ML20236F830

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Forwards Revised Pages and Addenda I & II to Welding Project Phase II Rept Transmitted on 870425
ML20236F830
Person / Time
Site: Sequoyah  Tennessee Valley Authority icon.png
Issue date: 07/29/1987
From: Gridley R
TENNESSEE VALLEY AUTHORITY
To:
NRC OFFICE OF ADMINISTRATION & RESOURCES MANAGEMENT (ARM)
References
NUDOCS 8708040045
Download: ML20236F830 (34)


Text

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l TENNESSEE VALLEY AUTHORITY CH ATTANOOGA, TENNESSEE 374o1 3 1

SN 157B Lookout Place JUL 291987 U.S. Nuclear Regulatory Commission I ATTN: Document Control Desk Washington, D.C. 20555 Gentlemen:

In the Hatter of ) Docket 30s. 50-327 Tennersee Valley Authority ) 50-328 l

l SEQUOYAH NUCLE.AR PLANT (SQN) - WELDING PROJECT PHASE II REPORT ADDENDA

Reference:

TVA letter to URC dated April 25, 1987, submitting the SQN Welding Project Phase II Report The reference submitted TVA's Welding Project Phase II Report for SQN.

Enclosed are tuo revised pages and two addenda to that report.

The revision on page 11 was to correct a typographical error. The revision on page 12 was in response to section 7.2 of NRC Inspection Report j Nos. 50-32 7/8 7-21 and 50--328/8 7-21.

Addendum I was added to include the reinspection data collected on welds reinspected at NRC request. Addendum II was added to include the evaluation j of Watts Bar welding-related concerns for generic applicability for SQN J welding.

)

Please remove pages 11 and 12 of the report and add thase revisions to update it. Place the revision log in front of the report. Add Addenda I and II and associated information to the back of the report. Remove the old Table of ,

Contents and add the new Table of Contents. This will complete SQN Phase II l Report.

1 If you have any questions regarding these changes., please telephone R. H.

Shell at (615) 751-2038 in Chattanooga.

J Very truly yours, TENNESSEE VALLEY AUTHORITY I

R. Gr diey, Di ector Nuclear Safet and Licensing Enclosures cc: See page 2 970B040045 870729 g30l PDR ADOCK 05000327 p PDR f An Equal Opportunity Employer

.j

U.S. Nuclear Regulatory Commission

{j{ gg }Qg ec (Enclosures):

Mr. C. G. Zech, Assistant Director for Inspection Programs -

Office of Special Projects U.S. Nuclear Regulatory Commission a 101 Marietta Street, NW, Suite 2900 Atlanta, Georgia 30323 Mr. J. A. Zwolinski, Assistant Director for Projects Division of TVA Projects Office of Special Projects U.S. Nuclear Regulatory Commission 4350 East West Highway EWW 322 Bethesda, Maryland 20814 Sequoyah Resident Inspector Sequoyah Nuclear Plant 2600 Igou Ferry Road Soddy Daisy, Tennessee 37379 l

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VOLUME 3 TVA WELDING PROJECT SEQUOYAH PHASE II l REVIEW AND PROGRAMS RESULTS 1 l

TABLE OF CONTENTS _

1.0 INTRODUCTION

2.0 APTECH ENGINEERING REPORT (Supplemental Information) 3.0 BECHTEL AUDIT REPORT

3.1 INTRODUCTION

3.2

SUMMARY

l 3.3 REVIEW AND CONCLUSIONS 3.4 AUDIT WORK PLAN' 3.5 AUDIT REPORT l

4.0 '

SEQUOYAH WELDING REINSPECTION R3 PORT 4.1 SCOPE 4.2 REINSPECTION CRITERIA 4.2.1 MECHANICAL WELDS I 4.2.2 STRUCTURAL l 4.3 REINSPECTION RESULTS 4.2 ASS $SSMENT OF REINSPECTION RESULTS g 4.4.1 MECHANICAL WELDS 4.4.2 STRUCTURAL WELDS 4.4.3 OVERALL ASSESSMENT AS RELATFD TO EMPLOYEE CONCERNS 4.5 ROOT CAUSE EVALUATION AND CORRECTIVE ACTION TABLES 4.1 REINSPECTION

SUMMARY

FOR MECHANICAL WELDS 4.2 MECHANICAL PIPING SYSTEMS WELD REINSPECTION DATA j 4.3 REINSPECTION

SUMMARY

FOR STRUCTURAL WELDING-4.4 STRUCTURAL WELDING REINSPECTION DATA

]

