ML19281A445

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Responds to NRC Re Violations Noted in IE Insp Repts 50-329/78-17 & 50-330/78-17.Corrective Actions: Nonconforming Welds Will Be Corrected by Vendor by 790330. W/Encl Vendor Documentation
ML19281A445
Person / Time
Site: Midland
Issue date: 02/07/1979
From: Howell S
CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.)
To: James Keppler
NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
Shared Package
ML19281A441 List:
References
NUDOCS 7903130244
Download: ML19281A445 (20)
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Text

M 'A consumers mduk Power (Q@pQQ{

Stephen H. HoweH Senior Vice President General of fices: 1945 West Parnell Road, Jackson, Michigan 49201. (517) 788-0453 February 7, 1979 Hove-32-79 Mr J G Keppler, Regional Director Office of Inspection and Enforcement US Nuclear Regulatory Co= mission

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Region III 799 Roosevelt Road Glen Ellyn, IL 60137 MIDLAND NUCLEAR PLANT - NRC ITEMS OF NONCCtGLIANCE IESPECTION REPORT NO 50-329/78-17ANDFO50-330/78-17

Reference:

1) Letter, R F Heishtan to S H Howell, IE Inspection of November 7-9, 1978, dated January 3, 1979
2) Letter, S H Howell to J G Keppler; Midland Nuclear Plant; Unit No 1, Docket No 50-329; Unit No 2, Docket No 50-330; Conteinment Building Personnel Air Locks, Hove-181-78, dated September 29, 1978 This letter, with enclosure 1, is in response to reference 1 which transmitted the results of your inspection of the Midland site on Nove=ber 7-9, 1978 and which requested our written statement on the item of noncompliance.

Reference 2 was Consumers Power Co=pany's final 50 55(e) report on the Conteintent Personnel Air Locks. During the November 7-9 inspection, a request was made for us to supplement the final report by providing the detailed repair procedure. Enclosure 2 provides this infomation.

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s Enclosures T

8 1979 7903130JVt/

Hove-32-79 CO:iSUMERS POWER COMPANY RESPON iE TO THE ITEM OF UQUC0f'PLIAUCE DESCRIBED IU URC IIUPECTIOU REP 03T NO. '30-329f(6-17 AND UO. 50-330/76-17 FAILURE TO FOLLOW WELD REPAIR INSTRUCTION A.

Descriptions of Honcompliance Appendix A of Report No 50-329/78-17 and no 50-330/78-17 provides the following:

"10 CF3 Part 50, Apicndix B, Criterion V ctates in part,

' Activities affecting quality shall be prescribed by documented instructions, procedures, or drawings of a type appropriate to the circumstances and shall be accomplished in accordance with these instructions, procedures, or drawings. '

The Bechtel Midland Nuclear Quality Assurance Manuel, Section 0, Number 2, Paragraph 7 0 states that ' Activities affecting quality shall be accomplished in accordance with these instructions, procedures, or drawings. '

The Bechtel UCR Ho 1185 regarding the personnel air locks stiffener velding for both Units 1 and 2 prescribed an instruction for repair velding of the cracked velds provided by the manufacturer, W J Woolley Co. This velding instruction required that uelding shall be done on both sides of the stiffener plates only (W J Woolley Co instruction S. O. 1011).

Contrary to the above, the inspector observed that the repair velding, of the Unit 1 cracked welds for the stiffener strengthened by splice plates, had been velded not only along both sides as specified but also along the end face of the splice plates and stiffener."

B.

Consu:cers Power Company's Response The discrepant conditions noted during and subsequent to the subject NRC Inspection vere addressed in a CPCo nonconformance report (NCR M-01-9-8-096) and in a Bechtel nonconformance report (HCR 1185).

This latter UCR was originally closed on November 1, 1978 and was reopened on December 12, 1978 to reflect the undersize conditions.

