ML19347F610

Responds to NRC 801023 Ltr Re Violations Noted in IE Insp Repts 50-456/80-12 & 50-457/80-11.Corrective Actions: Extensive Statistical Sampling Insp of Shop Welds Being Conducted & Shop Inspectors Informed of Irregular Welds

ML19347F610
Person / Time
Site:	Braidwood
Issue date:	04/02/1981
From:	Abel J COMMONWEALTH EDISON CO.
To:	James Keppler NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
Shared Package
ML19347F609	List: ML19347F610
References
NUDOCS 8105220102
Download: ML19347F610 (8)

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Commonwealth Edison O One First National Address Reply to: Post Office Box 767 Chicago, Illinois 60690 Plaza Chicago. Illinois Apri1 2, 1981 Mr. James G. Keppler, Director Directorate of Inspection and Enforcement - Region III U.S. Nuclear Regulatory Commission 799 Roosevelt Road Glen Ellyn, IL 60137

Subject:

Braidwood Station Units 1 and 2 Supplemental Response to IE Inspection Report Nos. 50-455/80-12 and 50-457/80-11 NRC Docket Nos. 50-456 and 50-457 References (a): October 23, 1980 letter frnm G. Fiorelli to C. Reed.

(b): December 4, 1980 letter from J. S. Abel to J. G. Keppler. ,

(c): December 29, 1980 letter from G. Fiorelli to C. Reed.

(d): March 13, 1981 letter from J. S. Abel to J. G. Keppler.

Dear Mr. Keppler:

This is to provide information which supplements our response to an item of noncompliance identified in Reference (a).

i Status reports on our programs of corrective action on this item are l also being provided.

In our response to infraction 2 we indicated that weld acceptance criteria were being modificd and that the welds will be inspected and repaired as necessary. As documented in Reference (c), the IE inspector has requested additional information regarding this program. There are three suppliers involved so the information is being provided for each supplier.

l Pullman HVAC Duct Welas l

The majority of the silicone bronze shop welded ductwork is at Braidwood so an extensive statistical sampling inspection of the shop welds is being conducted. Attachment A to this letter outlines the program for inspection to criteria established in January, 1981. Any future silicone bronze shop welding will be 100%

inspected at the shop using the same inspection criteria. These inspection criteria will also be used on all other weld inspections.

810 5 2 20 /CWZ-app n 1981

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Pullman has met with their shop inspectors to inform them of the small percenta9a of irregular welds that were released and to reiterate to them the basic weld inspection techniques. The intent of this meeting was to assure that all future Pullman materials conform to the requirements of the code, specification or procedure prior to release.

At present, we expect the site inspection and repair work to be complete by June, 1981.

Main Control Boards

1. Westinghouse Supplied MCB's: The inspection of the welds was initially made using a Westinghouse Specification document which is not part of the design requiremc.ats for the Byron /Braidwood MCB's and should not have. bee.' used in inspection of equipment. A subsequent inspection was made on the Byron Station main control boards and the we:ds were found to be satisfactory. We expect that an inspection of the Braidwood main control board welds will yield a similar result. The Braidwood boards will be inspected by Westinghouse personnel and a determination made of their adequacy by June 1, 1981.

2. System Control MCB's: Revised weld inspection criteria have been received, reviewed and approved. Currently, the inspection effort is being directed towards the Byron main control boards. Upon completion of the Byron safety related panel weld inspection, inspection will begin at Braidwood Station. This is anticipated to occur within four months. Resolution of any weld deficiencies that are found on the Byron main control boards will be rcviewed for applicability to the Braidwood main control boards.

System Control Hangers Revised weld inspection criteria are now being developed by Sargent & Lundy in conjunction with Systems Control. The delay in the development of these criteria was caused by the field effort required to document the extent and location of apparent weld discrepancies in the Systems Control hanger support welds. Inspection to these criteria, as in the instances above, will be delayed until the weld inspection effort at Byron is completed due to limited inspector manpower.

l Please contact me if there are further questions on'this i matter or if further reports on this work are.needed.

Very truly yours, j/f<h&s" J. S. Abel Director of Nuclear.

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Attachment A Inspection Program for Pullman HVAC Duct Welds I

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FULLmfin nm.:

. P SAMPLING INSPECTION ME'll!OD

. . l'b-Ji h ' r-rirne-w-LfJI12 Iik- 3 ppysenb IIU SEcTION f40. REVISION NO. PAGE OF 2~ lilDUSTRIES,inE. SUPERSEDES No. oAlED O i EF F ECTIVE DATE 2

g 2/3/81 APPROVED BY:

QUALITY ASSURANCE PROGRAM # 2 #kf fY SAMPLING !!ETilCD FOR INSPECTION OF SILICON BRON'/E SIIOP WELDS FOR BRAIDWOOD L-2782 ,

1. It shall be the responsibility of the Jobsite Quality Asssurance Representative to perform a statistical sampling wcld inspection of silicon-bronze shop welds and the documentation of same. - .

