Text

Revised Const & Matl Verification Program Final Rept.
	ML20004D358
Person / Time
Site:	Marble Hill
Issue date:	05/31/1981
From:	; PSI ENERGY, INC. A/K/A PUBLIC SERVICE CO. OF INDIANA
To:	;
Shared Package
ML20004D356	List: ML20004D357; ML20004D358;
References
	NUDOCS 8106090295
	Download: ML20004D358 (375)
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h INDEX OF CHANGES CONSTRUCTION AND MATERIAL VERIFICATION PROGRAM FINAL REPORT l New Transmittal Letter with Index of Changes Section 1.0 No Revisions Section 2.0 Revised Attachment 2.6.5 Section 3.0 I

Revised Pages 6, 7, Attachment 3.6.4 Page 2 of 5 and Attachment 3.6.5 Section 4.0 Revised Page 5 Section 5.0 Revised Attachment 5.6.4 Section 6.0 Revised Pages 1-13.

Revised Attachments 6.6.3, Pages 2, 6, 10, 11, a nd 14 o f 14 ; 6. 6.4. 3 ; 6. 6.4.4 ; and I 6.6.8, Pages 8, 9, 10, 11, 12, 17 and 19 of 25.

Added Attachment 6.6.9 Section 7.0 Revised Pages 5, 6, 8-12, 14, 16, 18, 21, &

23-25.

Revised Attachments 7.6.1, 7.6.2, 7.6.3, 7.6.7.

I Section 8.0 Added Note Page 5, Paragraph 8.4 I Section 9.0 Revised Pages 2, 4, 5, 7, 9, 12-15, 17, 18, 20 and 21.

I Attachments 9.7.1-2, 9.7.1-4, 9.7.1-12 and 9.7.1-23 Section 10.0 No Revisions I Section 11.0 Added Note Page 5, Paragraph 11.3.7.5 Revised Attachment 11.6.1, SPP-12 Attachment 1, Pages 2 of 4 and 4 of 4 Section 12.0 Revised Paragraphs 12.3.4.1.3, 12.3.4.1.5, 12.3.4.2.1, 12.3.4.2.4, 12.3.4.2.13 and I

12.3.4.2.14; Attachment 12.6.3.

I Note: Revisions are noted in the right margin by an R.

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PUBLIC .

SERVICE l INDIANA '

September 12, 1980 S. W. Shields I Senior Vice President -

Nuclear Division I Mr. J. G. Keppler, Director U.S. Nuclear Regulatory Commission Docket Nos.: STN 50-546 STN 50-547 I Region III 799 Roosevelt Road Glen Ellyn, IL 60137 Construction Permit Nos:

CPPR-170 CPPR-171 Marble Hill Nuclear Generating Station Units 1 and 2 Order Confirming Suspension of Construction Graduated Rescission of Order

Dear Mr. Keppler:

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' I On August 15, 1979, the U. S. Nuclear Regulatory Commission (NRC), Office of Inspection and Enforcement, issued an Order Confirming Suspension of Safety-related Construction (Confirming Order) at the Public Service Company of Indiana, Inc. (PSI) Marble Hill Station, Units 1 and 2. That order required, as a condition of the restart of construction, that PSI submit a description of its Quality Assurance program and the steps taken to assure that safety-related constructon will be conducted in accordance with I 10 CFR 50, Appendix B. Anuther requirement of the Confirming Order was that PSI review the work completed as of the date of suspension of construction to assure that such work was properly parformed.

PSI's submittal, " Description of Licensee Activities Addressing Order Confirming Suspension of Construction", was made to the NRC on February 28, 1580 and accepted by the staff on May 15, 1980 as an adequ.te basis for the I gradual resumption of safety-related construction. Two o the elements of the review of work previously completed were the material and construct ion verification programs described in Section III, Al and A2 of PSI's l Feb ruary 28, 1980 report. This submittal presents the results and conclusions E of that program as directed in Appendix Item C, 1 & 2 and Item D, 1 & 2 of Mr.

Stello's Graduated Rescission Order of May 15, 1980.

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l I e.o. eex ieo. ~e- w h'noten. >ne>8n. 47,e2 e > 2. 2ea . 444,

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= PUBUC l SERVICE Mr. J.G. Keppler l INDIANA It is concluded that the inspections made as a part of this program have clearly established those materials and structures that meet specified I requirements and those that require rework or repair that can be accomplished within the appropriate codes and standards.

I With transmi.tal of this letter, PSI is requesting the NRC to review the construction and material verification final report in accordance with Mr.

Ste11o's graduated rescission order of May 15, 1980, Appendix Item C, 3 and j

4 Item D, 3.

Sincerel ,

I W. Shields JB/kdt Attachment cc: Mr. Victor Stello, Jr., Director Office of Inspection and Enforcement U. S. Nuclear Regulatory Commission Washington, D.C. 20555 I E.R. Schweibinz, P.E.

J.J. Harrison I

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, CONSTRUCTION AND MATERIAL VERIFICATION PROGRAM

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t FINAL REPORT i

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!I i SEPTEMBER, 1980 I

I REVISED MAY, 1981 I

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TABLE OF CONTENTS I

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SECTION REFERENCE 1.0 Introduction Licensee Activities Addressing g Confirming Order g and Graduated Rescission Order 2.0 Category I Reinforcing Steel SPP 2 3.0 Category I Structural Steel SPP 3 4.0 In-Place Category I Piping and llangers SPP 4 5.0 Category I Concrete Surface SPP 5 Irregularities 6.0 Mechanical (Cadweld) Splices SPP 6 7.0 Procedure for Physical Inspection SPP 7 and Verification of Previously Accepted Purchased Items 8.0 In-Place Category I Buried and Embedded SPP 8 >

Piping 9.0 Checking of Category I Backfill Data SPP 10 10.0 Document Verification for Containment SPP 11 ,

Liners, Fuel Pool Liners, Refueling Pool Liners and Miscellaneous Field Frected Tanks i

l 11.0 Document Verification Procedure for ASME SPP 12 Section III Piping, llangers and Materials 12.0 Category I Concrete Pour Package, Concrete SPP 13 Constituent Materials and Embedded Metals Records Review I

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CONSTRUCTION AND MATERIAL. VERIFICATION FINAL REPORT

1.0 INTRODUCTION

1.1 ABSTRACT I This report is submitted in response to the NRC's documents entitled

" Order Confirming Suspension of Construction" dated August 15, 1979 I and " Graduated Rescission of Order Dated August 15, 1979" (" Graduated Rescission Order") dated May 15, 1980. This report presents the results of the Construction and Material Verification Program, which I was conducted by Public Service Company of Indiana, Inc. (PSI) to assess the suitability of material received and work accomplished prior to the August 7, 1979 work stoppage. This report also identifies non-conforming conditions found during the verification I program, the significance of those conditions, and remedial actions to be taken where appropriate.

1.2 INTRODUCTION

On August 15, 1979, Mr. Victor Stello, Jr., issued the " Order Confirm-g ing Suspension of Construction" to PSI. That order prevented further 3 safety-related construction at PSI's Marble Hill Nuclear Generating Station until such time as PSI performed certain reviews and improved its Quality Assurance Program.

On February 28, 1980, PSI submitted its response to the Confirming Order. That report and a subsequent report provided a decription of PSI's modified Quality Assurance Program and provide a response to the nine items of concern in the original Confirming Order, including the proposed Material and Construction Verification Program identi-fied as Items IIIA 1 and 2, respectively, in the report.

The February PSI report was reviewed by the NRC and judged acceptable in Mr. Ste11o's May 15, 1980, " Graduated Rescission Order." In the I " Graduated Rescission Order," the NRC directed that PSI complete appropriate project management procedures, conduct the Construction and Material Verification Program, approve the results of the program and notify the Director of Region III in writing of those results.

lI This report identifies the results of the Construction and Material Verification Program and is hereby submitted to the NRC in accordance I with Appendix Item C3 and Item D3 of the "Craduated Rescission Order" so that the NRC may review the adequacy of this program prior to releasing PSI to restart Category I work.

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1.3 DISCUSSION The PSI Construction and Material Verification Program was separated into distinct types of activities. A governing procedure, which was reviewed and approved by appropriate PSI management, was written to control each activity. In addition, each procedure was reviewed by NRC's Region III staff and concurrence from Region III was received prior to performance of activities in accordance with each procedure. These procedures were designated "Special Process l

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Procedures" (SPPs) and were intended to be utilized only for the duration of the inspection activity being performed. Since the Material Verification Program consisted of essentially one inspection l activity, one SPP was developed for that program (i.e. , - SPP-7, 5

" Procedure for Physical Inspection and Verification of Previously Accepted Purchased Items.") Several procedures were developed for g the various phases of Construction Verification (i.e., - SPP-2 g through 6, 8 and SPP-10 through 13, inclusive.) nese SPPs are identified in the Table of Contents. Each report section deals with a specific activity, such as inspection of structural steel or concrete. Sections identify the PSI commitments made in the February 18, 1980 Confirming Order response, and the following items:

o The activity to be inspected.

o The results of the inspection.

o Remedial actions to be taken if appropriate.

o Conclusions.

Each report section also contains a copy of the SPP governing that activity as well as sample inspection forms, marked-up drawings and l other attachments necessary to support the narrative portion of that a section.

1.4 CONCLUSION

S Based on the results of the Material and Construction Verification Program, PSI has concluded that most of the werk was properly i

[ performed. PSI concludes that it has identified dispositions and I corrective actions for the nonconforming conditions identified by the ;

program and that, with NRC review of and concurrence with such actions, one or more construction disciplines can be selected for restart.

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I l 2.0 CATECORY I REINFORCING STEEL 2.1 ABSTRACT This section describes the results of an inspection program conducted by Public Service Company of Indiana, Inc. (PSI) and Newberg-Marble 11i11 (N-Mil) on partially embedded reinforcing steel and sample areas of non-embedded reinforcing steel located in Category I structures at the Marble Hill Nuclear Generating Station. The resulting I conclusions, evaluations and proposed follow up actions to be taken are discussed. This program consisted of documented visual examinations conducted by qualified and trained teams in accordance with an approved Special Process Procedure, SPP-2.

Based on the results of these examinations and subsequent engineering evaluations, it is concluded that the reinforcing steel placed at Marble Hill is acceptable. Some dowels were found to be missing from equipment pads. PSI will take corrective measures to meet the design requirements for these pads. These corrective measures will be implemented when safety-related construction activities are resumed.

In addition to these corrective measures, PSI and Newberg-Marble Hill will conduct a training program for production and it.spection personnel. This training program will be structured to identify the causes which directly or indirectly led to the deficiencies and instruct personnel how to eliminate or minimize these causes.

2.2 INTRODUCTION

l 2.2.1 Commitments PSI committed to a verification program for reinforcing steel in Article III. A.2.d.ii. of the " Description of Licensee Activities Addressing Order Confirming Suspension of Construction". The verification program was to consist of examining visible installed Category I reinforcing steel to determine if placement is adequate to satisfy design requirements. The items to be checked were i

reinforcing steel bar size, number and cover. The detail to which these items were to be checked was to be consistent with the stage of installation of reinforcing steel in a particular area.

The inspection which was performed for partially embedded reinforcing ll

,a steel included a visual examination for bar size, number and spacing. The concrete member thickness and the clear cover over )

I reinforcing steel was measured. For the reinforcing steel which had ;

been erected, but had not been previously inspected and accepted, l

! five representative areas were chosen and examined to determine the general quality of workmanship.

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Procedure Outline I

2.2.2 The steps taken to perform the examination of reinforcing steel consisted of the following:

(1) Preparation and approval of a procedure, SPP-2, for physical inspection and verification of Category I reinforcing steel; (2) Establishment and qualification / training of Physical Survey Teams; (3) Compilation of up-to-date Sargent & Lundy (S&L) structural l drawings for use in the verification and documentation of areas W ins pe c ted ;

(4) Physical inspection of partially embedded reinforcing steel and the inspection of a sample of non-embedded reinforcing steel in Category I structures and the documentation of those inspections; and (5) Preparation of Corrective Action Requests (CARS) to formally identify nonconforming items and to track the progress of any corrective actions required as a result of the evaluations made in the disposition of the CARS.

2.3 DISCUSSION 2.3.1 Procedures Special Process Procedure SPP-2, entitled " Category I Reinforcing Stael," was prepared by S&L and approved by the PSI Project Engineering Manager and the PSI Quality Assurance Manager. This g procedure established written criteria and instructions for g systematic identification, location, inspection, and documentation of partially embedded reinforcing steel. The inspection of partially embedded reinforcing steel included the verification of the bar size and spacing, the number of bars, the concrete member thickness and the clear cover to the bar.

In addition to the inspection of the partially embedded reinforcing steel, five areas were chosen where reinforcing steel had been erected but where no inspection had yet been performed. An inspection was made in these areas only to assess the quality of the workmanship. These areas will be completely inspected after

! installation of bars is complete and prior to concrete placement.

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A copy of SPP-2 is incorporated as Attachment 2.6.1.

2.3.2 Establishment, Qualification and Training of Physical Survey Teams i

Physical Survey Teams were established, organized and staffed with qualified personnel as described in SPP-2. The commitments made in Section III.A.2.b. of the " Description of Licensee Activities I

Addressing Order Confirming Suspension of Construction" were incorporated into SPP-2. In addition, survey team members attended documented training sessions which dealt specifically with the SPP-2 procedure.

2.3.3 Compilation of Survey Data The teams conducted an initial walk-through survey to locate and map partially embedded reinforcing steel on S&L drawings. Using this information, verification packages were prepared for use in the field. These packages contained drawings which were clearly marked to indicate the size, spacing and number of bars and any special reinforcing patterns that the inspection teams should find during the inspection.

A list of the drawings used to complete this inspection is shown on Attachment 2.6.4. Each S&L drawing used for the inspection was the latest revision of the drawing available on August 7, 1979 or a later revision.

2.3.4 Inspection and Documentation of Inspection Results The inspections were performed between February,1980 and June,1980 I 2.3.4.1 The results of the inspection of embedded reinforcing were recorded under the direction of a PSI Level II inspector as follows:

(1) Each area that had been visually inspected was clearly indicated by marking the drawing. A typical inspection drawing and comment form are shown as Attachments 2.6.2 and 2.6.3.

(2) The total number of bars in each face were counted and recorded on the drawing. Locations in which the as-counted number of bars was different than the number indicated on the drawings were further documented by the placing of a comment number on the drawing and the making of an applicable comment on Form SPP-2-3.2-1.

(3) Clear cover and concrete member thicknesses was measured and those which did not satisfy specification requirements were i indicated by a comment number on the drawing and comment on Form b SPP-2-3.2-1.

(4) Spacing errors such as bars spaced closer than one bar diameter I or farther apart than one and one-half times the required spacing (not to exceed 18 inches) were located on the drawings and described on Form SPP-2-3.2-1.

(5) Marked up drawings and comment forms were annotated with the names of the survey team members and the date the inspection was performed.