Bechtel provided the Supplier (W J Woolley Co) with sketches of the as velded condition with the unspecified wrap-around welds. Project

2 Engineering determined (upon the recommendation of the supplier) that the veld: are acceptable as is and will not adversely affect the structurcl integrity of the personnel locks. The end returns (vrap-around) that were made during the repair velding, or which were on the original structure, vill be shown on the Supplier's as-built drawings.

The undersize fillet velds are to be corrected for total conformance with the applicable Code and specification.

The above corrective actions are anticipated to be complete on or before March 30, 1979 at which time full compliance vill be achieved.

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ITEM LOCATION

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F raotured Vendor woldo and stiffenor G. P.O. OR SPEC NO.

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16. NONCONFORMING CONDITION:
24. DISPOSitlON CONCUHHENCE

_..Whilo velding out_the peraonnel_ Igok _to_. penetration

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'... it repair lZ-59 and 2Z-59 in containment unito 1 and 2, in prococo.viouat inopootton._ _ __

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revealed that a total of nino (9) vendor. welda _and ono.. (1).atiffener_rragtured,_._

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.. _. _. _ _ Field Engeneering Disposition D4 Field Engineering Hecommended Disposition to Proj& m as c.wDr*. IIIIIMBlock 25 MND D o c, -

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23. PHOJECT ENGINEERING DISPOSITION Project Engi_neering_has reviewed the nonconforming conditions and determined the -

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The vendor veld on'the horizontal stiffener of the Unit #2 personnel locks, reported as being_ cracked. was proven to be cound by magnetic particle _ testing.

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Tlerefore, no repair is necessar_y__for..this weJd, N,' W l

2) The remaining 8 of 9 cracked vendor welds and the fractured stiffener shall be f/_ '

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> - s-78 NONCONFORMANCE REPORT (CONT *D) e easeb so.mc no.. U U j

Block #23 Project Engineering Disposition:

Wontd. from pare 131__.____..._-.._

repaired per the attached repair procedure by W. J. Woolley Co, Bechtel. vendor print _ number _1220 C-50Il.-22.4-2, and specifications.7220-C-111(Q), Rev. 11._and 7_220-C-27.(Q), Rev.

7... All the. repair welds are Eq_bs._ipopccInd by magnetic particle examination per specification 7220_C-111(Q), Rev. 11.

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S.o. m 1 WELD REPAIR PROCED*.*RE FOR

~ MIDLAND PERSONNEL AIR LOCKS FILLET WELDS BEWEEN STIFFENERS AND THE WELD COLLAR-SHELL WELDMENT, Rev. 1, 5-12-78 1.0 Prerequisites 1.1 All field welds that are to be perfomed by Bechtel.are to be completed.

1.2 Cracks are to be completely removed from the weld.

Verification of removal is to be by Magnetic Particle Inspection.

1.3 The remaining portions of the weld, in the area of crack removal, shall be removed completely. This may be accceplished simultaneously with the crack removal.

Magnetic Particle Inspection shall be performed in all areas of weld metal removal.

1.4 The areas to be welded shall be clean of all oil, grease and any foreign material that may be harmful to the weld.

1.5 The shielded metal are welding process shall be used. Welding shall be perfomed to the Bechtel Welding Procedure WPS, Pl-A-Lh that is qualified according to Section IX of the Code.

Welders shall be qualified according to Section IX of,the Code.

1.6 Process sheets or Travelers, compatible with the Bechtel Quality Assurance cystem, shall be utilized to record the weld history.

2.0 Procedure 2.1 Measure the gap between the stiffener and the shell-collar weldment. The width of the gap will determine the method of repair.

2.1.1 A gap of 1/16 inch or less will require a 3/4 inch size fillet weld.

2.1.2 For each additional 1/16 inch the required fillet weld size is to be '.ncreased by 1/16 inch. The mim gap that is acceptable for a

repair by a fillet veld is 3/8 inch. This would require a 1-1/16 E

inch fillet veld. A 1-1/16 inch fillet veld has a throat thickness of 3/4 inch.

This is the largest fillet weld that can be made without Post Weld Heat Treatment.

