ML18031A853

Rev 0 to Welding Project Reinsp Plan.

ML18031A853
Person / Time
Site:	Browns Ferry
Issue date:	07/08/1986
From:	Kron B TENNESSEE VALLEY AUTHORITY
To:
Shared Package
ML18031A852	List: ML18031A849 ML18031A853
References
PROC-860708, NUDOCS 8610080202
Download: ML18031A853 (37)

Text

BROWNS PERRY NUCLEAR PLANT WELDING PROJECT REINSPECTION PLAN REVISION 0 E

PreParer Date

~vs Welding Project Date Engineer B P Px'oje t Engineer p p ate 86i0080202 860917 096169.01 PDR ADOCK 05000259 8 PDR,. L

TABLE OP CONTENTS SECTION PAGE REV.

Scope Regulatory Commitments Schedule Assumptions IV Schedule V Activity Descriptions VI Tracking VII Reporting 096169.01

REVISION, STATUS Revision Date Descri tion of Chan e 0 Initial Issue 096169.01

I'COPE The Welding Program Reinspection Plan (WPRP) is to provide additional data addressing the adequacy of the Browns Ferry veld program and to provide indicators regarding the suitability of velding in relation to restarting the BFN units and address nonspecific employee concerns related to welding. For detailed Scope and Plan, see Attachment A.

(Welding Project Phase II, Part 2, Brovns Ferry Reinspection of Selected Welds Reins ection Plan). This will be accomplished utilizing 300+ pipe velds and 58+ structural items.

II~ REGULATORY COMMITMENTS Commitment 1: Docket Wo. 50-390 Docket No. 50-391 Elinor G. Adensam show cause letter to H. G. Parris dated October 29, 1985.

Commitment 2: Letter from TVA Licensing to H. R. Denton dated January 17, 1986.

Committed to program description and to TVA Action Plan.

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III SCHEDULE ASS IONS

l. Mork plan, USQD, and all other procedural requirements will be approved by BPEP by 7/7/86.

2. Certified weld inspectors (CMIs) will be supplied by the Procurement Quality Assurance Branch in sufficient number to complete structural reinspection in three weeks (7/10/86 through 7/31/86).

3. Stress evaluation of welds will be performed by BFEP personnel in a four week period from 7/13/86 through 8/15/86.

4. Meld project personnel

~C will evaluate results of inspection between 7/13/86 and "9/2/86.

5. APTECH ISI Report will"be favorable and not expand piping or pipe support weld inspections.

6. TVA ISI inspectors will be supplied in sufficient number to complete piping reinspection in three weeks (7/10/86 through 7/31/86).

7. BFEP will provide personnel to accompany the weld inspector to sketch up the items and provide weld maps.

8. Any additions to the scope or modification to the work plan required by the welding reinspection will be completed by 9/2/86.

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IV. SCHEDULE TVA WELDING PROJECT BROWNS FERRY SCHEDULE DESCRIPTION 6/23 7/11

1. APTECH ISI Report 6/10 7/1

2. Selection of Reinspection Items 7/1 7/7

3. Work Plan and Approved Procedures 7/7 7/10

4. Site Training 7/10 7/31

5. Reinspection 7/13 9/2

6. Evaluation of Reinspection jl 9/2 - 10/14

7. - ~ Phase II Report 10/14 10/31

8. TVA Licensing Review Final Report

9. NRC Inspect. & Evaluation (Unscheduled)

10. Resolve NRC Concerns (Unscheduled)

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V. ACTIVITY DES PTIONS Activity 1: APTECH ISI REPORT APTECH Engineering Services is performing a review of the inservice inspection program at BFNP, Units 1, 2, and 3 in order to verify that the quality of welds at the plant is suf ficient for their intended use. This review consists of three parts: a review of the welding and quality assurance program to determine whether the necessary controls were in place to ensure quality welds, a revie~

of preservi'ce and inservice inspection results to determine the rate of indications in welds, and a review of the operational history to determine the failure rate due to initial weld quality. Prepare a report and if

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needed provide assistance'o ZVA in the defense of the report in meetings with regulatory bodies.

Activity 2: SELECTION OF REINSPECTION ITEMS Members of the Welding Project along with Browns Ferry Engineering Project personnel will walk through the facility selecting from the appropriate systems the items to be reinspected.

