians, March 11, 1986. Lettar to Hugh Parris fr om 2. P. Wilkinson, INDO, January 13, 1904 I l 12. (RIMS A02 843116 016) Meuorandom to N. E. Scott from C. C. Mason, " Health Physics 13, Technician (HPT) ar.c Radio, chemical Laboratcry. Analyst (RLA) Treining Piccram Evaluat;on" (EIMS L53 830621 954) l et-er to F-G. Parris nrom Davic M. Verelli, USNRC, " Reports l )

14. 327/84-34 and 509-328/34-34," (RIMS 902 P41130 005/L44 841208 020)

Pomorandum to H. L. Abere.*ombio frem KJ 11. Whitt, "Ruclear Safety 15. Review Staff InvestiQstion Report Trsntmittal*' (MATS 6230) 16. SQr) Tech Spee po'its 1 and 2 17. ANSI Nl9.1-197J ( 1J. NURB2 0041 4 19. TVA Area Prcgram NsWUal 0301.06 20. Radiological Incident Reports 83-28 /. 83-29 n*f;f " O' .,-i 8A-05 84-C7 E7-08 P 84-05 El-31 84-32 84-33 Sequoyah tuclear Plant - Office of Quality Assurance Audit Report l 21. CSI-s400*14 "Healtn Physics Trainihg and Staff Qualifications." j (RIMS S53 840926 936) l k j I Fage C of 10 I _ _ -..., ~.,,..... _. _... _. _

Memoran'dutn te H. L. Abercrotbie fnam G. W. Millian, "Evaluntion of Ccrrective Artian Response - Deviation Report CH-3400-14-02" l 22. (RIMS L17 841003 802) ' from G. W. Killian, " Evaluation of .Mamcrandum to H. L. AbercronhieCorrectise Action Response - Dav 23. (RIMS L17 841030 802) Nenorandam to H. L. Abercremble from G. W. Killian, "Sequoyah Nuclear Plant - Office of Quality Assurance Audit ReportHealth 24. CH-6400-14, L17 850104 001) Memonsedun to G. W. Killian f rom John Hatton, " Division of Quality Health Physict Training and 25. Assuranco Audit Raport CH-6400-14, Staf f Qualific aticns." (RIMS L47 850117 806) Memorandum to G. W. Killian from H. L. Abercroabie, "S;quoyah Nuclear Flant - Office of Qcality Assurance Audit Report CH-3400-14 26. ll I $ S$3 - Haalth Physics Training and Staff Qualifications" (R M 650205 923) Memorandym to H. L. Abercrcmbie from G. W. Killian, "Cvaluation of Corr 6ctive Action Response te Deviation 'Roport CH-8400-14-01" 27. 2 (RIMS L17 850228 800) Memorandum to G. W. Killian frem J. W. Mutten. "Divisien of quality Health Physics Training and 29. - Assurance Audit Report CH-8400 Staff Qualifications" (RIMS L44 850327 301) Memorandum to J. Hutton from G. H. Killian, " Evaluation of (RIMS L17 Corrective Action Takan - Deviation Report Closu'ra' 29. 850530 805) Memoranduin to H. L. Abercrombic from G. W. Killian, "Cualuation of Corrective Action Taken - Deviation Reoort CH-8400-14-01" 30. I (RIMS L17 85C807 600) Me:norandum to 0. Hutton from G. W. Killian, " Evaluation of(RIMO L17 Corrective Action Taken-4'Ouviation Report Closure" 21. ,. 4 "

• 850816 802)

Audit . emorandam to G. W. Killian from H. L. Abercrombie, "SQN DQA ^ Hoalth Physics Training and Staff 32. Roport CH-6400 Qualifications" (R1MS S53 850328 928) Mamorandum to H. L. Abercrombio from G. W. Killian, Evaluation of Correctise Action Response - Deviation Report CH-B400-14-01" 33. (RIMS L17 850920 602) Letter to J. A. Coffey frcn G. W. Killian, "Diuiston of Quality Healtn Ph3 sics Training and 34. Assurance Audit Recort CH-8400 1984 (RIMS L17 8409G5 803) Staff Qualifications." dated August 24, Page 9 of 10 9 m --, 7 m-,y,-

e t' i Memorandum te Those listed from G. W Killian, "'fransmittal of QAB Rudit Report Q55-A-85-0012" (RIMS L17 050905 300) 35. 1 Rsgulatory Guide 8.15-Octobpr 1976 i 36. f. Regulatory Guide G.6, Revision 3-1978 37. 10 CFR 20, " Code of Federal Regulations" t 30. i = 39. ANSI.3.1 - 1961~ -TVA Program Manual - 02G2.12, Revision 2--March 10,1986 4G. r TVa HPT002L.002 Radiation Monitoring Equipment," Revision 2, 41. June, 9, 1986 Controlled TVA hPT002.013 "Cources of Radiation and Contamination: Zones and Limits," Revision 2, June 11, 1986 42. Revision 0, July 21,1983, " Radiation, Conta: air.ation, TVA HPT*LP14 and Air. borne survey Techniques and Evaluations I 43. TV A HPT-LP16 " Respiratory Equipment and Protective Clothing!' 44 Health Physics Retraining Program Evaluations Feriodic Evaluation Questionnaires for 1965, CHPST-51L-T-6, Revision 1, Novetaber 11, 45. j 1982 I. mediate or Long-Term Corrective Actions VII. m r Nona t

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• TENNESSEE VALLEY AUTP.ORITY SEQUOYAH hUCLEAR P'_ ANT EMPLOYEE CONCERNS TASK GROUP OPERATIONS CEG 1

Subcategory: Security Element: Management and Personnel Issues . Report Number: 312.04 - SQN XX-85-043-003 J. ' .., ;.. a.. f/2 Vf( C

• Evaluator:

Date g .i R./G. Jones Reviewedby:'D2 (( N.

• fd_

~/Date Ort'Ce pember Z.1!$ (4, Approved by: ~ ' Date "W.R.Lagehfen f 1549T t l--

r-o ~ I. Management and Personnel Issues The concern addressed by this evaluation is the apparent inconsistency in the way Public Safety Service Supervision implements regulatory, requirements at Sequoyah Nuclear Plant.

e

) m' cr' l-2Y7.SpecificEvaluationMeth'hd$,1ogy The employee concern was listed as a closed concern based upon I management response. The response on file was addressed response directed to SQN. As a consequence this concern specifically to Watts Bar Nuclear Plant. was evaluated as an open concern at SQN. The employee concern is stated as follows: "Public safety supervision changes regulations at A. XX-85-043-003 their own discretion." This evaluation is based on a review of appropriate sections of the plant Public Safety Services personnel were interviewed, sec Quality Assurance. audit reports from August 1984 through January 1985 from March' were reviewed and security related NRC region II audit reports 1984 through May 1985 were reviewed to determine if any regulatory non-compliance were identified during the period in question. 'III. Findings Public Safety proceoures, Section Instruction Letters (SILs) "and post A orders provide guidelines for the conduct of security ac individual supervisors some flexibility to change the requirements of ani Plan post station as long as such changes do not violate the SQN Secu li,c the individual assigned to that' post and are subject to review by Pub or NRC committments. Safety Management on a daily basis. .u A review of security related NRC audit reports March,1984 through May ~ Exemples 1 1985 identified instances of regulatory non-compliance. i Pl"* %It. include-Vital area boundary found open and unmanned. A. B. Improper vehicle search. Vehicle found inside the protected area with keys in the ignition. C. switch. Om Page 1 of 3 ~ 1

III. Findings (Continued) Lack of increased surveillance' activity during partial loss of D. protected area lighting. Badge to protected area taken outside protected area. E. While these deficiencies hay be indicative of progr atic problems at kpl'SQN,noobjectiveevideqce.,couldbefoundtodemonstratethatthesede y/' ..n ) a A Supervisors directing changes that create instances of non-compliance. review of Quality Assurance Security related audit reports for 1984 and 1985, also provided.no objective evidence to support this concern. An example of post order changes within the prerogative of the public Safety Shift Supervisor would be his requirements for manning access control to the power block. During periods of high activity several On a backshif t during low officers may be required.to man this post. activity periods the shif t supervisor may decrease.the number of officers manning the post yet.still meet regulatory requirements to control access to the power block. Interviews with Public Safety line management documented their concurrence.that such' post order changes occur frequently, but they are reviewed.by management to ensure they do'not violate regulatory requi'rements. The interview. process also determined that any problem

• areas which might be created by shift supervisory variations on post orders have a vehicle Officers can submit problems and for investigation and resolution.

questions to their supervision or union officers for discussion at a Results monthly meeting between security management and union officers. of these union / management meetings are posted on the security bulletin ' A review of the meeting results for the last'three months found ' board. no major complaints with the conduct of individual shifts. The interview process also identified that additional opportunities for discussion between security management and Public Se'rvice Officers (PS0)

1) each shift supervisor holds meetings with members of his shift to discuss any potential problems, and 2) security management holds are:

I meetings with each class of PSS, officers during retraining to discuss any problem areas. . -i Conclusions was not substantiated. Within the g 1 Employee concern XX-85-043-003 Pl"* guidelines of the SQN pecurity P1, n, NRC requirfments, and post orders: 'i.p.. a supervisory preogative is allowed to fit changing security conditions as long as regulatory requirements are not compromised. il As for the indications relating to programatic problems at SQN found The SQN during this evaluation, these are not newly ideetified. systemmatic assessment of License Performance (SALP) conducted by the NRC NRC has also increased their has identified these for line management. security audit frequency at SQN as a result of the declining SALP report rating for security during the report period. i l Page 2 of 3 I - -. - ~

e I IV. Root Cause This concern was not substantiated, therefore, no root cause was identifiable. 4 V. Generic Applicability ,l 'These concerns were determined to be not generic. FSupervisory perogative * - e') i was allowed by SQN procedures and were not foundlto violate programmatic requirements. VI. References Code of Federal Regulations, 10CFR73 1, 2. SQN Security Plan PSS SIL 19, " Post Orders, Post 3 " Rev 11 3.

• PSS SIL 20, " Post Orders, Post 4," Rev 10 4.

PSS SIL 21, " Post Orders, Post 5," Rev 13 5. Region II NRC Security Inspection Reports for periods: 6. a. March 20-22, 1984 b. November 18-22, 1985 c. September 3-6, 1985 d. July 8-11, 1985. e. January 21-25,.1985 f. July 22-26, 1984 ~ g. May 8, 1985 7. SALP Reports dated September 17, 1985 QAB Audit Report for periods: 8. OSS-A-85-006 - Januarys7-22. 1985 a. b. SQ-6400-05 - Februaryr -10,.1984 6

q

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1 'WII. Immediate or Long-Term Corrective Action pin. o i The concern was not. valid and corrective action.is not required. I Page 3 of 3 e n ,n.

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\\ '( 1 g 4 t .s k c.) 1 TENNESSEE VALLEY AUTHORITY s SEQUOYAH NUCLEAR _ PLANT; EMPLOYEE CONCERNS TASK GROUP ... i 4T I OPERATIONS 3 i / . CEG t ~ i D-s .,n' 'T t Subcategory: Miscellaneous

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T Element: Personnel Safety-(Hardware) 313.02 Report Number: 313.02 - SQN RfH-8 5-001. 's RMM-85-OO2 4 N s. s e .., ;. +- (( Evaluator: / ' Da'te r J. S.. Marfuel

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Reviewed by: [ / -(( 8S [ OPS Ggmber Date' /4 b . Approved by: ( / W. R. Lagergren Date I I k 1536T t qs s Lo

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o h..< .t o I. Personnel Safety (Hardware) This element report addresses employee concerns RMM-85-OO1 and RMM-85-002 which are specific to SQN and which were closed out via CI's supervisory and maintenance department actions and changes. II. Specific Evaluation Methodology The following employee concerns were investigated: RMM-85-001 - Lights out in stairwell in Office & Power Stores (O&PS) Duilding. Light out again in stairwell in O&PS Building. PM RMM-85-002 - program needed. The evaluation of this concern and the associated line management' response will concentrate on four aspects: 1. The validity of the concern 2. Verification of the line response Verification of corrective action taken by line management 3. The adequacy of corrective action to resolve the concern and ~ 4. prevent its recurrence Appropriate Regulatory requirements and SQN's specific procedures were reviewed to ensure ' programmatic compliance for preventative maintenance at SQN. III.. Findings A. Line Response to Concerns On the same day as RMM-85-OO1 was filed (8/14/85), MR-A-116723 1. was written to repair th'eglights. The lighting was repaired the following day. i , 't i,p " #7 ,-s Five days af ter the lighting was repaired (8/20/85), the CI was 2. informed of the same. One month later (9/17/85)' at the safety meeting, a member of the f 3. Plant Manager's Staff reminded employees to know the hazards and to be careful. On the same day, the same CI reported, via RMM-85-002, the lights were out again. The CI also requested a check on a Preventative Maintenance (PM) program for lighting. ( s g i i +, \\\\ i Page 1 of 3 i

I* The following day (9/18/85) a SQN electrical maintenance o 4. There it was determined that the O&PS employee was interviewed. Building's south stairwell lights were not in a PM program, and that the Electrical Maintenance Group would not be responsible The for the office building maintenance af ter October 1,1985. interviewer was then referred to a third person (a different department, no department name was mentioned) who said they had not gotten word that they were to be responsible for building maintenance yet so they could not say what kind of program they They would call the interviewer when they get the -would have. l official word and tell the interviewer what kind of preventative maintenance program they would have. Two months later (11/19/85), the new maintenance unit responded 5. that they were now responsible for building lighting. To report lights out or general building maintenance call extension 7160 The or leave a note at the office located in O&PS-1 south end. same day, the CI was given a form TVA 45 containing this resolution. B. Corrective Action When the first concern (RMM-85-001) was filed (8/14/85), 1. Maintenance Request (MR) A-116723 was written to repair the The' lights were reportedly fixed the next day. lights. However, this investigator was unable to obtain a copy of the A computer search failed to turn up the MR. MR. When the second concern (RMM-85-002) was filed (9/17/85), no MR 2. was written. The lights were later repaired. No documentation could be located to substantiat'e the repair work. ~ The supervisor of the new maintenance unit for O&PS could not 3. locate a copy of MR A-116723. He also indicated that under their present operating situation, most of their work is phoned The resulting corrective action is then in by other employees. Only on rare occasions does an performed without any paperwork. item come in on paper, He' went on to say that a problem like the lights being out in th'e stairwell would be handled within a day.' It would'inyb5dh' dispatching maintenance personnel to ~ l correct the problem. No-paperwork would be created to document the action. The maintenance supervisor stated that under the new maintenance 4. units's program, a problem could be voiced either in person or Their office is located in the O&PS by calling extension 7160. which makes for very good responsiveness. l t I l l l Page 2 of 3 i I

