ML19329E430
| ML19329E430 | |
| Person / Time | |
|---|---|
| Site: | Midland |
| Issue date: | 05/12/1978 |
| From: | Howell S CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.) |
| To: | |
| Shared Package | |
| ML19329E424 | List: |
| References | |
| HOWR-75-78, NUDOCS 8006120802 | |
| Download: ML19329E430 (9) | |
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j CompEny Generes Offices: 212 West u6cnsgen Avenue. Jackson. Michigen 49201
'May 12, 1978 Howe-75-78 l
l Mr J. G. Keppler, Regional Director US Nuclear Regulatory Commission Office of Inspection and Enforcement Region III 799 Roosevelt Road Glen Ellyn, IL 6013T MIDLAND NUCLEAR PIANT -
UNIT NO. 1, DOC M NO. 50-329 UNIT NO. 2, DOC M NO. 50-330 SEISMIC CABLE TRAY SUPPORTS In accordance with the requirements of 10 CFR 50 55(e), this letter constitutes an interim report of the status of nonconforming velds in cable tray supports.
Attachments 1 and 2 to this letter provide a description of the nonconforming conditions, corrective action plans and a report of the initial actions taken.
Another report, either interin or final, vill be sent on or before June 30, 1978.
k Attachments:
- 1) Quality Assurance Program Management Corrective Action Report, MCAR-1, Report No. 23, dated April 17, 1978.
- 2) Interim Report #1, dated May 1,1978, MCAR-23, Cable Tray Support Construction Welding Discrepancy.
CC: Dr Ernst Volgenau, USNRC (15)
Director, Office of Management Information and Program Control, USNRC (1) p.ru 151978 1
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Att chm;nt 1 How0-75-78 QUALITY ASSURANCE PROGRAM MANAGEMENT CORRECTIVE ACTION REPORT li MCAR 1 2
REPORT NO.
JOB NO.
- 7220 Q NO.
3.005 DATE April 17, 1978 1 ' DESCRIPTION (Including references):
Seismic Cable Tray Supports were audited by CPCo on August 29, 1977 (F-77-31) and found that welding of raceway supports did not comply with design drawings.
The drawings called for transverse welds, and on two type 3 supports, longitudinal welds were used.
This was resolved by Specification C-304 revision to allow Field Engineering to approve additional welds.
Bechtel QC perforned an inspection of seismic cable tray supports in the Cable Spreading Room Elevation 646 on 10/13/77.
There were 59 Hold Tags applied on columne
'RECOMME'NDED ACTION (Optional)
(Contd)
- 1) Project Engineering evaluate the conditions on NCRs 1287 and 1306 and provide disposition.
- 2) Project Engineering determine if the remainder of the fillet welds on electrical supports not reinspected can be deemed adequate without further reinspection or if additional reinspection is required to provide confidence that the as-built condition meets design requirements.
3)
If reinspection of additional welds is required, Quality Control is to establish a schedule.
(CONT'D.)
REFERRED TO ENGINEERING X CONSTRUCTION OA MANAGEMENT
- Potentially Reportable ISSUED B MI r ] M '4/21/78
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11 REPORTABLE DISCREPANCY N
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CORRECTIVE ACTION TAKEN iF; s
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.,4 MCAR-23 April 17, 1978 Page 2 I
DESCRIPTION (Including references):
(CONT'D.)~
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in the lower spreading room because of coarse ripples, high crovns, excessive convexity and undercut.
NCR-987 recains open.
'e Inspecticn of seismic cable tray support installation was audited by CPCo on December 21, 1977 (F-77-45) and found that fillet welds were undersize and painted.
The weld had not been accepted by QC.
The action was closed by preparation of a Discrepancy Report to document incomplete work and assurance that welds would not be painted until after inspection.
The NRC performed an inspection on March 21, 1978 and found that cable tray supports in the cable spreading room had several* unacceptable fillet welds.
This is a potential item of nonce =pliance, as the inspection report has not been issued as of this date.
Bechtel QC reinspected ten (10) vrirtical columns consisting of forty (40) welds in the lower spreading room, elevation 646 feet, to determine if the NRC 7
finding is an isolated case.
All ten columns were detected to have undersized welds. NCR-1287 was issued March 23, 1978.
This reinspection was performed using the same criteria and instructions as the original inspection, but after training of the inspectors by QC on how to measure fillet welds.
The Project Manager called a meeting en 3/24/78 with the Project Engineer, E1cetrical APE, and the PQAE. A telephone discussion with the Construction Superintendent and the PFQCE resulted in t.he following action items.
1)
Construction Superintendent to determine why undersize welds are occurring and to instruct welders on the icportance of making welds within specifica-tion tolerances.
- 2) PFQCE to perform 100" reinspection of cable tray supports until further notice.
- 3) Project Engineer to determine acceptability of welds, disposition NCR-1237 and determine if a revision to Specification C-304 is required.
- 4) PQAE to review Quality Trend Analysis charts to determine if Discrepancy Reports (DRs) prepared during in-process inspection of electrical cable tray supports involved velding problems.
The PQAE was also to de'termine if the original inspection was performed before er after Specification C-304 had been revised to include weld size tolerances.
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MCAR-23 April 17, 1973 Page 3 I
DESCRIPTIO;1 (Including references):
(C'0NT'D.)