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Activity 3: PLAN AND APPROVED PROCEDURES~

Browns Perry Project personnel will prepare and get approved all work plans/USQDs and any other procedures needed to perform the inspection.

Activity 4: SITE TRAINING Provide necessary site specific training for inspectors.

Activity 5: REINSPECTION BFEP personnel will prepare weld maps as required.

Certified Weld Inspectors/TVA ISI inspectors will perform inspections, prepare inspection reports, and submit inspec'tion reports to Welding Project personnel.

Activity 6: EVALUATION OP REINSPECTION Welding Project personnel evaluate reinspection reports and submit items requiring additional stress evaluation to BFEP personnel. BFEP personnel perform and document stress evaluations and submit back to Welding Project. Welding Project reevaluates and determines any additional items that may be required to be reinspected.

Mechanical items that require evaluation will be sent to NEB CSM, CEB analysis, or BFEP as appropriate.

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Activity 7: AL REPORT Upon completion of all activities the Welding Project prepares a final report for submittal to TVA Licensing.

Activity 8: TVA LICENSING REVIEWS FINAL REPORT TVA Licensing reviews final report and then submits to NRC.

VI. TRACKING Activities may be entered in the BFN tracking/scheduling system (P2) for those activities to be performed by BFEP. The Welding Project vill

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track all activities in its own tracking system.

VII'EPORTING Periodic status/reports vill be available from the Welding Project.

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4 MELDING PROJECT PHASE 2, PART-2 BROMNS FERRY REINSPECTION OF SELECTED MELDS REINSPECTION PLAN OBJECTIVE The objective of the program described in this reinspection plan is to provide additional data addressing the adequacy of the Brovns Ferry veld program and to provide indicators regarding the r suitability of velding in relation to restarting the BFN units and address nonspecific employee concerns related to velding.

BACKGROUND

'mploye'e concerns from Matts Bar have possible generic implications to the Brovns Ferry plant. Some of these concerns relate to: quality of veld fil)er materials, control of veld filler materials, velder qualifications) inadequate training of velders, inspector qualifications, falsification of records, veld adequacy, and record keeping. A reinspection of hardvare to design requirements and comparison to the records package cuts across these and other issues to address the concerns, the velding program adequacy, and provides additional data regarding the suitability for restart of BFN units.

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I Nonspecific emplo e concerns are best addressed reestablishing confidence in the original programs. -Inadequacies in the welding program in the areas of these <oncerns would be reflected in the hardware quality and the relevant records. While the concerns have generic implications, this reinspecti'on will address them by focusing on safety-related portions of the plant where there have been fewer previous inspections and, therefore, fewer opportunities for weld defects to have been identified.

For this reason, piping system welds which receive Inservice Inspection are excluded. This is a conservative approach and biases the reinspection toward items which have had only one required inspection, and, therefore, have the most likelihood of having previously unreported defects.

Due to an employee concern about the quality of TVA butt welds in duct work made from spiral welded pipe at Watts Bar Nuclear Plant and its subsequent investigation, TVA'ill reexamine a portion of a like system at BFH to verify-'that field welded joints meet: the design requirements.

Due to normal construction sequence at a job site, the selection of different systems at various elevations and various units of the plant will cut across different timeframes of plant construction. The reinspection effort also includes some modifications performed by Nuclear Operations.

SCOPE The reinspection of the safety-related features described in the groups below addresses the concerns described above for various installation craf ts and various timeframes.

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1. Selected pip and attachment welds in Clas F, & P systems at various units and elevations in the Reactor and Diesel Generator Buildings. The sample vill include carbon, aluminum, and stainless steel piping components.

2. Welds of supports for piping (related to above piping components).

3. Welds of cable tray supports and conduit supports.

4. Structurally significant velds on miscellaneous structural steel in the Reactor and Control Building.

5. HVAC support velds in the reactor Building.

6. Spiral veld pipe used as ductvork in the Reactor Building.

r The scope of this reinspection is limited to visual, surface (magnetic particle or liquid penetrant), and radiographic methods vhich are required by TVA General Construction Specification G-28 for the piping classification and-weld types involved. It is not the intent of this vork

. plan to cause- reinspection .of welds by any method not explicitly required by G-28.

Piping velds to be reinspected vill be as designated by the Welding Project (WP) from Class E, F~ and P systems as defined in G-28. When velds vhich received radiography at installation are included in systems ox portions of systems designated for reinspection a review of radiographic film for conformance to applicable requirements vill constitute the reinspection.