C. Conclusions 1. Both concerns have bee.n correctly validated by line management. Corrective action was implemented and the problems have been completely corrected. The resulting new maintenance unit will be capable of responding to similar concerns, even if they do not discover the problem. themselves. 2. There are no regulatory requirements to govern this situation. These concerns are not safety-significant or safety-related. This element can therefore be considered closed. 3. Stairwell lighting is an important personnel safety concern which has been validated at SQN. Although backup lights are available during a power outage, the loss of individual lighting could result in personal injury. As mentioned in the Institute of Nuclear Power Operations (INPO) Good Practice MA-307, a good PM program should be an evolutionary process. It should start with the scheduling of routine tasks to be ac.complished (based on vendor recommendations, past experience, etc.) and then ~ revised as additional operational experience is gained., Although guidelines on the preparation of PM instructions are only mandatory for all safety-related instruction (including 10 CFR 50.49 scope equipment), they should also be followed in the preparation of nonsafety-related maintenance instructions when applicable. IV. Root Cause Based on the eva'luation it appears t' hat SQN is respon'sive to corrective action needs when identified by employees thus no root cause determination has been made. V. Generic Applicability Based on report findings these two concerns were isolated incidents at SQN. There is no reason to considbr these concerns as generically applicable to other TVk'nucl'esi plants. ' References VI. A. Institute of Nuclear Power Operations (INPO) Good Practice MA-307, Proventative Maintenance, INPO 85-032, September 1985 B. 10 CFR 50.49, " Environmental Qualification of Electric Equipment Important to Safety for Nuclear Power Plants" VII. Immediate or Long-Term Corrective Action No additional corrective actions are necessary. Page 3 of 3 y ~ y -w 7-- --~, -,m-y a y -ww< s_..

r-WELDING PROJECT GENERIC EMPLOYEE CONCERN s EVALUATION REPORT REPORT NUMBER: WP-02-SON R2 DATE 08-26-86

SUBJECT:

INSPECTION OF WELDS THROUGH PAINT CONCERNS CONSIDERED: WI-85-013-003 WI-85-041-006 WI-85-041-008 IN-85-458-001 PH-85-040-001 IN-85-767-003 NS-85-001-001 l IN-86-019-001 lR1 PREPARED BY .E. b b , OC, WP ) % 15 % , OC, WP REVIEWED SY 8kI/M , @, WP REVIEWED BY a, Q 0mw REVIEWED BY 8# 4 , CEG-H, WELDING // f, ' y ~ b,l k IQ, PROGRAM MANAGER APPROVED BY g3- !I Revision 1 to this report is being issued to add an employee concern which has been evaluated and determined to involve isues previously evaluated, dispositioned, and closed by the WP. Revision 2 to this report incorporates comments made by the Senior Review l Panel on 8/19/86. 00350 i

GENERIC EMPLOYEE CONCERN

SUMMARY

SHEET Report Number: VP-02-SON R2 Report

Title:

INSPECTION OF WELDS THROUGH PAINT f I. CONCERNS CONSIDERED: WI-85-013-003 WI-85-041-006 WI-85-041-008 IN-85-458-001 PH-85-040-001 IN-85-767-003 NS-85-001-001 l IN-86-019-001 lR1 II. ISSUES INVOLVED

1. Specifications allow inspection of welds after coating in violation of FSAR and AWS requirements after tests demonstrated that adequate inspections could not be made.

2. There may have been/were welds inspected through primer.

3. Inspectors did not understand thickness provisions for primer and could not have performed an adequate inspection.

4. NRC involvement. in approving procedure for inspecting welds through paint.

III. STATEMENT OF CONCERN / ISSUE VALIDITY Validity: Y ,N I , Substantiated: Y ,N I f IV. EFFECT ON HARDWARE AND/0R PR0".4 None /, .+. i Page 1 of 2 00350 o. 1

WP SQN, R2 V. JUSTIFICATION OC and N0 procedures did not allow inspections at SQN to be made after priming for original construction. OC procedures specifically stated welding inspections were to be done prior to priming. Nuclear Operations procedures repeat AWS and ASME Codes requirements for the condition of weld surfaces prior to inspection. They do not specifically prohibit painting prior to welding inspections; they do infer it. This has been historically interpreted as a prohibition of painting prior to visual inspection. N0 procedures provide for PSI /ISI inspections after painting, but this is after initial installation inspections are performed prior to primer being applied. The N0 procedures for in service inspection of previously [ coated welds are in accordance with ASME Section XI requirements. [R2 The audit and inspection verified the procedural commitment. VI. RECOMMENDATION AND/OR CORRECTIVE ACTION NEEDED None VII. REINSPECTION NEEDED: Y ,N X VIII. ISSUE CLOSURE Close based on this report. I IX. ATTACHMENTS ~ l lR1 1. Text of Employee Concerns 1 2. Excerpts From Bechtel Audit - Key Elements 10.0 and 14.0 1 i ( Page 2 of 2 00350

e i g GENERIC EMPLOYEE CONCERN Report Number: WP-02-SON R2 Report

Title:

INSPECTION OF WELDS THROUGH PAINT I. SCOPE OF EVALUATION This engineering analysis covers the following WBN concerns determined to have possible generic implications at SQN: WI-85-013-003 WI-85-041-006 WI-85-041-008 IN-85-458-001 PH-85-040-001 IN-85-767-003 l NS-85-001-001 lR1 IN-86-019-001 II. ISSUES ADDRESSED BY CONCERNS Each concern was analyzed to determine the issues voiced by the concerned individuals. These issues are as follows: Specifications allow inspection of welds after painting or coating 1. with inorganic zine primer in violation of FSAR and AWS 4 requirements after tests demonstrated that adequate inspections could not be made. 2. There may have been/were welds inspected through primer. Inspectors did not understand thickness provisions for primer and 3. could not have performed an adequate inspection. NRC involvement in approving procedure for inspecting welds through 4. l paint. I J. ' III. CONCERN VALIDITY OR SUBSTANTIATION ( Review of the OC procedures used at SQN during construction specifically prohibited the practice of inspection of welds after painting. (See Section 4.c.to SNP Inspection Instruction No. II-75, " Visual Examination of Weld Joints.") l The Process Specification which allows this practice was initiated in 1982, one year after construction was completed. This specification was not applicable nor was it implemented at SQN. l l ( i Page 1 of 2 ^ ^ 1 * ^

a WP-02-SQN, R2 A review of NO PSI /ISI NDE procedure (N-VT-1) indicates that welds in completed systems which have been originally installed, inspected, and documented to AWS requirements may be inspected without coating removal. l This procedure is in accordance with ASME Section XI requirements l for in service inspection and applicable only to operational systems which lR2 have been previously certified to have been constructed and inspected l in accordance with the constructional requirements. l Issue 4 has no relevancy because the NRC is an Enforcement Regulatory Agency which performs audits and surveillance inspections to ensure compliance with Procedures, Standards, and Regulatory Guides committed to by licenses. NRC reviews and approves the QA program descriptions to assure compliance with regulations. Specific implementing procedures must comply with NRC-approved QA program requirements. Compliance of detailed implementing procedures is accomplished through internal review required by the approved QA program. Verification of implementation is accomplished through NRC inspections and audits, not through formal approval. In summary, the four issues considered in these concerns are not substantiated due to the following factors: 1. Procedures were and are in effect for OC and N0 respectively which provide for initial inspection of welds prior to painting. 2. The Bechtel audit established that those procedures were effectively implemented for both OC and NO. 3. NRC does not formally approve or disapprove specific construction practices. The results of this analysis confirm that the correct program elements for the control of these activities were addressed and implemented at SQN by both OC and NO. Based upon the foregoing analysis, the issues I addressed in the Employee Concerns are closed. ( J. l t l Page 2 of 2 l 00350

AttacIntnt 1 04/03/85 CEMPLOYEE CONCERNS) Page 1 of 3 l 07:52:17 ' PROBLEM LOC' STATUS RESP -DIC ,PPP-CFR 'INSP TC ------CONCERN-- ID r 013 DO SR WI-85-013-OO3 WCDPW N./WORDS: REINSPECTION PROGRAM PAINT CRITERIA X: W Y: C 2: N GESC CCONSTRUCTION SPECIFICATION) ALLOWED WELDS TO BE' INSPECTED AFTER P FROM 1981 THROUGH THE END OF THE WELDING SAMPLING PROGRAM. THIS IS IN VIOLATION OF AWS D1.1. CI.HAS NO MORE.INFORMATION. (NOTE: THIS ITEM IS CURRENTLY UNDER I INVESTIGATION BY ERT. THE REVISON WAS MADE TO SEPARATE THE ORIGINAL OO3. CONCERN-I INTO TWO DISTINCT CONCERNS.). '~ TECHNICAL COMMENTARY: l ISSUE CONSIDERED: -. INSPECTION OF WELDS THROUGH PAINT. j-LOC STATUS RESP -0TC- -PPP CFR INSP TC ------CONCERN------- PROBLEM so P3 SR WI-85-041-OOE WCPTI XEYWORDS: REINSPECTION PROGRAM PAINT ,X : W .Y: N' Z: N j J AWS WELD INSPECTORCS) (UNXNOWN) DID NOT UNDERSTAND THE "5 MIL" PROVISION FOR -INSPECTION OF COATED (CARBO-2INC PRIMER) WELDS AS CONTAINED IN REVISIONS OF 4 SPECIFICATION G-2SC, PROCEDURE OCP-4.13, AND MEMORANDUM DATED NOVEMBER 1981. l INSPECTOR (S) REFERRED TO CRITERIA AS "MILLIAMPS" AND THEREFORE COULD NOT HA j IMPLEMENTED / INSPECTED FOR CONFORMANCE. CI HAS NO ADDITIONAL INFORMATION. NUC ! POWER DEPT. CONCERN. f' :HNICAL COMMENTARY: i ISSUE CONSIDERED: LACX OF UNDERSTANDING OF PAINT THICKNESS MEASUREMENT FOR 4 UISUAL WELD INSPECTION; LOC STATUS RESP -0TC-PPP CFR INSP TC ------CONCERN------- PROBLEM ID-PS SR WI-BS-041-OO8 WCDPW i i ! XEYWORDS: REINSPECTION PROGRAM PAINT X: W Y: N 2: N l PROCESS SPECIFICATION #3.C.S.4 OF G-2SC PERMITTED INSPECTION OF AWS WELDS THROUGH COATING (CARBO-ZINC PRIMER)$FOR ELEVEN MONTHS AFTER ENGINEERING EUALUATION/ TEST SHOWED THAT WELD.QUACII,YsCPOROSITY,.CRACXS, ETC) COULD NOT BE INSPECTED THROUGH PAINT. NUC POWER DEPT. CONCERN. CI HAS NO ADDITIONAL INFORMATION. 4 1 TECHNICAL COMMENTARY: ISSUE CONSIDERET-INSPECTION OF WELDS THROUGH PAINT. 1 ? I I !t 4 I ~

Attachm:nt 1 Page 2 of 3 04/03/85 CEMPLOYEE CONCERNS) 07:S2:17 LOC STATUS RESP -QTC-.PPP CFR 'INSP TC ------CONCERN------- PROBLEM ID ERT PB SR IN-BS-4SB-001 WCDPW A fWORDS: REINSPECTION PROGRAM PAINT X: W Y: C 2: X w TUA USED IMPROPER INSPECTION CRITERI A FOR AWS UELDS - MEMO FROM KNOXVILLE-- CPOSSIBLY ENDES, 1980 OR 1981) ALLOWED INSPECTION THROUGH PAINT. INDIVIDdAL FROM XNOXVILLE CKNOWN) INVESTIGATED THIS, BUT RESULTS ARE UNXNOWN. CI HAS NO MORE i INFORMATION. TECHNICAL COMMENTARY: ISSUE CONSIDERED: INSPECTION OF WELDS THROUGH PAINT. i LOC STATUS RESP -QTC-PPP CFR INSP TC ------CONCERN------- PROBLEM ID PB SR PH-BS-040-001 WCDPW XEYWORDS: INSPECTION IMPLEMENTATION PAINT PRIOR-TO X: W Y: C 2: N DA HANGERS WERE FREQUENTLY PAINTED BEFORE THE WELDS WERE INSPECTED. AUX. BUILDING, REACTOR BUILDING #1, ELEU. 74E'-O", & 74S'-O". 1583. CONSTRUCTION DEPT. CONCERN. CI HAS NO FURTHER DETAILS. TECHNICAL COMMENTARY: ISSUE CONSIDERED: INSPECTION OF WELDS THROUGH PAINT. 1C STATUS RESP -0TC-PPP CFR INSP TC ------CONCERN------- PROBLEM ID PB SR IN-BS-767-OO3 WCDPW XEYWORDS: REINSPECTION PROGRAM PAINT C91TERIA X: W Y: C 2: Y CI EXPRESSED CONCERN REGARDING THE INSPECTION OF PAINTED WELDS. CI FEELS NRC IS INUOLVED DUE TO HAVING APPROUED THE PROCEDURE OF INSPECTING WELDS THAT ARE PAINTED. DETAILS KNOWN TO QTC, WITHHELD DUE TO CONFIDENTIALITY. CONSTRUCTION DEPT CONCERN. CI HAS NO FURTHER INFORMATION. TECHNICAL COMMENTARY:

1. INSPECTION OF? EhDS THROUGH PAINT.

U ISSUE CONSIDERED: 2.NRC INUOLVEMENT IN APPROVING PROCEDURE FOR INSPECTING WELDS THROUGH PAINT. e e ,.. ~ - -.. -__r.---- ~, - -

r Page 3 of 3 C 07/25/86 (EMPLOYEE CONCERNS) Pag'e : 1 03:19:46 CAT ISSUE PLANT PRIORITY ORG QTC EGG INSP SD RD GD IO ------CONCERN---- J-- WE SFB W 1 EGG 571 Y SR B NS-85-001-001 KEYWORDS: REINSPECTION PROGRAM PAINT PROB: WCDPV l WELDS (AWS) INSPECTED SUBSEQUENT TO PROTECTIVE COATING (CARB0 ZING PRIMER) l APPLICATION; FINAL VISUAL WELD EXAMINATION OF STRUCTURAL WELDS IN CATEGORY I STRUCTURES, INCLUDING PIPE HANGERS, CABLE TRAY SUPPORTS AND DUCT SUPPORTS; UNIT 1&2 IR: NS-85-001-001 V STAT: RC: EC-SPL-8 WP-02-SQN ~ TECHNICAL COMMENTARY: CAT ISSUE PLANT PRIORITY ORG QTC EGG INSP SD RD GD IO ------CONCERN------ l l WE W 1 EGG 571 Y SR IN-86-019-001 3 i I l KEYWORDS: REINSPECTION PROGRAM PAINT PROB: WCDPW l \\ l (, l CI IS CONCERNED THAT WELDS WERE ACCEPTED THROUGH CARBO-ZINC. INSPECTORS WERE R1 l DIRECTED VIA HEMO TO ACCEPT WELDS THROUGH PAINT. CI COULD NOT PROVIDE ANY I I ADDITIONAL INFORMATION. UNIT 1. CONSTRUCTION DEPT. CONCERN. l l IR: STAT: RC: EC-SPL-8 WP-02-SQN I l TECHNICAL COMMENTARY: I I e o h .,., 4 * 's: l l i ( i

a Attachm nt 2 P;g: 1 of 18 KEY ELDENT NO. 1.0 OFFICE OF CCNSTRUCTICN PREPARATICN FOR AUDIT OF WELDIMG ACTIVITIES Prior to the start of the audit, the audit team developed an audit plan and identified applicable documents, specific manuals, specifications and procedures which described and implemented the TVA welding activities. The audit team developed an audit checklist to addr'ess a'll elements ~ identified in the TVA work plan in addition to analysis of employee concerns for significance and integration into the checklist. The audit team identified and selected a crcss section of welded systems from applicable TVA specifications. Welds were randomly colected from drawings applicable to each individual systep for programmatic audit. KEY ELDTMT 2.0 OFFICE OF CCNSTRUCTICN ADECUACY OF DESIGN OUTPUT DCCUP.EMTS For items selected for audit, drawings, weldir:q procedures and supporting records were reviewed and showed compliance with the TVA program and C procedures. OBSERVATICN ~ s One observation was noted during the audit of the welding output documents. The TVA detailed welding procedures (DWP) did not show the name of the key organizational group. By showing the name..of..the key unit that is responsible for the welding control documents, any questions concerning the welding documents could have been readily resolved. J. .,' KEY ELD 1EMT 3.0 OFFICE 5FCCNSTRUCTICN IUITIAL WELDER OR WELDIMG OPERATOR QUALIFICATICMS Dased on audit of welder qualification records and supporting documentation, TVA welders were qualified in accordance with TVA programs and procedures. 0031X ~ I Page 3 of 11 1 t

e-Attcchment 2 Pags 2 of 18 A.; KEY ELD 4DIT 4.0 OFFICE OF CONSTRUCTICN MAIt!TCIANCE OF WELDER OR WELDING OPERATOR OUALIFICATICNS Based on audit of welder maintenance records, TVA welders demonstrated welding within certification expiration dates as required by TVA programs and procedures. KEY ELD 4ENT 5.0 OFFICE OF COMSTRUCTION RENEWAL OF WELDER OR WELDING OPERATOR OUALIFICATIONS Based on audit of welder quall'fication recordsand maintenance records, TVA welders were requalified in accordance with TVA programs and procedures. In many cases TVA welders were given the original qualification tesc for renewal which exceeded ASME IX and AWS Dl.1 requirements for renewal. KEY ELD 4DIT 6.0 OFFICE OF CONSTRUCTION ' ('" . INITIAL WELDING INSPECTION PERSOMMEL OUALIFICATION (k. Qualification / Certification records for. nondestructive examination personnel (weld inspection) were reviewed for compliance with TVA NDE personnel qualification procedtires covering a time span from January,1971 through March, 1983. TVA personnel qualification procedures used for the qualification / certification of NDE personnel complied with and referenced the applicable edition of SNT-TC-1A (American Socle.ty of Nondestructive-Testing). Records evidencing qualifications;.' J and certifications contained sufficient detail to confirm compliance'!with appli' cable codes, istandards and specifications in effect during construction activities. 0031X ( Page 4 of 11 i,, 4

[ e. . i Page 3 of 18 .1,. KEY ELE 4DIT 7.0 ' OFFICE OF CONSTRUCTION

(

MAINTENANCE OF WELDING INSPECTICN PERSO? RIEL CUALIFICATICN-i ( Review of inspection personnel qualification records for completeness' and recertification confirmed compliance with TVA procedures used for qualification certification of NDE personnel. Recertification of inspection personnel was accomplished as required by app.licable procedures. In many instances recertification of personnel was accomplished on a more frequent schedule than' required by TVA procedures or industry standards, (SNT-TC-1A). j KEY ELE 4ENT 8.0 i OFFICE OF CONSTRUCTION l RDIEWAL OF WELDING INSPECTION PERSO? RIEL CUALIFICATIC!! Renewal of all welding inspection personnel qualifications selected for i audit indicated compliance with referenced TVA programs and procedures. ( KEY ELE 4ENT 9.0 ) OFFICE OF CONSTRUCTIO!! USE OF APPROPRIATE WELDING PROCEDURES l ~ l Detailed welding procedures and qualification records applicable to the audit items were reviewed. Postweld heat treatment records were audited and. l showed compliance with the TVA program and procedures. KEY ELDtENT 10.0 I OFFIOf 0F.CO!!STRUCTION USE GF APPROPRIATE If!SPECTIO!! PROCEDURES For items selected for audit, appropriate inspection procedures were Identified for use. Procedure review showed compliance with TVA program requirements and referenced codes and standards. 1 s t* i i 0031X 1 Page 5 of 11 j l

^ Attcchment 2 Page 4 of 18 1 KEY ELE:iE'IT 11.0 I-OFFICE OF CC?!STRUCTIC?T ( . USE OF APPROPRIATELY TRAI TED AND OUALIFIED PERSC:: ret. Records of all certified personnel audited indicated that appropriat'e training had been administered and qualifications were in accordance with TVA programs and procedures. For personnel trained and qualified in visual examinations, actual copies of ~ written examinations were maintained as evidence of training and qualification. Training records of personnel not requiring certification were not maintained since they were classified as Duration of Construction (DOC) documents. Classification as DOC documents was in accordance with TVA programs and procedures and referenced codes and standards.

3. '

,.,,,.+- 0031X / t Page 6 of 11 4 +

J Attacha;nt 2 Prgs 5 ef 18 ~' KEY ELEMENT 12.0 C. OFFICE OF CCMSTRUCTION USE AND CCMTROL OF WELDING FILLER METALS Audit Finding - AF-01-OC Certified material test reports (C4TR's) for welding filler metals did not comply with TVA project specifications. Deta,ils on.each package are identified in Attachment A. ~ In general, TVA procedures required criteria over and above ASME filler metal specifications.and had no impact on weld quality. For example, a C4TR stated that heat treatment was done at ll50*F for 6 hours. The TVA project specification required the heat treatment to be 1150*F for 10 hours. A letter in the contract file from TVA addressed this deviation and gave permission to use as is. However, the letter was not signed and did not identify manufacturer, heat or lot number. l This finding indicates that the TVA procedures were not followed although referenced code requirements ware complied with. The data reviewed during the audit strongly supports the conclusion that there was no impact on the actual weld quality related to control of welding filler materials. i J l l l ). .. +. 5 1 4 [ 1 l 0031x i t Page 7 of 11 l g L

-- ~ SUlmARY OF FINDINGS FOR ELEMENT 12.0 (Office of Construction) (AF-01-OC) Weld Filler !!etal Project SFA Pcckage Classification Specification Spec. Heat No. Lot No. Comments (As referenced in checklist) 29. E 7018 PF 1012 rev. 2 5.1 422N1151 See comment 1. 30. E 70S-3 PF 1019 rev. 2 5.18 623389 See comment 21L3 34. E 7013 PF 1012 rev. 2 5.1 01U019 2241342 See comment 1. 35. E 7018 d'PF1012rev. 2 5.1 412L7101 3034015 See comment 1.

1. o 36.

E 7018 PF 1012 rev. 2 5.1 402N8581 2443662 See comment 1. { ', 37. E 70S-3 PF~1019. rev. 2 5.18 431J5621 See comment 3. 38. E 70S-3 "PF 1019 rev. 2 5.18 625537 See comment 3. .3 9. E 7018 PF 1012* ' 5.1 411N0471 See comment 1. 40. E 7018 PF 1012 rev. 2 5.1 08R217 See comment 1. ~ See comments 2 & 3. 46. E 70S-3 PF 1019 rev. 2 5.18 421E9101 48. E 70S-3 PF 1019 rev. 4 5.18 422T7432 See comment3. ~ .y Comment (1): CitTR states heat treatment (h.t.) @ 1125* Fi 25* for 8 hours. The project spec. required the h.t. m> to be @ 1150* F for 10 hrs. fh o Comment (2): CliTR states h.c. @ 1150' F for 6 hours. The project spec. required the h.t. to be 1150' for 10 hrs.

• E' oe mD comment (3): The project spec. and SFA 5.18 requires the ycild strength. CHTR did not state this information.

r. "

o3 b3 No rev. given on Cl!TR or receiving report. Assumerev.}2 023

Attschment 2 f e' Page 7 of 18 KEY ELD!ENT 13.0 ( OFFICE OF CCNSTRUCTION Ill PROCESS CONTROL OF WELDING The inprocess control procedures for welding were identified for the items that were selected for the audit. TVA documents that controlled welding activities and operation checklists were reviewed..The review results showed the construction work was accomplished in accordance with the TVA welding program ar.d procedures. KEY ELEMDIT NO. 14.0 OFFICE OF CONSTRUCTION + DOCUMDJTATION OF TECICIICAL AND OUALITY ACTIVITIES 4 Reference Key Elements 2.0 through 13.0, and 15.0 through 17.0. KEY ELD!ENT 15.0 i OFFICE OF CONSTRUCTION 3 NONCONFORMANCES AND CORRECTIVE ACTIONS i ss. Review of nonconformances and corrective action reports for completion and closure, confirmed compliances with TVA program and procedural requirements for this activity. - i KEY ELDIENT.16.0 OFFICE OP.CCNSTRUCTION TRAINING PROGRAMS ..cg " A,,, Training requirements for personnel 'not requiring certification were reviewed for compliance to the TVA program training manual and referenced i procedures. Since limited data was required to be retained on individual ~ attendance and participation, verification of program existance and control within TVA was the primary objective accomplished by the audit element. For training programs requiring certification, reference Key Element 11.0 of, this report for details. 0031X ( i ~ Page 9 of 11 i ,.,,,__.,..-_..__.....,_y. ._,e... _.,y ,y_ ..o.,,,,,

Attechmint 2' Psgs 8 of 18 KEY ELC!ENT 17.0 OFFICE OF CCHSTRUCTICH DIPLOYEE CONCERNS E t l 17.1- " Concern No. XX-85-049-XO3 and XX-85-101-006 regarding welder certification. This concern was not substantiated by the audit of a random sampling of 37 welders which involved 124 welder qualification records from 1970 to 1979. j 17.2 Concern No. XX-85-69-001 and XX-85-069-X05 regarding welder certification and on-the-job training. This concern was not substantiated by the audit of a randem sampling of 37 welders which i involved 124 welder qualification records from 197G to 1979. I 17.3 Concern No. XX-85-108-001 and XX-85-108-002 regarding weld Inspections. 7his concern could not be substantiated as evidenced by audit of a minimum of 14 inspection precedures. l~ 17.4 Concern No. IN-85-476-004 and WI-85-041-002 reg 6eding welding I ' inspectors training program. This concern could not be suostantiated l as evidenced by audit of training programs. I { 17.5 Concern No. W1-85-053-004 and XX-85-68-006 regarding weld rod control j (", ~ satisfying code requirements.. This concern was not substantiated by j-audit of a random sampling of 48 receiving documents and associated ~ l CMTR's which involved 83 heat and/or lot number, 8 types of weld metal covering,the years 1972 to 1930. This represents approximately l 572,000 pounds of weld metal. Although audit finding, AF-01-01, against Key Element No. 12 of this report is documented against the 1 l TVA program, it involves details required by TVA procedures over and above that required by ASME filler metal specifications and had no l impact on weld quality. f The~ statement in the concern?shows a lack of understanding of the i code. For example, ASMS,.III, NB-4122 ~ requires traceability of the I weld fille' metal buiIgives two Eethods to chose from. Either trace r to each component or ensure th'e specified material is used by a control procedure. TVA's program required that all the material meet the standards and, therefore, did not require traccability to a

omponent.

l + l i l 0031X i 2 ( [ Page 10 of 11 e k

Attcchment 2 Page 9 of 18 KEY EE.rtert 17.0 OFFICE OF CCNSTRUCTICM EMPLOYEE CCNCERJIS (continued) 17.6 Concern No. XX-85-051-001 regarding weld inspection by craft. This concern was not substantiated by the audit of 13 inspectors pulled from the weld history records for the welds reviewed in the audit as well as by an additional random sampling of 13 inspectors. No holdpoints were found to have been signad off by anyone other than certified inspectors. This concern may be referring to structural welds instead of piping. Structural welds and piping have different code requirements fot fit up and final inspection. No holdpoints are required by the TVA procedures for structural welds. 17.7 Concern No. EX-85-039-001 regarding weld control (stubs a$d unused rod). This concern was not substantiated by the audit of applicable procedures. A daily surveillance program was maintained which included verification of welder identification. the feature being welded and the procedure being used. Variables frcm the procodura (such as amperage) were verified to assure that welders were using g-the procedure properly. Welding rods, ovens and controls dele monitored to assure that the welder had requested the proper rod, was t (; issued the proper rod and was using the preper rod. A(Jero::imately 300 surveillances a month were performed during years of peak construction. J. + i 0031X e ( Page 11 cf 11 e

