ML19340B049

Forwards IE Bulletin 78-12, Atypical Weld Matl in Reactor Pressure Vessel Welds. Action Required

ML19340B049
Person / Time
Site:	Dresden, Byron, Braidwood, Quad Cities, Zion, LaSalle
Issue date:	09/29/1978
From:	James Keppler NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
To:	Brian Lee COMMONWEALTH EDISON CO.
References
NUDOCS 8010170760
Download: ML19340B049 (1)

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UNITED STATES At NUCLEAR REGULATORY COMMISSION

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799 ROOSEVELT ROAD 5,

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GLEN ELLYN, ILLINOIS 60137 SEP 2 01978

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- 56, 50-457, 50-454,

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50-374 50-265 50-29 nd 50-304

=...i Commonwealth Edison Company ATTN:

Mr. Byron Lee, Jr.

Vice President Post Office Box 767

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Chicago, IL 60690 Gentlemen:

Enclosed is IE Bulletin No. 78-12 which requires action by you with regard to your power reactor facilities with an operating license or a construction permit.

7 Should you have questions regarding this Bulletin or the actions required of you, please contact this office.

Sincerely, h As-JamesG.KeMer

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Director

Enclosures:

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IE Bulletin No. 78-12 2.

List of IE Bulletins

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Issued in 1978 m

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Mr. B. B. Stephenson, Mr. R. Cosaro, Project s

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p Station Superintendent Superintendent y, C

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Mr. N. Kalivianakis, Central Files o

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Station Superintendent Director, NRR/DPM bS N

Mr. N. Wandke, Station Director, NRR/ DOR MY Y(( $

Superintendent

/ PDR Mr. L. J. Burke, Site Local PDR 2,

Proj ect Superintendent NSIC Mr. Gunner Sorensen, Site TIC Project Superintendent Anthony Roistan, Esq., Attorney Mr. Dean Hansell, Office of Attorney General 8010170 -..

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.l U.S. NUCLEAR REGULATORY COMMISSION

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OFFICE OF INSPECTION AND ENFORCEMENT s'

Y REGION III September 29, 1978 IE Bulletin No. 78-12 ATYPICAL WELD MATERIAL IN REACTOR PRESSURE VESSEL WELDS j

Description of Circumstances

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On August 4,1978, the NRC was inforced by the Duke Power Company and

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the Babcock and Wilcox Company (B&W) that the veld wire used in some of the reactor vessel velds in Oconee Unit No. 3 may have differed from that

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specified. A chemical analysis of one sample of archive material by B&W disclosed that the nickel content was measured to be 0.1 percent (versus 3

0.45 to 0.8 percent nominal specified) and the silicon content was measured to be 1.0 percent (versus 0.3 to 0.6 percent nominal specified).

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The heat of weld metal in question was supplied by the Page Company, a

sq Division of the American Chain & Cable Co., Bowling Green, Kentucky to

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B&W, the manufacturer of the Oconee, Unit 3 vessel. Further checks by B&W of its records have identified eleven additional vessels in which the incorrect veld material may have been used. Owners of these vessels have been notified.

The NRC staff has made a determination of the possible effects on reactor vessel integrity of the use, or possible use, of the improper veld -

g material. Weldments containing the atypical material are likely to have W

higher than normal nil-ductility transition temperature characteristics.

Therefore to maintain reactor vessel safety margins, implementation of new conservative pressure / temperature operating limits may be required.

=J While the specific problem has been identified as possibly affecting

..S twelve vessels manufactured by B&W, it is not possible to conclude in the absence of specific information that similar atypical weld material was not also supnlied to other vessel manufacturers and used in reactor pressure vessel fabrication.

Action To Be Taken By Licensees and Permit Holders:

For all power reactor facilities with an operating license or a

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construction permit, except those already identified as possibly having l

atypical weld material :

I The twelve nuclear units identified as having possible atypical pressure vessel veldcents are: Three Mile Island Unit Nos. I and 2,

.j Crystal River Unit No. 3. Arkansas N w lear One Unit No. 1, Oconee

........j Unit No. 3, Rancho Seco Unit No. 1, Midland Unit No. 1, Quad Cities Unit No. 2, Browns Ferry Unit No. 1, Turkey Point Unit No. 4 and Zion Unit Nos. 1 and 2.