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Approximately 300+ piping and spiral veld pipe velds and approximately 58+

structures will be reinspected in the above groups. The items to be reinspected vill be selected to provide a representative look at each of the above classes and to cover vork that vas performed during the construction phase and during the operating phase. The reinspection is to be in areas vhich will minimize inspector exposure to radiation. Welds vhich are inaccessible due to wall or floor penetrations, or fireproofing vill be excluded.

For all velds, the generic type, carbon steel as opposed to stainless steel or aluminum, will be checked by magnetic means.

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4 For the structural'teel and support velds, the veld attributes to be addressed 'are presence, size, length, and location. Existing coatings .vill not affect this inspection. However, coating thickness as measured by a dry film thickness indicator vill be reported for information. The generic type of filler metal is also to be reported.

CRITERIA All inspections will be conducted in accordance vith established inspection procedures and this work plan. In case of conflicts, this vork plan shall govern.

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1 For purposes of t reinspection, the examinatio~thods and acceptance criteria shall be as follovs:

A. Class E Pi e Welds

1. Complete penetration butt welds and welds attaching branch connection larger than 4" nominal pipe size method re-interpretation of radiographic film to N-RT-1(R4) of DPM N80E3 criteria velds meeting the acceptance criteria of N-RT-l(R4) as amended by Attachment 1 or ASME Section XI are acceptable. The reporting form shall be the standard form RT interpretation used at BFN.

2. All other welds in or to Class E Systems

- ",meth'od -'erform PT or MT examination'using- the methods as required by N-PT-l(R6) or N-MT-l(R5) of DPH N80E3 respectively. The method used should be that used originally.

criteria - velds meeting the acceptance criteria of N-MZ-1(R5) or N-PT-l(R6), as applicable, are acceptable. Welds not meeting these criteria but meeting those of ASME Section XI are acceptable. The reporting form shall be the standard form for the particular methods at BFN.

B. Class F and Class P Welds method - perform visual examination to the requiremente of N-VT-3(R5) of DPM N80E3.

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<<an' aaM~&we ~jun'. ~~~at>> t

P criteria~ velds vhich meet the criteria of N-VT-3(R5) and attachment 2 or ASME Section XI are ac'ceptable. The reporting form is included in Attachment 2.

C, Structural Welds Method Structural steel and support velds vhich were designed based upon the AISC specification vill be reinspected visually to drawing requirements in accordance vith N-VT-6(RO) of DPM N80E3. Coatings vill not be removed unless authorized by the Criteria - Welds meeting the criteria of N-VT-6(RO) and attachment 3 are acceptable. The reporting form is included in atta*chment 3.

D. S iral Duct Butt Welds Method Perform visual examination Criteria The acceptance criteria for spiral duct butt welds will be the presence of weld supplemented by the special data section.

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E. All Welds The generic filler metal type for all welds vill be checked by the use of magnets. The acceptability will be based upon the weld metal being of the correct type; carbon steel (magnetic), stainless steel (not magnetic or slightly magnetic), or aluminum (not magnetic) as appropriate for the materials being joined. The confirmation of generic filler material type does not require a special procedure, as it is an accept/reject test. The results of filler metal type shall be recorded on the respective visual examination records.

REINSPECTION PERSONNEL All structural and support inspection personnel shall be qualified AWS-Certified Welding 'Inspectors (CWIs). The CWIs vill be from TVA's

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Procurement Quality Assurance Branch (Vendor Surveillance..). For piping, inspection personnel shall be qualified in accordance with SNT-TC-1A or equivalent (certification program for visual patterned after the format for NDE established in SNT-TC-1A) Level II or III.

UALITY ASSURANCE Overview of this reinspection effort will be provided by a person or persons independent of TVA who have current certification as AWS Certified Welding Inspectors (CWIs) for structural steel, supports, and duct and SNT-TC-1A Level III for piping. The independent inspector(s) will provide a written report to the Welding Project Engineer summarizing the overview activity and their concurrence or reason for disagreement with the results.

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SPECIAL DATA In addition to accepting or rejecting a weld, the inspectors will note their own opinion regarding the workmanship of the welders work: better than average, average, or does not meet requirements. In making the judgement, the inspectors will consider undercut, porosity, convexity, spatter, overlap, or rollover and/or other specific indicators which they observe. This opinion is to be recorded on the inspection record. The inspector will note if the r weld has been coated.