i< At*:cchment 2 ~ Page 10 of 18 KET E*,ECIT NO. 1.0 l NUCLEAR CPERhTIGeg -PREPARAT7CT FOR AUDIT OF WELOIMG 7.C**IVITIES Friar to th.t start of the audit, t'ne audit team develcred an audit pian an.1 id*ntified applic.ible documents, specific manuals, specifications and procedyrt which described and implemented the TVA ut '. dang activities. The audit team developed an audit checkUst to' add;a5s all elementz + . ider.tified in the "VA work plan in additjon to analysis of enployee concerns l fo; cignificance arti integration i,nto the checkljst. The audit team idantified and selecte3 a cross section of valded systems based on availability, eg: only Systems which had been codified, repaired or replaced fcil under Nue? ear (Yeratlocs program fcr audit. Welds were i rar.domly celected from drawings. applicable to each irtiV dual systen for i prograranatic /.udit. KF? ELD E r 2.0 NUC;' EAR OPERTIO IS 1 ADEQUAC" OF CESIO.'I Ol'TFUT OCCU:GITS For items tele.cted for audit, dr.awings, welding procedures acd suppornng i l reCCed were revi1wed and shcwed compliance wic.t the TVA t.regram and procedures. l Cy ER"ATICH Oae obs*rv.tiott was noted daring the audit of the welding output documen'.s. i The TVh detailed velding procedures (D;IP) did not sho's th rame of the ksy i organisational group. By shawiner the name oli the key unit that is 1 respcnsibla fe; tho (eldi.rg control.dce nents, any questions coaccrning the welding docurr ente s'ould have been*.ieadily resolved. i , q ".+ , 3 l TSf_EL @ F.'t!' NO. 3.0 1 !!UCC EAR CPERTIOffS 4 IN!rI4t, WELLkR I'R WELGING OPFRATOR QUALI3'ICATICf!S i Based on audit of Welser qualification cecords and supportirg doetmentation,, l TYA we16.rc are qualified in accordance with TVA programs and procedurcs. 0031.v

i

\\ \\ P1ge 3 of 11

e; 3..; Attachacnc 2 Page 11 of 18 KE'l ELE'1DIT ? 0_.y NUCLEAR OPERATIO!!S 4 MATPTTCfAllCE OF VJLDSR CR WELDI?IG OPERATCR QUALIFICATI0!!S Sued on audit of welder maintenance records, TVA welders demonstrated welding within certificatien expiration dates as required by TVA pecgrams and procadures. KEY ELEMDIT NO. 5.0 jNU tDR OPERAT10tJS _RDIE"AT. CT WELDER _OR NELDI??G OPETATOR OUALIFICATIC::S Based en audit cf veldar qualification reccrds and maintenance records. TVA welders are requalified in acccedance with TVA programs and procedures. Krt ELDiCT 6.0 NUCLEAR CPERATIO!IS I!!ITIAL WELDI!!G INSCECTICil PERS0!rtir*. QUALIFICATIC?;5 (~ k( '- All ins,nector qualf.fication recor:in (NDE, to include vi:ual examination) audited indicated crxnpliance with TVA prcgrams and procedures and tho Teferenced codes a;td standards. CESFRVATIO!! TVA Form 6780 (as referecced in peccedure 0202.14) used to docment !IDE qualificatien and certification does net clearly idantify tha recirtification statut of the individual. Additionally, certificatien authority is referor:ced as being in. compliance with TVA proger.m requirements when individuals are actually cert'ified in accordance with the specific requirements of Procedure Q202.,1la(formerly N75C01), Qualification Certification Program for WCE'f/ersonn,hl.' Program clarity and definition could bir improved by adding either the certification expiration tlace or recertification status as an entry on Forta is780. Specific raference to Procedure 4202.1% on certification fcems (6780) wculd provide for direct refere.tec and compliance with TVA PCE personnel qualification, certification requiremcnts and practices for cach !!DE method + + umployed. i 0031X (~( 2 \\ Page 4 of 11

Attcciva:_nt 2 Pag,e 12 of 18 KZ*/ ELCCMT 7.0 ffUCLEAR OPERATIO'13 MAIllTCIA!!CE OF WELDI?!G I!!SPECTIC?f ~ PERSOI'ICL Q'JALIFICATICTiS All welding inspection personnel qualification records audited were in compliance with TVA programs and procedures and the referenced codes and standards. The observation detailed in 6.0, " Initial Welding Inspectica Personnel Qualifications" is also applicable to this element with no changes or delt:tions. KCf ELE" CIT 8.0 ?IUCLEAR OPERATIC?IS FUTE'3AL OF MELDI!!G I?!SPE; TIC 1 FERSO qlEL CUALIFICATIC!i For all records of personnel audited, renewal of welding inspection persennel qualifications are in compliance with TVA progra.is and procedures. KE'l ELCE'IT 9.0 PJUCLEAR OPERATIC"S USE OF APPROPRIATE %ELDING PRCCECUNC3 I Welding procedures ar.d heat treating peccedures were audited against the referenced !Juclear Operations documents and found to be in compliance. Krl E*. PEE!!T 10.0_ ?IUCLbR'UPEGTIC?!S USE Or A'PPN E U,TE'IllSI)ECTICI PROCEDURTs For all items audited, applicable inspection proceduras were identified for u:e as referencad in TV\\ program and procedures. 0031:( ( Page 5 of 11 e a

e Attechment 2 Page 13 of 18 KEY ELEMErlT 11.0 .( NUCLEAR OPERATIC?!S USE OF APPROPRIATELY TRAI IED AFID OUALIFIED PERSC:: TEL Personnel Recuirino Certification: By review of personnel training records and governing TVA training procedures, use of appropriately trained and qualified personnel was verified. Personnel Not Recuirino Certification: 4 Training records for personnel not requiring certifications were reviewed to TVA program procedures, (General Employee Training - GET-4). 2 OBSERVATION Procedure AI-14 (Plant Training Program) Revision 31 and Area. Plan 0202.04 Revision 0 require retraining on a biennial basis for general employee GET-4 Instructions to QA/QC. A review of training records for general employee training GET-4, revealed 4 out of 12 individuals were overdue for retraining. Procedure AI-14 and Area Plan 0202.04 do not provide 'for any penalty or restriction of activity fer failure to comply with the retraining time frame, f-k Recommendation - Subject plant training program AI-14 should be evaluated to g' determine need for retraining time frame and provide for restrictions or ' 4 deletion of the requirement. ). ' ..4 ..,? - -.. 1 f l 0031X \\ Page 6 of 11

a

• Attcchm:nt 2 o

Page 14 of 18 KEY ELEMENT 12.0 ( NUCLEAR OPERATICNS USE AND CCMTRCL OF WELDING FILLER METALS OBSERVATICH ~. The site co'ntrolling procedure for " Receipt Inspection" is unnecessarily long and confusing (reference AI-ll, Revision 38, 66 pages). Extractions are for example: "2.5.2 As part of the receipt inspection of Level I items, Level II substituted items, or Level II items to which Part 21 applies, either purchaced by UUC pR or EN DES and shipped from the vendor to NUC PR, the QC inspector shall review and verify manufacturing documentation and material certifications of physical properties as follows: Manufacturino Documentation--Assurance that the item received a. was fabricated, tested, and inspected prior to shipment in accordance with applicable code, specification, purchase contract, and/or drawings. b. Physical Procerties--Assurance that physical properties conform to the specified requirements and that chemical and physical test reports, if required, meet the requirements." ( 3 Another controlling procedure, power stores SIL-8, "QA Records," is poorly worded and organi=ed. personnel can infer four places for CMTR's to be filed. For example: J. The receivi' g report (TVA 209), packing list w/related documents, n SQA45 (Attachment 11), TVA 2652 (Purchase Request), Quality Assurance Certifications, changed QA Level Assignments, Material Receipt Inspection Report (AI-ll, Attachment 1), ECM Material Receipt Inspection Report AI-ll, Attachment 5), AI-11, Attachment 16, MCI Tag (TVA 7830), Recommended Disposition of Nonconforming Items (AI-ll, Attachment 10). OSSD or D (TVA 210), TVA 9640, and TVA 5050 are filed in tip, procurement document folder or attached to the TVA Form 575 gr attached to the procurement document or filed under procurement document number." Yet another controlling document, N73M2 " process Specification for Welding, Heat Treatment and Allied Field Operations" requires that CMTR's shall be materials from power stores.appecved by the metallurgy and standards group prior to re 0031X ( Page 7 of 11

Attechnent 2 ,.7 e-Page.15 of 18 KEY ELE:4ENT 12.0 lf. NUCLEAR OPERATIONS k' USE AND COfTROL OF WELDING FILLER ~ METALS (continued) Too many controlling procedures are required to be used simultaneously to~do the job of control of welding filler material effectively. This puts the program and the people trying to enforce the_ program in a vulnerable position. The material receipt inspection report (Attachment 1 of AI-11) refers to an item on a shipping ticket or a contract document. It does not list'what is being inspected, such as weld filler metal with heat number. One document ties to another before either gives the complete information. The progra.a could be condensed and simplified'to be more functional and less vulnerable to error and' misinterpretation by the usee ( J. ' .,< if " A' 0031X ( Page 8 of 11 E

e Attcchm:nt 2

• .e

o Page 16 of 18 KE7 ELEMDIT 13.0 (.. NUCLEAR OPERATIONS .INPRCCESS C071 TROL OF WELDING Auditing covered the TVA documents that controlled the welding operations. The audit'results confirmed compliance with the inprocess control of the referenced TVA documents. KEY ELEMDIT NO.14.0 NUCLEAR OPERATICMS DOCIR4E!!TATION OF TEC1CIICAL AND QUALITY ' ACTIVITIES Reference Key Elements 2.0 through 13.0 and 15".0 through 17.0. KEY ELC4ENT 15.0 NUCLEAR OPERATICNS NONCO?TFORMANCES AND CCRRECTIVE ACTIONS C(- Review of nonconformances and corrective action reports for completion and closure, confirmed compliances with TVA program and procedural cequirements for..this activity. KEY T.LC4ENT 16.0 NUCLEAR OPERATIONS TRAINING PROGRAMS ~ Training requirements for personngl not requiring certification applicable to the welding program were revi,e'4ed Tor compliance to the TVA program. Reference Key Element No. IU.C ' ' .+nt 0031X i E, Page 9 of 11 v...,a. f,,---- ---ae,

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• ** o Attcchm:nt 2 Page 17 of 18 i:E't ELCII'rr 17.0 f

Ih(. OFFICE OF NUCLEAR OPERATICMS k 17.1 Concern No. E(-85-049-X03 and XX-85-101-006 regardir.g welder certification. This concern was not substantiated by the audit of a random sampling of 25 welders which inyolved.107 welder qualification records from 1972 to 1985. 17.2 Concern No. XX-85-69-001 and XX-85-069-X05 regarding welder certification and on-the-job training. This concern was not substantiated by the audit of a random sampling of 25 welders which involved 107 welder qualification records from 1972 to 1985. 17.3 Concern No. XX-85-108-001 and XX-85-108-002 regarding weld inspections. This concern could not be substantiated as evidenced by audit of a minimum of 14 inspection procedures. 17.4 Concern No. IM-85-476-004 and WI-85-041-002 regarding welding inspectors training program. This concern could not be substatiated as evidenced by audit of training programs. 17.5-Concern No. Wl-85-053-004 and XX-85-68-006 regarding weld rod control r' satisfying code requirements. This concern was not substantiated by / audit of a random sampling of 25 receiving documents and associated CMIR's which involved 25 heat and/or lot number, 6 different types of 3; weld metal covering the years 1976 to 1985. This represents y approximately 19,000 pounds of weld filler metal. The statement in the concern shows a lack of understanding of the i code. For example, ASME III, NB-4122 requires traceability of the weld filler metal but gives two methods to chose from. Either trace to each component or ensure.the specified material is used by a control procedure. TVA's program required that all the material meet the standards and, therefore'; did nct require traceability to a component. .. + 17.6 Concern No. XX-85-054-201 rega'rding weld inspection by craft. This concern was not substantiated by the audit of 4 inspectors pulled from the weld historf records for the welds reviewed in the audit as well as by an additioaal random sampling of 10 inspectors. No holdpoints were found to have been signed off by anyone other than certified inspectors. k-0031X ( Page 10 of 11 Y e e -^ e

a Attcchment 2

• C Page 16 of 18

.~ KEY ELC4EPIT 17.0 OFFICE OF NUCLEAR OPERATIC?!S i (continued) . [- This concern may be referring to structural velds instead of piping. Structural welds and piping have different code requirements for fit up and final inspection. No holdpoint.s are required by the TVA procedures for structural welds. 17.7 Concern No. EX-85-039-001 regarding weld control (stubs and unused rod). This concern was not substantiated by the audit of applicable procedures. A surveillance program is maintained which included verification of welder identification, the feature being welded and the procedure being used. Variables from the procedure (such as amperage) are verified to assure that w' elders are using the procedure properly.- Welding rods, ovens and controls are monitored to assure that the welder has requested the proper rod, was issued the proper rod, and is using the proper rod. I t ,c. V E-i J. ' ~.s

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i-0031x (_ l s l-Page 11 of 11 s l. t

WELDING PROJECT GENERIC EMPLOYEE CONCERN EVALUATION REPORT REPORT NUMBER: WP-14-SON, R1 DATE 08-26-86

SUBJECT:

ADMINISTRATIVE POLICY CONCERN (S) CONSIDERED: IN-86-047-00l* IN-86-158-006

• ALSO CONSIDERED IN WP REPORT WP-01-SQN
• N.

3 a5 % , OC, WP PREPARED BY REVIEWED BY E. 6[Y8(, , OC, WP f:- Mt 8 I 85 , QA, WP REVIEWED BY / g Y ///p

1. ' # d

, CEG-H, WELDING REVIEWED BY t( 7,/ b l b, PROGRAM MANAGER APPROVED BY t x s,. Revision 1 was issued to incorporate comments made by the Senior Review Panel on 8/19/86 to clarify the justification of these concerns being administrative in nature, i 00330 i

s GENERIC EMPLOYEE CONCERN

SUMMARY

SHEET Report Number: WP-14-SON. R1 Report

Title:

ADMINISTRATIVE POLICY I. CCNCERNS CONSIDERED: IN-86-047-00l* IN-86-158-006

• Also considered in WP Report WP-01-SQN.

II. ISSUES INVOLVED A system is needed which will provide the welder a receipt to prove 1. welding material was correctly returned to the rod. issue centers. 2. TVA does not allow apprentices to weld. III. STATEMENT OF CONCERN / ISSUE VALIDITY Validity: Y X ,N , Substantiated: Y ,N X IV. EFFECT ON HARDWARE AND/OR PROGRAM c. None V. JUSTIFICATION: These issues are administrative in nature. They have no quality ~ implication. VI. RECOMMENDATION AND/OR CORRECTIVE ACTION NEEDED l None ( VII. REINSPECTION NEEDED: Y ,' N X I VIII. ISSUE CLOSURE By_this report. f f IX. ATTACHMENT l 1. Text of Employee Concerns Page 1 of l' l 00330

GENERIC EMPLOYEE CONCERN Report Number: WP-14-SON R1 Report

Title:

ADMINISTRATIVE POLICY J I. . SCOPE OF EVALUATION This engineering analysis-covers the following WBN concerns determined to have possible generic implications at SQN: IN-86-047-001* IN-86-158-006

• Also considered in WP Report WP-01-SQN.

