ML19261E311
| ML19261E311 | |
| Person / Time | |
|---|---|
| Issue date: | 04/27/1979 |
| From: | Ellershaw L, Hunnicutt D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19261E305 | List: |
| References | |
| REF-QA-99900362 99900362-79-1, NUDOCS 7907050536 | |
| Download: ML19261E311 (4) | |
Text
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U.S. NUCLEAR REGULATORY COT 1ISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No. 99900362/79-01 Program No. 51400 Company: Unistrut Corporation 4118 South Wayne Road Wayne, Michigan 48184 Inspection Conducted: March 26-27, 1979 Inspectod.
[,I wM 27!77 v L. E. Ellershaw, Principal Ins?ector Date Vendor Inspection Branch Approved by:
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_ /A7/79 D. M. Hunnicutt, Chief, Components II ate /
Vendor Inspection Branch Summary Special Inspection on March 26-27, 1979 (99900362/79-01)
Areas Inspected:
Fcllow-up on a 10 CFR 50.55(e) Construction Deficiency Report relative to failed resistance welds in strut material.
The inspection involved seven (7) inspector hours by one NRC inspector.
Results:
In the one area inspected, no deviations or unresolved items were identified.
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2 Details Section (Prepared by L. E. Ellershaw)
A.
Persons Contacted C. L. Cook, Manager, Quality Control A. Kluska, Manufacturing Engineer B. McClure, Assistant Manager, Quality Control B.
Introduction Pennsylvania Power & Light Company (PP&L) documented a reportable deficiency under the provisions of 10 CFR 50.55(e), to B. H. Grier, Region I, dated April 26, 1978, regarding inadequate spot welding of strut material used in field fabricated supports for safety related electrical raceways, HVAC ducts, and instrumentation panels (PP&L Reference No. PLA-249), as producted by Unistrut Corporation (UC),
Wayne, Michigan.
C.
Follow-up on 10 CFR 50.55(e) Report 1.
Objectives The objectives of this follow-up inspection were to ascertain that an evaluation of the condition had been performed, including making an' assessment of generic implications, and that responsibility for effecting corrective action and preventing recurrence had been assigned.
2.
Method of Accomplishment The preceding objectives were accomplished by:
Review of 10 CFR 50.55(e) Report.
a.
b.
Review of Procedure No. 20-01-015, " Spot Welding Proce-dure-Low Carbon Steel," dated February 10, 1978.
c.
Review of Procedure No. 20-01-016, " Spot Welding -
Coated Low Carbon Steel," dated November 10, 1978.
d.
Review of " Addendum - Unistrut Weld Procedures -
Revision 1," dated October 20, 1978.
e.
Review of Bechtel Power Corporation Specification 8856-C-92, " Technical Specification For Furnishing and D
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a
3 Delivering of Spot Welded Strut Material for the Susquehanna Steam Electric Station Units 1 and 2," Revision 2, dated October 10, 1978.
f.
Observation of in process resistance (spot) welding.
g.
Observation of the following tests:
Shear test, pull test, peel test, and chisel test.
b.
Discussions with cognizant personnel.
3.
Findings Prior to the detection of failed spot welds at the job site, the strut material had been purchased as standard off-the-shelf items, with no formal Quality Assurance / Quality Control program invoked.
Testing was performed by UC on a random basis, however, this was very limited in scope.
The type of testing and frequency included:
Pull Test - no established frequency.
a.
b.
Shear Test - no established frequency, as this was performed only on engineering request.
c.
Chisel Test - no established frequency, and.only pertormed on strut material whose configuration would not allow a Pull Test.
~
d.
Peel Test performed at the time er spot weld machine set-up, for a given job.
It was also determined that monitoring of weld machines and welding operators was virtually non-existent.
The assessment of the failed spct welds brought about the creation of a formal Quality Control (QC) program, with definitive procedures for welding, testing, and calibration of welding equip-ment.
A welding machine refurbishment took place and a calibra-tion program implemented.
UCs procedure for testing and frequencies now include:
a.
Pull Test - the first three (3) pieces welded at the start of each shift, the last piece welded prior to cleaning weld tips, and the first two pieces welded after cleaning the weld tips.
This is done by the welding operators and audited by QC, with the results being recorded and the tested piece stamped.
b
4 b.
Shear Test performed daily on every welding machine set-up, with results recorded.
Chisel Test performed once on every twenty (20) welded c.
pieces (only on configurations that cannot be pull tested),
with results recorded and pieces stamped.
d.
Peel Test performed aily on every welding machine set-up, with results recorded.
It was indicated, that as a result of the implementation of a formal QC program, there have been no known failures of spot welds.
However, it must be noted that any material which was spot welded prior to the initiation of the formal QC program (about February - March, 1978) may have defective spot welds.
D.
Exit Interview The scope and findings of this 10 CFR 50.55(e) follow-up inspection were summarized with C. L. Cook, Manager of Quality Control, who acknewledged the comments relative to the findings.
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