2. The figures in #4 rnd #5 were determined by ?!IL-STD-105D based on a lot of 5776 duct pieces at the jobsite having an average of 120 welds per duct.

3. Duct pieces sha17 be randomly sc1ceted and shall be inspected using the criteria as delineated in Addendum A dated 1/13/81 to PSM-h'P-307.

4. Individual duct inspection shall be as follows:

a) Twenty (20) welds shall be inspected per duct picco!

b) If zero (0) or one (1) defective weld is noted the duct picco shall be consi'dered acceptabic and require no additional weld inspection.

c) If two (2) or more defective welds are noted, all accessible welds on the subject duct picte shall be inspected.

d) If during the 1001, inspection (as referenced in C) 'seven (7) additional defective welds or fewer are noted th'e duct picco shall be considered acceptabic, requiring no further action.

e) If during the 100's inspection (as referenced in C) cight (8) or more additional defective welds are noted, the duct piece shall be considered rejectabic and all defective welds shall be reworked.

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P00R [RN 14fE EAST P7TH PLACE. CHICAGO. lLUNOlS M322. 012 / 374-8505

mEe T S PULLrilFin SAnetixc issrece ucmo 4

' li E005T8m' 8*ETIDil8 SECTION NO. REVISION NO. PAGE OF d~ lilull5TR!ES,IriE. SUPERSEDES NO. DATED o 2 EFFECTIVE DATE 2

n 2/3/81 APPHOVED BY: 1

// 9 QUALITY ASSURANCE PROGRAM '

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5) Total duct inspection. ,

a) A total of 200 randomly selected duct pieces shall be . inspected, b) If seven (7) or fewer duct pieces have been rejected (see #4) entire lot shall be considered acceptable.

c) If eight (3) or more duct pieces have been rejected (see #4) the entire lot shall require 1005 weld inspection per section 4.

6. References.

Addendum A (dated 1/13/81) to PSM-WP-307 MIL-STD-105D - Military Standard Sampling Procedures and Tables for Inspection by Attributes (dated April 29, 1963).

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"",n PULLmRD viTu:

• • - PSM-WP-307 ADDENDUM A y'- ! EDDSTRUETIi D sEc1,oa uo. u vision n o. moe ce

J ' INDUSTRIES IDE. 8 SUPERSEDES No. DATED O i EFFECT,VE DATE 2

A 1/13/81 7J>l OVED 3Y: /)

QUALITY ASSURANCE PROGRAM D QAM Delete In Its Entirety:

/ O Section 11 of PSM-WP-307 (Silic' nc Bronze Braze Welding Procedure) Revision Original dated February 16, 1978. -

ADD: ~

SECTION 11 INSPECTION Inspection of subject welds shall be visual without the aid of magnification (prescription eye glasses for vision correction are accepted) .

The acceptance criteria shall be as follows: ,

A. Bonding - No separation between weld metal and base metal.

B. Penetration - Required joint penetration as specified for the application.

C. Porosity - Not more than three visable pores or slag inclu-sions per inch of weld which are larger than 0.2St and no more than one visabic pore or slag inclusion per inch of wcld wh.ich is larger than 0.St, where t is the base metal thickness.

D. Und.:rcut - ??o undercut exceeding IS's of the sheet metal thickness being welded.

E. Neld Spatter - No loose weld spatter.

F. Cracks - No cracks parallel to the weldment.

G. Throat of Eillet Welds - A minimum throat equal to. the thick- -

ness of the thinner member joined.

1400 EAST 97TH PLACEe CHlCAGO,ILUNOIS 60623,3121374-8505

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PSM-WP-307 ADDENDUM A

. . h.Ti ' ECD 5TRUCTlun sEcrios so. REVISION NO. PAGE OF C" inDU5TR!25,inE. SUPERSEDES NO. DATED 2

EFFECIIVE DATE 2

/) 1/13/81 47 PROVED DY; QUALITY ASSURANCE PROGRAM / QAM 11.

/ 0 Weld Length - Minimum weld length shall be 1\" including coldlap - -

and crater. Occasional welds of lesser length or of rejectabid ,

quality may be disregarded in the remaining percentage of weld to girth is above 15%.

I. Weld Size - 1/8" minimum.

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4 1400 EAST 97TH PLACE, CHICAGO. ILLINO!S 60623,312 / 374-8505