ML19329E419

Interim Deficiency Rept Re Defective Welds in Containment Bldg Personnel Locks Which Attach Stiffners to Lock Structure.Bechtel QA Program Mgt Corrective Action Rept MCAR-1,780301 Ltr & Interim Rept MCAR-20 Encl

ML19329E419
Person / Time
Site:	Midland
Issue date:	03/03/1978
From:	Howell S CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.)
To:
Shared Package
ML19329E418	List: ML19329E419
References
HOWE-22-78, NUDOCS 8006120766
Download: ML19329E419 (8)

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March 3,1978 Hove-22-78 Mr J. G. Keppler, Regional Director Office of Inspection and Enforce =ent US Nuclear Reguletory Co==ission Region III 799 Roosevelt Road Glen Ellyn, IL 60137 MIDLAND NUCISAR PLAhT -

UNIT NO.1, DOCKET NO. 50-329 UNIT NO. 2, DOCKET NO. 50-330 CONTAIIMEM BUILDING PERSONT:L AIR LOCKS In accordance with the require =ents of 10 CFR 50 55(e), this letter c'onstitutes an interi= report of the status of the contaic=ent building personnel locks vhich have nine defective vendor velds (four in the Unit i lock and five in the Unit 2 lock) used to attach stiffeners to the personnel lock structure.

A co=plete description of the defective conditions, the analysis which is being conducted to deter =ine the safety i= plication of the defects and the plan to obtain corrective action are docu=ented in the attach =ents to this letter.

Another report, either interim or final, vill be sent on or before April 21, 1978.

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8006 120 Q Attach =ents: 1) Quality Assurance Progrs=, Management Corrective Action Report, MCAR-1, Report No. 20

2) Letter JMKlackin6 to WRBird, BLC 5623, Interim Report il for MCAR-20, with attached report. .

CC: Dr Ernst Volgenau, USNBC (15)

Director, Office of Management Information and Program Control, USNRC (1)

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Attachment 1 Howe-22-78

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QUALITY ASSURANCE PROGRAM MANAGEMENT CORRECTIVE ACTION REPORT MCAR 1 g glg 20 REPORT NO.

1.1013 DATE Februarv 1, 1978 o no.

JOS NO. 7220

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• DESCRIPTION (including referenen):

13, paragraph 7.4, locks and hatchesPer must AS 2;beSection constructed Per Spec. 7220-C-50, Rev.

N VIII, stenped in accordance with the ASME Code for Class l in B of the vcid aren (based en minicum leg di=ension), the allovabic efficiency of 55 percent. stress va ue tension of the material being velded, and a joint Nonconformance Report f1185 was written because in process visual inspection for the contain=ent personnel lochs revealed that a total of nine

• RECOMMENDED ACTION (Optionall

1) Determine'the cause and extent of the failure.

2)

Deter =ine if an apprcved procedure was followed by t.hc canufacturer ssure a the procedure and the nondestructive ext.=ination of the velded joints to a that the inspection technique and acceptance criteria were acceptabic.

proper approval 3)

Deter =ine the extent of the required repairs and assure that procedure vill be utilized for the necessary repair work.

(cont'd.)

CONSTR UCTION QA MANAGEMENT REFERRED TO X ENGINEERING e*

• Fotentially Reportabic Pending ISSUED t% Md::pN i

y[jI Results of Investigation [o/q.Mdse

, 4sa IFIED CLIEllT_ Feuruarf 1, 11 REPORTABLE DISCPEPANCY s' - b b< U

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111 CAUSE CORRECTlvE ACTION TAKEN AUTHORIZED BY om

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oest minutioee: J. B. Violette FORMAL REPORT TO CLIENT tu sociioa n 4pe ..is s

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c.. T. M. Leverette .

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G. L. Richardson

%. < e. c T. Amaral (Gaithersburg) CORRECTIVE ACTION IMPLEMENTED -.

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Move-22-78 Page 2 of 2 l

• MANACDIC;T CORPICTIVE ACTION REPORT (!! CAR-1)

Report No. 20 Page 2 t l

l Descriptiott (including references): (cont'd.) i I

2) fractured. These fractured for contain=ent 1 and five for containment welds attached the stif feners to the personnel lock structure and were to Investigation for the fractured velds be of 3/4 inch fillet vcid.

confirmed that the veld fit-up gap between the stiffencrs and the loch structure cessured approxicately 1/2 inch and, contrary to' the AS:E require =ent, this excessive gap reduced the effective 3/4 inch fillet veld leg. .