2.3.4.2 The documentation for the verification of non-embedded reinforcing steel consisted of a drawing c1carly indicating the sample areas inspected. In addition, Form SPP-2-3.2-2 was completed to evaluate whether or not the bars were placed in a workmanlike manner as defined in SPP-2. A sample of this form is shown in SPP-2, Attachment 2.6.1. Marked up drawings and forms were annotated with the names of the survey team members and the date that the inspection was performed.

2.3.5 Discussion of Physical Inspection Results 2.3.5.1 The inspection of partially embedded reinforcing steel resulted in the following findings:

(1) 14 cases where the member thickness is out of tolerance.

(2) 209 cases where the clear cover is out of tolerance.

(3) 27 cases where the wrong size reinforcirg bar was placed.

(4) 266 cases of missing reinforcing bars.

(5) 177 cases where bar spacing is out of tolerance.

(6) 412 cases of extra reinforcing bars.

2.3.5.2 Each case noted above corresponds to a comment made on the forms described in Subsection 2.3.4.1.

Inspection of the five sample areas where reinforcing was erected but not yet inspected or embedded showed the bars were sufficiently tied to prevent displacement, sufficient bar supports were used and the general workmanship was of good quality.

2.3.6 Preparation of Corrective Action Requests (CARS)

Using the documentation generated during the inspections, the Lead PSI Level II Inspector generated CARS to identify nonconforming conditions. These CARS indicate the type of nonconformance, e.g.,

incorrect bar size, insuf ficient number of bars or improper cover, and the location of the nonconformances. A list of the CARS generated by the SPP-2 program is shown as Attachment 2.6.5.

2.3.7 Corrective Action 2.3.7.1 Sargent & Lundy reviewed the nonconformances shown on the CARS. Each

! item of nonconformance was examined by an engineer to determine if the as-built structure satisfies the structural design requirements.

I Where the as-built structure was determined to be structurally adequate, the disposition of the CAR was "use-as-is". Nonconforming items which did not satisfy the design requirements will be corrected using appropriate measures. The corrective actions are discussed below.

2.3.7.2 There were 223 cases (Items 1 and 2, Subsection 2.3.5.1) where either the concrete cover or the member thickness did not meet specified tolerances. Twenty three could not be resolved using the guidelines in Attachment 2.6.6. For these 23 cases, the concrete section was I

I reviewed by an enginecr. It was found in each case that the capacity of the section exceeds the capacity required to resist the design loads. The engineering disposition for these CARS is "use-as-is".

2.3.7.3 Of the 2/ cases (Item 3, Subsection 2.3.5.1) where the wrong size reinforcing bar was placed, there were seven cases where a smaller sized bar than indicated on the S&L drawing was installed. In each case, a review of the design calculations was made. The review showed that the concrete sections with the instsiled bars have sufficient capacity to resist the design loads. The engineering disposition for these CARS is "use-as-is".

There were 20 cases where a larger sized bar than indicated on the S&L drawing was installed. The use of these 19rger bars is not detrimental to the structure. The engineering disposition for these CARS is "use-as-is".

2.3.7.4 There were 266 cases (Item 4, Subsection 2.3.5.1) where reinforcing steel was omitted. Twenty-four of these cases were dowels projacting from floor slabs for equipment pads and curbs. For these cases, the disposition was to require that dowels be replaced as necessary by core drilling the slabs and grouting into the slabs a sufficient number of bars to satisfy the design requirements. The drilling and grouting operations will be performed in accordance with approved procedures.

There are equipment pads that have been placed and for which the dowels cannot be visually inspected. These equipment pads have been evaluated and it has been determined that the pads are adequate to resist the design loads with the dowels shown on the reinforcing steel shop drawings. Each pad has been evaluated and it has been I determined either by review of inspection reports or by use of a metal detector (Model C4952 R-Meter, James Electronics, Inc.) that the dowels shown on the reinforcing steel shop drawings are in place.

There were 30 cases where the diagonal bars at the corners of openings were omitted and 32 cases where the bars for the face of the opening were omitted. These bars are not required to carry the design loads. Therefore, the engineering disposition for these CARS is "use-as-is".

There were three cases where bars at the support for beams were omitted. The omitted bars were dowels to splice with side bars in the beams. Since these bars are not designed as stressed bars, the engineering disposition for these CARS is "use-as-is".

There were three cases where a significant number of wall dowels in shear walls were omitted. These dowels were the additional bars I required to replace the wall bars that are interrupted at an opening. In each case, the wall capacity was reviewed and it was found that the wall is capable of resisting the design loads. The engineering disposition for these CARS is "use-as-is".

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For the remaining cases the omitted bars account for less than 5% of the reinforcing within the concrete section. These cases were bars omitted from walls and slabs. The engineering disposition is "use-as-is".

2.3.7.5 There were 177 cases (Item 5, subsection 2.3.5.1) where bars were either spaced farther apart than one and one-half times the nominal bar spacing or closer together than one bar diameter. Most of the cases involving wide bar spacing actually involve a missing bar. The missing bats are discussed in Section 2.3.4. The cases involving close bar spacing generally occurred in areas of heavy reinforcing bar congestion. Fince these isolated cases of spacing errors do not jeopardize the structural integrity, the engineering disposition for these CARS is "use-as-is".

2.3.).6 There were 412 cases (Item 6, Subsqrtion 2.3.5.1) where additional bars were found in place that were not shown on the S&L drawings.

These bars are not detrimental to the structure. The engineering disposition for these CARS is "use-as-is".

2.3.7.7 In general, it was found that the bars were installed as shown on the reinforcing steel shop drawings. At the time the reinforcing steel was placed, the practice was to install and inspect the reinforcing bars using the shop drawings. Therefore, the reinforcing steel shop drawings are assumed to represent the condition which exists in walls which cannot be inspected. The shop drawings for the walls which have been placed have been reviewed by the design engineer. This review shows that the reinfercing steel shown on reinforcing steel shop drawings satisfies the design requirements.

2.3.8 Actions to Prevent Recurre nce 2.3.8.1 Quality Assurance / Control, Construction, Engineering, and Production otaf fs will be supplemented with personnel qualified in reinforcing steel placement work.

2.3.8.2 Existing procedures will be revised and additional procedures will be developed to prevent recurrence of these conditions.

2.3.8.3 Procedural " hold points" will be added to allow effective inspection of work-in-progres s.

2.3.8.4 An indoctrination and training program in reinforcing steel placement work will be developed and implemented for inspection and production personnel.

2.3.8.5 Qualified detailers and checkers have been added to the staff involved in preparing shop detail drawings for reinforcing steel. A more detailed review of the shop drawings will be performed by the checkers to assure that the shop detail drawings adequately reflect l the requirements of the S&L drawings.

I 2.3.8.6 Inspection of installed reinforcing steel will be made using the S&L design drawings as well as the reinforcing steel shop drawings.

2.4 CONCLUSION

S The purpose of the visual inspection of reinforcing steel was to I detect any substandard conditions which could affect the integrity of the structure.

The generic problems in detailing, placing and inspecting reinforcing I steel have been identified and evaluated. These problems have been addressed and will be corrected.

I The only arear identified which require corrective action to eliminate deficiencies are missing dowels for equipment pads. The missing dowels for the pads which have not been placed will be It has been determined that the dowels for the pads which I installed.

have been placed are adequate.

The methods used to detail, install and inspect the reinforcing steel I were essentially used throughout the projec t. There were no cases, other than dowels for curbs and equipment pads, where corrective action is required to correct deficiencies. Therefore, the in-place I reinforcing steel which was inspected under SPP-2 as well as the reinforcing steel which was not accessible for inspection is acceptable.

2.5 REFERENCES

2.6 ATTACHMENTS 2.6.1 SPP-2, " Category I Reinforcing Steel", Rev. 7.

2.6.2 Example of Marked-Up Inspection Drawings.

2.6.3 Typical Inspection Comment Sheet.

2.6.4 List of Structural Drawings Used for SPP-2.

2.6.5 List of CARS.

2.6.6 Acceptance Criteria for Reinforcing Placement.

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SUMMARY

OF REVISIONS PROC. NO. SUBJECT SPP-2 CATECORY I REINFORCING STEEL N

t, REVjSl REVISION DESCRIPTION g gER 6 1) Describeri responsibilities of Team Leaders and PSI QA Level II Lead Inspectors

2) Redefined responsibilities and processing of nonconforming conditions.

7 1) Changed Scope (Added 2nd paragraph)

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2) Changed 3.1 B. 3. to Verification of Number of Reinforcing I,

Bars.

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REVISION AUTHORIZATION REVISION f NUMBER 6 7 l OATE ISSUED \ 05-02-8.0 05-06-Q0 s ki&lv J W NN l

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05-06-80 MARBLE HILL GENERATING STATION ost.

jl; Revision 7

'PUBLIC SPECI AL PROCESS PROCEDURE SERVICE

Title:

l lNDIANA See-2 CArsc0av i astNroaCINc STest i

il TABLE OF CONTENTS SeC11eN T11<e ig 1.0 SC0eE 2.0 L'EFINITIONS AND ABBaEVIATIONS j 3.0 INSTRUCTIONS ig i 4.0 FLOWCHART 5.0 asFzasNCES 6.0 TABLES 1

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MARBLE HILL GENERATING STATION Date .05-06-80 Revleion

'PUBLIC SPECIAL PROCESS PROCEDURE Page 2 of 7

13 SERVICE

Title:

INDIANA SPP-2 CATEGORY I REINFORCING STEEL 1.0 SCOPE This procedure establishes a method of verification to determine if the visible Category I reinforcing bars are adequately placed to satisfy design requirements. Two distinct types of reinforcing bars will be examined. The first type is any area which has exposed partially embedded reinforcing bara, and the other is any location where reinforcing bars have been placed but complete QA inspections have not bee conducted.

Spacing tolerances and splice lengths are not included in the scope of inspections for SPP-2. These inspections are performed as a part of the normal inspection sequence during Category I work.

2.0 DEFINITIONS AND ABBREVIATIONS N-MH - Newberg-Marble 11t11 NRC - Nuclear Regulatory Commission Physical Surveyor - An individual who performs any work involved in the verification procedure.

PST - Physical Survey Team - A group of individuals, including a Team l Leader and Physical Surveyors, who perform all work involved in the W verification procedure.

PSI - Public Service Indiana PSI /CM - Public Service Indiana Construction Manager PSI /PEM - Public Service Indiana Project Engineering Manager S&L - Sargent & Lundy Engineers Team Leader - An individual who is responsible for the performance of the field work.

3.0 INSTRUCTIONS 3.1 Establishment of Physical Survey Team The establishment of Physical Survey Teams shall be the responsibility of the PSI Construction Manager with the concurrence of the PSI Project Engineering and Quality Assurance Managers. All Physical Survey Teams shall work under the supervision of a Team g Leader. Each Team Leader shall be_a PSI engineer who satisfies one E of the following qualifications.

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I MARBLE HILL GENERATING STATION oste 05-06-80 I PUBLIC SERVICE

Title:

SPECIAL PROCESS PROCEDURE Revision p**

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g INDIANA SPP-2 CATEGORY I REINFORCING STEEL I 1. BS degree plus one year experience in concrete-related work.

2. High School Graduate plus five years experience in concrete related work.

I Each Physical Survey Team will contain at least two PSI QA Engineer / Inspectors qualified to Level II under ANSI N45.2.6-1973.

Other inspectors from PSI or Contractors qualified to Level I may be I assigned to the Physical Survey Team as necessary. Each Team Leader shall be under the supervision of the PSI Construction Area Manager for the performance of the physical survey, who in turn is responsible to the PSI Construction Manager for the performance of the work. The PSI Project Engineering Manager is responsible for providing technical support to the entire program. One of the two PSI QA Engineer / Inspectors shall be assigned as Lead I Engineer / Inspector by the QA Superintendent of Inspection who is responsible to the QA Manage . The recording of data shall be under the direction of the PSI Level II Inspector.

RESPONSIBILITIES TEAM LEADER PSI LEVEL II LEAD Responsible To: Responsible To:

I e Area Manager e Construction Manager e

e QA Superintendent Insoection QA Manager Responsible For The: Responsible For The:

o Performance of the field e Supervision of the inspection, work as it relates to man- including ability to stop work I power; schedule; generating inspection packages; setting priorities; providing drawings ; e on SPP-2 activities.

Assuring conformance to providing copies of approved procedure requirements I procedures to Team Members; provide scaffolding, lighting access to inspection areas.

e Adequacy of data generated by the PST, including the I e Interfaces with Project Engineering for Technical completeness and accuracy of the data.

Support _ and to give Status e Signinj; of the section labelled I Reports.

Recommend procedure revisions.

" Initiator" on the CAR Form and QA Inspector on the SPP-2 g e Forms to document adequacy and I A d

acceptance of the data produced.

MARBLE HILL GENERATING STATION Date 05-05-80 I,

Revisio,

'PUBLIC SPECIAL PROCESS PROCEDURE p"'

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E INDIANA SPP-2 CATEGORY I REINFORCING STEEL I

e Recommend procedure revisions.

e Verify measurements.

e Directing the recording of all data.

All Category I Concrete areas shall be examined in a systematic manner for the location of partially embedded reinforcing steel and any areas where reinforcing steel had been placed but not inspected at the time of the issuance of the NRC Confirming Order to stop work l in Category I areas. 5 It shall be the responsibility of the Physical Survey Team (PST) to g originate any nonconformances with design requirements on Corrective Action Report Forms (CARS) per PMP 1.07. The PSI Level 11 Lead g

Inspector shall be responsible for assuring the adequacy (completeness and accuracy) of the CAR and shall also be responsible for signing the signature block labelled " Initiator". When =

completing the block labelled " Method of Discovery", it shall be noted that the adverse condition was identified by the SPP-2 PST.

Note: The Manager of Quality Engineering is not required to review SPP-2 CARS for potential reporting to the NRC per 10 CFR 21 or 10 CFR 50.55(e).

All CARS initiated by the PSI QA Level II Lead Inspector shall be hand carried to the Manager of Quality Engineering for processing in accordance with PMP 1.07.

A. Reinforcing Steel Location and Identification

1. An initial walk-through survey of all Category I areas shall be conducted. Notes and marks indicating areas I ,

where partially embedded bars are encountered shall be made on drawings as the survey progresses. The names of the individuals who performed the survey and the date the survey was performed shall be clearly indicated on the drawings.

2. Using the survey information, one Sargent & Lundy structural drawings applicable to each area shall be determined. Prints of the latest revision shall be l

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obtained. In some locations the reinforcing size, location, or spacing may have been changed by a g Contractor Change Request. For example, in some walls g g the horizontal rebar may have been changed from being A located outside the vertical bars to the inside. Also in

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I MARBLE HILL GENERATING STATION Date 05-06-80

'PUBLIC SPECIAL PROCESS PROCEDURE Revision 7 5 of 13 I SERVICE P*e

Title:

INDIANA I SPP-2 CATEGORY I REINFORCING STEEL I some cases 2-#8 bars may have been substituted for each

11 bar, etc. A review of the Contractor Change Requests I shall be made by the PST to determine if any apply to the areas identified in the initial survey. If any apply, then a note shall be placed on the drawing at the I applicable location. The note shall read "See CCR-for this area". A copy of the approved Contractor Change Request shall be used to aid in the verification I conducted in the field and included in the verification documentation package.

