ML19329E383
| ML19329E383 | |
| Person / Time | |
|---|---|
| Site: | Midland |
| Issue date: | 09/29/1978 |
| From: | Howell S CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.) |
| To: | |
| References | |
| HOWE-181-78, NUDOCS 8006120697 | |
| Download: ML19329E383 (17) | |
Text
-
e.
. g
% CORSu m 8IS H
H Power THIS DOCUMENT CONTAINS Stephen H. Howell C0Hipany P00R QUAUTY PAGES ve<< n<><s<,
General Of fices: 1945 West Pernell Road, Jackson, Michagen 49201
- Aree Code 517 788-0453 September 29, 1978 h
[
[
Hr J G Keppler, Regional Director Office of Inspection and Enforcement
]
Region III r?
US Nuclear ReBulatory Co= mission L'
a 799 Roosevelt Road a
B Glen Ellyn, IL 60137 goEg 50 g
em MIDLAND NUCLEAR PLAh"f -
beh UE!
UNIT NO 1, DOCKET No 50-329 9
O
,Ljh' UNIT NO 2, DOCKUP NO 50-330 M
=
"5 CONTAIUMENT BUILDING PERSONNEL AIR LOCKS g
g
Reference:
S H Howell letters to J G Keppler; Midland Nuclear Plant; Unit No 1, Docket No 50-329; Unit No 2, Docket No 50-330; Containment Building Personnel Air Locks -
- 1) Serial Howe-22-78, dated March 3,1978
- 2) Serial Hove-58-78, dated April 19, 1978
- 3) Serial Hove-86-78, dated May 26, 1978
- 4) Serial Hove-106-78, dated June 30, 1978
- 5) Serial Howe-137-78, dated August 4,1978 The referenced letters were interim 50 55(e) reports. This letter is the final report. The enclosure provides a description of the nonecnformance and of the required part corrective action which vill be complete by October 16, 1978. The enclosure also provides a description of the process corrective action which has been initiated to avoid recurrence of problems for the air locks still being fabricated by Progressive Fabricators.
Y eMR 8006 120 QG7
Enclosure:
Letter, P A Martinez (Bechtel Power Corporation) to G S Keeley (Consumers Power Company), MCAR-20 Final Report, BLc-6563 dated September 20, 1978; with MCAR-20 Final Report dated September 20, 1978 as an attachment.
CC: Director, Office of Inspection & Enforcement M
Att: Mr John G Davis, Acting Director, USNRC (15) hog g[f Director, Office of Management Information and Program Control, USNRC (1)
J
Enclosure to Houe-181-78 Bechtel Power Corporation 777 East Eisenhower Parkway Ann Arbor, Michigan u.naa,es P.O. Box 1000. Ann Arbor. Michigan 48106 September 20, 1978 BLC-6563 Mr. G. S. Keeley Project Manager CONSUMERS POWER COMPAIN 1945 West Parnall Road Jackson, Michigan 49201 Midland Units 1 and 2 Consumers Power Company Bechtel Job'7220 MCAR 20 FINAL REPORT Files 2417/2801
Dear Mr. Keeley:
Attached is the Pinal Report for MCAR 20, Containment Building Personnel Locks, for your information and use.
The Report addresses all corrective actions required and completes our response to the MCAR.
Very truly yours,
/
./
^
P. A. Martinez Project Manager PAM/WGM/pp cc:
Mr. R. C. Bauman Mr. W. R. Bird Mr. J. L. Corley Mr. B. W. Marguglio is,'
t{'.;gjg:},
Attachment (14 pages) b
'!.*ll SEP 211978 QllAUiY ash!n!;.: ICE e
\\
O y
Bechtel Associates Professional Corporation N
Attachment to BLC-6563 September 20, 1978
SUBJECT:
MCAR #20 (Issued 2/1/78)
Cracked ucid between stiffener and welding ring of personnel lock FINAL REPORT DATE:
September 20, 1978 PROJECT:
Consumers Power Company Midland Plant Units 1 & 2 Bechtel Jcb 7220 Introduction
,khisreportissubmittedtoadviseofthefinalstatusandcourseof action required pursuant to MCAR #20 and NCR 1185. Six interim reports were issued.