Recor= ended Action O Determine reportability under 10 CFR 50, Section 50.55(c), as soon as possibic. Prepcre an interi= report and incue to the together Projcet l'sns:;tr with a

' within 15 days containing cil availabic information, statement as to when a complete report vill be issued.

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Attachment 2 s* Howc-22 -(8 Bechtel Power Corporation 777 East User. Sower Parkway Ann Arbor, Michigan 7 an.nas,ess P.O Box 1000 Ann Atbor,u.e.e.g,n n March 1, 1978 BLC-5623 Consu _crs Power Cocpany Mr. C. S. Keeley Project Manager 1945 West Parnall Road .

Jackson, Michigan 49201 Midland Units 1 and 2 Consu=ers Pouer Company -

Bechtel Job 7220.

IN1' ERD 1 REPORT 1 FOR MCP.-20 Files 2417/2801

Dear Mr. Keeley:

, Interi Report 1 addressing the cracked welds in the contain=ent persennel locks is transmitted for your information and use. The report provides a description of the proble=, a statecent of safety implications, and a status of the corrective actions.

In addition to the report, ve offer the follouing inforcation. W. J.

Woolley has been requested to evaluate the structural integrity of the cracked inner door to determine safety irplications. Bechtel has been infor=ed that the structural integrity of the inner bulkhead against imposed loading cannot be guaranteed i:. its present state. Under normal reactor operation, both denrs of the personnel lock are closed. However, the outer door ray be open for norcal entry and exit to and from the containcent 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 Intent in nature and would have been detected during the structural integrity test when the inner door uas closed, we feel that the deficiency is still to be considered reportable under 10 CFR 50:55(e) requirec.cnts as it exposes the pri=ary pressure boundary to potential breach under a ce=bination of cost unfavorable conditions.

Very truly yours, f

. .- "O P. A. Martinez Project Manager

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INTERIM REPORT FOR NCAR # 20 SUBJECT CRACKED WELD BETWEEN STIFFENER .

AND b'ELDING RING OF PERSO::NEL LOCK .

MIDLAND PLANT L"iITS 1 & 2 JOB 7220 5 1 SUBMITTED BY:

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APPROVED BY: g s d '.

CONCURP.ENCE BY:

REPORT'DATE: 2 - /7- 78 Se t ._

• INTRODUCTION This report summarizes Project Engineering's action on the problem of cracked welds between the stif feners and the velding ring of the per-sonnel locks of the Containment structures.

The evaluation of the problem and the actions requested on MCAR No. 20 cannot be completed until further input is received from W. J. Woolley &

Co., the vendor for the personnel locks. They will be included in the final report scheduled to be coopleted by March 31, 1978.

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DEFICIENCY While velding the personnel locks to penetrations 12-59 and 2Z-59 in the -

Midland Units 1 & 2 ccntainment buildings, in-proccss visual inspection revealed that a total of 9 vendor velds between the stiffeners and the

- welding ring were cracked. Figure 1 shows the general arrangement of the personnel lock. Figure 2 shows the location of the cracked welds.

• SAFETY IMPLICATIONS W. J. Woolicy Co. has been requested to evaluate the integrity of.the' inner door and the adjoining barrier under design loads t,aking into con-sideration, the deficient welding between the stiffener and the welding collar. The results of this analysis will be available by February 28, 1978.

Bechtel has been infor=ed that the outside barrier and door' design of the personnel locks is adequate to withstand imposed loads should there be a failure of the inner door. W. J. Woolley is being requested to perform a complete evaluation of this aspe.ct.

Based on present inf ormation, the failure of the welds does not appear to have any safety implications. On completion of the analysis by W. J.

Woolley, the safety i=plications vill be discussed in detail in the final report.

CORRECTIVE ACTION Dne of the cracked welds has been ground out in the presence of Bechtel personnel and the W. J. Woolley representatives to examine the extent of the crack. It was found that the gap between the stiffener and the weld collar is approximately 1/2 inch.

l W. J. Woolley has agreed to submit a repair procedure to Bechtel for  ;

review by March 15, 1978. On receipt of this report questions regarding cause and extent of the failure will be addressed. The existing and repair veld procedures will also be discussed in the final report on the subject MCAR. ,

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