ML19294A513

Significant Deficiency:During Installation of Embeds Supplied by Acme Steel Engr Co,In Nonsafety Related Area, 1/2 Nelson Studs Found to Be Defective.Nonconformance Rept to Be Issued 781208

ML19294A513
Person / Time
Site:	Hope Creek, 05000355
Issue date:	11/22/1978
From:	Martin T Public Service Enterprise Group
To:	Grier B NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I)
References
NUDOCS 7812070224
Download: ML19294A513 (3)

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Thomas J. Martin Public Service Electric and Gas Company 80 Park Place Newark, N.J. 07101 201/430-8316 Vice President .t we a:.. s Engineering and Construction November 22, 1978 Mr. Boyce H. Grier, Director U. S. Nuclear Regulatory Commission Office of Inspection and Enforcement Region 1 631 Park Avenue King of Prussia, Pennsylvania 19406

Dear Mr. Grier:

FAILURE OF NELSON STUDS , ,

10CFR50.55(e), "SIGINIFICANT DEFICIENCY" - 05 '-

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- NO. 1 AND 2 UNITS . *-

HOPE CREEK GENERATING STATION v '

On October 26, 1978 a verbal report was made to Regioh 1,-Office . < t" c -

,.'s of Inspection and Enforcement representative, Mr. S. Ebneter,' "'^

advising that a potential significant item regarding 1/2"' Nelson .

studs had been identified. This verbal report was provided' in r =1 a accordance with the provisions of 10CFR50.55(e).

The following supplemental information is t'ereby submitted pur s ua n t: .- .6, to our initial report and in accordance with the requiremebestof ' '-

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10CFR50.55(e): I ' ' ' - --

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1. Description of~the D e f i c l e'n c y : *F -

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During installation of embeds supplied by AcEe Steel - '

Engineering Company in a nonsa'fety related area,'several 1/2" Nelson studs were'f6~dhd to be de'fective. An inv e s t'i-gation was performed whereby approximately 500 studs on installed embeds (none of which were 1/2" size) in the safety related areas were tested and revealed no similar problem. However, a shi~pment from Acme Steel in the laydown area revealed a. failure rate of aproximately 15% for the 1/2" size. ,.

It was determined by in @e s t ig a t t6ht ha t the defective:l/2"

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studs were welded without an approved procedure. The.

amperage being used during welding was too low and the D.C. lead was incorrectly terminated to the power generator, b

No\ D

'8120702 2 S

Mr. Boyce H. Grier, Dir. 11/22/78

2. Analysis of the Safety Implications:

Bechtel Engineering reviewed all embedded items with 1/2" Nelson studs supplied by Acme S teel. Their analysis was based on the conservative assumption of failure of all 1/2" Nelson studs identified to be installed. It has been concluded that had this condition remained uncorrected and stud failure occurred on certain embedded items, the safety of operations could have adversely been affected.

3. Corrective Action:

Bechtel's Field Construction placed a hold on all safety related concrete placements containing Acme Steel supplied 1/2" studded items. Nonconformance Reports Nos. 368 and 369 were issued to identify the stored and installed embeds that are involved and a list was given to their engineering department for determination of safety implications. The disposition and corrective action to be taken for the Nonconformance Reports is scheduled to be completed and issued to the field by December 8, 1978.

Bechtel conducted an investigation at Acme Steel and initiated the following corrective steps:

1. Acme weld procedure was updated to include 1/2" studs.

2. Eqisipment Maintenance / Calibration Program per Nelson Stud Company instruction manual was initiated.

3. Operator training and requalification was initiated to comply with requirements of AWS Dl.l.

4. Bechtel's supplier representative was instructed to increase surveillance and add stud welding / testing operations as a witness point to assure compliance to approved procedure and AWS D.l.1 until confidence is ret sred that Acme can supply satisfactory material with stud .

4. pethlehem Fabricators Inc. Supplied Material:

During receiving inspection of structural steel furnished by Bethlehem Fabricators, Inc., it was noted that the Nelson Steel Welds did not meet AWS requirements. Further investiga-tion by bend testing studs on installed beams resulted in three of seven failures. A full investigation into this problem has been completed and it has been concluded that had the defective studs identified remained uncorrected, they would not have adversely affected the safety of operations of the plant at any time throughout the expected lifetime.

Mr. Boyce 11 . Grier, Dir. 11/22/78 If you require additional information, we will be pleased to discuss it with you.

Very truly yours, ORIC C;CNED BY.

T..J. 9:ARTlN CC: Mr. J o hn II . Davis Bethesda, Maryland

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