3. The perimeters of all areas with partially exposed rebar I shall be clearly marked on the drawing using a bold, black felt tip pen. No additional identification of these areas is required.

B. Verification of Partially Embedded Reinforcement 1.

I In order to verify the reinforcement depth, two (2) measurements shall be taken. These are the concrete thickness and the clear cover. A thickness shall be considered acceptable if the nominal thickness is within I -1/4", +1/2" of the value shown on the drawing.

Likewise, the clear cover shall be acceptable if the as-measured value is within the tolerances indicated in Table 3.2-2. When a rebar is located between the concrete face and the partially exposed rebar, the clear cover to the exposed bar is equal to the clear cover to the bar nearest the concrete face plus the diameter of I that bar. In order to account for the bar deformations, the diameter of the bar nearest the concrete face shall be considered as indicated in Table 3.2-1. For example, if on one face of a wall (formed and exposed to weather)

I there is a totally embedded #9 straight horizontal on the outside face with a #11 partially exposed vertical, the maximum clear cover would be 2" (clear cover to

, l horizontal) plus 1 1/4" (#9 bar including deformations) 5 plus 1/4" (allowable cover tolerance). This gives a maximum value of 3 1/2" for the distance between the I concrete face and the #11 vertical. The minimum value would be 2" (clear cover to horizontal) plus 1 1/8" (#9 bar not including deformations) minus 1/4" (allowable c'over tolerance). This gives a minimum value of 2 7/8" I g for the distance between the concrete face and the #11 vertical. If the measurements of the wall thickness and the clear cover fall within the above described ranges I E G

the reinforcement depth is verified. These measurements shall be taken at the locations of the observation points C:

T MARBLE HILL GENERATING STATION Date I

05-06-80 Revhlon j -

.PUBLIC SPECIAL PROCESS PROCEDURE 7

~

"" 6 f '3 4 SERVICE

Title:

INDIANA SPP-2 CATEGORY I REINFORCING STEEL I

only. The first, last, and a bar near the center of each continuous layer of reinforcement shall be chosen as observation points. Should any of the observation points not meet the acceptance requirements, the adjacent bar location shall be measured. Locations shall be measured until the concrete thickness and clear cover fall within the allowable ranges. Only locations which fall within the ranges shall be used as the observation points. All g deviations shall be documented by a comment number on the g drawing and the initiation of Form SPP 2-3.2-1. The clear cover and concrete thickness of the remaining portion shall be visually compared to these observation l points. Any material which obstructs the Physical B Surveyor's view of a concrete edge (snow, mud, etc.)

shall be removed before the verification proceeds.

If the Physical Survery Team determines, for any reason, that additional observation points are required so that an accurate visual check of the remaining bars and concrete thicknesses can be made, then they shail strategically choose additional observation points.

Likewise, if a continuous run of bars is relatively short E and the Physical Surveyors determine that an accurate g check can be made using only one or two observation points, then they shall use fewer points. Only bars and thicknesses which appear to fall outside the verification ranges shall be measured and recorded on Form W SPP-2-3.2-1. A comment number shall be indicated on the drawing at each location of a discrepancy. This comment number shall also be indicated on Form SPP-2-3.2-1.

The as measured clear cover and thickness at each observation point shall be written on the print. For example, if the as-measured clear cover on one face is 2 3/4" it shall be recorded on the print as CC=2 3/4";

likewise, if the as-measured thickness was 36 1/4", then g it shall be recorded on the print as t=36 1/4". If the 5 values are within the acceptable range, then a check mark M) shall be indicated next to each value.

The names of the Physical Surveyors and the dates that the work was performed shall be clearly indicated on the drawing.

2. Size of Reinforcement 3

g The size of all bars shall be compared to the indicated

size on the drawing. When a given area has been verified 5

t

l I MARBLE HILL GENERATING STATION Date 05-06-80 Revleion 7

.PUBLIC SPECIAL PROCESS PROCEDURE j

l ' '3 SERVICE

Title:

g INDIANA SPP-2 CATEGORY I REINFORCING STEEL g .

for bar size, the size notation on the print shall be marked w;th a check mark (/).

I I' a disagreement occurs, then the difference between the bar sizes shall be noted on Form SPP-2-3.2-1. Also the comment number indicated on Form SPP-2-3.2-1 shall be clearly marked on the print so that the location of the dis crepancy is known.

In some areas the Sargent & Lundy drawings may not I clearly indicate the required size and spacing of reinforcement. For these areas, the S&L drawing shall be clearly marked "SEE SHOP DRAWING FOR THIS AREA".

Prints of the latest revision of the reviewed reinforcing steel shop drawings shall be obtained and marked in the same mannec as the Sargent & Lundy drawings. The shop drawings constitute a suitable supplement for the Sargent I & Lundy drawings and shall be maintained as a verification document.

3. Verification of Number of Reinforcing Bars I The Physical Survey Team shall perform the following activities to verify the number of reinforcing bars:

a. Establish Reference Points I

Reference points are locations such as wall edges / corners, slab edges / corners, column lines, or easily identifiable locations between which the bars will be counted. The number of reference points I shall be determined by the Physical Survey Team. The locations of all reference points shall be clearly marked on the drawing.

b. Calculate the Number of Expected Bars Between each set of reference points , the number of I expected bars shall be calculated by dividing the distance between the reference points (in inches) by the spacing shown on the drawing. All decimals from I this calculation shall be dropped. Record this number on the drawing.

This calculation allows for one-half bar space between each reference pont and the first bar.

g c. Count the Number of Bars in the Field i

R r

U l I $

MARBLE HILL GENERATING STATION Date .05-06-80

'PUBLIC SPECI AL PROCESS PROCEDURE Revhion Page 7

8 of 13 l

E SERVICE

Title:

SPP-2 CATEGORY I REINFORCING STEEL The Physical Survey Team shall count the number of I

bars between each set of reference. points and record this number in parentheses on the drawing.

d. Check for Additional Reinforcing Steel At the edges of openings in walls and slabs, additional bars were to be provided as per S&L standard details. The expected number of additonal bars on each side of the ope..ing shall be indicated on the drawing. The counted number of additional bars shall be indicated on the drawing and enclosed g in parentheses.

E

e. Check for Large Spacing Errors The Physical Survey Team shall examine each location for bars which are spaced farther apart than one ara one-half times the specified spacing or where the bars are spaced closer than one bar diameter. Any l W

such spacings shall be noted on the comment sheet and the locations of such spacings shall be approximately loca ted on the drawings.

C. Ver ification of Areas with Unchecked Reinforcing Steel The unchecked reinforcing steel located in the exterior wall of the Unit 2 Containment Building shall be checked. It s ha l l t'a the responsibility of the PSI Construction Manager to select additional sample areas with unchecked reinforcing E g

steel. If possible, there shall be one sample area each for a wa l l , a bea m, a co lumn , a nd a s lab . These areas shall be inspected to determine if the rei.: forcing steel has been erected in a quality workman-like manner. Form SPP-2-3.2-2 shall be used for this verifica tion. The location of these areas shall be clearly indicated on the appropriate Sargent & g Lundy drawings. The perimeters of these areas shall be g clearly marked using a bold black felt tip pen and denoted as

" UNCHECKED ARE A. "

There sL:ll be no nonconformances, genera ted f rom this surveillance since normal QA procedures have not been fully implemented in these areas. When work resumes, this reinforcing steel will be fully inspected as these areas are being prepared for concrete placement. When this inspection g; is conducted, the Contractor shall resolve any comments noted c on Form SPP-2-3. 2-2.

R

<0 l

I .05-06-80 l

MARBLE HILL GENERATING STATION Date Rev W n 7 l .PUBLIC SPECIAL PROCESS PROCEDURE

" ' ' '3 SERVICE

Title:

INDIANA SPP-2 CATEGORY I REINFORCING STEEL I

I 3.3 Records Checklists and marked up drawings for this reinspection are quality records. In addition to their being maintained as quality I documents, a complete set shall be maintained separately until the results of the reinspection have been evaluated and authorization for construction has been received.

I I

I s

I A b

I

J MARBLE HILL GENERATING STATION Date 05-06-80 Revleion l 7

l f .PUBLIC SPECIAL PROCESS PROCEDURE

""* ' ' '3 -

SERVICE

Title:

INDIANA a SPP-2 CATECORY I REINFORCING STEEL 5

Il 4.0 FLOWCHART 3.1 Establic'- Physical Survey Teans

, PSI / C?,!

t I, 3.2 Locate Verification Areas PST 32 ebtain Prints, Identify and Locate Verification Areas PST 3.2 [ Output Dacument

./ rSr /

l 3.2 Conduct Physical Survey '

Indi ate Data on Prints PST YES 3. Are there any deviations?

Initiate 3.2 a Form SPP-2-3. 2-1 S NO o o l P rocess 3.2 3.2 File All Verification Documents Nonconformances pg

=

I

i I MARBLE HILL GENERATING STATION Dem .05-06-80 l Revleion 7 g .PUBLIC SPECIAL PROCESS PROCEDURE Page 11 of 13

Title:

INDIANA SPP-2 CATEGORY I REINFORCING STEEL

' I .

5.0 REFERENCES

1. PMP 5.16, "Special Process Procedures", Marble Hill Nuclear Generating Station, Public Service Indiana.

, 2. ANSI N45.2.6-1973, " Qualifications of Inspection, Examination, and

= Tes(ing Personae'. for the Construction Phase of Nuclear Power Plants," ASMF, ';ew York, New York.

3. Concrete Reinforcing Steel Institute - Western Concrete Reinforcing Steel Institute, " Placing Reinforcing Bars," 3rd Edition, 1976, CRSI, Chicago.

I 4. Sargent & Lundy Drawing S-387 Rev. K (containing General Notes-Concrete Work for Specification Y-2944.)

W 5. Sargent & Lundy Drawing S-497 Rev. R (containing General Notes-Concrete Work for Specification Y-2722.)

6. Sargent & Lundy Specification Y-2722, " Concrete Struct< ires and Site Work," Marble Hill Nuclear Generating Station - Units 1 and 2, Amendment 4, 10-30-79, Public Service Indiana.

I I

a I e c

6 I _,

~

Date 05-06-80 I

MARBLE HILL GENERATING STATION

.PUBLIC SPECIAL PROCESS PROCEDURE RevW m 7 E

"'S' '2 ' 3 "

SERVICE 7, ,,, ;

SPP-2 CATEGORY I REINFORCING STEEL I'

6.0 TABLES TABLE 3.2-1 bar Diameters to be used in Reinforcement Cover Calculations E' W

i BAR SIZE MINIMUM COVER,in.

MAXIMUM COVER,in.

I;

3 3/8 7/16

4 1/2 9/16 :

5 5/8 11/16

6 3/4 7/8

7 7/8 1

8 1 1-1/8 l

9 1-1/8 1-1/4 f

10 1-1/4 1-7/16 1-3/8 1-5/8

11

14 1-5/8 1-7/8 I

18 -

2-1/4 2-1/2 i

i I

i I:

I 8

1 e

--4.#

- - _ _ _ - w~ '-,v m--- - wr -. e - -m--e m ,--,,,,,,---y ~-<

LF 61173_2.j]

TABLE 3.2-2 Clear Cover Requirements and Tolerances Tolerances, in.

Z$[

s2 m .

Concrete Surface Clear Cover Bent Bars Straight Bars M C Situation

3-#11 #14&#18 #3-#11 #146#18 2OO

>Q S. E

. p Concrete Deposited 3" 1/2 I1 I 1/4 I 1/2 0 $N Against Ground hm

>I Formed Surfa es in n FFI Contact with Soil or 2" I 1/2 +1,-1/2 I 1/4 I 1/2 h n Exposed to Weather 8 m i

Q o$

$:D Slabs and Walls not l Exposed to Ground I" for #3-11 +1/2,-1/3 I 1/4' 3h j or Weather 1 1/2" for #146#18 +1,-0 +1/2,-0 h QE i

$ mO l Interior Bars of g @$

Containment Shell' I1 0 (measured from inside 8 3/4" I 1/2 1/4 I 1/2 g $ -4 g

face of liner) m z N

5 20 All Other Work 1 1/2' + 1/2

+1,-0 + 1/4 +1/2 , -0 tg

@' I

"?

,, "8 C

I I

MA?2LE HILL GETI? CI :G S~A!!O" Date 5-06-80 g t

PUBLIC **V181

7 5'

, SERVICE s?rcIAr. PROCESS PROCrnrREs

[ INDIANA .,a E A ..

SPP-2 CATECORY I REI ;FORCI:!G STEEL g l

P2INFORCE"E:!T CO:SENT SHEET PIV. DATE:

SIG'!ATUFIS OF P :YSICAL SURVEYORS: PAGE OF S&L DRAUING NO. Ii

. COMMENT -

NU'OER COM:ENT I

I s

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y.AR3LI HILL GriERA niG S ATION Date 5-06-80 f 5 PUBLIC Revision 7 ;

SERVICE SPECIAL PROCESS PROCEDURES !

[ INDIANA . .,.

l SPP-2 CATEGORY I REI'IFORCING STEEL )

3 SURVEILLANCE OF BARS IN AREAS WHICH -

ARE NOT CONTRACTOR INSPECIED REV. DATE:

SIGNATURES OF PHYSICAL SURVEYORS: PAGE OF S&L DRAWING NO.

3 Are the bars adequately tied to prevent displacement *t YES/NO Are sufficient bar supports used? YES/NO Does general workmanship appear of good quality? YES/NO Additional Comments:

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y_ust. ar :. crnna Inc s A :cx 5-06-80 l , SERVICE SPECIAL PROCESS PROCEDURES

j W E ON INDIANA nm. ,

SPP-2 CATEGORY I REI'EORCD!G STEEL REI'WORCE"ENT COM!ENT SHEET 4

REV. . DATE: 5/I9l&o SIG"ATURES OF PhTSICAL SURVEYORS:

j PAGE / OFJ M SULLIVAN) T. 4-4AZ.E L. S&L DRAWING NO. 6 /M 1 REV I Ed' C0 m sr - E *OD'O E

1 OPENIM6 lM 6 LAB @ 38S'-o"8ETWEEM 60L LINE 804 91 AMO I 40L.LINE L14 F MORTH FACE 6/6 TOP OF 6 LAB THE l$t." ![W'c WA9 Ab FOGLOW9'; C/c =2h' 2hf 2'2,'1'2 i #2 OPENIW6 IM SLAB @ 388'-o" 8ETWEEM COL LIME S04 si AND 40L LIME hl & P, 600TH FACE c/d:: TOP OF SLA6 WERE l AS FOLLOWs: c/c -=2.k!f 2.}#2$,' p,"9l9' bk.'bl,'p['sh'p)' pf

f. . #9 OPEMIMG lM 9LAe> #p&b'-o#BETWEEN COL LlWE pofpl AMD l

40L . LIME M 4 P WEST FACE c/c e TOP OF 6 LAD WERE

9" 5'S f 5 ,'5 ," 5 '9A h1P l , j

4 l 40L. LIWe P To 60L LIWE M lo'-o' sooth OF 60Ltl To f IZ'-O' 600TH OF 40L LIME po. TOP MAT, ApoL STEEL,

E OME #11 @ G" FOOR.TH LAYER.