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U.S. NUCLEAR REGULATORY CO>Df1SSION OFFICE OF INSPECTION AND ENFORCEMENT REGION III September 29, 1978 IE Bulletin No. 78-12 ATYPICAL WELD MATERIAL IN REACTOR PRESSURE VESSEL WELDS Description of Circumstances

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On August 4,1978, the NRC was inforced by the Duke Power Cocpany and the Babcock and Wilcox Co=pany (B&W) that the veld wire used in some of the reactor vessel velds in Oconee Unit No. 3 may have differed from that specified. A chemical analysis of one sseple of archive material by B&W disclosed that the nickel content was measured to be 0.1 percent (versus 0.45 to 0.8 percent nominal specified) and' the silicon content was ceasured to be 1.0 percent (versus 0.3 to 0.6 percent nominal specified).

The heat of weld metal in question was supplied by the Page Company, a Division of the American Chain & Cable Co., Bowling Green, Kentucky to B&W, the manufacturer of the Oconee, Unit 3 vessel.

Further checks by B&W of its records have identified eleven additional vessels in which the incorrect veld material may have been used. Owners of these vessels have been notified.

The NRC staff has made a deter =ination of the possible effects on reactor vessel integrity of the use, or possible use, of the improper ve.1d f

material. Weldcents containing the atypical material are likely to have higher than normal nil-ductility transition temperature characteristics.

U Therefore to maintain reactor vessel safety margins, implementation of new conservative pressure / temperature operating limits may be required.

While the specific problem has been identified as possibly affecting twelve vessels manufactured by B&W, it is not possible to conclude in the absence of specific information that similar atypical veld material was not also supplied to other vessel manufacturers and used in reactor pressure vessel f abrication.

Action To Be Taken By Licensees and Permit Holders:

For all power reactor facilities with an operating license or a construction permit, except those already identified as possibly having I

atypical veld material :

1 The twelve nuclear units identified as having possible atypical pressure vessel veldcents are: Three Mile Island Unit Nos. I and 2, Crystal River Unit No. 3, Arkansas Nuclear One Unit No.1, Oconee Unit No. 3, Rancho Seco Unit No. 1, Midland Unit No. 1, Quad Cities Unit No. 2, Browns Ferry Unit No.1, Turkey Point Unit No. 4 and Zion Unit Nos 1 and 2.

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IE Bulletin No. 78-12 September 29, 1978

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1.

Conduct a record search 2 of all primary reactor pressure vessel weldments(excludinggartialpenetrationwelds)andsubmitthe 475 following information :

a.

The principal vessel manufacturer.

If other manufacturers were utilized, identify those companies and the veldments completed by those firms.

b.

The type and form of weld materials and the identifying heat

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and lot numbers used in each weldment.

c.

The weld material manufacturer (s) and the types and form of materials supplied.

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The specified properties of the weld materials and the completed weldments (Chemistry, tensile and impact properties, as appropriate).

2.

Describe the procedures utilized during fabrication to verify confor=ance to the specifications. Specifically provide the

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following:

a.

Describe the type, nu=ber and dates of tests performed on velding materials to satisfy the caterial conformance testing requirements for each heat, lot or combination of heat and 5=?

batch, etc., of welding materials used in the construction or C

repair of the reactor pressure vessel in your facility. Indicate whether each heat, lot or batch subdivision (coil or spool) was tested and the extent of such testing, i.e., were both ends of a coil or spool of wire tested for each sub-arc flux-wire

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combination or heat-flux batch combination.

b.

Describe the type, number and dates of other tests such as procedure qualification, velder performance tests, in process checks on post-weld tests which were performed.

2 The record search may be performed by the vessel manufacturer and the requested information reviewed as appropriate by each licensee prior to forwarding to the NRC. It is not the intent of this Bulletin to require each. licensee to individually examine manufacturing records of a generic nature. Records of nonconforming conditions that may be identified by the manufacturer and are uniquely applicable to a specific vessel should

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however be carefully examined by the owner.

3 some of the information requested by this Bulletin may have been previously supplied to the NRC under the Surveillance Progra=.

j Information previously submitted =ay be referenced in lieu of resubmittal.

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Conduct a record search 2 of all primary reactor pressure vessel Elgs:p weldments(excludinggartialpenetrationvelds)andsubmitthe

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a.