II. ISSUES ADDRESSED BY CONCERN Each concern was analyzed to determine the issues voiced by the concerned individuals. These issues are as follows: A system is needed which will provide the welder a receipt which can 1. prove welding material was correctly returned to the rod issue centers. 2. TVA does not allow apprentices to weld. III. CONCERN VALIDITY OR SUBSTANTIATION l Issue one is a valid suggestion and observation concerning a perceived l~ need to provide individual protection and proof of procedural compliance. lR1 Providing welders with a receipt of returned electrodes would not enchance l the electrode control program and is not necessary. Issue two is a general statement of a perceived policy. Apprentices that have l lR1 received training and certification in appropriate welder qualification tests l are allowed to weld. The two issues addressed i,n.these concerns have no quality or technical basis. They~ affect only administrative policy. Based on the foregoing analysis, they are to be closed due to their f i administrative nature. The issues in these concerns are to be closed based on this report. l l l l i Page 1 of 1 i 00330 -.o

Attcchm:nt 1 - PAGE:1 of 1. 03/24/85 CEMPLOYEE CONCERNS) 11:39:22 LOC , STATUS RESP -0TC-PPP CFR INSP TC ------CONCERN------- PROBLEM ID { DO SR IN-85-1SB-OOE WCPTI KEYWORDS: QUALIFICATION CRAFTSMAN APPRENTICE X: W Y: C 2: N UNTIL 1973 TVA DID NOT LET THEIR APPRENTICESHIP PEOPLE WELD. DURING THAT YEAR,. EVEN WITH TWO OR'THREE MONTHS EXPERIENCE, AND BE ABLE TO' WELD IN THE FIELD. THE SYSTEM HAS WORKED THAT WAY EVEN SINCE 1973. CONST. DEPT. CONCERN. C/I HAS NO FURTHER INFORMATION. TECHNICAL COMMENTARY: ISSUE CONSIDERED: TVA DOES NOT ALLOW APPRENTICES TO WELD. LOC STATUS RESP -QTC-PPP CFR INSP TC ------CONCERN------- PROBLEM ID L2 SR IN-85-047-OO1 WCPME KEYWORDS: ELECTRODE IMPLEMENTATION CONTROL ACCOUNT X: W Y: C 2: N A SYSTEM IS NEEDED THAT-VERIFYS THAT THE WELDER DID RETURN THE UNUSED WELD ROD AND STUBS AND WILL PROVIDE THE WELDER A RECEIPT SO THAT THE WELDER CAN PROVE HE DID RETURN THE MATERIAL IN CASE AN ERROR WAS MADE. CI HAS NO ADDITIONAL INFORMATION.' CONSTRUCTION DEPARTMENT. TECHNICAL COMMENTARY: lE CbNSIDERED: ELE'CTRODE ACCOUNTABILITY. e 4 J. '.. ,,;f +,, a ,--e ---,w---,-,

.., m. WELDING PROJECT ^ EMPLOYEE CONCERN EVALUATION REPORT REPORT NUMBER: WP-20-SON, R1 DATE 08-26-86 UNDERSIZED SOCKET WELDS ON THE SAFETY INJECTION SYSTEM

SUBJECT:

CONCERN (S) CONSIDERED: SQM-6-008-001 _) E 25 % OC, WP PREPARED BY NWOb OC, WP REVIEWED BY \\.E-OS REVIEWED BY ud f 85 Q%. WP c/ X / 4 CEG-H, WELDING REVIEWED BY / ~ f/ PROGRAM MANAGER APPROVED BY t t v-f Per Senior Revision 1 clarified the review of previously conducted reinspections. Review Panel coments on 8/19/86. j 3 .b 'I { r.3 01300 '~ '~

EMPLOYEE CONCERN _ {)

SUMMARY

SHEET Report Number: WP-20-SON. R1 Report

Title:

UNDERSIZED SOCKET WELDS ON THE SAFETY INJECTION SYSTEM I. CONCERN CONSIDERED: SQM-6-008-001 II. ISSUES INVOLVED. Undersized socket welds on the Safety Injection System in 1. Accumulator Room #5, Reactor II. III. STATEMENT OF CONCERN / ISSUE VALIDITY Validity: Y X ,N , Substantiated: Y X ,N IV. EFFECT ON HARDWARE AND/OR PROGRAM None (effects of hardware and program were previously evaluated per NCRs 2398 and 2630). V. JUSTIFICATION: There has been reinspections, repairs, and evaluations performed on undersized-socket welds per NCRs 2398 and 2630 on the identified system. The location stated in.the Employee. Concern does not exist. r VI. RECOMMENDATION AND/0R CORRECTIVE ACTION NEEDED l None l VII. REINSPECTION NEEDED: Y ,N X VIII. ISSUE CLOSURE Closed based on this report. i IX. ATTACHMENTS 1. Text of Employee Concern 2. NCR 2398 3. NCR 2630 4. Repcrt Number SQN CEB 8107 ,..s Y Page 1 of 1 ( 01300

I 1 EMPLOYEE CONCERN b( Report Number: WP-20-SON. R1 Report

Title:

UNDERSIZED SOCKET WELDS ON THE SAFETY INJECTION SYSTEM I. SCOPE OF EVALUATION This engineering analysis covers the following SQN concern: SQM-6-008-001 II. ISSUE (S) ADDRESSED BY CONCERN The concern was analyzed to determine the issue voiced by the concerned individual. This issue is as follows: 1. Socket welds on the Safety Injection System in A'ccumulator Room #5, Reactor II are undersized. J III. CONCERN VALIDITY OR SUBSTANTIATION Construction NCRs 2398, 2630, and the final 50.55(e) report (A17 810406 022) document the identification and resolution of undersized socket welds at SQN unit 2. Corrective actions taken included: 1. Development of a sampling plan and performing reinspections. 2. An alternate weld size criteria was provided by the Division of Engineering Design (EN DES) based on revised criteria for weld size calculations in ANSI B31.1, 1971 Edition, which clarified fillet size for socket welds to be calculated at 1.25t minimum nominal pipe wall thickness. 3. All accessible fillet welds that were reinspected and did not meet this alternate criteria were repaired by adding appropriate filler metal and reinspected in accordance with the QA Program after repair. 4. EN DES evaluated on a case-by-case basis those fillet welds which were not accessible for examination using the worst case of 96 percent of the fillet welds that'were found to be undersized. Based on the results of these sample reinspections and evaluations performed on inaccessible welds,.the undersized socket weld conditions were resolved. h Page 1 of 2 01300 . ~..

WP-20-SQN, R1' A detailed review of the weld monitoring computer program and ^ '4 construction weld maps for the unit 2 Safety Injection System indicate that Accumulator Room #5 for Reactor II does not exist as stated in the subject Employee Concern. A detailed review of weld maps determined that there are approximately 479 socket welds in the Safety Injection System located in all four Accumulator rooms within Reactor Building unit 2. NCRs 2398 and 2630 document reinspection and repair of schedule l 160 socket welds for numerous unit two piping systems. A review l of these NCRs as they relate to welds on the Safety Injection System lR1 (SI -system abbreviation) indicates that all accessible socket welds l were reinspected in the Accumulator Rooms and 15 welds were repaired "l ~ due to undersize conditions. NCR 2398 states an additional sampling of 170 welds in the Safety Injection and Chemical Volume Control System revealed 12 welds to be undersized by 1/32-inch - 5/32-inch on one leg only (a detail listing of these welds are not available to account for the specific numbers within each system dr in the Accumulator rooms). In sununary, this issue has been substantiated and resolved based on the following: 1. NCRs 2398 and 2630 identified the subject concern and implemented corrective actions to perform sample reinspection for accessible welds and an evaluation of inaccessible welds that were within the identified system and area. 2.- The subject concern does not sufficiently identify a definite location of undersized socket welds. This issue is closed by this report. ) eage 2 f2

Attaciment 1 Pags 1 of 1 06/18/86 (EMPLOYEE CONCERNS) PAGE: 1 15:14:47 s (4 c__ _____ _____ ________ ___G )AT ISSUE PLANT PRIORITY OR OTC EGG INSP SD RD GD 10 ------CONCERN------- ~ WE S 569 ~ SOM-6-008-001 KEYWORDS: WELDMENT'OUALITY SPECIFIC PROB: WCMHY WELDS ON PIPING IN ACCUMLATOR ROOM #5. REACTOR 11 SPECIFICALLY SOCKET WELDS Of THE SAFETY INJECTION SYSTEM, ARE UNDERSIZED. NUCLEAR POWER DEPARTMENT CONCERN. NO FURTHER INFORMATION IN FILE. IR: \\ STAT: ..RC: TECHNICAL COMMENTARY: ISSUE CONSIDERED :. UNDERSIZED SOCKET WELDS ON THE SAFETY INJECTION SYSTEM. Total For'This Selection: 1 CO o l I 1

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During inspection of reactor coolant piping for arc strikes, the inspector noticed sosee adjacent schedule 160 reactor coolant (RfD Nanifold Piping) system socket (fillet) welds ht appeared to be smaller than required. (See page 2l n am.a o ima. G pa.-= 0 a ca O a aw O u= A.* O osa-(cs.c. inch & Deta.i e*N*) Add weld metal as required. Inspect additiceal sempling of schedule 160 socket (fillet) welds. utna no.we

t. Pr ae naure ace.

- / Provide additional traininst to inspectors that inspected W undersized welds. ]i F -ite to all Welding Inspectors and Craft Supervision that future inspections of socket welds (in regard to weld size 'equirementa) will be conservative to ensure that weld sizes meet the required mini.nm. In addition, lead welding inspectors willd.instru,3gd,,tg.gi;;,aafsg.,gljpg.oy,t k i i them. d. 4 ........1V EYMb. -<r (,,,, poetyy,a,giyi,g #, to i ~ a~t, / o... sc-> s u e.e o n ), .. t.eu a o, a.i,4oeo2u ota.a vn O ~.- cao co-oa.= c=ua

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1 \\ me p% NONCONFOR.*AING CONDITION REPORT "C"' 8 ** Sequoyah Nuclear Plant CONTINUATION PAGE g [ ntuanns 6. Nonconformance

Description:

continued Subsequent inspection of these velds and others in the sa:me area revealed approximately 12 of 35 to be undersized by 3/32" or less on one leg only (other leg sizes varied from correct size to 1/8".._-,,. ) oversize). Ba. sed on these findings, it was decided to reinspect all socket welds in the RID manifold piping. This reinspection I revealed approximately 109 of 38$ velds to be undersized on one leg only (maximum of 7/32"--one case only) while 18 others were undersized on both legs (vorst case was S/32" x 1/16" undersized). An additional sampling of approximately 170 schedule 160 socket welds in the Safety Injection and Chemical and Volume Control e systems revealed 12 velds to be undersized by 1/32"-5/32" (5/32" on one veld only) on one leg only. Apparent cause of discrepancies was the failure to inspect as thoroughly as necessary. Most of these velds have only a portion that is undersized. The inspector apparently failed to steasure the asallest portion. CO FILMED FRBM BEST AV AILABLf. COPT 1 i. kb' s. 4 0 ,.. '.. r.s _ -{' [.[ -k.' 7. f, (_ , -...<...],. .L.,VZ..%. s. ') , 4 (.[ ' f. 5, ' J, [.T 6,,* ,Yh. "l ,#_;m.

ff_? 5 .-;.;....f m 9:. p;.,+.lr..g.- 7.. L 0 i M,.fM ' hs. i / y a 9 [*] - gP' 4 .J ' 1 e rrm re,n1 /VdA" 43ff P!FE 101 R EQ 'D IEASURED Amtyr (EER3IZED JD{ CLASS kTL D HO. 512E IIK. 512E SIZE LEG"A" LEG *8* ) 69 8 RX1245tl 3/4*.218 1/4' 9/32x3/16 1/16 ~ *- 5 B RX1453 3/4".218 1/4" 9/32x3/16 1/16 b I. 41 B RK1490XI 3/4*.218 1/4" 7/32x5/32 1/32 3/32 j$ { = ) 35 B RX1500 3/4'.218 1/4* II/32x7/32 1/32 [$}== i 36 A RX!503 3/4*.218 1/4" 9/32x3/16 t/16 j 20 A RX1530 3/4".218 1/4" 9/32x7/32 1/32 f 21 A RX1531 3/4*.218 1/4" 13/32x7/32 1/32 105 A RK1576 3/4".218 1/4" 7/32x7/32 1/32 1/32 13 8 512174 3/4'.218 1/4* 1/4x3/16 1/16 j 72 B S12417 3/4".210 1/4" 1/4x3/16 1/16 t ^ j 74 A 512425 3/4".218 1/4* 1/4x5/32 3/32 i 75 B S!2427 3/4*.218 1/4" 1/4x3/16 1/16 76 B 512428 3/4".218 1/4* 1/4x3/16 1/16 69 A RX1315 l' .250 9/32* 13/32xl/4 1/32 68 A RX1337 l' .250 9/32" 13/3247/32 1/16 67 A RX 1343 l' .250 9/32' 5/16xl/4 1/J2 55 A RX1366 l' .250 9/32" 3/16xt/4 3/32 1/32 g, [ 52 A RX1370 l' .250 9/32* 3/841/4 1/32 51 A RX1372 la .250 9/32' 5/16x1/4 1/32 m 50 A RX1377 1" .250 9/32' 9/16xl/4 1/32 144 A RX1433 l' .250 9/32" 13/3241/4 1/32 145 A RX1434 l' .250 9/32* 9/32x3/16 3/32 145 A RX1436 l' .250 9/32" 5/16xl/4 1/32 J . (_ 147 A RX1438 l' .250 9/32' 5/16x7/32 1/16 } { d 148 A RK1439 l' .250 9/32" 3/8x1/4 1/32 f 149 A RX1440 l' .250 9/32* 9/32x7/32 1/16 156 A R11464 l' .250 9/32' 11/32x1/4 1/32 I .V*..