This report concerns the cracked fillet welds identified on NCR 1185 and MCAR #20.
The fillet we]ds cracked due to undersize weld dimensions and excessive fit-up gap. This led to concern as to the adequacy of the remaining welds on the personnel locks.
The remaining welds were inspected, and the undersize welds have been identified.
All investigation necessiry for the formulation of the weld repair procedure has been completed.
The weld repair procedure has been approved by project engineering and is included in the disposition of NCR 1185.
The revised stress report concerning the evaluation of the undersize welds has been completed. The report has been reviewed and approved by project engineering.
This report completas project engineering's action on the cracked and undersize fillet welds on the personnel air locks.
'ause C
The cause of the cracked fillet welds has been determined by Woolley and Bechtel to have been due to fit-up gap in excess of procedure requirements.
it caused insufficient dimensions of the fillet velds when they.were not increased to compensate for the gap (Figures 1-6).
The cracks developed when these weldu were stressed during welding between the weld collar and the reactor building penetration sleeve.
The undersize welds were caused by errors in fabrication that were not detected prior to the shipment of the personnel locks.
.--e
.e
Bechtel Associates Professional Corporation NCAR #20 FINAL REPORT Page 2 Attachment to BLC-6563 September 20, 1978 Deficiency While welding the personnel locks to penetrations 1Z-59 and 2Z-59 in the Midland Units 1 and 2 containment buildings, inprocess visual inspection revealed that a total of nine vendor welds between the stiffeners and the welding ring were cracked.
Figure 1 shows the general arrangement of the personnel lock.
Figures 1 and 2 show the lo' cation of the cracked welds. Magnetic particle testing was performed on these welds by Bechtel construction and it was determined that the weld for the horizontal.
stiffener of the personnel lock in Unit 2 was not cracked as originally reported (Figure 2).
The testing also verified that the remaining eight reportedly cracked vendor welds had failed.
NCR 1185 reported that one stiffener in the personnel loch of reactor building Unit I had fractured. Figure 1 shows the location of the fractured stiffener.
The extent of the undersize welds was determined in a joint inspection of accessible welds by Bechtel and Woolley personnel.
The findings of the inspection are shown in Figures 7 through 10.
Safety Implications W.J. Woolley Company, the designer of the subject locks, has advised Bechtel that the structural integrity of the inner bulkhead against imposed loading cannot be guaranteed with the cracked welds. Under normal reactor operation, both doors of the personnel lock are closed.
However, the outer door may be open for normal entry and exit to and from the containment or when the lock is being tested to verify that only one door in each lock can be operated at 'a time.
Hence, for a limited time,.the inner door may act as a primary pressure boundary.
Even though the deficiency is.not latent in nature and would have been I
detected during the structural integrity test when the inner door was closed, the deficiency is considered to be reportable under 10 CFR 50:
55(e) requirements because it exposes the primary pressure boundary to potential breach.
1 e
4 S
ma4-
Bechtel Associates ProfessionalCorporation HCAR #20 FINAL REPORT Page 3 Attachment to BLC-6563 September 20, 1978 Woolley has revised the stress report for the personnel locks to consider the effects if all fillet welds were undersize similar to those shown on Figures 7 through 10.
Additional calculations were performed on those welds considered critical in the undersize state.
The revised analysis concludes that possible undersize welds of the magnitude reported would not affect the structural integrity of the lock and would pose no potential breach to the primary pressure boundary.
Corrective Action The veld and nondestructive examination procedures used for the subject fillet welds have been reviewed by project engineering.
It has been determined that groove weld procedures, reviewed and approved by project This substitution engineering, were substituted for fillet veld proc'edures.
of procedures is permitted under Section IX, Subsection QW-202.2 of the 1974 ASME Code. The nondestructive examination technique and the acceptance criteria used for these welds were also found to be acceptable.