APPENDICES 4.1 MECHANICAL INDEPENDENT OVERVIEW 4.2 STRUCTURAL INDEPENDENT OVERVIEW 4.3 EVALUATION REPORT OF PIPE WELDS 4.4 EVALUATION OF UNDERFILL, INADEQUATE LEG LENGTH OR EXCESSIVE REINFORCEMENT 4.5 EVALUATION REPORT OF PIPE STANCHIONS 4.6 EVALUATION REPORT SPIRAL WELD DUCT 4.7 METALLURGICAL EVALUATION OF AUSTENITIC STAINLESS STEEL ARC STRIKES  ;

4.3 DISCUSSION AND ASSESSMENT OF INDICATIONS i 4.9 INSPECTABILITY AND DOCUMENT ASSESSMENT i

5.0 SEQUOYAH FROGRAM RESULTS REPORTS 5.1 PHASE I RECOMMENDATIONS STATUS  !

5.2 EMPlafER CONCERNS CONCLUSIONS 5.3 APTdCH CONCLUSIONS 5.4 BECHTEL AUDIT CONCLUSIONS 1

DNE1 - 0449N I

TABLE OF CONTENTS (Continued) 5.0 SEQUOYAH PROGRAM RESULTS REPORTS (Continued) 5.5 REINSPECTION CONCLUSIONS / RECOMMENDATIONS 5.6 OVERALL CONCLUSIONS / RECOMMENDATIONS APPENDICES 5.1

SUMMARY

OF WBN EMPLOYEE CONCERNS DETERMINED TO HAVE POSSIBLE GENERIC IMPLICATIONS TO SQN 5.2

SUMMARY

OF SQN SPECIFIC EMPLOYEE CONCERNS REVIEWED BY WELDING PROJECT ADDENDA l

I ADDITIONAL REINSPECTION DATA REQUESTED BY NRC R2 ,

.II EVALUATION OF WATTS BAR WELDING-RELATED CONCERNS FOR GENERIC APPLICABILITY l l

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-I VOLUME 3 l

l TVA WELDING PROJECT SEQUOYAH PHASE II  !

REVIEW AND PROGRAMS RESULTS

~ REVISION LOG 'I Date Comments .,

R0 April 15, 1986 Original Issue R1 Section 4.0 Pages 11 and 12 R2 Addition of NRC requested inspections (Addendum I).

Addition of~ reports on welding '

related concerns for their generic applicability to SQN (Addendum II).

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. _ _ _ _ _ _ _ . _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ . _ . _ _ _ . _ _ _ _ . _ _ _ _ _ . _ _ . . . . _ ____._.__._._.m___ _ _ _ _ _ _ _ _ _ _ _ _ . - _ _ _ _ _ _ _ _ _ _ _ _ . _ _ ___

TVA PIPING WELDS No. of Weld  %

No. of Welds Attributes Weld Attribute Attribute Reinspected Acceptable / Rejectable Acceptable / Rejectable Contour / Transition 333 317 16 95.2 4.8 Offset / Alignment 333 331 2 99.4 0.6 Undercut 333 331 2 99.4 0.6 Reinforcement 333 326 7 97.9 2.1 Weld spatter /

Arc strike 333 229 104 68.8 31.2 Weld Location 333 333 0 100.0 0.0 Weld Size 333 320 13 96.1 3.9 Weld Metal /

Base Metal 333 333 0 100.0 0.0 l Weld Convexity ;i33 333 0 100.0 0.0 j Incomplete Fusion 333 328 5 98.5 1.5 l l Weld Overlap 333 325 8 97.6 2.4 Underfilled 333 321 12 96.4 3.6 R1 Surface Porosity 333 318 15 95.5 4.5 Surface Slag 333 333 0 100.0 0.0 l

l l 4,662 4,478 184 96.0 4.0 l

P6ge 11 DNE1 - 0202N

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F Spiral wald duct butt-walds were visually reinspected by CWIs for weld quality indicators such~as porosity, undercut, convexity, and overlap. .The weld filler metal )

was evalunted magnetically and found acceptabla. The .

welder's skill was also evaluated and recorded by the inspector, j The 15 welds reinspected were of average quality, with the exception of cortions of eight-(8) of the welds in which accessibility to the weld joint was restricted' because.of adjacent walls. However, inspoetion windows were cut in l

come of the ducts to confirm that the typically used ';

practice of performing I.D. welds in such restricted access situations had in fact taken place. The duct butt welds were found to be free of cracks and other significant indications. All reinspected spiral weld duct l

l butt-welds were accepted (see Appendix 4.6) and w- of sufficient quality to assure structural adequacy of the  !

duct to meet the design requirement.

l l-In summary, the NDE indications and visual imperfections identified during the reinspection are not injurious or in any way detrimental'to tne function of the welds. All 333 piping welds and the 15 duct butt-welds are acceptable.