The principal vessel manufacturer.

If other manufacturers were utilized, identify those co:panies and the weldments co=pleted by those firas.

b.

The type and form of weld materials and the identifying heat

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and lot numbers used in each weldment.

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The weld material manufacturer (s) and the types and form of

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The specified properties of the weld materials and the

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completed weld:ents (Chemistry, tensile and impact properties, as appropriate).

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2.

Describe the procedures utilized during fabrication to verify conformance to the specifications.

Specifically provide the following:

a.

Describe the type, number and dates of tests performed on welding materials to satisfy the material conformance testing

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requirements for each heat, lot or combination of heat and

-dj batch, etc., of welding materials used in the construction or C

repair of the reactor pressure vessel in your facility. Indicate

'5 whether each heat, lot or batch subdivision (coil or spool) was "5:?

tested and the extent of such testing, i.e., were both ends

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of a coil or spool of wire tested for each sub-arc flux-wire combination or heat-flux batch combination.

b.

Describe the type, number and datus of other tests such as j

procedure qualification, welder performance tests, in process H

checks on post-weld tests which were performed.

2 The record search may be performed by the vessel manufacturer and the il requested information reviewed as appropriate by each licensee prior to forwarding to the NRC. It is not the intent of this Bulletin to require

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each. licensee to individually examine manufacturing records of a generic nature.

Records of nonconforming conditions that may be identified by the manufacturer and are uniquely applicable to a specific vessel should

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however be carefully exacined by the owner.

3 Some of the information requested by this Bulletin may have been previously supplied to the NRC under the Surveillance Program.

Inforcation previously submitted may be referenced in lieu of resubmittal.

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IE Bulletin No. 78-12 September 29, 1978

..sj For each of the tests described in 2(a) and 2(b) above,

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describe the parameters of each test and provide the results 2.5M.l obtained. Identify the applicability to specific weldments s"ff=

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Identify those cases of weld filler material which did not meet

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procurement specifications based on verification tests, i.e.

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mechanical or chemical properties. Describe the dispositien.

action taken or the acceptance basis for utilization in vessel ~

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fabrication. In such cases, discuss the effect that the atypical C

veld composition has on the fracture toughness of the veld. metal..

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Provide information on the availability of archive weld materials which might be used for verification purposes.

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5.

Please provide your response in writing within 60 days. Reports

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should be submitted to the Director of the appropriate NRC Regional Office and a copy should be forwarded to the U.S. Nuclear Regulatory Commission, Office of Inspection and Enforcement, Division of

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Reactor Construction Inspection, Washington, D.C.

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Approved b'y GAO, B180225 (R0072); clearance expires 7/31/80.. Approval

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vas given under a blanket clearance specifically for identified generic problems. ~

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For each of the tests described in 2(a) and 2(b) above, c.

describe the parameters of each test and provide the results

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obtained. Identify the applicability to specific weldments by correlation of he,at, lot or batch as appropriate.

Identify those cases of veld filler material which did not meet

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procurement specifications based on verification tests, i.e.

mechanical or chemical properties. Describe the disposition action taken or the acceptance basis for utilization in vessel fabrication. In such cases, discuss the effect that the atypical C

veld composition has on the fracture toughness. of the veld metal.

4.

Provide information on the availability of archive veld materials which might be used for verification purposes.

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Please provide your response in writing within 60 days. Reports

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should be submitted to the Director of the appropriate NRC Regional Office and a copy should be forwarded to the U.S. Nuclear Regulatory 2

Commission, Office of Inspection and Enforcement, Division of 2

Reactor Construction Inspection, Washington, D.C.

20555.

Approved by GAO, B180225 (R0072); clearance expires 7/31/80. Approval was given under a blanket clearance specifically for identified generic

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problems.

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IE Bulletin No. 78-12 September 29, 1978 LISTING OF IE-BULLETINS T=

ISSUED IN 1978

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Bulletin Subject Date Issued Issued To No.

78-01 Fla=mable Contact -

1/16/78 All Power Reactor Arm Retainers in G.E.