The documentation for the personnel lock has been reviewed by the supplier quality representative. Minor descrepancies have been discovered and are Resolution is to be completed by October 1, being resolved with the vendor.
1978.
The repair procedure for the deficiencies described in NCR 1185 has been completed by the W.J. Voolley Company.
This procedure has been reviewed and approved by project engineering. The disposition of NCR 1185 specified the cracked welds be repaired per this procedure and Specifications that 7220-C-111(Q) and 7220-G-27(Q).
The repair welds are also to be inspected by visual and magnetic particle examination per Specification 7220-C-The weld repair of the personnel lock is to be completed and in 111(Q).
compliance with Specification 7220-C50(Q) by October 16, 1978.
Bechtel's supplier quality representative (SQFl h't1 increased inspection "w' Beintel SQR has specifically of fabrication'on Woolicy purchase orders.
elding, and documentation been instructed to ensure that the materist,
for the emergency air locks currently ba ar; f
- deated meet all applicable code and specification requirements.
e 9
9
Bechtel Associates Professional Corporation MCAR #20 FINAL REPORT Page 4 Attachment to BLC-6563 September 20, 1978 Woolley has increased their surveillance of fabrication performed by Progressive Fabricators, fabricators of the personnel lock.
The emergency air locks, currently being built by Pro-Fab, have been inspected for proper welding and documentation.
In future contracts Woolley will have an increased number of witness-points, including the inspection of fit-up for critical veld joints.
The revised stress report for the locks was performed by Woolley and determined that the welds are structurally adequate in their present condition.
Therefore, no further corrective action vill be necessary for the undersize welds.
Submitted by M,
Reviewed by
\\
v Approved by M_ M i A izd 1 % 5 A Y
d RB/ cap 9/7/2 e
e
m travwmesas wesws -
/l S:ptemb:r 20, 1978 Attachment to BLC-6563 N
- h f~
"h STIFFENER li X
l
]
\\\\^
\\
ll li ll
\\
>i
^--
\\ e
\\\\.
/
\\k_
l[
h s:q
=--
16 N
- j N
h.-
LOCATlON 9/32 FR4cTugED.
STlFFENER
~
REACTOR BLDG. **1 GAPS BETWEEN THE STlFFENERS
~AND THE WELD RING
~
FIGURE 1 e
I b
MCAR UN@ 1r10$& kIQK@Cf September 20, 1973 Attechment to BLC-6563 Y4 x.=
ll
~
32
/
l l
- l
\\
ll I
l n
N ll
\\
/
flFFENER
\\
~
ll2 REACTOR BLDG.#2.
' GAPS BETWEEN THE STIFFENERS AND THE WEED RING
. FIGURE 2 4
)
b t4 T".
2.
W 7 O 9 E. L LUC-DE3C-227I U15ET cb kSD0tL"T'.
MCAR #20 FINAL REPOR~
September 20,'1978 Att. to BLC-6563 U.L.
'}yR c.) ? ? E R f,
mar u;e s s
G-4 3
h S.
s
\\
Yi
.4Mi$
%,e
.f 3
O t_.w.
t
' s p-N
\\fg L L'
\\
9
\\q
\\h I.
/,
co$ {t.
j~
3;%.y
/
4N./
r W@V
'/e,, /
W
/
- s,;4+yo;,
.- n
\\.
,a f
\\
t*
.y o
A [Sh
~
f
\\
U PP E R.
l' LEFT vg-N' t
(
75 M
U FIGu m 3
7 Sept. 20, 1978 Att. to BLC-6563 Co.or, 2.
e Lowse LEFC gf
=~
N
- ai / ~
W1-wg(
6
~
i V
24
- p/
}
2.
J.** i L J.,%.
j s--
s
~
y
~MTh e
Erra g 6
N r.