THE RESULTS OF THE REINSPECTION AND THE ENGINEERING EVALUATION AND DISPOSITION OF THE REPORTABLE CONDITIONS . .:

t j

CONFIRM THAT THE REINSPECTED MECHANICAL WELDS MEET CODE '

R1 REQUIREMENTS AND ARE_ ACCEPTABLE FOR USE: THEREFORE.

ADDITIONAL REINSPECTION ARE~NOT REQUIRED.

Page 12 DNE1 - 0202N L- _

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i ADDENDUM I TVA WELDING PROJECT SEQUOYAH PHASE II  ;

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REVIEW AND PROGRAM RESULTS ADDITIONAL REINSPECTION DATA REQUESTED BY NRC l

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ADDENDUM I TVA WELDING PROJECT SEQUOYAH PHASE II REVIEW AND PROGRAM RESULTS ADDITIONAL REINSPECTION DATA REQUESTED BY NRC TABLE OF CONTENTS

1. Introduction l
2. Additional Structural Welding Data Requested by NRC
3. Additional Mechanical Welding Data Requested by NRC
4. Conclusions l

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ADDENDUM I TVA WELDING PROJECT SEQUOYAH PHASE II REVIEW AND PROGRAM RESULTS

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ADDITIONAL REINSPECTION DATA REQUESTED BY NRC INTRODUCTION:

In the process of reviewing the Sequoyah Phase II Report, the NRC l requested additional reinspection of structural and mechanical items.

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The data collected is herein presented as Addendum I of the Sequoyah Phase II Report.

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ADDENDUM I TVA WELDING PROJECT SEQUOYAH NUCLEAR PLANT l RESULTS OF ADDITIONAL REINSPECTION REQUESTED BY NRC l

l STRUCTURAL WE_LDING REINSPECTION DATA l

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l ADDITIONAL REINSPECTION REQUESTED BY NRC I l

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ADDENDUM I TVA WELDIN3 PROJECT SEQUOYAH NUCLEAR PLANT RESULTS OF ADDITIONAL REINSPECTION REQUESTED BY NRC CONCLUSIONS:

The evaluation of the results of this additional reinspection does not  !

chango any conclusion reached in the Seguoyah Phase II Peport.

DNE1 - 0444N.

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l ADDENDUM II TVA WELDING PROJECT l

SEQUOYAH PHASE II EVALUATION OF WATTS BAR WELDING-RELATED CONCERNS FOR GENERIC APPLICABILITY l l

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1 ADDENDUM II i i

TVA WELDING PROJECT l SEQUOYAH PflASE II EVALUATION OF WATTS BAR WELDING-RELATED CONCERNS FOR GENERIC APPLICABILITY 1

TABLE OF CONTENTS I

)

1. Introduction
2. Sample Reinspection of Steam Generator Tang Plate Welds
3. Engineering Investigation of Diagonal Bracing
4. Evaluation of Need to Review Radiographic Film ll 1

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ADDENDUM II TVA WELDING PROJECT SEQUOYAH PHASE II EVALUATION OF WATTS BAR WELDING-RELATED CONCERNS ;

FOR GENERIC APPLICABILITY '

INTRODUCTION:

This addendum Sddresses additional weldins-related concerns for their applicability to SQN. The following are contained herein:

, 1. Sample Reinspection of Steam Generator Tang Plate Welds 1

2. Engineering Investigation of Diagonal Bracing
3. Evaluation of Need to Review Radiographic Film l

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SEQU0YAli NUCLEAR PLANI SAMPLE REINSPECTION OF STEAM GENERATOR TANG PLATE WELDS' As part of the reinspection effort at Watts Bar. Nuclear Plant (ONP), a number of upper-steam gennrator support tang' plate Weld joints were ultrasonically' examined to resolve employee concerns about excessive slag. The examinations revealed a number of indications that are currently under evaluation by the Weld Task Group and Division of Nuclear Engineering for suitability' for service. Because of the preliminary results, a sample reinspection of a portion of these same woldF was conducted at SQN to determine if similar conditions exiat. Yn addition, a sample of the documentation associated with these welds was collected and reviewed.