! MI6blM4 REPAR TOP MATj SEcoWO LAYER OME #ll 612 #AMD j

OME # lle G/'. ~ IboTTOM MAT, MisblMG REBAR. 9560MD L AY ER.3 0ME # llel2/#4 #WE #il @ct.FOORTH LAYER

5 40L LIME 0, 2'-O"500TH OF OOL LINE 30, THIRD LAYER DOTTOM MAT, #llG11j OME #11AOplTIOMAL.

4r, 60L LIWE M 7 2' 0"500TH OF COL LlWE So TOP MAT, SEdoND LAYER 2 PLACES,#11Gl1 00 WoT HAVE MIMIMdM SPACIMG k87 8'-o'560TH OF COL LINE Za amp d'-o'EA6T OF COL LIME P OME AOolTioMAL #4 @ 12" E-W AMD Two. ADDITIOMAL #4 @l2# N-5 l ATTACHMENT 1.G.B i TYFICAL INSPECTION COMMENT SHEET I

_ .-__ _ .y._.,- _ _ . - _ _ . . , ,,,,,,,w... ...,_,,yy.-_w,

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, nastr 212. GI:7I2.CI::G Sn~!CN Dal, g , 5-06-80 SEFiVICE SPEcut rR0 CESS PRocEcunES

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l' SPP-2 . CATEGORY I REINFORCING STEEL REINFORCE"ENT C0!?!ENT SHEET REV. ,DATE: S/l%bo sic :ATURES OF PNYSICAL SURVEYORS:

PAGE 1 0F @

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11 P LlWE. WALL, col. LIM'E 28 3 To col. LIME 2G # 11 @ 9 #

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14 P L lWE WALL, FROM COL LlWE bo TO COL LIME 28 S OME ADDITIOMAL d"ll @ l2# EAST FACE AMO. CNE AOolTIONAL d'Il @ 12# WEST ICAcE t

15 P LINE WALL FROM COL LIME Bo To d'-o#MOETH OF l q col LiWE ei, OWE AooiTjowAL eiies"oM TsE wEeT FACE AlJO ONE ADolTIONAL # ll @ G"oM THE EAST FACE.

ATTACHMENT 2.6.3 TYPlcAL Ikist*ECTtoN cc+ AMENT SHEET l

I .

~

, PUBLIC

81 *

', SERVICE SPECIAL PROCESS PROCEDURES

@s /' INDIANA nu.

SPP-2 CATEGORY I REINFORCING STEEL ,

l PII'! FORCE?ENT C0!NENT SHEET P2V. ,DATE:._5)I*1)80 SIG'iATURES OF P:IYSICAL SURVEYORS: PAGE ~ $ OF $

K'. SOLLIVAM T. M A7_EL S&L DRAWING NO. S-G92 EEV.J

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NUM3ER EL@g3.o#ARgA; 4 C0! CENT

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FACE AT AFFRox. EL. 969'-o#AMD 4 ADDITIOMAL 4 DAR9 AT EL 789'-o' coOTH FACE 1

16 M LIWE WALL AT col. LINE 90- 2#6 OIAGOMALS

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ADDITioMAL OM MORTH FACE AT EL pa7Lo" AMP 2 #

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ATTACHMENT 2.G.3 TYFicAL [MSPECTION COMMENT SHEET l

I DRAWING DRAWING Il:

DRAWING NO. REV. DATE NO. REV. DATE NO. REV. DATE S-379 F 08-08-79 S-696 Y 03-03-80 . S-910 V 02-20-80 S-380 F 08-08-79 S-697 W 12-10-79 S-911 P 11-16-79 S-670 K 12-22-78 S-698 K 12-19-79 S-916 E 08-21-79 S-671 F 02-09-78 S-700 L 12-19-79 S-917 B 06-01-78 l

=

S-672 V 09-26-79 S-702 F 09-12-79 S-965 K 08-21-78 S-673 S-674 U 05-08-79 09-12-79 S-704 J 12-10-79 S-966 K 08-21-78 g G S-705 G 08-28-78 S-967 J 08-21-78 5 S-675 N 12-19-79 S-706 H 01-18-80 S-968 F 11-10-78 S-676 G 10-26-79 S-707 J 12-19-79 S-969 L 05-22-79 S-678 G 08-15-78 S-708 K 03-09-79 S-970 M 06-08-79 S-679 V 07-06-79 S-715 G 05-08-79 S-995 K 04-14-80 S-680 T 09-26-79 S-717

R 07-20-79 S-996 M 04-25-80 S-681 P 03-06-80 S-741 P 09-26-79 S-1057 U 12-21-79 g S-682 N 04-10-80 S-744 R 09-26-79 S-1061 P 12-21-79 3 S-683 R 09-26-79 S-750 F 12-22-78 S-1077 E 09-25-79 S-684 H 08-25-78 S-763 C 11-15-77 S-1402 H 05-09-78 S-685 M 12-10-79 S-811 .( 12-18-79 S-1550 J 05-31-79 S-686 J 09-26-79 S-812 S 12-21-80 M-1216-1 C 06-26-79 S-688 M 01-02-79 S-876 Z 03-07-80 M-1218-1 G 08-28-79 S-689 L 05-08-79 S-895 R 07-18-79 M-1219-1 C 02-22-79 l S-690 R 03-06-80 S-896 K 12-11-78 M-1220-1 C 02-22-79 5 S-691 R 03-06-80 S-900 L 11-09-79 M-1221-1 E 08-28-79 S-692 J 08-24-79 S-904 R 04-25-80 M-1222-1 C 04-06-79 g S-693 G 10-20-78 S-905 P 04-25-80 M-1222-3 G 04-07-80 g S-694 D 10-20-78 S-906 L 12-19-80 M-1224-1 C 02-22-79 S-695 L 12-19-79 S-907 M 10-15-79 M-1225-1 D 02-06-80 I

I I

ATTACHMENT 2.6.4 I

LIST OF DRAWINGS USED FOR SPP-2 I

I

I I PC-0425 PC-0648 PC-0668 PC-0680

0493 0649 0669 0681 I

0546 0587 0637 0650 0651 0652 0670 0671 0672 0682 0683 0684 I 0638 0639 0640 0653 0654 0663 0673 0674 0675 0685 0686 0687 I 0664 0641 0676 0688 0642 0665 0677 0702 0643 0666 0678 0703 0644 0667 0679 0704 I 0645 0646 0647 I *(R)-Revision I

I I

I I l I

I

( ATTACHMENT 2.6.5 LIST OF CARS I

\

l l

l l TOLERANCE IN SPECIFICATION TOLERANCE FOR REJECTION ITEM CRITERIA SOURCE REJECTION SOURCE R

R 3

s R Ef fective depth "d" 1 3/8' ACI 318-77 1 3/8" ACI 318-77 O

y ., d <8"

$ N y M ACI 318-77 ACI 318-77 y i 8(d(24" 1/2" 1 1/2" o 5

" 4 1 1/2" ACI 318-77 1 1" for 24" d 48" See Note 1 M y d)24" M g i 2" for 48" d 96" See Note 1

@ g- 1 4" for 96" d See Note 1 f Cover - Tolerance same as "d" but cover not to be de-ACI 318-77 - 1/3 Minimum Cover ACI 318-77 or

[

g creased by more than 1/3 of specified cover, nor

+ See Tolerance on "a" See Note 1 g decreased more than 1/4" g to formed soffits.

+ Tolerance same as "d" NOTE 1. Maximum stress is within 5% of allowable stress.

I 3.0 CATEGORY I STRUCTURAL STEEL 3.1 ABSTRACT This section describes the results of an inspection program conducted by Public Service Company of Indiana, Inc. (PSI) and Newberg-Marble I Hill (N-MH) for the physical verification of Category I structural steel at the Marble Hill Nuclear Generating Station. The resulting conclusions, evaluations and proposed follow-up actions to be taken are discussed. The program consisted of documented visual and I physical inspections conducted by qualified and trained teams in accordance with an approved Special Process Procedure, SPP-3.

Based on the results of these examinations and subsequent engineering evaluations, PSI will take corrective measures to replace or repair items causing unsatisfactory conditione upon restart of I safety-related construction activities. Since the structural steel is exposed and can be inspected and repaired, the completion of necessary repairs will ensure the integrity of the structure. In addition to the immediate corrective actions, PSI and N-MH will I conduct a training program for production and inspection personnel.

The training program will be structured to identify the probable causes which directly or indirectly led to the problems encountered I and will instruct personnel how to prevent these conditions in future work.

3.2 INTRODUCTION

3.2.1 Commitments PSI committed to a verification program for structural steel in Article III. A.2.d.iii. of the " Description of Licensee Activities Addressing Order Confirming Suspension of Construction". The commitment was as follows:

Category I itructural steel will be examined to verify that the following items comply with the design requirements.

(1) M:;2er sizes , including the detection of missing members.

(2) Bolted connections including: bolt material, size, count, and tightness, and the existence of correct washers. Torquing of one hundred percent (100%) of structural joints that have not been previously documented by U.S. Testing Company. Joints that have been previously documented will be tested in a statistical sample providing ninety-five percent (95%) reliability at a I ninety-five percent (95%) confidence leve. . The torquing will be as required by specification; a minimum of ten percent (10%)

of the bolts in each joint, but not less that two bolts per joint will be torqued unless a rejection is made, in which case I the sample size is increased.

I I'

(3) A documented visual check will be made to assure member configurations are in accordance with design drawings.

These commitments were met as discussed in the remaining sections of l this report. W 3.2.2 Procedure Outline This report summarizes the measures taken to identify and document the nonconformances observed in the Category I structural steel and determine the necessary corrective actions. The measures are described in detail in Subsection 3.3 and consist of the following:

(1) Preparation and approval of a procedure, SPP-3, for the physical inspection and verification of the in place Category I structural steel; (2) Establishment and qualification / training of the Physical Survey Team (PST);

(3) Compilation of applicable Sargent & Lundy (S&L) structural drawings and the fabricator's erection and shop drawings and ensuring that design changes are specified on the erection drawings; (4) Physical inspection of the structural steel; (5) Documentation of inspection results; (6) Field marking of structural members, connections and shear connectors as the inspection progressed; and (7) Preparation of Corrective Action Requests (CARS) to formally identify nonconforming items and to track the progress of any corrective actions required as a result of the evaluations made l

=

in the disposition of the CARS.

3.3 DISCUSSION 3.3.1 Procedure for Physical Verification Special Process Procedure SPP-3, " Category I Structural Steel", was l prepared by S&L and reviewed and approved by the PSI Project Engineering and Quality Assurance Managers. This procedure

, established written criteria and instructions for the physical l W

I verification of erected structural steel by specifying methods of identification, evaluation and documentation.

Verification activities included documented inspection of member sizes, high strength bolted connections, unauthorized alterations to member configurations, field welds and shear studs.

l Procedure SPP-3 is included as Attachment 3.6.1.

I b

I 3.3.2 Establishment, Qualification and Training of Physical Survey Teams 1 I The survey teams were established, organized and staf fed as described I

in SPP-3. The commitments made in Section III.A.2.b. of the I " Description of Licensee Activities Addressing Order Confirming Suspension of Construction" were incorporated into SPP-3.

In addition, survey team members attended documented training sassions which dealt with the SPP-3 procedure.

3.3.3 Compilation of Survey Data Prior to the physical inspection, applicable structural steel erection drawings and fabrication drawings were reviewed. Approved design changes per Contractor Change Requests, Engineering Change I Notices, Field Change Requests and Nonconformance Reports (CCRs, ECNs, FCRS and NCRs) were compiled. These documents formed the basis of the physical inspection. The drawings showed the structural steel revisions as of August 7, 1979 or later revisions for the areas I inspected. A list of the drcuings used is given in Attachment 3.6.2.

3.3.4 Physical Inspection The scope of the physical inspection included the following areas, which are shown in Attachment 3.6.3:

(1) In-place steel erected by American Bridge (AB) and N-MH which had been inspected and accepted, (2) In-place steel erected by N-MH which had not been inspected and accepted and (3) In-place steel erected by AB which had not been inspected and accepted.

The structural steel was fabricated by INRYCO, Inc.

Verification activities for structural steel identified in (1) and (2) above consisted of:

(1) Member size verification, (2) Verification of high strength bolted connections (visual inspection and torque test),

(3) Identification of unauthorized alterations, (4) Verification of shear studs for composite beams and (5) Field weld verification.

For in-place steel erected by American Bridge whi@ bs1 not been inspected and accepted, a 10% sample was verified tot member sizes.

I

I Although erection in these areas was in progress and work was incomplete, the inspection was carried out to review the general nature of workmanship and compliance with design specifications. No nonconformances were generated for this group since inspections by the contractor had not yet been initiated. These areas will be inspected again after restart of Category I activities and the erection of these areas is completed.

The inspection procedure, accept-reject criteria and the forms for filing the survey reports are described in detail in SPP-3. A typical drawing and typical inspection forms are shown as Attachments in 3.6.6 and 3.6.7.

3.3.5 Documentation of Results The results of the inspections of in-place structural steel erected by AB and N-MH which had been inspected and accepted and in-place I

structural steel erected by N-MH which had not been inspected and l accepted were recorded under the direction of a PSI Level II 5 inspector as follows:

(NOTE: The forms described below are part of Attachment 3.6.1, unless otherwise noted.)

(1) Each area that was visually inspected was clearly indicated by marking the drawing.

(2) The member sizes and piece marks were checked and the results l were recorded on Form SPP-3-3.2.1-1, SPP-3-3.2.1-2 and 5 SPP-3-3.2.1-3.

(3) Members were inspected for unauthorized alterations such as field coped beams, unauthorized welds or damaged flanges. The results were recorded on Form SPP-3-3.2.3-1.

(4) Connections were visually inspected for number, size and I material of bolts and for the presence of hardened steel washers or plate washers. The results were recorded on Form SPP-3-3.2.2-1 l

us (5) Bolts in connections which were not visually rejected were then g torque tested and the results were recorded on Form g SPP-3-3.2.1-2.

(6) Field welding was inspected in accordance with Article 8.15.1 of AWS D1.1-80 and the results were recorded on Form SPP-3-3.2.5-1.

(7) Shear studs for composite beams were visually inspected and those studs not found to be visually acceptable were bend tested. Studs which did not " ring" when tapped with a hammer were also bend tested. The results were recorded on Form SPP-3-3.2.4-1.

I I

I (8) Areas where the inspection could not be conducted were noted as such on the drawings or on the inspection forms, together with the reason for not completing the inspection. Structural steet I members and connections which could not be inspected under the guidelines of this program are listed on Attachment 3.6.3.

(9) Inspection forms were annotated with the names of survey team members and with the date of the inspection.