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SIZE T iK. SIZE _ SIZE tfG"A" LEG'8* 157 A RX1465 l' .250 9/32* 13/32xt/4 11/32 ~ 153 A RX1467 la .250 9/32' 9/32xt/4 1/32 154 A RX1463 1" .250 9/32* 3/8:l/4 1/32 UE 155 A RX1475 l' .250 9/32' 5/16x7/32 1/16

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11 A RX1548 1" .250 9/32' 9/32x7/32 1/16 $y 12 A RX1543 l' .250 9/32" 7/16xt/4 1/32 ad p 14 A RXI552 1* .250 9/32' 11/32x1/4 1/32 3E 114 A RX1594 l' .250 9/32* 1/4xt/4 1/32 1/32 115 A RX1595 l' .250 9/32* 3/843/16 3/32 111 A RX1597 l' .250 9/32* 9/32xl/4 1/32 118 A RX1598 l' .250 9/32' 11/32x7/32 1/16 ] 119 A RX1599 l' .250 9/32" 13/32x1/4 1/32 j 120 A RX1600 1" .250 9/32' II/32x3/16 3/32 121 A RX1601 l' .250 9/32" 5/16x3/16 3/32 122 A RX1602 l' .250 9/32" 7/16xt/4 1/32 l 123 A RX1603 1* .250 9/32' 9/32x7/32 1/16 5 124 A RX1604 l' .250 9/32" 9/32x3/16 3/32 125 A RX1606 l' .250 9/32* 1/4x7/32 1/32 1/16 i 127 A RX1611 l' .250 9/32* 13/32x1/4 1/32 128 A RX1612 l' .250 9/32* 13/32xl/4 1/32 l 129 A RX1613 l' .250 9/32* 5/16x5/32 1/8 130 A RX1614 l' .250 9/32' 5/16x3/16 3/32 l 131 A RX1616 l' .250 9/32" 3/8xl/4 1/32 64 8 RX1354 3/4*.338 3/8" 1/32x9/32 5/32 3/32 J 65 8 RX1355 3/4".338 3/8* 3/821/4 1/8 4 8 RX1452 3/4".338 3/8* 5/16x3/16 1/16 3/15 48 8 RX1486 3/4".338 3/8" 7/32xl/4 32 1/2 ( * *,

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kn J b, N c> 1 $I 3NN ) PIFE hat. REQ'O K ASURED AFOU!II ILTETcIZED I M CL ASS l.T L D F10. SIZE TIK. SIZE SIZE LEG A* LEG'B' ~ 34 B RX1499 3/4*.338 3/8" 3/8x7/32 5/32 k 78 A CX1173 2* ,.343 3/8' 7/16x5/16 1/16 7, "- * "~~T j' 79 A CX1174 2* .343 3/8" 1/2x5/16 1/16 Mg EO A CX1184 2* .343 3/8* 13/32x7/32 5/32 2 81 A CX1187XI 2" .343 3/8" 15/32x9/32 3/32 2 N }~ w 82 A CX1200 2* .343 3/8" 13/32xil/32 1/32 83 A RX1235 2* .343 3/8" 3/845/16 1/16 e =a 85 A RX1237 2* .343 3/8" 13/32x9/32 3/32 f! 86 A RX1238 2* .343 3/3* 1/2x5/16 1/16 l 92 A RX1251 2" .343 3/8" 1/2x5/16 1/16 93 A RX1252 2' .343 3/8" 3/8x9/32 3/32 1 96 A RX1265 2" .343 3/8" 7/16x9/32 3/32 98 A R11267 2* .343 3/8" 13/32xil/32 1/32 l 100 A RX1269 2* .343 3/8' 1/2x5/16 1/16 66 A RX1344 2" .343 3/8" 7/16x5/16 1/16 l 58 A RX1346 2" .343 3/8" II/32xil/32 1/32 1/32 i 59 A RX1347 2" .343 3/8* 15/32x5/16 1/16 p j 60 A RX1348 2* .343 3/8* 13/32x9/32 3/32 yt (_ = 61 A RX1351 2" .343 3/8" 13/32x9/32 3/32 62 A RX135211 2' .343 3/8" 13/32x5/16 1/16 4 l 63 A RX1353 2* .343 3/8" 7/16x5/16 1/16 10 A RX1362 2* .343 3/8' 1/2xil/32 1/32 57 A RX1363 2* .343 3/8" 3/16x5/16 3/16 1/16 56 A RX1364 2* .343 3/S" II/32xl/4 1/32 1/8 54 A RX1365 2" .343 3/G" 3/849/32 3/32 53 A RX136S 2* .313 3/8" 13/32x11/32 1/32 135 A R!l379RI 2' .343 3/8* 9/16s7/32 5/32 l!E'*""". ""~"" ~ ~ - -

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m cf U.ch s u ket 1.n ceder to Wrify that tM keld are adequate to perftr'a d,'

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1. r.tx.n Oqelead to Proverit Docunevxis Dttaild M OS D 23N.

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i y, Of all lats secl*d, a totri of il los W re awptan1% ar.A s tad v s M G.. .M vere rejec;tel. All velds n the rd em i 1:t4 nre isL:g,.cte,1. M f ^ i d mh Md n, v p. y }f ps A t:tal c." S,LU Ech.1% s yh c 'sch'a h n beu identified, Of thu <7 is tctai 1,113 Lw bee:1 rejected t r ics tr'&ct tillet site., cu

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I ' M[d 4 recccumid dityrsiti~1 fr.r tLuo 1,10. vel.3, ther thu tM es 1 dS cosit':n d ca T3 EO, is shva en tt.2 ettrbnts ta t'41s L.m -) [jf 'l: W, Q, 9i-M , m.g E e L.tadred cmi twer/ nin s vlis ud of ehe %tal of S,4.0 taw hu W;.n y j d&r1:wl tn M ivecessible dua t'a lu htia, p1M sqwrts, bu.t. f'I+' , -;4 %'^' insecessible veld is sh%.2 ca the att< cur.t a to thia IR. L ids m b- ']') ' Nd;p t u c% a:d pi N alceres. Our recer..It t ct rp:41t1 *n f;r th u -a ' 6P. I ..c 'ii g,' . ll? listed by catepries cf itr:cenibility, ..~ y- <y 4 v.m ]j '3 g';.{, ) A acrA cr LOC Sch. LO rad Och to tem wid;, wtte31, egge,t437 G 'q bl/2 3:cer.t. c' t'.e trul veld in W a sch Mbe in Unt t 2, e IL, ' qs ' 3 s :latut far reinspecties. Cem u lu vea rxfa ta t prieig g;,., p g; W W 1 ,,,n c1 rom pt :cces hw tcen iritietM ler en'.h c2 ilten mlb., Inw. i < 'j th rejectica n*:e of Sch. LO e.ul 3ch. 50 velds idev.ec.ted f a c:q f. i

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M S.Q - vg g r_R,: c y%M EU3JLCT: SIGCIA3 3CCITXt PUJ?. RC.VCG7CSNAC PSCP.T (NG) 30 2395 4.. g p N $ 1 Rs,v%; M.c% x e ww e. .r: W~ f *; O T ';. % Rafersne : ET In-IP 1.26 yg g os^ g;g Ey" for ybar z'Aview and approval. 71este pcpan v qyt g ww M,c#.~ ~hW517 i ~ cm pv 4 Attached is the subject NG.fer :y signitu.rir indicating the dispositic-2 g@yw:1 W 5 G-k M_ a y e e - h to G. G. Stack .;Lt M:glN of thia 73 within 5 v:rking days. 7te original NG in to be att4rhta to M2h vM.M [FM9pM/ ^O Q Ad5 this swr., cts.atra with ymr initials in section 6 ir.dicatirg revi-v and

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2sC. x - d,QjW Y.h Q a.ppron1. Incit:da in tha r.un:trr.cto;s s statenent en vbet5er drwinp are b retiri to be 2 evised ta a usult of.th TC. .s

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m'yW;.hR 3 290 .n. kggs , R. N. Cs22trell, Sequeych tr.4 Vatts CI*WfpregvisswraggTC,4 c3.r ( g :.i. k, j gg TO - J r< y -. fq me y%v '-72Q. John A. F.tuiston, Chiaf Neslear Tyi: ;rr Wicc26 C-I o Ile.%nw M i y@;w % a ,,3 pym t gm-e .. w .%"E z @h i bt h.Jmwry 30, ISJn,- g,gj y % o y p* 't hk Em Er@CIAH IUTAR FIAW - 3C'ICMXPANCE PSCRT (FCR) 20.' ' ?2 93 t. .iQ Q% m'r jfj'y.,$$ w,g w J f.:. eR QJM j? %g/Cn# is b m C.w.h-Q Y r 9 ~; c% . p& .r n y s 4 N)MIb:h w Uf 3M1 Q Attached is a :wzorandus to C. C. Stack for your signature givir4 the f*fd4MS , Mhhh disposition of the subject NG with the originti UG attached.

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Q 'Q j+.p8%T,M g w [ \\ $jf.h W., CI f Hr. . e n P. Retlly, Director $QM N 84 flies of In pestf on and Enforcebt Apg y $g U.S. Nuolca Esgulatory C 0 1ssien i 1337 QQN%, M Regico II Salt I 101 Marietta Strp/ 31co.

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Dear P. C'Peilly:

f a i g w :p lf j%yy; t m wwd DWM SECT 0 TAM N0 CLEAR PLihT 1; NIT 2 - FAULTY FILLIT VELC3 NCR 2333 AND 2630 - p -M,, gJ::i?t,f M..t..M ../ 6, FINAL BrPOW c.Ch. y , 2,,g WQ bg%. ggh$pg Of<Q Q The auNoot deficicncy van initinut reported to MC-01E Inspector R. V. Wrir.ht on Nomber 7,1930, in accordance with 10 CFR 50.55(e) as b !!CR 2 MS. Ir.teriet reports were subsitted on Deccctser 3,1930 and Mh E February 11,19St. Enclosed is our fir.al report. l ~h ~ vith D. 1,. L u bert at FTS 557 25S1. YkDhjf'b/dMdh 8 *W* e.vM %e If yco tsvo any questicos coaccrning this ritter, plesas get in touch TI([,% g%m z w. 4 [ m. u QAMf Nkf95M.0 k.%'W' M 8 g Very truly yours, i' Qf.rA %g %W

• %. c M

( ,7 g f, h.% ) TILHED FRCH EEST TEsnsstr. VALLEY AttruoaITY ggg . %g A.IAllABLE CCPL g %g g fL g MmW F,3 yd c,%, A s) Z m dyy?;rK(p.. gN tQ f L. H. Hills, Kaneser MMW Uuolcar

• Fegulation and Safety M dN5bf M.r.g ggMhM i

Df[e, @p g.% Enolosure 1 s 3 DLL:DAK:XEH y 9*,.qq $y g g g.M4P @.. N.$QN.h Office of Inspection and Enforce:cct mm Cc: It*. Victor Stello, Directer (Enclostre) L ';t.L: .5 {l U.S. Fuolear Regulatory Comissien yjyEL SM%E( 4 '*d .i W[ m p %.hh f .y Vashtraten, EC 20555 l 1 g g.gy QQ j' co (Enclosure):

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MP g hMk W-WM "D AE'U, 640 CST 2-C MfMD M dfd i'. A. W. Crevsssa, 401 UEB 4 N,7 SN '. ~= N C- $bN[M M MN H. N. Culver, 2:19A HLK ".Z0 ~l g% g{M hk E. Ford, Seqtnyah-NBC MM Z MlJy Q C 7,: gspp S H. J. Creen. 1750 CST 2-C, ' gbQ'4;gg J. A. Raulston, W10C126 C-K ...JDe'" g$ j [p $, c, $1Mg H. S. Singer, Jr., E11833 K - D,~.. g ggg%% f$5Kg C. C. Stack, Sequoyah 0 ~~ o u w g 1J %k F. A. Szczepaisi1 D 17'UES ,y,'*~~,/, -y%*R W W hi& Q l QQMfM COCRDN TED: S. Stout /EN CES b' ' ~ ' J[d; A a 7l-dGp ,7.. H, M$MQh$ h qw'1y.*'i%g p q id - ~,,, - - g

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,, l% SEQUOYA!! NUCt. EAR PLAht UNIT 2 M@,h*g ,2., " NCR'S 2393 AND 2630 @M,qd FAULTY FILLET VELDS Qd i., l!Mi%N.@ ' &@#@;q/g .J. /, 10cr350.55(e)

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Mg tcQt,4 - PIN AL. REPCRT $ %y ?)y9qg.:%v W4Q$ r a Rym ',J n. {qpdy pyg ,. [.h.ehM ,1 scriptica of Nficiency b g$g y4es gqn A e%v%m% f.".[, During inspection or reactor coolant pip' : for.are strikes, the fg plSpQC,'l 'd W inspector noticed some adjacent schedule iC0 Beactor Coolant Systes W,Ig4g N'.f'. hh pI 9:%[$h$ socket (fillet) welds that appeared to be smaller than required. Further, inspection revealed that a significant percentage of 2" Ffp@MMMf i d h4t"k*- schedule 160 tillet velds were undersized. Therercre, in creer to ' h $ y g$ $g y' Qh@pk; d M "f d determine the total scope of the problem, the following reinspection 4, 4% program was implemented. gg%g %p!.y.f%(gyg, df N b f n, Q, All accessible 2" schedule 160 socket velds were reinspected. h k M(q g .M/ Approximately 25 percent were undersized. A sampling plan for the Fjg$g/g d;Qg Q . E; g4g 7bg y re= air. der of schedule 160 socket welds was develcped as outlined in %gp&ikj % p-MIL-STD 414, "Sa:plin6 Proced'ures and Tables for Inspection by f60d

• *rd Variables for Percent Defective." This is a reference standard in RDT f

B.9. y r+f g fcq Standard F2-7T " Acceptance Sa:pling Plana." The welds were segregated gfg } 'k'. by pipe size (1/2", 3/4", 1", 1.5") into in:pection lots of 100 (an h j D .g l,h inspection lot is defined as a specific quantity of similar caterials g %[ gg g $de 4.M M -l.,$ or units on which acceptance sampling is to be performed). The welds @gh L) gk' M y,'d to be inspected in each Ict were identified by using a table of randos p ff % fg? nucters from RDT Standard F2-7T to select a randera sample of' units

e

gg* M.j A total of 20 welds per lot, as required by Table 3 4

Y fros each lot.

1. g % %

"U. - (Sarple size Ccde Letter F) of the mil standard were randomly selected' i f g '$ I' .,I h h[h 5-and reinspection of these welds was performed. For those welds 9 F. fh inspected under this assalin;., a percent deficient rate of 4.0 percent N 7M,d ([,f ( h; **Uf M was established. According to the.section entitled "Satpling Risks Q and Operating Characteristics (CC) Curves" in RDT Standard F2-7T, "g Syyh " Studies have shown that 100 percent inspection under opticum Df h Iq[

• iM.1 Mi,

' d7 D* conditions is only 85 to 95 percent, effective in separating bad ,@y; gl $ 1* MQ h I

• J' product froa good product (in tha abcence of ecmpletely automated

- Y -inspecticn methods)." Therefore, no further inspection of schedule 160 lf4[ .n pipe is planned.

g ed Tfifh,I 7

A sample of I.80 schedule 40 and 80 nocket welds, which is A $ $ @h Q.m igm;;h]{y g; h,hfh - T. appnaximately 2.5 percent of the total welds in these schedules in 3 1 f unit 2, were selected for reinspectien. Seven welds were found to be deficient. This is a rejection rate of 1.45 percent. Therefore, no n: ,94 $$(%'g { kby further inspecticn of schedule.40 and 80 welds is planned. g_ h ~N M A previous saspling of 400 schedule 160 socket welds in unit 1 A[ M(f[Jh, revealed only one weld undersized on a portien of cne leg cnly. ~' @N 7 Sy h' 6 >Ms. Therefore, there is no indication that this problem exists for unit 1. 2 ?P Aq $n w. ,h %e4 m + 4 wt, s cp y f '~ fRQQ ' {$. %ancdg?