[+
h 1
x
/r,<a w )-
N'
./~
/
& '842
\\
A
+
N Q
..i. ~
5
(
.. f,. _.
,, p
.p
~
s, w,
\\g il
\\
- hlGURE 4-
\\
3cAn $20 YUUd E#0 p
.(oC.%
e C. dot-(
P' b -
.))J E b sspeceber 20, 8
~
AttEChCCUt c-656%
gow er N E. L D gg avu f o
,3g b (q) i f
~
- 3. \\ G6 D.W J
3 x g
b
+
' ]&.
43s.
T y
L p" j:p p ':.- x v
a u.%.
t
- g.
1 g,y y /, ---
e y
/
/
\\
.\\
\\'
s
%'x
.*g tp** es t.t.
t.v..
si t\\
1 v;Oh8 ru k o
pr.r or so x
+8 32.)
- V,,.
g A
wm.
l U ?? 6?~
.P Md>
Leer t
\\ and
'f p
/
/
4 N.1 g,
~2 s.
d.
v e
FtGoRE 5
C '.
~.
~
Sept. 20, 1978 Att. to BLC-6563
, (, o p y., [
Lowea t_ c es-l
..A te
+5
.b 'NN 1
)
(
/
f %,,
=
is V
^W 4
/
i
- e.
LQ-G N'/'h y.
%c
/
<M Lowce
% uwr v_
\\
f
'/d# h 8
gy.
Ys4A
/
X
\\
.c A c a-5 1
- b*
./
Sie
(,8 )
FIGURE 6
nviu..
N\\/Et.D kU 'SH2E'T~
UNIT #~l NOTE.,'s,-THROAT OF FilldT -
WELD f, SHCRT)
I
. o
.= m-mu p.g.h gyp.: 7, t
gy g
.. a 313 M:a J S
I
_m - _u w w-O'
\\
a=,s.
4 3
04 Y; sr-10 ?
"'n)
- s..
.#..... -g
\\
)
v 3
.A
~.
.,.o._u.e.
.. g c~dh
/ U
- = ';:.7 r-t;&;;
y
-- n.y k
,t
$u-7N.,,,
i T N N 'y $.d g,
~
=.
9 l@j l,
93 iLOEC I Iff jyM-
.y l
,i a
.. _ _.. I g i
tm nnam_ s_e M, e. -a., ;p.bf_
naw 74.
' ll :1 i
I ) n
\\ !' 4 i
I l-I t. *i
- .,,w' -
!e 'l 2
l l
ti
-[;
.,i,'..,
1
.i.
-l t :y~ -
1
_ - -n.,
,l y l;;
\\
...a.. 4,M :.~.
g O
14E l \\ f %,h * ' X gD ,j _ p
- y:-
g
<=:-
wrc c : b mf (. " _. O. ' E. ~ l NOTc'h" n c !i u I SEE _,aw% ,jemw_ 'a .NorEA' _ag%c SEE NOTE 7A" i i lt l ~ e ,e
- i W. J. Y.C OLt.E'" Cg 7CT~-
'.~. -~ . E.~ It B5t m*Wh*WWYWu_ w]i C f
r-Anaus_ur.: :2.
M.. i t.M* '. ia. 2;.:; : f.. ;.:- t A 1.:iw n.. .m..,.,,,,, I ,,,,,-p,.._ .....:.,,.........:~,. !l
- I.
ER?5F W ffI!.?#.5 l.r:y r; + FIGUR'E. 7 L.i _ - Attachment to BLC-6: September 20,,1978 MCAR #20 FINAL REPOI
NOTE. A Lt# OF FTCT E I-f" WELO jU" SHORT.- it UNIT i e N g __rt_gv estt ket . %**t LL _ ".n,m., s', a sMg., . c..w) s.- s og a q yg num SEC Nor6,h,, ,e, n...s l W hl -I = l -~p,,. \\'. psf <lMl/..NN,- JDF o /i
- - !P N I
I R_ N/ [!. i i=;.% s.gs 5-
- gg,
_t,[' 4-i.,.?.. l O.,..3.... I 'O_.. sr p ..r r i l t s /, l., i-- ,l .= i t ' 8,l 1 \\*# ) -l .s...* 2 '..g" ' C. i [. L .-l - ~ {i_.. -*f *""* *- 'f.,.i,- ~ - f., 9.,, ir .;tortfQ:r
- y >..