The results of the inspection of in-place structural steel erected by I AB which had not been inspected and accepted were recorded under the direction of a PSI Level II Inspector. The steel that wt inspected was clearly indicated by marking the drawing. The member sizes and piece marks were checked and the results were recorded on Forms SPP-3-3.3.0-1, SPP-3.3.3.0-2 and SPP-3.3.0-3. Inspection forms were annotated with the names of survey team members and i .th the date of the inspection.

The results of the inspection of in-place structural steel erected by AB which had not been inspected and accepted show that one out of 122 I members inspected was missing. This missing member was in an area where work was still in progress. It will be installed after safety-related construction activities resume.

3.3.6 Marking and Identification Inspected steel was marked in accordance with Section 4.4 (Field I Markings) of SPP-3. These field markings along with marked-up erection drawings and corresponding inspection forms will assure that the nonconformance can be located in the future to complete corrective actions as required.

3.3.7 Identification of Inaccessible Areas I ,

Areas which remain inaccessible for inspection were recorded as described in Subsection 3.3.5. The connections which could not be inspected because the inspectors could not safely gain access, I because of interferences with metal decking or because the connections are temporarily covered will be inspected af ter safety-ulated construction activities resume. If any nonconforming conditions are found, they will be addressed on Nonconformance I Reports and the subsequent disposit requirements are satisfied.

i ons will assure that the design In addicion, some members could not be inspected because they are embedded in concrete. These members and I connections which are embedded in concrete were provided to facilitate construction. These members are not required to resist loads after the concrete has been placed. The connections which could not be inspected because of interferences with other structural I steel members are connections for diagonal bracing members. These diagonal bracing members are part of a horimntal truss. This horizontal truss provides stability during construction but it is I

i not required to resist loads after the concrete slab at that l

elevation is placed. The re fore , further inspection of these diagonal l bracing members will not be required under this verification program.

I I

3.3.8 I

Preparation of Corrective Action Requests Based on the results of the physical inspections, the Corrective Action Requests (CARS) were addressed to either N-MH or INRYCO, Inc.,

depending on the nature of the noncomformance encountered. A list of the 155 CARS generated under the SPP-3 program is shown as Attachment R 3.6.5.

3.3.8.1 The nonconforming items discovered and forwarded to N-MH for resolution consisted of the following general categories:

(1) Member Size Verification.

Noncomformances in this category addressed missing members and members installed in the wrong location. ,

(2) Visual and Torque Inspection of Bolted Connections.

Most of the adverse conditions in this categor3 indicate that the joints were incomplete. The conditions encountered were loose and/or missing bolts and nuts; missing hardened or beve11ed washers; wrong type or size of bolts; damaged bolts, nuts or washers; foreign material in bolted connections; mating surfaces not snug; insufficient bolt projection; under or oversized filler plates in column splices ; excessive galling or peening at connections; and improper bolt torque.

l (3) Unauthorized Alterations.

CARS in this category addressed damaged webs and flanges of columns and beams, varped or twistad members, bent and/or iamaged stiffener plates and geard plates, deformed gusset plates or clip angles, field coping at ends of beams, unauthorized welding of hardware to structural members and alterations to bolt hole sizes to facilitate fit up.

(4) Shear Studs for Composite Beams.

Composite beam studs which failed the visual or subsequent bend tests were identified as nonconformances. E 3

(5) Field Welds Field welds were unacceptable at various locations duu to undercut, weld porosity, poor configuration or profile, incomplete fusion, insufficient throat thickness or cracked welds. Missing field welds were also addressed. Most of the missing welds occurred in instances where embedded plates were missing or miolocated.

I 3.3.8.2 The nonconforming items discovered and forwarded to INRYCOs Inc. for I

resolution consisted of the following general categories:

I I

I (1) Missing Members and Wrong Piece Marks.

Certain members were not shown on erection drawings, and were thus not fabricated. One case of erroneous piece mark I identification was also identified, however the member size was in accordance with the design dre. sings.

(2) Verification of Bolted Connections.

Missing plate washers constituted the nonconformances in this category.

3) Unauthorized Alterations.

Several nonconformances of a minor nature pertaining to unauthorized alterations were addressed. These related to the differences in the number of bolt holes actually provided in certain structural steel members.

3.3.8.3 Oct of a total of 155 CARS generated under the SPP-3 procedure, 140 were addressed to N-Mit and the remaining 15 to INRYCO. Inc. Each CAR R pertained to one or more of the generic nonconformances described above, and identified locations where nonconformances were observed and the requirement of the applicable specifications.

3.3.9 Corrective Action The disposition of each CAR was proposed by a representative of the I contractor (N-Mil or INRYCO, Inc.). Since American Bridge is a subcontractor to N-MH, each CAR written against American Bridge erected structural steel was addressed to N-Mll. The I architect / engineers (S&L) reviewed the design adequacy of each disposition and PSI Quality and Project Engineering then reviewed and approved the disposition. Where the responsible contractor requested an engineering evaluation by S&L to determine the acceptability of I the as-built condition or the requirement for rework, S&L's engineering dispostion was then reviewed and approved by PSI Quality and Project Engineering.

3.3.9.1 The proposed corrective actions for CARS addressed to N-Mit ware as follows:

(1) Member Size Verification:

Missing members will be installed. For identical members which I have been interchanged in location, the resolution is to accept the members as erected since the integrity of the structure is not affected. Out of a total of 44 nonconformances encountered I in this category, five vere related to mislocated members and 39 were related to missing members. Most of the missing members

'were in areas where inspection had not been completed as work was still in progress.

I' (2) Verification of Bolted Connections:

Six hundred and forty three connections failed visual inspection. The bolts will be installed in these joints per design specifications. Connections which satisfied the visual inspection were torque tested. Three hundred and ninety connections failed to pass the torque inspection. The l uisposition of the CARS related to torque test failures is to E re-torque the bolts in each connection and to retest to insure the bolts in the connection meet the minimum values required by specification.

(3) Unauthorized Alterations.

The discrepancies in this category were reviewed to determine if the as-built condition would satisfy the design requirements.

This review was made by the consulting engineers.

There were 19 instances where clip angles or gusset plates were damaged. Where the load transfer mechanism was unimpaired, the as-built condition was accepted. However, where it was determined that the deformations of the angles or plates reduced the contact area of the mating surfaces, the resolution was to replace the clip angles or gusset plates. Two damaged guard E plates were found. The guard plates are not structural members 3 and damage to these plates is not of structural significance.

There were 95 damaged beams and columns. For each damaged beam or column, the extent of the damaged area and its location in relation to points of high stress was considered. For example, on simply supported beams, a locally damaged bottom flange is E not detrimental if the damage is lcca ted near the support where W bending stresses are very low. Such uamage was investigated by comparing the flexural and/or shear stresses in the damaged g section against the design stresses. Where the damage occurred g in a stressed portion of the member, the member will be repaired by welding a cover plate over the damaged area, or the member will be replaced.

There were 46 nonconformances where small angles, washers, nuts and pipes were found welded to structural members. The attachments were used as guides for safety cables or for

. temporary braces and supports for the various trades employed.

l These welds are of a local nature and are not detrimental to the structure.

The AISC Code of Standard Practice states that normal erection operations include the correction of minor misfits by moderate 3 i amounts of reaming, chipping or cutting. Field coping of beams g

. was reviewed to assure that member capacity and stability were not jeop'ardized. Where calculations showed that capacities were not adequate, the coped ends will be reinforced. In cases where the members are adequate with the additional coping, the =

as-built condition was accepted, however, such field alterations

_g_

1 l

I will be ground smooth to a 1/2 inch minimum radius to avoid local stress concentration. Thirty-five such nonconfoming conditions were identified and documented.

There were seven nonconformances pertaining to warped or twisted members, or members with a transverse sweep. These members were I checked against allowable fabrication and mill tolerances and an engineering review was made for stress levels at the affected areas to determined which members could be accepted or needed replacement.

(4) Shear Stude:

The resolution for the 22 failed shear studs is to remove them and to replace them as per design specifications.

(5) Field Welds:

CARS in this category were primarily addressed to the welds required for clip angles for beam and block wall column connections.

Where field welds are required for block wall column connections ar for beam clip angles, the weld needed to meet design requirements is the fillet weld at the toe of the connection angle. Weld returns are required by the AISC Specification for the Design, Fabrication & Erection of Structural Steel for I Buildings only where practicable, and do not constitute a design requirement. The welds to the beam seat angles are required only for erection purposes. Thus, welds other than those required for design considerations are accepted as is. Parts of the welding required by design considerations which do not conform to the specifications will be repaired in accordance with approved procedures.

Out of the 810 welding nonconformances, 423 were ettributed to undercutting. The permissible undercut valuea used for the inspection were determined from Figure 8.15.1.5 of AWS D1.1-80.

This figure permits various allowable undercut values depending upon the direction of primary stress at the weld. Since the welding inspectors did not have any way of detemining the direction of the primary stress, they were instructed to use the most conservative value. shown. Therefore, nonconformances were generated for undercut depths in excess of 0.01 inches. As I discussed above, the welds required by design are those parallel to the web of the beam or blockwall column. At these locations the primary stress which is induced by transfer of shear f rom I the beam or column to the embedded plate is parallel to the weld line, llence the resolution to the CARS addressing the welding violations are to:

(A) Consider the welds required by design I 9-

I (B) Evaluate permissible undercut values from Fig. 8.15.1.5 of AWS DI.1-80, based on primary tensile stress parallel to undr cut and to repair the welds as necessary.

Of the remaining 387 nonconformances, there were 250 instances of missing welds and 61 instances of unauthorized welding.

Missing welds were encountered where the embedded plates were misaligned or missing. The resolution to these CARS was to install plates by using expansion anchors and to make the required connections. Unauthorized welding was encountered g where bolt holes fer clip angles were either out of place or g omitted. The steel erector welded clip angles directly to the supporting members. These nonconformances were resolved by comparing the shear capacity of the weld groups with ' the respective member capacities. If the weld capacity exceeded member capacity, the field weld substitution was accepted, otherwise additional welding was specified.

The orientation of each unauthorized weld uns reviewed to assure that welding across the flange was not done. In instances where such welds appear, a cover plate will be welded across the af fected area.

3.3.9.2 Corrective Actions for CARS addressed to INRYCO, Inc. were as follows:

(1) Member Size Verification:

Two cases of missirg members on erection drawings were reported. The resolution is to revise the erection drawings and to supply the required members.

(2) Verification of High Strength Bolted Connection:

There are 88 instances of missing plate washers. These were g caused by inconsistencies in shop drawing and field bolt g placement lists. The bolt placement lists will be revised and the required plate washers will be fabricated, shipped and installed.

(3) Unauthorized Alteration The seven items in this category pertained to members where the number of bolt holes on shop drawings did not agree with the number of bolt holes in the member. Where more bolt holes are requ i red , they will be field drilled. Where additional holes are provided, the sections were chacked for adequacy and accepted as-built since they are structurally adequate to support the design loads.

3.3.10 Actions to Prevent Recur renc e 3.3.10.1 Quality Assurance / Control, Construction, Engineering and Production staffs will be supplemented with personnel qualified in structural steel work in accordance with specified codes and standards.

I

I 3.3.10.2 Existing procedures will be revised and additional procedures will be developed to prevent recurrence of these conditions.

3.3.10.3 Procedural "lloid Points" will be added to allow ef fective inspection of work-in-progress.

I 3.3.10.4 An indoctrination and training program in structural steel work will be developed and implemented for inspection and production personnel.

3.4 CONCLUSION

S Through the extensive physical verification of in-place Category I structural steel, areas not in confonnance with design documents have been identified and documented. The adverse condit'ons encountered can be directly attributed to the lack of ef fective installation procedures and the lack of ef fective inspection.

I The generic problems in installation and inspection of structural steel have been identified and evaluated. These problems have been addressed and will be corrected.

A training program will be established for construction and inspection personnel to cover the interpretation of design and erection documents and the erection procedures for structural steel.

Special emphasis will be given to the inspection of structural steci received from the fabricator, installation of bolted connections and field welding. The establishment of the training program and its I implementation will be accomplished prior to either performing the remedial work discussed in this report or erecting any additional structural steel.

Structural steel that could not be inspected due to accessioility will be inspected and repaired as necessary af ter the resumption of safety-related construction activities. Since exposed steel work can I be repaired as per the resolutions of the CARS addressed in this program, these repairs will ensure that the erected Category I structural steel adequately meets the design requirements.

3.5 REFERENCES

3.5.1 AISC, Code of Standard Practice 3.5.2 AISC, Specification for the Design Fabrication & Erection of Structural Steel for Buildings 3.5.3 AWS D1.1-80, 1980 Structural Welding Code-Steel I'

I 3.6 ATTACIMENTS

3.6.1 SPP-3

Category I Structural Steel.

3.6.2 List of Drawings Used.

3. 6. "1 List of Inaccessible Structural Members and Connections.

3.6.4 Scope of Erection and Inspection 3.6.5 List of CARS.

3.6.6 Example of Erection Drawing Used for Inspection.

3.6.7 Typical Inspection Forms.

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SUMMARY

OF REVISIONS PROC. NO. SUBJECT SPP 3.00 CATEGORY I STRUCTURAL STEEL REVIS ON REvi$lON DESCRIPTION p

I~ 4 Format change to conform to PMP 5.16.

Procedural changes in bolted connection inspection, field weld inspection, and field markings. -

Added Attachment 11.

5 Revised procedure for inspection of Shear Studs for I Composite Beams, Paragraph 4.2.4.

6 Revised Paragraph 2.1 and 2.2.

Attachment 3.6.1 REVISION AUTHORIZATION REVISION l NUMBER 4 5 6 lb^UED 04-29-80 05-13-8,0 06-06-80

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MARBLE HILL GENERATING STATION o. 3 06-06-80 PUBLIC SPECIAL PROCESS PROCEDURE Revklon 6

u SERVICE 7, , ,, .

INDIANA SPP-3 CATECORY I STRUCTURAL STEEL TABLE OF C0tiTEtiTS SECT 10t1 TITLE 1.0 PURPOSE 2.0 APPLICABILITY 3.0 DEFIllITIO:1S 4.0 IrlSTRUCTI0 tis 5.0 REFEREliCES Ii

! 6.0 ATTACitMEllTS h

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MARBLE HILL GENERATING STATION Dag 06-06-80 6

PUBLIC SPECI AL PROCESS PROCEDURE Revision I SERVICE INDIANA

Title:

p*** 2 of 13 I SPP-3 CATEGORY I STRUCTURAL STEEL 1.0 PURPOSE This document establishes the procedure for inspecting, by physical I verification, in place Safety Category I structural steel for agreement with design requirements; or, where discrepancies exist, to document the deviations in accordance with existing PSI procedures.

2.0 APPLICABILITY ,

2.1 Two distinct types of in place steel will be examined. The first type is all in place steel erectad, inspected / accepted by Newberg-Marble Hill and American Bridge.

I 2.2 The second type is in place steel erected by Newberg-Marble Hill and American Bridge which has not been inspected / accepted, work-in process.

i.e.,

Nuclear Steam Supply System (NSSS) support steel is not included in 2.3 the scope of this SPP-3. This support steel is generally adjusted during its installation, and these in place adjusted conditions are I taken into account in the development of a Final Stress Report.