RECORDS For each weld there will be a record of acceptability as to presence, size, I

length, location of defects, the generic type of filler metal, and the inspectors opinion of the welder workmanship as shown in attachments 2 and 3.

PLANT SAFETY 6 SECURITY Plant safety and security procedures shall apply.

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DISPOSITION OF D CREPANT CONDITION Discrepancies vill be documented on attached forms in accordance vith TVA quality assurance program and dispositioned by the design organization using engineering justification to use as-is or to provide corrective action. Determination of generic importance of discrepancies to the velding program vill be performed by the Welding Project. All defects vhich require design disposition will be reported along vith the ultimate disposition. The NRC will be notified immediately if significant discrepancies are identified during the reinspection. Root causes will be iavestigated. All this vill be included in the Phase 2 Final Report.

INSPECTION REPORT The Inspection Report on this reinspection vill be forvarded to TVA Management and NRC and vil'1 subsequently be included 'in 'the overall report on the Welding Project activities on BFN.

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I cILTTACHMENT 1

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Exceptions to N-RT-l(R4) for reinterpretation of radiographs are tabulated below Paragraph From N-RT-1 Exce tion To Be Taken 4.6 Penetrameters will be per Table DW-51. The 5, 7, and 10 penetrameters will also contain a 1/4" long slit parallel to its long axis.

5.2 There are no restrictions on the double-wall technique.

5.3 There are no restrictions on geometrical unsharpness.

5.6 The 2T hole shall be visible on all radiographs; except that for penetramenters 5, 7, and 10 the slit shall appear clearly and the hole need not appear. For each sector not meeting these requirements, record the minimum hole size visible.

5-.9 There are no restrictions on max2mum density.

6.1, 6.2, These paragraphs do not apply.

6.3.4 8.1.5 Porosity should be evaluated to Page 2 of this attachment entitled "Appendix IV".

YAOI.K OR $ 1 STANDARD tftffTRAcrfTRRSI285 Th 1 t hrt os ~ of Tht ~ Loots of Toll Thithrtooo Rooocrosotor Doaf8ooOeo Rortetrosotor Detlfllottorl Roose ~o Soerco 514 ~ rt Frfa $ 14 ~ rl ffa.) I fo.l R so et re root er (ia.l Rooelrowtor UR to If Iacl. 0.00$ 5 0.00$ 5 Oter If thn '6 0.001$ T O.OOT 5 ~

T Dree 44 thn ll 0.010 10 0.010 10 Deer II thn '4 OAI25 12 0.010 10 Oeer t4 thn II OAI 5 15 0.012 12 Otec ff thra '6 O.OITS IT 0.01 5 1$

Oter r4 thn I 0.020 20 O.OIT IT Deer I thra Iff 0.025 25 0.020 Orat Ilf thn III 0.0$ 0 $0 0.02 5 25 Oter III thn 2 OPS $5 0.0$ 0 Oeer 2 thn 2II 0.040 0.010 $0 Orer2II thea 5 0.04$ 45 0.025 $$

Oeec 5 thrs 4 ILOSO 50 Oo040 Orer 4 thn 6 0.060 0.050 50 (her 6 thn 8 0.080 80 0.060 60 Deer 8 tLra 10 0.100 100 0.080 80 Onr IO tLn 12 0.120 120 0.100 100 Orer 12 thn 16 Deer 16 thn 20 0.160 0400 160 0.120 120 096176,03 200 0.160 160

APPENDIX% IU Porosity Charts UA-65 Acceptance Standards for Radiographical- number and aixe of indications permitted. %her ly Detertttined Porosity Ia Welds porosity indications differ significantly from thr (a) These standards are applicable to ferritic, porosity charta, the actual numbers and sizes o austenitic, and nonferrous materials. the pores may be measured and the total area o (b) The total area of porosity as determined porosity calculated+

from the radiographic 'film shall not exceed (d) ln any one inch length of weld or 2T, which.