• N,$

r, 8'M ? gj ss i n x 1 k + .v g0 e b h M ^ al w$-pw-N < l u n ~ M ij) n! M - @ n $7$ e!}@ M 1 en nea f N NNvNMr%$@ F i wuygywm,= n-s + wy ww yp g b1d Ikkh ~~ ~ N kk k h G.

b;pr *, .%.*d!48 y p N MYMII9l)lM/d:W- $Qpjf%t*@:@ Y. N h hh h. k' hE[Ih;,) f f: $)[. ( w#ww -W ' .Y ~~ .._t ;, -

• fg%fQ%'QQ. Te%b h

cn ~.- 44' : TMiSRd. . d, h e M, 5EQ$pdfi@ lEsf h *'

• Qfht' WU

~p M 9 ;, A.?.e JQ .$V, ' g' hgfh5 $$5{M;[3pp Q 'R$$ M S"(-, The apparent cause of this condition is a failure to thoroughly ~ 1% ,W q. ., a r, Q{g(y/8!aflM [ t <qq t p,.6 .,j, 4u inspect the cceplete weld since many of the deficient welds are undersized only. by 1/32" on a portion of one leg. The inspector t rg l'. gg j,, apparently failed to c.easure the smallest portion, U Safety I plications 3 m x 4 fgn [;,'[. A large nucber of schedule 160 socket welds in safety-related systems y [, JM h*y!'y, 5 were undersized, which r.:icht adversely affect the strength of the 4 " M*- t ? O "' D i ', ' ' weld. 'Therefore, if this condition had rc ained uncorrected, nt.nerous [ ' '5%y2b7 [h[g leaks ce small pipe breaks may have resulted (especially during a QR 'g j seismic event) hhich may collectively have affected adversely the MI. ..e h W D, $'?j *k, YN d j [ b 'I operatica of that safety-related systen. t .h'* h y/i!M[ 'Y Y Corrective Action. [Th. e5-M@$ 'd $l &b y k k . iY,){$ ifh .9,9.,. Undersized fillet ' welds are being evaluated to the alternate weld size . Y*201 T-' *j f g' r, criterien (included as Attachment A). Those welds meeting this fg a ,t y;4-criterien are accepted without rework. All accessible fillet welds Q ..gwi?., 4 -gr .binypp(W s' M which were found to be undersized, and which'did not meet this r f f 4 criterion,,will be repaired before fuel lead by adding weld metal as p 43 O g ay g -appropriate. h h' h.' *. ( MN/[ g M M I"'QA. Tn addition, T'lA's Division of Engineering Design is evaluating on a J ( (s ' s 3 t' case-by. case basis those fillet welds which are not accessible for g 5 Bf examination. The worst case of 96% of the fillet wclds which have Y $4"' jj@4 6 QQ been found to be undersized is being used to evaluate (i.e., 961 of the G 2j % >hgW welds that were found to be undersized, are undersized by less than the $1p[kI/[ r5 f4)$ M

• ! M amount used for the evaluation) the reserve stress carrying capability f

ytpy 4..4 of each socket in order to verify that the welds are adequate to perfers -@<,%f f h pQ,g ?d g/4) .. j the intended function.- If the design calculations do not then show g Jg py g gwg

• p ','.

adequacy of these 1:.ucesaible welds, the effects of weld failure en a, Qfg 'J, plant safety will be evaluated. All inaccessible undersized fillet gM h f,y$gffj;'N J'hh ' F,.s f gsg% welds fcund to have a negative effect on plant safety will be resolved h before fuel load. k*elding inspectors and crafts personnel have teen g*~ jg (ypt)Ja ,; dgrx retrained with ecchasis placed on fillet weld size requirements. l.ead v-ddh

• *.' ' I

' welding inspectors have been instructed to increase surveillance of the [rfbh s [ r.7 work of inspectors assigned to the':. u. A ~~ ru .a v h L i, &,tm,3 G l... ! % to,a " "'SI i., % nd 'Y ~9h MAILABL *Pr 3%$)

1. u%.e W

Qi;M p 9 [q.g t. u. ,M s m-e A i N ,f, w 1. fb ~ $m u a swo.&ga webaD n_ kmA

h~~bt i s-h$ $N$ $m 1 -- s %l 3 m(- g.g _ 7.- - gpgggp.y.; g. .gg w r... $R.T. - ATTTCllMENT A h.N ,jh;}$ysk Jy T'""", VAu.EY Abm mTY smus 1. w 1 eIf h ,,,ouct [ y9 &h sunner (ocer v/rt.o strr - /uremarrs Ufl.4,w l_;f;[gQ.. @ ***"'o.J. Err u r re 2 oI pi fg Q yWp1 .i yu== = -'

== au ~ - "p% TklM ' 7:. (0 <ce.e-y,,,,m F. u. n,-,,s,w s "" I [. " g{d3 u N 8* h "*". ) [gf N20$g h* a. E. MIS" s'm'r teve,re to "" o c. noum m Ar n n. rte rou m yusucry tem cetic o.7 a t... .qg j g te ' W#pf E - 40 o.rz r 'Is -~

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'In h . vtG Y ~ 1;b.% % a ~ s . qq. @[lN%y@IO ~ d f f,$ 2. 'k - O 9[ d 0.115 'l8 ~ o.059 g ?' g[k M ' To s.t;a 3/it. '4 2. _ h 'le i o.fm M W Ay sd e.o m "{> n. r,, $5 ^- . 1 - 'lo. o.,45 Nn. 'Is ^ h -~~- o.;oq ?p M-k+g g ' "@jg$-. n o.nr vu ll:. m.

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1,:f44l i is o c.272 Vfz %i Tr. 7/rz h c. it e-IY, - 9t ,. ?. . /32 he X ... l Y - 'to o.tS 3 I 'I. Yi @ff I o.11 0 ft f t - 10 0.10 6 ~U t h. 'I4 '!n 5 e.Init $$ hts d

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h'" b j $$h l'4. .'40 0.851 % '01 NG '6L o.Ilst gr% h(k -;f.*. ~ it s 0. W. 'Itt. 'In 'IA 'in e.no u o.us % u u

o. ass.

? ~j ~ ?, ] l, j$$h. 2 '" 40 0.16 8 % '$L. 'bL 'Ig lit c.gy "'%Q NA3~4? i.[ T B3 a.237 '/4 h 'In 'I. N 0.170 m, JP st $f }.

• 0 1:0 o.37 tl 3l.3 "b t '

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? I h!g ,.,t., P"CP N 81 ' (1) - The.. f,ite.t le3 d.tl nof Le les s + /w,, '/s, ', h ' ' N i,$ hb 5 'i h. MLHED FROM BEST N ,(2) Welaf s hall be f/of to co nvex d.Q Jj 1' . AVAILABLE COPT

dME

.3{ d

• -[( 4;.

6h5. Y ~ h,j.f$l[ h..'.,' '. T he. reguired f, y 4 /> c. f.II.winj h hh orce. was calculo/ed U j g$ ' p,. - f 2 5 2': regujred %eod = 0.78 4..w j. ,t; hijid 4..x.s n o m e n.1 p 7, wa It Rickness 3>- ,j ^ j Xs rwea su rect shorler be b 3$ j 'l Y-re gus' ed lo np r le3 (g r rounded f. / A e. next /i,jler '/n). g* - .l E6 .6-X P 1 y p. v.9 ty[gos.t g)] 7, t /- m ld ( pg 'N .E.%i 1 JL 1. M {- t: h* 'm. ' .w p r a 'b 4. \\- U 'e gff 4 [ k. hM i ..gp} ' yp.Q = [w g 149 $jgg f ggg v - c 3;7 y M7&n

• L 3;A

wppdws, 3 m, _

e a _ _._ sa g. 9 s h gkfffh $Nfh, h kr 4 c a m -A.w4& w e %n m m ; ,at mm wasams aw w.

mp ' W g g s c q m q %q p e p q @ M i s p & n n A b.s s b 4 Swe b m% n p & be g fxpsr race a or 40 p%pM. %.mgpp RWlRWglyp$MM$;&%QWidmpWgum ig M 4; 3kt Eik uff y~ %e ;p. wwwmm.ay,g xm m m mww w wmum mm x g M(Sy . f4pp, g,.

• v s...m u tprrto strits covraxutur qw $-

D66@) ' MeinorandMm TEMESSEE VALLEY AUTHORITY WM tEB '81 0 4 0 6 020 iM @ TO C. C. tack, Project Manager, Sequoyah Nuclear Plant CONST (li) R. W.,Cantrell, Sequoyah and Watts Bar-D's e jects Manager, 202: CD- {ff FRm e bEb b19s1 DATC :

1. q mf n

h@ f h st*BJ tCT: SECUOTAH NUCLEAR PLANT -JC$CONFORMANCE FEPORT'(NCR) *S30 - trJDERSIZED MSh FILLS? kELDS ON PlPS SCN 810302 603). ) g;jggy W k. VW.W..% D' H p p$.Y%E wny

5 JO The subject NCR is concerned with the undersizing of socket welds en i b Y@

2-inch end less size schedule 160 piping with respect to the code f,, s j% A require = en ts. I NN.N From r.n analysis pcint of view an undersized weld could result in localized' SI N M overstress. In the analysis stress, an intensification factnr is used for hh the weld. When the weld is undersized, a larger stress intensificatien M ,t ),jh $[m$p factor is required. 'g b i

f. n$ 5 %

4 9, 3 A* .R 4 I N,p wShhO s The alternate analysis criteria is a conservative method of qualifying I k rsall pipes. However, it is not possible to provide less conservative 2 N criteria as a generic basis. Relief can,te provided en a systen basis ce h "hh hfdC h [h N'AMy fer specific locations in a systern. Rigerously analyzed lines have FA kN*M.O approached allcwable strees at specific Iccations. Cccputed stresses are h[ he h/ h available, and the actual weld requirements can be deter:sined if the ygg undersized weld locaticas are provided to the analyst. .g.pg E tatgqF J Qan Wqrt c . NI Se0tiens D and E of your NCR identify accessible welds, and we agree with

• Th.'E Mh;f.dlNb your recocsended disposition.

-h['k M Mi g).bp$f[ r

• 9

.s

• ectico C refers to welds that are temporarily inaccessible. Your

$dGht rececuended dispcsition is to s einspect as soon as they recc<te accessible Q%'} q.m.h:h[h. hh$lk, rnd repair t.s requ). red. This task shwld be cc:pleted b-fore fuel leading. f ', { 3-, -_g .i^- P stat es thtt a:pr axirately ~S percent of each o i d is acem ble. 70 lN'. y. h )g 6o

• l-Q% )

Late. rep:rts frcs tM field indier that this is not t'. cas. Th!1 k.h e$g $[.r ; M p&es the Mlds in a rctions A, B, C, and F inaccessible walds. ygg &W $$!D,&y"ri';T d' ih Sequoyah e.u Watts Bar Desig,n Projects will locate each of these welds on Q c h @[;.r,$$ pp the rigorous piping isocetric cr on the physical for alternately analyzed S jh gly@i, khh/4 Q pipe. The Civil Engineering Branch (CEB) will look at each one en a case-g [p 9.8 M,MU by-case basis and will see if the analysis has enough reserve stress so that it would be qualified if the stresses were increased by a factor that 1; At'.UJ$..n - %, #y;m&If s. A ...w Q F q W ~ Q~plllllllI h \\ ~ !cM > yhm 's I,Iii.. @Jna;W fil!JED FROLI g[37 Q 7L d '~ P wllhl1l%l l 7 %1 qM AVAllACLE COPT ? m%w,% J 3 %. ps g W t x ve ,.h 3e %e r~b .t.n. c r.,., M v. h..t.,.. m

a y.

e U X*

• ~ **

't"h ~ d C.. $s WW.t)fl,Ti 'b{h}Y J h I lf i h $f &,%gQ4k k$$ k $w[A; N arcs 2.ot aa W..' < W a - 3 4 q 5 La w n. +, e 4,. s,. v. w' n ! .i ww.w wym~e wn n$[n r an s. a he- - m! m[kDj n [. hh fk h $ 4(h3 h1Mki M 4iC h d N lk IF ( & w& h. n, %g./ g % e w a n ?w@.qrvMc. #uf& y a. W*w&.ci epf Q:M MME .. Q. M fE ~9%w$ yg

.m.4As g m Nh6 q w.

E.e S,A,~.. e n m m., pg i).rg[,M W m)R.Nk NNTbf2 D M e -a w ym m.x 4,.. m > g y.~ k.MwM[ Nf, NE.f*.g 37 MMA.M$NY9 h-iihtE ^^ ~~ a %W w ww max M

b - ~ uw _ m._ m = 1, y _ _ > m _.u 7 ~

1. $pGjoh2%

%.y bsew% 2 J ph ty ,,us. C. C. Stack ., x f tQr -*/ April 6, 1981 7 ) if[f 7M:Id i-i t )y[ SEQUOYAH NUCI. EAR Pl. ANT - NONCCSTCRMANCE REPCRT (NCR) 2630 (SQN 810302 608) e.g ny A t ,,e 92/*.4 N g$$j$Wf$q%"fa Yk yh 1 lT Fu ? e%'ygi 3p, [I+Q:' ? by ^ :gg.$ hi., represents the worst case of 96 percent of the undersized welds (f res [ N Qg. section E) that were inspected. If the point is qualified, no inspection jr ,,j,7}'$ [.g is required. If the point will not qualify, CES will provide a series of ',.M f Qe.' weld sizes that vill be acceptable. If the inspected weld does not meet r53 4.% ). h_: ta these requirements, it :ust be repaired. The r:11estone for inspection and

i. *

• A

[% ' Q repair vill be determined on a case-by-case basis. A package identifying q fgh 5 p the velds that require inspection was infor: ally transmitted to your Ricky -heq 1 $7. - Miles from our R. C. Pratt on April 3, 1981. We vill dispositicn this NCR i," b' ff after receipt of your inspection data. MC s. f.