Therefore, verification of this support steel shall be performed during normal construction activities. Containment circular crane girder steel is also not included in the scope of SPP-3. Erection I of this crane girder steel has not progressed to stage which could lend itself to an inspection. This crane girder steel shall be fully inspected per nonnal QA procedures when work resumes.

E 3.0 DE FINITIONS Structural Steel Erection Data Documents - Contractor prepared file containing all documents applicable to the preparation of a particular area for structural steel erection including S&L Design drawings, Shop drawings, and Contractors Change Requests.

Member Configuration - The physical characteristics of a structural steel member as received' f rom the fab rica to r.

Erection Drawing - A document indicating structural steel members to be erected at a given elevation in a building. All such members are ;

identified by a piece mark number. l Piece Mark Number - A series of alpha numeric characters which is written on each structural steel member.

Shop Drawing - A document which shows the configuration of a structural

@ steel member as fabricated by the Contractor furnishing structural steel; each member being identified by a piece mark number.

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MARBLE HILL GENERATING STATION Dao 06-06-80 6

PUBLIC SPECIAL PROCESS PROCEDURE Revision 3 of 13

"'S' SERVICE

Title:

INDIANA SPP-3 CATECORY I STRUCTURAL STEEL E

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1 NRC - Nuclear Regulatory Commission PSI - Public Service Indiana Physical Surveyor (PS) - An individual who performs the inspection work involved in the verification procedure.

I Physical Survey Team (PST) - A group of individuals, includin,g a Team Leader and Physical Surveyors, who are responsible for the performance of the visual inspection and documentation.

N-Mll - Newberg-Marble 11i11 S&L - Sargent & Lundy Engineers USTCo - United States Testing Company, Incorpo ra ted Team Leader (TL) - An individual who is a member of the Physical Survey Team and supervises the work of the Physical Surveyors.

Bolting Inspection Technician - A member of USTCo who is also a member of l the Physical Survey Team, and attests to all data collected regarding 5 torque inspections of bolted connections.

Flash: Wetness area witnessed at the junction of a shear stud and the base metal (structural steel) due to the liquification and subsequent cooling of the metals, during the physical stud welding procedure.

4.0 INSTRUCTION 4.1 Establishment of Physical Survey Team The establishment of the Physical Survey Teams shall be the responsibility of the PSI Construction Manager with the concurrence of the PSI / Project Engineering Manager. All Physical Survey Teams shall work under the direct supervision of the Team Leader. Each =

j Team Leader shall be a PSI Engineer who satisfies one of the following qualifications:

1. BS degree plus one year experience in structural steel related I work.

2. Five years experience in structural steel related work. I Each Physical Survey Team will contain at least one PSI QA l Engineer / Inspector qualified to Level II under ANSI N45.2.6-1973, at E S least one USTCo Bolting Inspection Technician qualified to Level II E and a PSI Welding Inspector qualified to Level II. Other inspectors g E from PSI or N-Mll qualified to Level I may be assigned to the g G

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MARBLE HILL GENERATING STATION D:te 06-06-80 6

PUBLIC SPECI AL PROCESS PROCEDURE Revision 4 of 13 I SERVICE INDIANA

Title:

"'S' SPP-3 CATEGORY I STRUCTURAL STEEL

~rnysical Survey Team as necessary. Each Team Leader shall be under the direct supervision of the PSI Construction Area Manager for the performance of the physical survey, who in turn is responsible to I the PSI Construction Manager for the perfonnance of the work. The PSI Project Engineering Manager is responsible for providing technical support to the entire program. The recording of data shall be under the direction of the PSI Level II Inspector.

All PSI /NRC communications associated witi implementation of the verification program shall go through the PSI Project Engineering Manager.

Prior to actuat inspection, the Physical Survey Team shall be I re s pons ib le for obtaining all applicable Erection drawings, Shop drawings and the Structural Steel Erection Data Documents; including American Bridge release records indicating items released as inspected / accepted. The Physical Survey Team shall review all S&L approved design changes (CCRs, ECNs, FCRs, NCRs) and note any changes on Erection drawings. In addition, the Physical Survey Team shall determine which American BrMge erected members have been I documented as being inspected /acce:.ted and note the following on the Erection drawings:

a. For steel members that have been inspected / accepted "1" next to the member size.

b. Fo r s t ee l n.embe rs r.o t yet inspected / accepted "N" next to the member size.

For all Newberg-Marble tiill erected members, the Physical Survey Team shall note an "A" next to the member size on the Erection I d ra wing -

At the discretion of the Team Leader, to r<tduce drawing mark up, a I note throughly documenting the scope of work involved may be added to the Erection drawing.

Af ter all applicable documents have been obtained, the following in place verification activities shall be carried out for each member and connection requiring verification.

I 4.2 Verification Activities for All In-Place Steel Erected by Newberg-Marble llill and In-Place Steel Erected, Inspected / Accepted by American Bridge.

4.2.1 Member sizes (Beams, Columns, and Braces)

E All in place member size , are to be verified by cor.. paring the I E G

f piece mark number of ar in place member, when accessible, with the piece mark nismber of that member as shown on the Erection O

MARBLE HILL GENERATING STATION D:te 06-36-80 6

PUBLIC SPECI AL PROCESS PROCEDURE Revk.c.i p"" 5 of 13 SERVICE

Title:

INDIANA SPP-3 CATECORY I STRUCTURAL STEEL d ra wing. When inaccessible, a physical measurement will be conducted to verify the member size. The documentation of the verification of member sizes shall be on Form SPP-3-3.2.1-1. If an in place piece mark in a given location is in agreement with what is shown on the Erection drawing, it shall be noted in the ar riate space on Form SPP-3-3. 2.1-1 and the veri t - uion of that particular member size can be considered complete.

If a discrepancy exists between the in place piece mark and l the piece mark shown on the Erection drawing, it shall be B noted in the appropriate space on Form SPP-3-3.2.1-1 and Form SPP-3-3.2.1-2, which shall include a free-hand sketch of the framing layout in tha vicinity of the discrepancy. As a g

g minimum this sketch shall include; beam location with respect to major column line coordinates (in the case of a column or vertical brace, the sketch shall include both plan and cleva tion views), eleva tion (e.g. 451'-0"), the in place size and piece mark, and the Erection drawing size and piece mark.

The verification shall also include a check for missing II members. The detection of missing members shall be performed by visually observing the in place framing and noting if any members, as shown on the Erection drawings, are missing (can also be detected by the Presence of exposed bolt holes). The documentation of such discrepancies shall be on Form SSP-3-3.2.1-3 Nonconformances shall be dispositioned in accordance with Paragraph 4.5. '

4.2.2 liigh Strength Bolted Connections All in place bolted member connections shall be verified with respect to: number of bolts, bolt sizes, bolt material, l W

and presence of hardened washers (where required). These items shall be reviewed against the data shown on the Shop g d ra wi ngs . In addition, for connretions with long slotted E holes on an outer ply *, it shall be verified that a plate washer or continuous bar of at least 5/16" thickness with standard holes has been provided. This washer or bar shall

Long slotted holes are normally 1/16" wider than the bolt diameter and a minimum length as follows: 1/4" larger than bolts 7/8" and less in diameter, 5/16" larger than bolts 1" i

S in diameter and 3/8" larger than bolts 1 1/8" and greater in I I $ d iame t e r. In no case shall the length be greater than 21/2 l l Q times the bolt diameter.

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MARBLE HILL GENERATING STATION D:te 06-06-80 PUBLIC SPECIAL PROCESS PROCEDURE I SERVICE

Title:

Revision 6 of 13 SPP-3 CATECORY I STRUCTURAL STEEL be of structural grade material and shcIl itself be separated from the bolt head (or nut) by a hardened washer (A490 Bolts shall have hardened washers on both bolt head and nut.) Form SPP-3-3.2.2-1 shall be used to document the above.

The verification team shall also perform an inspection for bolt tightness. This inspection for bolt tightness involves I visual inspections and torque inspections as specified below. Torque inspection shall not be undertaken for a connection if it has been identified as a nonconformance during visual inspection.

4.2.2.1 Visual Inspection for Bolt Tightness:

Each bolt shall be visually checked by observing if the point of the bolt is protruding a minimum of one-half (1/2) thread beyond the nut when completely I installed. The documentation of this visual inspection for bolt tightness shall also be on Form SPP-3-3.2.2-1.

4.2.2.2 Torque Inspection for Bolt Tightness:

Each connection shall be torque inspected with a

'I calibrated torque wrench in accordance with Subsection 6(d) of the AISC Specification for Structural Joints Using ASTM A325 or A490 Bolts.

I This AISC Specific.: tion includes the method by which the torque wrench is calibrated in establishing the job inspecting torque, and the number of bolts (per connection) to be subjected to the torque inspections ("... 10% of the bolts but not less than two (2) bolts, selected at random in each connection. If no nut or bolt head is turned by I this application of the job inspecting torque, the connection shall be accepted as properly tightened.

If any nut or bolt head is turned by the application I of the job inspecting torque, this torque shall be applied to all bolts in connection. . . . . .").

convenience, the requirements of the entire For Subsection 6(d) of this AISC Specification are given in Attachment 3.

The documentation of this torque inspection for bolt tightness shall be on Form SPP-3-3.2.2-2.

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MARBLE HILL GENERATING STATION Date 06-06-80 6

PUBLIC SPECIAL PROCESS PROCEDURE Revkhn p 7 of 13 SERVICE

Title:

INDIANA SPP-3 CATECORY I STRUCTURAL STEEL The 'JSTCo Bolting Inspection Technician shall attest to the bolt torque inspection data, including the torque wrench calibration data, by signing Form SPP-3-3.2.2-2.

The Connection Inspector shall enter a check mark (d in the appropriate column (either "C" denoting g

g conformance or "N" denoting nonconformance) of Fonn SPP-3-3.2.2-1 for verification of bolt material, bolt size, number of bolts, presence of hardened washers, visual check for bolt tightness and existence of place washers and hardened washers for slotted connections. Similarly, a check mark (A shall be entered in the appropriate column of Form SPP-3-3.2.2-2 denoting " pass" or " fail" of connection torque inspection. Note that nonconformance of any one bolt in a connection is cause for nonconformance of the entire connection.

Nonconformances shall be dispositioned in accordance j with Paragraph 4.5. E 4.2.3 Unauthorized Alterations to Member Configurations All in place members requiring verification shall be visually checked to assure that configurations are in conformance with the following:

a) the configurations as shown on the Shop drawings b) with approved member configuration alterations (i.e.

approved CCRs, FCRs, ECNs, or NCRs)

Unauthorized alterations include but are not limited to:

4.2.3.1 Evidence of unauthorized beam coping (can be found by quantity of bolt holes less than that shown on Shop drawings);

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4.2.3.2 Evidence of galling on a connection which is indicative of torquing a bolt head or nut without a washer; 4.2.3.3 Evidence of holes or other cuts not shown on Shop d rawings ; E 3

8 4.2.3.4 Evidence of unauthorized welds (not shown on Shop d ra wings ) ;

4 G 4.2.3.5 Evidence of any marked damage or deterioration; I

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MARBLE HILL GENERATING STATION Date 06-06-80 PUBLIC SPECIAL PROCES$ PROCEDURE Revkhn 6

! SERVICE

Title:

ease 8 of 13 SPP-3 CATEGORY I STRUCTURAL STEEL I 4.2.3.6 Evidence of unauthorized excessive beam flange cuts at column web connections (For convenience, I ,

Attachment 2 " Allowable Flange Cuts For Column Web Connections", is included to aid in detecting these cuts).

Form SPP-3-3.2.3-1 shall be used to document any evidence of unauthorized member alterations found during the visual check.

I Nonconformances shall be dispositioned in accordance with Paragraph 4.5.

4.2.4 Shear Studs for Composite Beams Shear Studs for composite beams shall be verified for the following design requirements: total number of studs, stud pattern, and the number of flutes including number of studs I per flute within the various sections in a stud pattern. The composite Beam Stud List (prepared by S&L) and the applicable I S&L drawings shall be used as the source of design requireme n t s.

In addition, all studs shall be visually and physically tested according to the following procedure:

a. All loose scale remains of arc shields and other foreign I matter shall be cleared away to reveal the flash at the base of the stud.

b. The base of the stud shall be inspected for a full 3600 I flash weld (wetness area). If this is observed, the head of the stud should be struck with a hammer to emit a sound. If a clear ringing tone is heard, the stud is acceptable.

c. If a full 3600 flash is not present, the base of the stud shank shall be inspected for any existing I undercuts.

rej ec ted.

If any undercut is detected, the stud is If any undercut is detected on the structural steel, the criteria given in Attachment 1, Page 2 of 4, should be used as acceptance / rejection criteria.

d. If no undercut is detected, or if a clear ringing note is not heard in Step b above, the stud shall be tested by f striking with a hammer and bending it to an angle of l g 150 from the vertical axis. The direction of bending l g shall be opposite to the missing weld area, or opposite ,

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the area with the least flash. A failure in the weld {

base metal or shank signified by cracking or separation

{ during the bend test, or during subsequent straightening l

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MARBLE HILL GENERATING STATION Ds3 06-06-80 PUBLIC SPECIAL PROCESS PROCEDURE RevWon 6

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SERVICE y ,,.

INDIANA SPP-3 CATECORY I STRUCTURAL STEEL if required to conform to Section 4.26.4 (AWS D1.1-80), shall constitute a nonconformance.

Form SPP-3-3.2.4-1 shall be used to document the verification of in place shear studs for composite beams. The in s pec tor shall enter a check mark (/) in the appropriate sections of g Form SPP-3-3.2.4-1 noting either conformance or 3 nonconformance with design requirements.

Nonconformances shall be dispositioned in accordance with Paragraph 4.5.

4.2.5 Field Welds All field welds, except those required for normal fit up, shall be visually inspected according to Article 8.15.1 of AWS DI.1-80. For convenience, the requirements of this Article are specified in Attachment 1.

The Team Leader and the PSI ,evel II Welding Inspector shall make a listing of all field welds requiring verification.

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The Welding Inspector shall inspect all field welds on this listing and document the findings. The findings of these visual inspections shall be documented on Form SPP-3-3.2.5-1. Completed Forms shall be givo to the Team Leader.

Nonconformances shall be dispositioned in accordance with Paragraph 4. 5.

4.3 Verification Activities For In-Place Structural Steel Members Erected By American Bridge Which llave Not Been Inspected / Accepted The Team Leader shall randomly select, for verification, 10 percent of the in place steel members which have not been inspected /

l accepted. These members shall be inspected to determine if in place i member sizes are the same as those indicated on the Erection drawings. The activities in Section 3.2.1 of this procedure shall be used for verification of member sizes for those members selected by the Team Leader, except that Forms SPP-3-3.3.0-1, SPP-3-3.3.0-2 and SPP-3-3.3.0-3 shall be used in lieu of the Forms stated in j Section 4.2.1.

There shall be no nonconformances generated from this check since normal QA procedures have not been fully implemented for these structural steel members. Iloweve r , the forms used for document ing k the findings of this inspection will flag the areas where corrective R action is required upon restart of Safety Category I construction.