This work was performed by an inspection team consisting of a welding engineer, a PSI /ISI-Level III Ultrasonic Inspector, and a metallurgical engineer.

A comparison made of design drawing requirements for each plant showed that the weld joints were different for the two plants. SQN's tang plates were regyired to have a partial penetration double-beveled, fillet reinforced weld whiJe WBN's were to be full penetration single and double-beveled joints.

WBN's joint detail required back grindinr, or gouging while SQN's do not. . Both designs call for PT examinations of the final weld surfaces.

For SQN, the double-beveled portlen of the weld was to have been 3/4 inch on a 45 degree bevel for both sides of the tang plate. . Tang plate thickness is 2.

inches. Fillet reinforcement was to be 7/16 inches inside and 11/16 inches outside. Using these dimensions, the final weld dimension should be 3-1/8 inches measured from toe to toe along the surface of the support ring flange.

Within this 3-1/8 length would be a 1/2 inches long unbeveled portion.

It was decided that a suitable assessment of the overall welding quality of

-these. tang plates could be arrived at by: 1) reinspection of a portion of the tang plate weld using an informational ultrasonic inspection of the accessible portions (top and bottom) of the welds using straight beam techniques;~ 2) .a full volume UT inspection of a representative sample of the welds using angle beam techniques for the full length of the tens plates and

3) visual examination of the welds in their as-found condition for obvious gross discontinuities, weld size, and location. The extent of this reinspection would be determined by the results obtained and expanded should those results warrant.- It was also decided that several weld record packages from CONST would be recovered from the records storace system and examined to determine that a proper welding procedure was used and that appropriate inspections were conducted.

Prior to the start of the reinspection, the team decided that they would spot j inspect at least one-half of the tang plates on two of the steam generators on i one unit and expand the sample if results were not satisfactory. Because there was not sufficient scaffolding in-place in unit 2, the reinspection w6c conducted in unit I with any expanded effort to be performed in unit 2 after erection of scaffolding.

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I On October 6,1986, the reinspection team conducted its examinations. Tang plate welds on loops 1 and 3 of unit I were ultrasonically spot examined. For each loop, five of ten tang plate welds were inspected on the upper ends and J three of ten wcre inspected on the lowee ends. All 16 spot inspections showed ]

that the welds esamined wne sound, proper.ly fused and of the correct size  ;

according to ddsign dr o hg 48N431. Overall visual appearance of all welds associated with these ttng plates and the attachment of the clevis assemblies on the oppocite ends of the snubbers to their embedments> appeared to be of 1 good quality with surface conditions fully adequate for their required 1 inspections. There was no evidence of service induced defects.

Following these inspections the team decided that two of the tang plate welds l l

would be randomly selected for full volume informational'UT examination.

Those incpoetions were conducted and the results were acceptable. The team i then. determined that there was no reason to expand the reinspection. J Attachment A is a summary of all the ultrasonic examination results. i 1

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SEQUOYAH NUCLEAR PLANT 3 AMPLE REINSPECTION OF STEAM GENERATOR TANG PLATE VELDS Attachment A Description _o_f Ultrasonic Examination An information only ultrasonic examination was performed on SQN unit 1 Steam Generators 1 and 3 upper-stema generator support ring to snubber tang plates.

A total of 16 tang plates (8 per S/G) were examined to determine the integrity of the welds.

The examination to determine fused weld area was conducted from the back surface of the support ring. A 1/4-inch slianeter dual element search unit producist longitudinal waves normal to the surface was used. The small diameter pitch-catch transducer was used to botter pinpoint the fusion areas.

Test sensitivity was established by obtaining a back surface refloction from i the support ring 1-1/4-inch thick plate, Accessible areas at both top'and bottom of the tang plate were investigated for lack o!* fusion and to determine if an unbevaled area was present at mid-wall of the Lang plate. The examination results indicated that the fusion area of each fillet weld was approximately 1-3/8 to 1-1/2-inches wide in the areas examined. Also, the results indicated that an unbeveled area was present approximately 1/2-inch wide and extends for the full length of the areas examined, excluding the top and bottom ends which are covered by th6 fillet weld. The accessible area was approximately 4 inches at the top and bottom. The examination to determine weld integrity was performed using the same procedure and techniques that are being employed on the WBN tang plates. The entire length of the two tang plates was examined for weld integrity. The results revealed no unusual or abnormal conditions but did corroborate the results of the fusion exam in that the unbeveled area could be partially mapped.

Eight weld record packages were recovered which included at least one tang plate weld on each loop of unit 1. Examination of these packages showed that an appropriate welding procedure was used and that all design required inspections were performed and properly documented. Based on the resultr of the initial sample it was decided not to expand the records revi(w.