0.060T square inches in any six inch length of ever is smaller, porosity may be clustered to t weld, where T is the thickness of the weld. lf the concentration four times that permitted by 0.06T weld is less than six inches long, the total area Such clustered porosity shall be included in tht of porosity will be reduced in proportion. porosity in any six inch length of weld whic)

(1) The maximum pore dimension shall be 20 includes the cluster.

per cent of T, or 'g in., whichever is smaller (e) Aligned porosity shell be acceptable pro.

except that an isolated pore separated f'rom an viding the summation ol the diameters of the pore:

adjacent pore by one inch or more msy be 30 per is no more than T in a length 12T, or 6 inches cent of T, or '/j in., whichever is less. whichever is less, providing each pore it (2) Dark itnages of a generally circular or separated by e distance at least six times the oval shape shall be interpreted as porosity for diameter of the largest adjacent pore. Aligner the purposes of this standard. porosity indications shall be counted in th>> tota (c) The poros ity charts in this hppendix .area of permissible indications in any six inc) illustrate various types of assorted and uniform, length of weld.

randomly dispersed porosity indications. These (f) Permissible porosity indications for welc charts for each thickness represent the maximum thicknesses intermediate to those illustrated ma) acceptable porosity. The charts represent full ~

be evaluated either by'comparison with the nex scale six inch radiographs, and shall not be en thtnner materiej or by calculation as shown ir larged- or reduced. The porosity distributions Table Uh65.

shown are 'not necessarily the patterns that may Maximum permissible porosity 0.060T squar appear on the radiograph, but are typical of the inches in any 6 in. length of weld.

TA8LE UAQS MAXIMUMPERMISSISLE POROSITY IHDICATIOHS IH RADIOGRAPHS PER 6 IH. LEHGTH OF WELD Totol Area of Permitted LARGE MEDIUM F IHE Weld Porosity Pore Size (ln.) Pore Size (In,) Pore Size (In.)

Thicknes s (Square Approx. Dec imal Approx. Decimal Approx. Decimal (Inches) Inches) Froct ion Yalue (1) No. Froction Value (1) Ho. Froction Volvo (1) Ho.

.0075 ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ 4g .014 49

.015 ~ ~ ~ ~ ~ ~ ~ ~ s4s .025 31 .0138 100

.030 .10 .031 40 r/ ~ .0195 101

)s .045 .125 4 .034 50 .024 99 I .060 t4 .125 5 sg .039 .0275 401 II( .090 lg ~ 125 7 lg .048 50 .034 99 2 .120 .125 10 Ars .055 51 s/ s .039 100

.150 .125 12 t/ .061 51 .044 99 2'.

3 .180 .125 15 I/ .068 50 sg .048 99 3)( .210 .125 17 Sg .073 .052 99

.240 tg .125 20 f4 .078 50 ,055 101 III Tbes>> sslues used ior calculating totel cree oi permissibl ~ porosity siren in second column.

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PRQE I OF Q ATTACHMENT 2

~i itp Exceptions to N-VT-3(R5) for reinspection of piping velds are tabulated below:

Paragraph From N-VT-3 Exce Cion To Be Taken 5.0 Examination prior to welding does not apply.

6.2. 1. 1 ~Overla Overlap for uhich the fusion zone can be seen is acceptable. If surf ace examination is performed and is acceptable, the overlap is acceptable.

~Porosit - Visually detected porosity is acceptable if surface examination is performed and the surface examination is acceptable.

If surface examination is

, ~ t not performed, porosity and slag inclusions shall be evaluated to the RT porosity chart in-Attachment 1". to this reinspection plan.

Arc Strikes - Report the number of arc strikes on the report form. Arc strikes are acceptable on ASTM A105, A106, A234 carbon steel materials and on type 304 and 316 stainless steel if no cracking is apparent and they do not reduce the base material thickness.

Report the depth of material reduction, to the nearest 1/32 inch, for rejectable arc strikes.

acceptable.

096176.04,

httachment 2 Page 2 of 3 Paragraph From H-VT-3 Exce tion To Be Taken 6.2.3 The maximum offset does not apply.

6.2.7.2 Figure 5 (c) applies to all socket veld joints, including flanges.

Documentation of examinations shall be on the fora attached.

The magnetic check is to be performed by touching a small permanent magnet to the veld deposit and noting vhether the veld deposit is strongly magnetic, veakly magnetic, or non-magnetic.

The judgmental evaluation vill consider undercut, porosity, convexity, spatter, overlap, or rollover and/or other specific indicators vhich are observed.

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MELD DISCREPAHCY REPORT QHQ/SKETCH 80. MELD HO.

I. Description of Discrepancy (Attach Sketch/Photograph).

Reported by Inspector Date II. Disposition OE Representative .

Date III. Corrective Action Taken SQN Personnel Date