34g, 4L i"

~ AdW $,,y$ Z41 % b "C ~ - y" .gg .y 'e 7 R. W. Cantrell jp J 4 t r-. 4 N E, ROB:JEM:DCC { ,M 7 k[ FM e cet J. H. Ballentine, Sequoyah h'UC PR ND R. O. Barnett, W9D224 C-K (2) ygg $f' kh {dg% E. C. Ecasley, V12B26 C-K U FR#g ggg7 [, y hg{j AllA8t[ g f'- Y R. A. Costner, W11D190 C-K 1 r4 W3g; p MEDS, E4B37 C-K M.11. Hull, E7824 C-K ,r - [] M. N. Sprouse, WilA9 C-K L,. 3, w a s n @ N.q .'f> I M - m tv+ W: a. 459 '., ~ 5 N,.:k,- ;f <,'j V / .s ?j?f t% .< tsj A85 f' i *,7 " $ $#4 fMM F[#ska[}e$. d.'. y I *hQ:.vtf w w. i f n -3 gM* i.jj is- -1 PJ dh h

• ty

$j 1 ( - f.0 M }n$ 1 g c .s , dj Wu q t 2 44 - At Q J;i ? /7 T M.A .f 5*

• 1i

@<.k) B i i eW:,vd t w ),).D-y g s k. % y. ^) A w Q _h^j cp ? EmerBIBB.i g a pe, e *e 9"

• 0 MNO* '$ M J a

J ___,__,...,_,.m_

.u.tacn:aent .3 JI g;,:as m.-- m- . h, ) Page.10 of 40 ,w d~y-wk w + m: As.)gp _ y7 d y v-s x fg m e. jg$ sZ m 1, y_ $@% 3 n;; @f+; $WP '8105 2 6 047 } ? mTra sTATos CovcRNnoxr .$ ' Memorandum Tennesses vatter turnoniry L.- -1 % ! 9 94 [ ~ C. C. Stack Project Manager, Sequoyah Nuclear Plant CONST (3) y To R. W. Cantrell, Sequoyah and Watts Bar Design Projects Manager, 204 CB-K r-TROM : m& j Hay 22, 1981 fg: 3 [ y DATE : SEQUOYAH NUC1. EAR P1. ANT UNIT 2 - NCR'S 2J98 AND 2630

SUBJECT:

w . h,y 5 L ..W W j g, F %I ffQ[ ? As an alternative to re-pressure testing socket-velded pipe joints which b [ have had veld buildup of fillet velds to correct dimensional deficiencies Jg ,) the following requirements ' *. r3 discovered after the system pressure test, h T shall be verified: T If

}} g' s

'Q There was no evidence of leakage during the system pressure test. 1. e .r The velding was performed by qualified welders using qualified 2. g3] ~p 4 y procedures. The surf ace of the completed veld buildup was examined by the liquid E z 'IC,. 3. penetrant er magnetic particle cethod in accordance with ANSI 331.7. -f ete ,, f Positive controls shall have been provided to ensure that veld repairs

t. :

7 4 'y are cade only on fillet velds 1/3 inch and greater. g f W Ip(?,A, 5. Each repaired weld shall c:eet the requirement; of ANSI B31.1-lS30, 13 ( g a y I 4 1 Paragraph 137.6 (Initial Service Leak Test). e 1 Paragraph 137.1 This position generally conf orms to ANSI B31.1-1980,- 1 1 (leak test requirements), and a draft code case entitled " Weld Buildup 1 y i Af ter Pressure Testing Section 111 Division 1. Class 1, 2, and 3 j "\\ ( Construction presently under censideration by the ASME Code Com:nittee. w .i ( 4 f i i 1 y y 'G'. y ~. i $h' 082/ h g. R. W. Cantrell [ Id U N' 9 RVC:RCP D3 1'l R. O. Barnett, W9D224 C-K t.h d ' g. E. C. Beasley, W12326 C-K fil!4[0 p g BES) cet R. A. Costner, W11D190 C-K AFAILANE COPT f $h[s r f J. M. Ballentine, Sequoyah NUC PR 3fC, ' 4 p~ m H. H. Hull, E7824 C-K L MI.DS, EAB37 C-K h' [ J. A. Raulston, W10C126 C-K S i v y. H. N. Sprouse, VllA9 C-K. [ 3, j 4 e M y n 3 .~ f - a f' ; l ~ Z ,W cw W ma u. ^ @} ~ , j. f r.. 2 d ( ,c'W*j) g g_ 4 '9} 3 j c. ! &g pm w k m. .r$ f.w uAm - ey j g 3 ) q L.

m. m wa

. s ne p we.wheiLJ PaEe 11 of 40 MQJum, 7.v;2 vm?.n.. !N%rWh.A-nyn-t%.a. ; pre.ygg,g @p,?.;3pp;,..,im.%ge mQ g.ne. A.; g y ;# w h w c,s I t m taw. w,A g;pg;m&, gq.r=m--.gr-ry,, Acw @m&w, n%xm.ing - v ~%m:MQ:;f.MlW;g;pg@gy&m,d:ww a.i,d.m&. W c c. D g+M.xg&f,gg nw g

• w:4xgm N

wg . n.;,;w < cm wd;q m wyg;%ms$m wrw m&L'a,d,pn h; .,y . eg.m g exmwk;; ye y m m M.c.wgr.w yk &qw%.k WB.,M,.fi?MW@MMJ,M_L n.g, man M. N,QYM M C % P'WW. w M WiW iM a~ w,rg,u p v,,p;w.. _ rv,

2..

~m. s e Fjm,. oc y. m g a-M6@n.h-k t-f f k d. *"sT,Arrs renm.vr C.,. @,.4j N .-.tatrrra f tr de n U psn.. a re emorand um. . TENNESSEE VALLEY -AUTHORITY 'L - MQQ& %yg& .m tEB '810629 022 MnMW W Q M 2 9 4-w To a Q C. C. Stack, Project Hansser, nequoyah ifuclear Plant CO::ST (3) - QqpW Q:h W wwm w w-h**"f}I hd M",.v*M H$* R. V. Cantrell Oequoyah and Watts Bar Design Projects Manager. O Di to b 204 CB-I .~ t W'4 MTE - JUN 2 01981 RsG M& m hk.yhYhhb SEC'JOTiH MIX 1 EAR PLANT - NONCCNFOPFANCE BEPC'tT (NCa) 2630 - UNESIZE3 FILLET VELD CN PIPES (00'l 810302 608) ??MMhMN @2 anac,@pMgA r ynw mm -4 m af. 4 *WwgM W 4 M e bn mp@Q W;P @h 4 w y Eeference: My memorandum to you dated April 6, 1931 3hfaggg s,gg' ydQgj.gyQ p@$;M@g{q Q (CE3 810M6 020). fSt = M3b v.v.,r ~ m@(jQ@f j y M We have finished our dispositicri of the subject NCR. All velds GeWi G M Wich were determined to be in.tecessible were evaluated as _ 7*g>,T... Attachments A, B, C, and F of the NCR had a total of 155 welds describcd in the rcfcrcnce. Q q %g.m,.,:- ~ c 9 w g t p$4 s b T @$ ,e - 3,,I M*7 'NL which were evalusted by the Civil Enginearing Branch (CE3). Ne h g'$ @g.g*ff*h h ..f$h-Lbe tam. ired thirty-one fillet welds were on rigorous analyted g <d ($g. piping and 24 were on alternatoly analyzed piping. Of these, 19 y of the welds on t.he rigorously analyzed piping and all 24 on the 3ygg gj%l , gg. f-7, , Dh alternately piping were ruinspected. Acceptable veld sizes were N H% cocwted fcz-tbe welds on the rigorous analyted piping. If the WMA ^ Wf $4'7 [, p' rp y,h i$ reseasured weld railed to reet this minieu:s site it was repaired

Je to full size. The actual weld sizes of all reinspected welds

.g g p%gg[ygg !M were then transmitted to CE3 so that the rigorous analysis would '3 1.gW' gr' Q -e ggy not be penalized if the probica is reanalyzed. All welds on MLg. alternately analyzed pipes were reinspected and were repaired to s MQ4 t y~};.4..M@kdWh. e.g.t;:. full size if necessary. Six of these were visually inspected fhl Wile the others were remeasured. e. g3% Attaeb sents D and E of the UCR identify welds as teing C" 'Y&## h l -fb < accessible. All wolds were necessible except one which was (3 37 t20Nr) g p,.4 gin cultntad by CE3 and determined to be necep abin as-is. We agree nb %.gA.h {M.6. ; h,,,( [.3%$.%,1-n.a,- N$$ with yc.ur recoecended disposition on the ot! er welds. w , e? r ^ w %@@6 .ng %r z, M[fff[YM)lg 9*.k' Attachment C refers to welds that are tesperar11y inaccessible. .T.i Q Qipt We agree with your recou:nended disposition to reinspect as soon [M*sM%M W N., as they becorse accessibic and repair as required, but this tasic dhD ih..A abould be ccampleted before fuel loading. h ~m Mi h hU Vs have received all data relative to reinspection of the iltt1D Gid O Wh., inaccessible welds and have concluded our disposition of MMLiiti fr$ igMh$g%$p,p f M[ed[C,W'My -h DC2 2630. Sh W h, h M w hk; r$ T.W This has been coordinated with your ran Calloway. W'M.l Original algned by g.9 %grQDusyp n :; 1 g%pg%DK // g M T1 5 (* m re11 @g e Yi[g

a. w. Cantrell

( \\g.g-N a:nn: $h b5h Ag@b N Ta .a ~, u. m. 2. n ii n..s L w 4 a kW Y24M'%W.,CH [4'y ,Q @. s - hW q.-*:#4 lTh-&wQ&~iQ. Q:$yg.u-[a,= g g g g wg.j g : b y g g g j g;g y g g.% g [ Q L. $, ; q m .en}',.}, Q. w s, q t M W 9-K M. w[ m?@m4@p@cn@bf.pn,,g ddW.a. W j G W ~ M p y m w. m% t M W 9 M-y.-d37th ..m.

y. M yn w5%y

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g, g9 (gQ

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M.. ~..auwamsanu,_AN#,5 m Qfo%. L m ff 1 g m hf* gydh'h gsNj$ UNITED STATE 3 COVERNMENT Memorandum vsxxzsses y,11xy turnouiry TO 8 Files 5f G. L. Wade, Constt :ction Engineering Associate, Mechanical and Welding '4 M9W 8 Inspectica Unit, Sequoyah Nuclear Plant CONST s nMk i } DATE : Septe=ber 3,1981 4 g SunJECT: SEOUOYAH NUCLEAR PLAhi UNIT 2 - NCR'S 2393 AND 2630 f W W[p 1 hR s y -u 4 9-l n# $$ i 1 9 ".

REFERENCE:

Memorandum frca R. W. Car.trell to G. G. Stack dated May ~ 22, 1981 (SWP 610526 047) y- ~ l d ~ As on altemate to re-pressure testing socket-welded pipe joint: which O b ye had weld tuildup of fillet welds to ccerect dimenstensi deficiencies . [f F kV [ discovered after the system pressure test, the following were verified: .$..CC[- ) d' h <[ (( f 1. There was no evidence of leakace curing the systes pressure test. W 2. The welding was performed by qualified welders using qualified I, ~2 % -h I 'ML procedures. (Docunented cn repair check lists, Attach ent A to W-7). p i 3 2: R J

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hk'[ 3. The surface cf the cc:pleted weld buildup was examined by the liquid penetrant txthod in acccedance with ANSI D31.7. (Documented cn repair 3f j $j ~. g check lists, Attachment A to W-7,and 11-76). ft + 4. Rehydro was perferced c>n all weld repairs that. could not te proved -kE[ p' ~ 2U / i g', that fillet sise was 1/8" and creater. i $f-WA p'(; egg k' 5. Each repaired weld neet the requirements on AN3I-B-31.1-1980, para &raph 137.6 (Initial Service Leak Test) documented en Work w if W yg N' Plca S-1823. 3 ) 4~ g A %~. p", 5 MWh]wv,M"g p: N % L. i c w r., G.. L. eaae . q, m h, -~ e m nu m gn. -m p g, g a u.# w; ;

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. *E DIVts!ON OF ENGINEERING DESIGN NONCONFORMANCE REPORT C aseoat an. S N 107 5 '**'*CT 8*qvovah Ituelear @ eta 887 coq @ U"'? I and ? ignoramempo.eamaario.woara J. E. McCord/ELDES-CEB/3-30-81 l g_ .o'.am.omo= , CM%f m.tm.d. 3( h Vl j n o.,e o..-._.m x .c e... ..o a v. oo i E svi.oo oso=coveny ,.yt e, e r ye, e on g moane. cant con omo= aavs asa To cuatin J c1 o caos <- o,' l v.. a e s - aT a. oa a- @ ~'-- " l 840301K0072 Ol e co.- - g . Q assaoasasta causse snaouinso se e.omiesca=T) t '19 Q Action esovento To easve=7 nacunasacas insouinso se sionie.cAnti B a Q.aa smome s a msview ano ce ecummamesi Lason sar.s a.acr. a n.n M sensouta ast. : 3. acv. s oars i g ace m n -o. Fava.=os.c,rno. m]oan.= man. 2 @ mea'amasa ,.,p. Not an WC1. ANSI B'31.i prior to '1911 required' socket veld filled size to be 1.25 times the EM'E {

==N1 pipe wall thickness. The stress intensification factor (1) for the design of socket h -d r a welds was 1.3. In 1971 the required fillet sina for socket welds was changed to be 1.25 t minlaum which is equivalent to 1.09 t nominal (as required by C-29M). The intensifica. tion %ah.o.cc.Mc~CL a v - - n..D.a x< u nwu o u _.,,-o..

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d 1 9 The Sequoyah Nuclear Plant's code of record is 0313 B31.1.0-1967 which required stress intensification factors for socket weld fittings and also a I ainimum size socket weld. ECR 2630 docusents that the weld sizes are as established by the ASMt code. The ASME minimum welds' sizes are less than those of B31.1. The ASMt code equaticca for piping analysis requires a M M stress latensification factor for socket welds. The margin of safety in the B31.1 piping analysis (SGI analysis) cannot be shown to qualify the ASME socket welds on a generio basis. This problem affects 2-inch and smaller lines. 4 = 2b" '@ f J l 3 j j +- m .,4. m 9.j'f*.'.. c;,. - -n; m m BW .. e '. I *,# ..,. i([ s ,'... -. 4.(.;.'. ', j g' T j f 4N;38l[fj$?._!j,7,' /r [,[7. ,,.g : h: ? ': y..ew n me m1...:. 1 \\ . :-.,.; x:.. a i l k 1 d ?;l hl :* $ N ;,.%.s..

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