The gap is determined by the max 2. mum 2

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measurement plus or minus 1/32".

bl 2.2 A gap of over 3/8 inch will require splice plates to avoid PWHT. The plates

. are to be made frcra A516 Grade 70 material with Certified Material Test Reports and sculptured to fit the joint.

The maximum gap in any place, g 5

to be welded shall be 1/16 inch.

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S.o. 1 m FILLET WELDS BETWEEN STIFFENERS AND THE WELD CC*.LAR-SF. ELL F_~OME:C,Re*r.

1, 5-12-78 Icontinued) 2.2.1 The minimum dimensions of the splice plates are to be 7/8 inch thick, 7/8 inch high and one inch in length. These dimensions are on the faces ce be welded.

See the attached sketch for a g

typical splice plate.

2.2.2 Tack weld splice plates into position. Pre-heat to 200 F before any welding.

2.3 Procedure for all fillet welds 2.3.1 Tack welds, if used, shall be cleaned of all slag and ground to f air the ends.

2.3.2 Preheat to 2000 F minimum.

Temperature indicating crayons may be used; a contact pyremeter is preferred.

2.3.3 Weld the fillet welds starting at the inboard end and welding toward the outside. Remove all slag and any visible defects between passes.

Interpass temperature shall be maintained at 200 minimum.

2.3.4 Weld to required size.

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2.3.5 Welding may be performed on alternate sides to balance stresses.

This also applies to both surf aces of the splice plates.

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5 7I4 Page 2 of Z Addendum No. 1 to Weld Repair Procedure For Midland Personnel Air Locks 1.0 Purpose 1.1 The pur y se of this' addendum is two-fold.

The first is to clarify fillet weld leg sizes to meet the required throat dimension of a 3/4" fillet weld. The second is to present a method of repair of the laminated stiffener.

2.0 Fillet weld leg size 2.1 The throat dimension of a 3/4" fillet weld is.53" or 17/32".

Figure No. 1 presents two conditions that exist on the Personnel Air Locks.

The welds as shown cannot technically be called a fillet weld because of the angles involved. H6 wever, the leg dimensions shown will result in acceptable sized weld.

2.2 Dimensions of the welds shown in Figure No.1 are minimum while the angles are approximate. A small change in the angle will not affect the weld dimensions very much.

3.0 Repair of the Laminated Stiffener 3.1 The portion of the stiffener that has the ir.ination is to be cut off by any suitable means. Tipe No. 2 shows the stiffener af ter the cut off operation. The 45 cut on the lower left corner of the stif-fener is to facilitate the main cut and is therefore optional.

3.2 Surfaces of the stiffener that have been cut shall be properly pre-pared for Liquid Penetrant Examination. The procedure to be used for the PT shall have been approved by the Bechtel Quality Assurance g

System. The cut s trfaces of the stiffener shall be examined to verify c

removal of the lar.ination.

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3.3 Splice plates as shown in Figure No. 2 shall be sculptured from SA 516, m

Grade 70 material with certified Material Test Reports. The depicted 1 1/2" thickness of the plate is a minimum dimension. The maximum gap in any place to be welded shall be 1/16 inch.

y 3.4 Applicable portions of the main weld repair procedure pertaining to prerequisites, procedure and procedure for all fillet welds apply to co to the repair of the Laminated Stiffener.

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NONCONFORMANCt: HEPORT (CONT *D) 20 MNCR NO meellOhem._.

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NONCONFORMANCE REPORT (CONT'D) ecasold_ar_18 e.. aca =o 1185..._

Block 16 Con't.

For further Engineering _ disposition.

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Personnel lock. cont,ainment il and_ f2 _ __._

The welds which were_ repaired in accordance with the_ disposition.of HCR_1185_da_not moet the ti7e i

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Block 16 Con't Size ne.asured size. required Weld #3 R-15/32" 3/4" 9/32" undersize H-15/16" 3/4" 3/16" oversize i

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NONCONFORMANCE REPORT (CONT'D) e easel 6 me 18

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Block 16 Con' t Size neasured.--

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