In summary, the review team could not substantiate that any potentially adverse conditions exist in the tang plate welds at SQN. This conclusion is based on the following: 1) the field weld joints correlate with the design drawing weld preps; 2) the satisfactory results of the visual and ultrasonic re-examinations; and 3) the satisfactory results of the records review.

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SEQUOYAH NUCLEAR PLANT ENGINEERING INVESTIGATION OF DIAGONAL BRACING The reinspection effort at Watts Bar Nuclear Plant.(WBN) identified, discrepancies in a number of. horizontal diagonal braces and end connections of structural steel beams. In order to perform a generic review for SQN, an engineering investigation of similar connections and diagonal bracing was performed. '

A SQN. drawing review identitled similar details and locations comparable to the problem areas identified at WBN. Examination was conducted by civil and welding engineers knowledgeable of the dAscrepant conditions found'at WBN paying particular attention to the occurrence of missing welds; the size and locetion of gusset plates; and the location, size, and excessive trimming of clip angles.

l l The review determined that bracing for platforms may not be installed as designed. SCR SQNCEB8711 (RI) (B25 870331 048) has been written and will address the discrepancies _ identified. The investigation did not identify any welding-related conditions similar to those identified at WBN.-

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SEQUOYAH NUCLEAR PLANT EVALUATION OF NEED TO REVIEW RADIOGRAPHIC FILM As a result of EG&G's review of radiographic film at WBNP, several discrepancies have been identified that caused expansion of the population and additional film review at WBNP. As a result of this issue, the Welding Project (WP) evaluated the generic implications at SQNP. The WP does not recommend that any film be reviewed at SQNP for the following reasons:

1. Preservice ultrasonic examinations have been performed on approximately 800 Code Class 1 and 2 welds for both units, and no rejectable indications in TVA field welds vere reported. This represents approximately 14% of the total number of safety-related welds for SQNP Units 1 and 2. In addition, approximately two-thirds of the first 4 10-year inservice inspection interval has been completed on Unit 1, and approximately one-third on Unit 2. No rejectable indications have been reported.
2. In October 1974. NRC issued a stop work order at SQNP due to a number of problems with the welding program. As a result of this action, a number of improvements in the welding program were made, and all radiographer welds from start of construction through 1974 were re-reviewed and appropriately dispositioned for acceptance. This effort involved approximately 150 welds.
3. From 1974 to commercial operation, TVA employed predominately two film readers (as compared with eleven at WBNP) who interpreted 95% of radiographic film at SQNP. These readers worked closely together and frequently read each others' film when questions arose. TVA believes that a greater degree of continuity and consistency in film interpretation is achieveable when a small number of readers are employed. In addition, none of the film readers at WBNP interprete-d any film at SQNP.
4. In 1984, as a result of employee allegations from one of TVA's radiography contractors that substandard radiography practices had been used by that contractor, TVA Level III personnel performed an in-depth investigation of all welds radiographer by this contractor at SQNP.

l This involved 320 welds in the RHR systems. Every radiographic image (tungsten, fusion, undercut, etc.) for each weld was recorded and i evaluated to determine whether the contractor substituted known good i radiographs of welds for other welds that had not been radiographer.

While TVA personnel did not review the subject film for density or code rejectable defects, any significant weld defects would have been identified.

In summary, for the above reasons, the Welding Project has high confidence i

in quality of welds accepted by radiographic examination at SQNP. A }

significant number of differences between SQNP and WBNP exist such that,  !

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' in the opinion of the Welding Project, a re-review of SQNP radiographs is not warranted.

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SEQUOYAH NUCLEAR PLANT EVALUATION OF NEED TO REVIEW RADIOGRAPHIC FILM-TVA is currently implementing two actions affecting Sequoyah piping fic1d welds as discussed below:

a. As a result of the radiography issue at Watts Bar TVA has strengthened its welding program by requiring independent re-review of all new radiographs by appropriately certified personnel at all nuclear plants.
b. In addition, as a result of the Sequoyah reinspection efforts, TVA has committed to an accelerated Section XI ISI program for Units 1 and 2 which completes the first 10-year in-service inspection interval in the next two consecutive refueling outages following {

restart of each unit. This means that an increased number of ASME j Class 1 and 2 piping field welds that were radiographer during  !

construction will be ultrasonically examined in the next two refuel {

outages.

l These two activities will increase TVA's confidence in the quality of past and future radiographic examinations.

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