Facilities with au r

CR120A Relays OL or CP 78 Terminal Block 1/30/78 All Power Reactor Qualification Facilities with an

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OL or CP

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78-03 Potential Explosive 2/8/78 All BWR-Power 2

Gas Mixture Accumula-Reactor Facilities tions Associated with with an~OL-or CP BWR Offgas System Operations 78-04 Environmental Quali-2/21/78 All Powar Reactor fication of Certain Facilities with an

• 1 Stes Mounted Limit OL or CP Switches Inside Reactor Containment 78-05 Malfunctioning of 4/14/78 All Power Reactor Circuit Breaker Facilities with an Auxiliary Contact OL or CP Mechanisc-General Model CR105X 78-06 Defective Cutler-5/31/78 All Power Reacter Hammer, Type M Relays Facilities with an With DC Coils OL or CP 78-07 Protection afforded 6/12/78 All Power Reactor by Air-Line Respirators Facilities with an and Supplied-Air Hoods OL, all class E and F

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Research Reactors with an OL, all Fuel Cycle Facilities with an OL, and all Priority 1 Material Licensees Enclosures 1 Page 1 of 2

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IE Bulletin No. 78-12 September 29, 1978 LISTING OF IE BULLETINS ISSUED IN 1978 Bulletin Subject Date Issued Issued To No.

78-01 Fla==able Contact -

1/16/78 All Power actor Ar= Retainers in G.E.

Facilitit. with an CR120A Relays OL or CP 78-02 Terminal Block 1/30/78 All Power Reactor Qualification Facilities with an OL or CP 78-03 Potential Explosive 2/8/7S All BWR Power Gas Mixture Accu =ula-Reactor Facilities tions Associated with with an OL or CP BWR Offgas Syste=

Operations 78-04 Environ = ental Quali-2/21/78 All Power Reactor fication of Certain Facilities with an Ste= Mounted L1=dt OL or CP Switches Intile Peactor Containment C.

78-05 Malfunctioning of 4/14/78 All Power Reactor Circuit Breaker Facilities with an Auxiliary Contact OL or CP Mechanis=-General Model CR105X 78-06 Defective Cutler-5/31/78 All Pcwer Reacter Hacner, Type M Relays Facilities with an With DC Coils OL or CP 78-07 Protection afforded 6/12/78 All Power Reactor by Air-Line Respirators Facilities with an and Supplied-Air Hoods OL, all class E and F Research Reactors with an OL, all Fuel Cycle Facilities with an OL, and all Priority 1 Material Licensees Enclosures 1 Page 1 of 2 4

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September 29, 1978

gf LISTING OF IE BULLETINS

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ISSUED IN 1978 5}i Bulletin Subj ect Date Issued Issued To

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No.

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78-08 Radiation Levels from 6/12/78 All Power and Fuel Element Transfer Research Reactor Tubes Facilities with a Fuel Element

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transfer tube and an OL.

78-09 BWR Drywell Leakage 6/14/78 All BWR Power Paths Associated with Reactor Facilities Inadequate Drywell with an OL or CP Closures

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78-10 Bergen-Paterson 6/27/78 All BWR Power..,

M Hydraulic Shock' Reactor Facilities Suppressor Accu =ulator with an OL or CP Spring Coils 78-11 Examination of Mark'I 7/21/78 BWR Power Reactor Contain=ent Torus Facilities for Welds action: Peach g

Bottom 2 and 3,

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Quad Cities 1 and 2, Hatch 1, Monti-

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cello and Vermont Yankee u=

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IE Bulletin No. 78-12 September 29, 1978

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LISTING OF IE BULLETINS ISSUED IN 1978 m

Bulletin Subject Date Issued Issued To gg; No.

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78-08 Radiation Levels from 6/12/78 All Power and Fuel Element Transfer Research Reactor Tubes Facilities with a Fuel Ele =ent

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transfer tube and an OL.

78-09 BWR Drywell Leakage 6/14/78 All BWR Power Paths Associated with Reactor Facilities

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Inadequate Drywell with an OL or CP Closures

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78-10 Bergen-Paterson 6/27/78 All BWR Power Hydraulic Shock Reactor Facilities Suppressor Accumulator with an OL or CP Spring Coils 78-11 Examination of Mark I 7/21/78 BWR Power Reactor Contain=ent Torus Facilities for Welds action: Peach Botton 2 and 3, C..

Quad Cities 1 and 2, Hatch 1, Monti-cello and Vermont Yankee f

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