J.... I, ;,, 4l - - _e. a. e .4 ,r. V .L p n n - p. m, c o a J..- s. i 1 y.- ..\\\\g. om + [< . c .--~ g->.j a i 4 -~. l f C ,w l_
=
b e ) ") I s %,. L '. l ...i o . w _M*O9
- Alf
- ?-M.
TEwgA i.N1 4:3- -kT + )$ !WCWr,,,N_ ~ * }
- t *'eu 'k k'
_n I ) ,r.==.r. f~ - w.a wec..u. cr co i .... ~ cosm .,tn.,., u..m,sso.s.g., .%g - - - -- g mcy) I et* - - " -1.:. A U. +.ap.:.. GC. :0':)?....- . %.....A,.;... s s e ,, : :,5_ .. r r.. _ . _.. _....,..,,.. _ _ f,,, ;, ;, _.,_.,_- U E8
==.:.===.==2.= :.... :: :..:.:..- - -=-====.=*:._... ' =: Att. to BLC-6563 September 20,.1978 MCAR #20 FINAL REPOP
~ g .i !. l.. WELD )[6 SHoRT yg NOTE B"- LEG OF FILLET.., WELD J6' 5HoRT ' GEE NOTE'c,, SEE NOTE =A* n ME NM"A .== mm -p2:gy g-
- m.
gg 'D g3 I io y e I l n l I \\g). ,,m 'n2 -r w2 v.m i t..., c.%,..I = " _,,.Q T3 c c-d';.- U I ..I,G t.L.x: 3 ..in... _60...,.g/I f3[/,p: . -.:g(,. A., - 'S i '.' 1. u N I
- . (...*
- = 3.s...h
= i y
- , N, l;
9 l[I;h! i{ 22 ',hhf; d.;.'fbs If },f", ~ T 5-l M"tT@r[',, C d, '. -hlh j j fI{i.l .di, ,- f'lE: . ;. -j.. .gm = i. I SEE 8 b-ffr.- r N 3. I ~i uh ~ I ' er-~'--- t Fq i'. ,i )]OTE"B" "\\ r} ~ i
- _2 ;
,s m i :u i. . u. . - h,. i g x . i -i l Q' -'~-t-S93,y c :! g_ _,___.,g' jy // \\.r5-;.g;. fg. f_If_j'M 'E.j~ j.... p. r - - - -- -- - -.-- -- e _. g-g, i . f l. qtgzsa 6 i; =- e
- U g
gm g. N ip y ll N l sm.m I I 'I c ~ 8'W ' < m . AMh% <,m e STWh NOTE"c"- TliROAT OP FitIET j WELD C SHORT, t \\ l ,,rgy..,_=. -+- W. J. WCOLLEY CJ .. =.;."...:z.. ..;;-l- = -l-gm yee- '-"- tm_ l wau. u:s:: z-g
- r..o..c.::.t.m..c. : v..,.-
4.,......,..,.. i, .~ 3.
- qq',g
...n ...n.._..,..----- tl plavRg 9
- -.:. :- :: :=.:~. ::.::.:.=:: r:-
. =.. .. - + I.s._ Att. to BLC-6563 September 20,.1978 MCAR#20FINALREP
WELD g SHORT UNIT 2. s S*pMN-;,q_, 14Sitts-- Miff. ' .rca3 c.= a s M NW g pg mo-s , -..i ev..s. } l /;l [E'% 1 I \\ ,- m. 'm'=, e 7,w..v.y-..._ ;- e ~.:- ' .-;3.n .r. _ - .M -c .. g- -dt._.l_ / L_d '.,. t p- .\\ i' b p-l y.c.. ...'l s o l \\. f .k. i p." U U. .::uw v /" %.. i .'T - A :-;.f,.. . j. . [. !j-.. b:'
- ..l, q.,. w...?