A reinspection made on 4/13/73 of completed fillet welds in the louer spreading room, elevation 646 feet, found 550 welds out of 2058 inspected, unacceptable to the latest criteria of Specification C-304, Rev. 3, plus SCN-8002.
Rejected welds consisted of oversize, undersize and weld defects.
The rejection rate for colu=ns was 50.5%; for unistruts,12%; and for cross-overs, 27.6%. NCR-1306 was issued April 13, 1978.
The Project Manager called a meeting on 4/20/78 of the Project Superintendent, Chief FQCE, Chief Civil Engineer, M&QS Supervisor, QA Manager, PQAE and other project representatives to discuss the safety aspects of the discrepancy as well as recc= mend corrective actions.
The discrepancy is considered potentially reportable until completion of a structural analysis.
RECON 1DED ACTION (Optional)
(CONT'D.)
- 4) Project Superintendent provide instruction to the responsible craf ts, supervision and field engineering personnel to assure they clearly under-stand the welding require =ent.
Completion of this action is to be documented.
- 5) Quality Control to evaluate the existing instructions and training for QCEs in this area and take any further actions, if necessary, to assure proper inspection of all future fillet welds.
Docu=ent results.
- 6) Quality Control to evaluate the need to inspect support velds prior to installation of cable trays.
Document the results of the evaluation.
- 7) Request Project Engineering to prepare an interim report and issue to the Project Manager within 15 days (May 1,1978), containing all available information, together with a statement as to when a co=plete report will be issued.
The interim report is to address clearly the question of reportability.
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Att:chment o
"" Att. to BLC-5918 Howa-7pT8 Bechtel Associates Professional Corporation 777 East Eisenhower Parkway Ann Atbor, Michigan v.
undAmess P.O.Gox 1000. Ann Atbor. Michigan 48106
SUBJECT:
11 CAR #23 (Issued 4/17/78)
,Y-Cable tray support construction welding discrepancy INTERD1 REPORT #
1 DATE: 5/lI78 PROJECT: Consumers Power Company lfidland Plant Units 1 & 2 Bechtel Job 7220 General This it terim report is prepared in response to }!idland Project ?!anagement C>rrective Action Report No. 23 dated April 17, 1978.
Project engineering's action following the issuing of Nonconformance Reports 1287 and 1306 up to liny 1,1978, is summarized in this report.
Engineering Evaluation on NCRs 1287 and 1306 NCR 1287 was issued by Bechtel QC on 11 arch 23, 1978.
This report contained the reinspectibn report of 10 vertical columns consisting of 40 welds in the lower spreading room at elevation 646'.
All 10 columns detected undersized welds. NCR 1306, issued on April 13, 1978, reported 550 weld discrepancies out of 2,058 inspected welds.
The discrepancies consisted of oversize, undersize, and weld defects in the lower cable spreading
. Engineering's evaluation effort is to examine the adequacy of the room.
cctual reported weldsize to the specified-design load at each t'onnection.
Problems 'related to oversize, weld defect, and violation of futa.: minimum weld size were evaluated by Bechtel wel. ding engineers.
4 There are four groups of typical connectons reported in the NCR 1287 cud NCR 1306.as shown in Figures 1 through 4.
Evaluation of the undersized weld is performed by examining the maximum load-carrying capacity of an u.ndersized weld connection to the minimum required load-carrying capacity from structural analysis of the support system.
End returns are in general not considered in the design evaluation.
Engineering's evaluation has concluded that both the undersized and eversized welds reported in both NCRs meet design requirememts and project design criteria and is not a significant deviation from performance EPecification.
(See CPCo Note. 1)
Howeve$, for the undersized welds, the minidium weld size required by AISC code was not accomplished and the oversized welds exceeded Specification 7220-C-304 Rev 3 requirements. ' Engineering is presently evaluating code and specification deviation cases as well as any possible adverse effect to the weld strength.
CPCo Note. 1:
This parag aph should be interpreted to say titat structurat design requirementa are not violated and tite deviat.Lon wilt not affect pcAformance.
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t Cable' Tray Support Welds for Areas Not Reinspected
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NCRs 1287 and 1306 reported weld' reinspection results limited to the lower spreading room at elevation 646' only.
Data obtained from these reports is sufficient to evaluate the weld c.o.ndition..in this arca, however, it is inadequate to extend these results to' evaluate welding in other areas.
This is due to the lack of sampling data obtained from other rooms.
To evaluate welding adequacy in the areas other than those welds in the lower spreading room, project engineering seiceted a sample of 50 welded support connections from installed cable tray support in t.he auxiliary building on April 25, 1978. These sample connections required the field quality control group to conduct a detailed inspection and provide results for project engineering to perform similar evaluation.
Results of this inspection are still pending as of this date.
Reportability Project engineering's evaluation to date tentatively indicates that the descrepancy of the veld size as reported in NCR 1287 and NCR 1306 does not present a potential detrimental effect to public safety and is not a reportable condition uithin the requirements of the Nuclear Quality Assurance Manual, Section 5, Number 10.
(See CPCo Note 2).
The final engineering report on this investigation Iis expected to be completed by May 31, 1978.
CPCo Note 2: The discrepancy will be.bteated as reportable by CPCo w1til such time as the evaluation of the conditions are complete and if final judgmeste can be made.to the conttary.
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