When work resume s , these members shall be fully inspected per these I

normal QA procedures.

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I MARBLE HILL GENERATING STATION D^te 06-06-80 PUBLIC SPECI AL PROCESS PROCEDURE Revision 6 l SERVICE

Title:

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INDIANA l SPP-3 CATEGORY I STRUCTURAL STEEL

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'5 4.4 Field Markings 4.4.1 Member Sizes and Unauthorized Alterations

!g g All members which are found to be in conformance with design requirements shall be painted with a blue mark on the bottom I flange of a beam or on either flange of a column where the mark will be clearly visible. A red mark shall be used if the member does not conform to design requirements, or has unauthorized alterations.

4.4.2 Bolted Connections All connections identified as a noncoaformance during visual inspection shall be painted red. Connections which are in nonconformance when torque tested shall be painted orange.

4.4.3 Field Welds Welds which are acceptable are to be painted blue. Any weld I identified as a nonconformance shall be painted red. These paint marks shall be along the weld line.

4.4.4 Composite Beam Studs A red mark shalt be placed on each stud that fails the bend test.

4.4.5 All existing markings in red, blue or orange that are to be disregarded shall be covered with black paint. Field

,I markings are not required for members erected by American Bridge, which have not been inspected / accepted.

4.5 Processing of Nonconformances It shall be the responsiblity of the P.S.T. to originate any deficiencies with design requirements in accordance with PMP 1.07 on

.E a Corrective Action Request (CAR). The PSI Level II inspectors are W responsible for assuring that the nonconformances are documented accurately with the findings of the P.S.T. and are responsible for I signing the signature block labeled " Initiator". NOTE: For SPP-3 deficiencies it shall be noted in the " Method of Discovery" block on the CAR Form that the deficiencies were discovered by SPP-3, P.S.T.

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1 The control of the nonconformances (CARS) shall be in accordance I fg with PMP 1.07 af ter the origination of the CAR by the P.S.T.

Numbers for the Cads shall be obtained by the PSI Superintendent of Civil Quality Engineering from the Nonconformance Computer I

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Coordinator.

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MARBLE HILL GENERATING STATION Dati 06-06-80 6

PUBLIC SPECIAL PROCESS PROCEDURE Revision 11 of 13 E SERVICE

Title:

3 INDIANA SPP-3 CATECORY I STRUCTURAL STEEL 4.6 Filing of Verification Data All original forms shall be maintained in a file by the Public Service Indiana / Project Engineering K1 nager for use in the fina l report to the Nuclear Regulatory Connnission.

4.7 Records checklists and r.urked-up drawings for this reinspection are quality records. In addition to their being maintained as quality g documents, the complete set shall be maintained separately until the g results of the reinspection have been evaluated and authorization for construction has been received.

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I MARBLE HILL GENERATING STATION Dew 06-06-80 Rev W n I .PUBLIC SERVICE 7m,.

SPECIAL PROCESS PROCEDURE Page 12 of 13 INDIANA I I SPP-3 CATEGORY I STRUCTURAL STEEL p Establish PST j Determine American Bridge erected member i documented as being insp./ accept. and ;

4.8 FLOWCHART . American Bridge erected members not insp .

1. # 8" ri a Brid,ge work not insp./ accept.

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{j4*4 PST performs phys verif. on in-place membe- sizes, bolted conns., member A1 TL PST select:

configurations, shear studs for. comp.

I PST beams and field welds. Apply Field Markings.

10% in-p1 members I

for verif.o1 e . e sizes

/ FORMS / / FORMS /

j et.n j l PST l

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, . i I SPP-3-3.2.1-1 Erect dwg. Pc.

Mks. vs in-plac SPP-3-3.2.2-1 Bolted Conns SPP-3-3.2.2-2 Bolted Conns Torque SPP-3-3.3.0-1 Erect dwg. Pc.

Mks. vs in-place Pc. Mks. Inspection Pc, eks.

y7gggL I INSPECTION

/ Pm // Pm // Pm / / PEM /

l l l SPP-3-3.2.1-2 SPP-3-3.2.3-1 SPP-3-3.0-2 Sketch of in- Unauthorized Sketch of in-alterations to place member I place discrepancies member- / discrepanies configuration

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I / Pm // PtM / / Pm I

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l l SPP-3-3.2.5-1 SPP-3-3.0-3 SPP-3.3.2.1-3 SPP-3-3.2.4-1 List of missin List of missing Composite beam Field Welds members members Shear Studs

/ Pm / / rm /

I 8 PEM i

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4 PEM i

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4.5 Process non-conformances N-Mii 1

4. 6 /4.7 l h _

$ PEM Files Forms / Maintain Records

l MARBLE HILL GENERATING STATION Date 06-06-80 6

PUBLIC SPECIAL PROCESS PROCEDURE Revklon 13 of 13 SERVICE

Title:

INDIANA SPP-3 CATEGORY l STRUCTURAL STEEL I

5.0 REFERENCES

1. PHP 5.16, "Special Process Procedures" Rev. O, Marble Ilill Nuclear Generation Station, Public Service Indiana.

2. ANSI N45.2.6-1973, " Qualifications of Inspection, Examination, and Testing Personnel for the Construction Phase of Nuclear I

Power Plants," ASME, New York, New York.

3. AWS D1.1-80, "1980 Structural Welding Code-Steel" American Welding Society, Miami, Florida.

4. " Specification for Structural Joints Using ASTM A325 or A490 Bolts", Research Council on Rivited and Bolted Structural Joints. February 4, 1976. American Institute of Steel Construction, New York, New York.

5. '%nual of Steel Construction", 7th Edition, 1970, American Institute of Steel Construction, New York, New York. E 3

6.0 ATTACllMENTS Attachment 1 - Requirements for Visual Inspections of Field Welds.

Attachment 2 - Allowable Flange Cuts For Column Web Connections Attachment 3 - Requirements for Torque Inspection of High Strength Bolted Connections Attachment 4 - Member Size Verification Attachment 5 - liigh Strength Bolted Connection Verification Attachment 6 - Unauthorized Alteration Verification Attachment 7 - Compos i t e Beam Shear Stud Verification I Attachment 8 - Field Weld Verification Attachment 9 - Verification of Category I Steel Not In s pec t ed /Acc ept ed Attachment 10 - Missing Member Verification 8 Attachment 11 - Designation of Connection Numbers R

Note: Effective date of all attachments is 05-13-80.

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I MARBLE HILL GENERATING STATION Date 5-13-80 PUBLIC I SERVICE 7;,,, .

SPECIAL PROCESd PROCEDURE INDIANA I SPP-3 Category I Structural Steel 6.1 ATTACIIMENT I I REQUIREMENTS FOR VISUAL INSPECTIONS OF FIELD WELDS 8.15 Quality of Welds I 8.15.1 Visual Inspection. All welds shall be visually inspected. A weld shall be acceptab!c by visual inspec-I tion if it r. hows that 8.15.1.1 The weld has no crr ?s.

8.15.I.2 Thorough fusion s .ists between adjacent layen of weld metal and between weld metal and base I metal. .

8.15.1.3 All crate. x filled to the full cross section of the weld.

8.15.1.4 Weld profiles are in accordance with 3.6. (This Attachment also 8.15.1.5 Irrespective of length. undercut shall not'ex includes the requirements cced the value shown in Fig. 8.15.1.5 for the primary of 3.6. See Page 3 stress direction categery appheable to the area containina of this attachment)

I the undercut. Further, the undercut may be twice the value permitted by I'ig. 8.15.1.5 (for the applicable stress cate.

gory) for an accumulated length of 2 in. in any 12 in. (51 mm in 305 mm) length of weld. but in no case may I undercut on one side be greater than 1/ifi m. (1.6 mm). For weld lengths less than 12 in. (305 mm), the pennitted length should be proportional to the actual length.

8.15.1.6 The sum of diameters of pipmg porosity in I fillet welds does not exceed 3/8 in. (9.5 mm) m any hnear inch of wcid and shall not exceed 3/4 in,(19.0 mm) in any 12 in. (305 mm) length of weld.

8.15.1.7 A fillet weld in any single continuous weld I shall be pennitted to underrun the nominal fillet sire requitrd by 1/16 in. (I.6 mm) without ectrection. pro-vided that the undenize portion of thq weld does not exceed 10% of the length of the weld. On web-to-Gance welds on girders, no undenun is penmtted at the ends for I a length equal to twice the width of the Gange.

8.15.1.8 Complete joint penetration groose weids in I butt joints transserse to the direction of wmputed tensile stress shall have no piping porosity. For all other groose welds, piping parmity shall not exceed 3/3 in. (9.5 mm) in any linear inch of weld and shall not exceed 3/4 in.

(19 mm)in any 12 in. (305 mm) length of welJ.

I 8.15.1.9 Visual impection of welds in all stects may begin immediately af:er the con,pleted v.cids have cooled to ambient tempcrature. Acceptance criteria for ASTM I A 14 and A517 steels shall be based on sisualinspection performed not less thaa 48 hours5.555556e-4 days 0.0133 hours 7.936508e-5 weeks 1.8264e-5 months after completion of the weld.

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$ The requirements on this page have been taken from page 133 of g AWS D1.1-80, "1980 Structural Welding Code - Steel",1979, Aracrican 3 Welding Society, Miami, Florida.

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MARBLE HILL GENERATING STATION 0;c 5-13-80 I

/ .PUBLIC SPECI AL PROCESS PROCEDURE Page 2 of 4 g

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Title:

INDIANA SPP-3 Category I Structural Steel 6.1 ATTACINENT 1 (CONTINUED) l I

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REQUIRDfENTS FOR VISUAL INSPECTIONS OF FIELD WELDS l I 0.00 g y 0.07 ------

/-g No calculated stress 0.00125

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(1/16) [*

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/ , % Primary Tensite Stres

" 0.04 raral'el to undercut; f

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g e shear, compr ession in 0 G3 7 ._ ,- d"Yd' 'i "

l 'e - Primary Tensde Stress O.02 Tranwerse to undercut 0.01 l _l eop 1 2 3 4 5 6 b Mernber thicknsss, in.

Fig. 8.15.1.5-Permissible undercut values for buildings I

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" The requirements on this page have been taken from page 134 of l 4 AWS D1.1-80, "1980 Structural Welding Code - Steel", 1979 American 3 G Welding Society, Miami, Florida, b

I MARBLE HILL GENERATING STATION Date 5-13-80 g .PUBLIC SPECIAL PROCESS PROCEDURE

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Title:

INDIANA I SPP-3 Category I Structural Steel I 6.1 ATTACIBIENT 1 (CONTINUED)

I REQUIREMENTS FOR VISUAL INSPECTIONS OF FIELD WELDS 3.6 Weld Profiles 3.6.1 The faces of fillet welds may be slightly convex, I flat, or slightly concave as shown in Fig.1.6 (A), and (B), with none of the unacceptable profiles shown in Fig.

3.6(C). Except at outside comer joints, the convexity sha!!

I not exceed 0.1 times actual leg size, or the longer leg in the case of an unequal leg filtet weld, plus 0.06 in. (1.5 mm).

See Fig. 3.6(B).

3.ti.2 Gmove welds shall preferably be made with slight I or minimum reinforcement except as may be otherwise pnnided. In the case of butt and ccrner joints, the rein-forcement shall net exceed I/8 in. (3.2 mm) in height I and shall have gradual transition to the plane of the base metal surface. See Fig. 3.6(D).They shall be free of the discontinuities shown for but joints in Fig. 3.6(E).

3.6.3 Surfaces of butt joints required to be flush shall be fibished so as not to reduce the thickness of the thinner base incial or weld metal by more than 1/32 in. (0.8 mm) or $G of the thickness, whichever is smaller, nor leave I reinforcement that exceeds 1/32 in. Ilowever. all rein-forcement must be removed where the weld forms past of a faying or contact surface. Any reinforcement must blend smoothly into the plate surfaces with innsition areas free from edge weld undercut. Chipping may be used provided it is followed by grinding. Where surface finishing is required, its roughness value' shall not ex-ceed 250 in. (6.3 pm). Surfaces finished to values I of over 125 pin. (3.2 pm) through 250 in. shall be ,

finished parallel to the direction of primarv stress. Sur-I faces finished te values of 125 pin. or less may be fin-ished in any direction.

3.6.3.1 Ends of butt joints required to be flush shall be finished so as not to reduce the width beyond the de- i I tailed width or the actual width furnished, whichever is greater, by more than 1/3 in. (3.2 mm) or so as not to leave reinforcement at each end that exceeds 1/8 m. (3.2 l

mm). Ends of butt welds shall be faired to adjacent plate -

I or shape edges at a slope not to exceed I in 10.

3.6.4 Wclds shall be free from overlap.

h@ The requirements on this page have been taken frota pages 39, 40 and 41 of AWS Dl.1-80, "1980 Structural Welding Code - Steel", 1979, American Welding Society, Miami, Florida.

3 I

MARBLE HILL GENERATING STATION Date 5-13-80 I

.PUBLIC SPECIAL PROCESS PROCEDURE

"'S' '

SERVICE 7;,,, .

!NDIANA 3 SPP-3 Category I Structural Steel 3 6.1 ATTACHMENT 1 (CONTINUED) REQUIREMENTS FOR VISUAL INSPECTIONS OF FIELD WELDS i I i

Size

~

4s 45' e N t

Sige i

Size i

e 'y, i

Sire n

l s

' \s , ,

- Size-+

Size- - Sire- C - Sir e- C Note: Convexity C shall not exceed 0.1 times actual leg size. or the longer leg in the case of en unequal leg fillet weld, n'us 0.06 in. (0.3 mm).

(A) Desirable f!'let weld profiles (B) Acceptable fillet weld proldes W fa N j 's ls l'

' \ I, \

s i\ i N N i N

g f N p \ '

l 1 '%

j \ ' \ I '- '

~ $?re- +- Size- - Size- - Size- - Size- - Size -+

Insuffkient Excessive Excessrve Overlap insufficient inadequate' throat convexity undercut leg penetration (C) Unacceptable fillet weld profiics ,

{R

\ / l

. I [~~ \ I l tn Note: Reinforcement R shalt not exceed I/8 in. (3.2 mm). See 3.6.2.

l (D) Acceptable butt welo profile l m m i'

t '

I / \ /

N / ./.

. Wg l='g

/ g s f

g Excessrve Insufficient Estessive Overlap convexity throat undercut See 3.G.4 See 3.6.2 See 3.6.3 See 8.15.l.5. 9 25.1.5 g or 10.17.1.5 5

(E) Unacceptable butt weld profiles 8

s Fig. 3.6-Acceptable and unacceptable weld p rofites cn

? The requirements on this page have been taken from page 40 of AWS Dl.1-80, G "1980 Structural Welding Code - Steel", 1979 American Welding Society, 5 Miami, Florida.