i 1
I M.i. _ l;:4' r li __. i. n +.i l q i __c,_ -.s. kN IN .,)52_%.x,l. Mslhl l d M I s. I p-I + I: I 7 j 7 $.h.' Y...t. Y. . _ v, s s N% ' -... __h .~ Ng' -Q[ 7g-t / %.e" i. t-l- SEE NOTE T Sw
- e
-h,m,.u m.. .m. - k3C 2l. R** 1 E. t l ggg,,-
- s., mu
.s..s _ s.ev m A.< n I .I l1 -==r W. J. WCCLLEY C< trO%'u'%.TJ...... ".;..;., =., .. r== - : r - - -.. _ -. -" " 2.r ' u Q'y g A ... -Q u....= '. :s
- 1...e.. s.'
- .i 'G.1.:&..1 *. 2.
3..,....,,..... .e
- 4
..i... ....,.., r T,., c ~......,n,,y....... FIGURG \\O 22.:.=-.:::5. ".: r=i :.56".=w.?i.:!.=.. ~.:=...... r =-...:... - --.- m =:.. =.- : :=: :. .~..-. l. t. Att. to DLC-6563 September 20, 1978 g MCAR #20 FINAL REPOJ
(OfO "f(
- e REGULATORY INFORMATION DISTRIDUTION SYSTEM (RIDS)
DISTRIDUTION FOR INCOt1ING MATERIAL '330 REC: KEPPLER J G ORG: HOWELL S H DOCDATE: 09/29/78 NRC CONSUMERS PWR DATE RCVD: 10/03/78 00CTYPE: LETTER NOTARIZED: NO COPIES RECEIVED SUBJECl: LTR 1 ENCL 15 FORWARDING FINAL CONSTRUCTION DEFICIENCY REPT CONCERNING CRACKED WELD BETWEEN STIFFENER AND WELDING RING OF PERSONNEL LOCK W/ATT SUPPORTING AND RELATING INFO. PLANT NAME: MIDLAND - UNIT 1 REVIEWER INITIAL: XJM l&]Q MIDLAND - UNIT 2 DISTRIDUTER INITIAL:
- n************
DISTRIDUTION OF THIS MATERIAL IS AS FOLLOWS ****************** CONSTRUCTION DEFICIENCY REPORT (10CFR50.55E) (DISTRIBUTION CODE B019) FOR ACTION: ASST DIR VASSALLO**W/ ENCL DR_CHIEFiLWR#4 BC**W/ ENCL ~ P _ MGR D HOOD **W/ENCE LIC' ASST LWR #4 LA**W/ENCE INTERNAL: REG FILE *'J/ ENCL NRC PDR**W/ ENCL s i a b**W/ 2 ENCL OELDu*W/ ENCL GOSSICK & STAFF **W/ ENCL MIPC**W/ ENCL DIRECTOR DPMu*W/ ENCL DEPUTY DIR DPM**W/ ENCL QAB**W/ ENCL DIRECTOR DSS **W/ ENCL AD FOR ENG**W/ ENCL AD FOR REAC SFTY**W/ ENCL AD FOR PLANT SYSTEMS **W/ ENCL AD FOR SYS & PROJ**W/ ENCL SYANDARDS DEV.**W/ ENCL K SEYFRIT/IE**W/ ENCL FERD DREHER/TE**W/ ENCL EXTERNAL: LPDR'S ~ MIDLAND, MIM*W/ ENCL TERA **W/ ENCL NSIC**W/ ENCL ACRS CAT A**W/16 ENCL DISTRIBUTION: LTR 41 ENCL 41 CONTROL NDR: 'JM3i4Fff SIZE: 1P+1P+14P g annooc***************************** THE END
- Mh***
-}}