I MARBLE HILL GENERATING STATION ost* 5-13-80 g .PUBLIC SPECIAL PROCESS PROCEDURE SERVICE Title.

l INDIANA SPP-3 Category I Structural Steel I 6.2 ATTACINENT 2 I

I I

ALLOWABLE FLANGE CUTS FOR COLUMN WEB CONNECTIONS BOL1 CLEARANCE-W COLUMNS Valuet enown above for clearances over trvet heads are conservative when applied to belts.

See "Specihcation for Stru:turas Joints utmg ASTM A125 or A430 Borts" to compute overall lengths for varsous gripe.

I FLAN 0E CUTS FOR COLUMN WEB CONNECTIONS tio't hand er rivat .

Q Q g i. I w Q Q When beams frammg to the f'seges e 2 2 2 r** Yi E 2 2 CI COP"S 'nterfere wit *s teams I g g re o Ii' ll g* 2 $ g 2 framing to tte web of the co umn.

~~

g ; g 3 fl, l 0 ; ; O the latter must be cut s * .hown.

r* o 3 g 2 U O. I, E S t l_ g S Dimensions are for bolts and rivets. e

-$ .=G G% TIE -

rC .%T I i j in all cases where members trust 9 M l6e Tel 4 , k! ki be erected by droppmr down.

A;q allow at least %* clearance.

Dolt head or revet ; ,,

9% W14x730 to 455 9 Wid1426 to 142 I 8 7

W14X136 to 87

, _l W14X84 to 78. W12xt90 to 65 6 l W14X74 to 61: W12t53 ad 53 Wl')x117 to 49 5 i W14x53 to 43: W12150 to 40. W10x45 ts 33.W8x67 to 31 4 W8X28 and 24 eased on cimensions of Structurai Riv.ts. pese a its and oosts, pas.s a.12o,4.tzt.

i 1

The requirements on this page have been taken from page 4-115 of " Manual of Steel Construction," 7th Edition, 1970, American g Institute of Steel Construction, New York, NY I e 6

I .

F MARBLE HILL GENERATING STATION o.te 5-13-80

.PUBLIC SPECIAL PROCESS PROCEDURE SERVICE

Title:

- *"3 l

INDIANA SPP-3 Category ,I Structural Steel 6.3 ATTACHMEW 3 E

ItEQUIRC:T.NTS FOR TORQUE INSPECTION OF lt!Gt STitENGTH BOLTED COMiLCT10m .

ASTbf M25 er Mm IMis

9 (d) When there is dingrument concerning the resulta ofinspection r,f holt tension m the turn-of-nut or cabbrased wrench methods speciGed in subsection 6f b), the followmg arbitration insportion procedure shall b used unins a def forent procedure is speciGed in the inquiry and osder for the work:

1. The Inspector shall uw an anspecting wrench. mhi.h may be either a torque urench or a power meench that can be adjusted in ac-cordance with the requirements of subsection S(db

2. Three bolts of the same grade, size.' and condition as th"** Noteet unde 6 inspution sh ll be placed indn1 dually in a cabbration devue 1. New bolta shall capable of indicatir; holt terision. The surface under the part to be be used for each

(

' turned in tightenmg each 6it shall be hie that uswier the corre,pondmg #8 * "*

part in the structure,i e , there shall be a washer under the part turned 2. The tern cond-if washers are so used in the structure or,if no washer is used, the ana-terial shuttmg the part turne~~section 5(a), page 6, of " Specification for Structural Joints Using ASTM A325 or A490 Bolts", February 4,1976, American Institute l of Steel Construction, New York, NY e~~

~~,I n 8 '~~

I

I!
MARBLE HILL GENERATING STATION Date 5-13-80
.PUBLIC SPECIAL PROCESS PROCEDURE E
" 3 f3 8 SERVICE y ,,, .
INDIANA SPP-3 Category I Structural Steel 6.3 ATTACINENT 3 (CONTINUED)
E I
E
~ ~
REQUIREMENTS FOR TdRkUE INSPECTION OF HII;H STRENGTli BOLT D CONNECTIONS Table 4 Nut Rotation
~~from Snug Tight Condition Disposition of Outer Faces of Bolted Parts M l'"Ch One face normal to toit Both faces sloped not a~~
un rs o b ad to Both faces normal gge ed not ore nan or to b as e estreme end of point) to bolt anos 1:20 (bevel wasner not (bevei washers not used) used)
Up to and locluding 4 diametert 1/3 turn 1/2 turn 2/3 turn Ovar4 diameters but nat esceeding 8 diameters 1/2 turn 2/3 turn 5/6 turn Over 8 diameters but not exceeding 12 diameters
2/3 turn 5/6 turn Iturn e Nut rotation es relative to bolt, regsrdless of the element (nut or bolt) been t turned. For b(Als installed by b turn and less, the tolerance should be plus or minus )Q'; for boats In-stalled by 4's turn and more, the toserance snoulo De plus or rninus W.
r procedure 6 No research work has been performed b,y rnein, Counc,el to establish
.vo e. ine reau,ream,eotat.or turn of must au be deter-when mined boit ienens by actuai e.ceed tests 2,d.amete
.n a su tabie tenss.,on d.v.c. 3,muiating tne actuai cond>tions.
I.
I The requirements on this page have been taken form subsection I
5(c), page 7, of " Specification for Structural Joints Using ASTM A325 or A490 Bolts, February 4, 1976, American Institute '
of Steel Construction, New York, NY
~
r G
b um l
l i
l I
I MARBLE HILL GENERATING STATION ost. 5-13-80 g PUBLIC SPECIAL PROCESS PROCEDURE
2 ' 3 SERVICE Title. i INDIANA I SPP-3 Category I Structural Steel i
j 6.4 ATTACIBfENT 4 MEMBER SIZE VERIFICATION PUBLIC SERVICE INDIANA MARBLE HILL NUCLEAR CENERATING STATION 1&2 VERIFICATION OF IN-PLACE SAFETT CATEGORY I STRUCTURAL SIIEL WHIQi HAS BEEN INSPECTED / ACCEPT' BLDG: TEAM LEADER ELEV: PSI QA ENCR/ LEVEL II INSP SHEET OF PSI LEVEL I INSP** l DATE OF VERIF.. REY: N-VJI LEVEL I INSP**
ERECIION DWC S&L DWC(S): As required per Tea:n Leader I ,
i i ate 1
n Er ion 2*
Me er Size & Piece mk. in-place t I .
I I
I e e
I
' cr:
i I l
~.
9 - 1 m
I 1
A 4
5 E.
~~If the member size and piece mk.~~
h in-place conforms with that shown on the Erectiors dwg I y O
8 -
ente r letter "S" in col .cn (2).
conformanceon torm SPP-3-3.2.1 2 If non-conformance exis ts , further document the non-f If the ;isc rari . ; ir.actu aibi:, h:-ter."ly r ss :r: - eche r dimensions to detr*.
Mao, enter letter "M' indicating that the size was measured.
s:
i i
D
.I
MARBLE HILL GENERATING STATION Date 5-13-80 I
.PUBLIC SPECIAL PROCESS PROCEDURE Pn. 2 or 3 SERVICE
~~Title:~~
INDIANA SPP-3 Category I Structural Steel 6.4 ATTACHMENT 4 MEMBER SIZE VERIFTCATTON PUBLIC SERVICE INDINIA MARBtZ !!ILL NUCLEAR GENERATING STATIci 1&2 VERIFICATION OF IN-PLACE SAFETY CATEGORY I STRUCTURAL STEEL Wi!IQ1 IIAS BEEN INSPECTED /ACCEPTE BLDC: TEAM LEADER I
ELEV: PSI QA ENCR/ LEVEL 11 INSP SIIEET OF PSI LEVEL I INSP** W ERECTICI DWG: N-}01 LEVEL I INSP**
S&L DWG:
DATE OF VERIF.: REV: a* As required per Team Leader I
I' I
I-e ll i
_4 5, I
~.
N, m 4 A ,
b The sketch above represents the approximate area where a non-ennforma ce of l
E members size exists.
w Note: "I" denotes in-place; "E" denotes data shown on erection drawinn i h
n g
=
5 I
1 I !
MARBLE HILL GENERATING STATION Date 5-13-80 I PUBLIC SERVICE SPECI AL PROCESS PROCEDURE
" 3 f3
~~Title:~~
l lNDIANA SPP-3 Category I Structural Steel I 6.4 ATTACHMENT 4 MEMBER SIZE VERIFICATION Pt3LIC SERVICE INDIANA MARBIZ HILL NUCLEAR CEliERATING STATIC'i. 162 VERIFICATION OF IN-PLACE SAFETY CATECORY I STRUCTURAL STEEL E1101 RAS BEEN INSPECTED /ACCEPTE I BLDC:
ELEY:
TEAM LEADER PSI QA E:;CR/ LEVEL II I;SP l PSI LEVEL I II;$P**
SHEET or DATE OF VIRIF.: REY.
N-MH LEVEL I INSP**
, ** As required per Team Leader I the following meuber piece markt have been identified as missing taembers.
PIECE MARK ERECTIO;I DWC. S&L DJC. CC )
I I i I
I b i i l A
4 I
5 8
l I I i
i I a
~
U l
MARBLE HILL GENERATING STATION o t. 5-13-80 I
E
'PUBLIC SPECIAL PROCESS PROCEDURE p"' I of 2 5 SERVICE
~~Title:~~
INDIANA I SPP-3 Category I Structural Steel 6.5 ATTACIIMENT 5 IIIGli STRENGT11 BOLTED CONNECTION VERIFICATION PUBLIC SERVICE INDIA'IA MARBLE HILL NUCLEAR CENERATING STATION, UllTS 1&2 DERIFICATIO:3 0F IN-PLACE SAFETt CATEGORY I STRUCTUhAL STEEL VHIO! H,.S .7EN INSFECTED/ACCEPTE:
BLDC: TEAM LEADER E1.EV: PSI QA ENCR/ LEVEL 11 INSP l SHEET OF PSI LEVEL 1 INSP**
DATE OF VERIF: REV.: N-Mll LEVEL 1 INSP**
~~As required per Team Leader CC'CI. BOLT MAT'L BOLT SIZE BOLT C0 CIT HARDE'IED PLATE # VISUAL OIEOC ^~~
NNR WASHER VASHER FOR BOLT (See Attach:nent 11) m'tW"? nonvirrt? TIcty;ESS C* N* C N fC N C N C N C N I i I i t I i I i i i i i i 3
d l I
> l l l l l a l I I l
I I i
! l
! I
> I l I l l ]
~~1 I I i :~~
j ! '
! I -
t I
g
+ l i l !
! I
~~a. .~~
l n .
l l l 2 l -
! l l l l !
3 y # .'or long slotted connections only
~~C denotes conf ormance with design requirements~~
~~9 denotes non-conformance with design requiremei l'~~
l
-MARBLE HILL GENERATING STATION oste 5-13-80
.PUBLIC SPECIAL PROCESS PROCEDURE l SERVICE p.ge 2 or 2
~~Title:~~
~~INDIANA I SPP-3 Category I Structural Steel I 6.5 ATTACHMEttr 5 HIGH STRENGTH BOLTED CONNECTION VERIFICATION I~~
~~PUBLIC SERVICE INDIANA MARBLE HILL NUCLEAR CENERATING STATION, UNITS 1&2 VERIFICATICL CF IN-PLACE SAFETY CATECORY I STRUCTURAL STEEL WHICH HAS BEEN INSPECTED /~~
ACCEPTED BLDC: TEA.M LEADER ELEV: PSI QA ENCR/ LEVEL II INSP, I SHEET DATE OF VERIF.
OF REY.*
PSI LEVEL I INSP**
N-MH LEVEL I INSP**
USTCO BOLT INSP TECENICAN g ** As required per Team Leader Torque Inspection Results Number I (See Attachment 11) " PASS" " FAIL" I
I I
I ;
E E l I Notes: 1. Use new bolts for each calibration TORQUE WRDiCH CALIBRATION I c.
4 4
1) 2)
feelb.
ft-lb 1) 2)
Ft-lb ft-lb
2. Re-calibrate Torque Wrench as necessary to reflect changes in ambient condition (See attachment 3. Note 2) 4 3. Re-calibration of Torque Wre I A E.
3)
Ave.
ft-lb ft-lb 3)
Ave.
ft-lb ft-lb is necessary if the wrench i accidentally dropped, hit or jarred.
O E I g g Size O Size 1 e
l Io j I i l
MARBLE HILL GENERATING STATION Date 5-13-80
'PUBLIC SPECIAL PROCESS PROCEDURE Page 1 of 1 SERVICE
~~Title:~~
INDIANA SPP-3 Category I Structural Steel 6.6 ATTACIDfENT 6 I
UNAUTHORIZED ALTERATION VERIFICATION PUBLIC SERVICE INDIANA MARBLE HILL NUCLEAR CE:TERATING STATION 1&2
=
VERIFICATION OF IN-PLACE SAFEIY CATEGORY I STRUCTURAL STEEL WHICI HAS BEEN INSPECTED /ACCEPTT BLDC:
TEAM LEADER ELEV: PSI QA ENCR/ LEVEL II INSP SHEET OF p$g ggygg g 733 pen DATE OF VERIF REV.:
N-t0! IIVEL I INSP**
ERECTION IMG:
As required per Team Leader The following mecber piece mks. haee been identified as having evidence of unauthorized alterations to macher configurations: 3 PIECE MK. SIZE MEMBER TYPE (BEAM, COLLMI, DESCRIPT10'I 0F UNAUTHORIZED BRACE) ALTERATION TO CO'4 FIGURATION W I
I
& : E I
A .
I d,
e
@ b o
2 2 e
I
I MARBLE HILL GENERATING STATION o*** 5-13-80 I '
PUBLIC SERVICE SPECIAL PROCESS PROCEDURE
~~Title:~~
I'
~
INDIANA SPP-3 Category I Structural Steel ,
I 6.7 ATTACIDfENT 7 COMPOSITE BEAM SHEAR STUD VERIFICATION P12LIC SERVICE INDIANA MAR 3LE HILL NUCLEAR CENERATING STATION, UNIIS 1&2 I
VERIFICATION OF IN-PLACE SAFETY CATECORY I STRUCTURAL STEEL WHIQI liAS BEEN INSPECTED / ACCEPT!
BLDC: M L W ER ELEY: PSI QA ENCR/ LEVEL II INSP SHEET OF , PSI LEVEL I INSP**
k DATE OF VERIF.: _ tV. H ll LEVEL I INSPa*
ExECnCN mC: - -
s&L WC(S): ** As required per Team Leader P CE STUD BEND STUD : NO. OF FLUTES NO. OF STUM PER D NC.
TESTS lTOTALNO.
S TI'DS PATTEFN IN SECTIONS TLUTE PER SECT.
,P S FAIL C* N* C N fC N C N l l l !
I I !
Ii I I i I i i i
M '
I _
4, c4 i
I 2 s ! I 5
i g 8 l j
I I
! I I i g *C denotes confor:2ance with design requirements
! " *N denotes non-confor: nance with design rec ui reren ts
MARBLE HILL GENERATING ST ATION o*** 5-13-80 I
.PUBLIC SPECIAL PROCESS PROCEDURE
""' f' SERVICE
~~Title:~~
)
INDIANA ,
SPP-3 Category I Structural Steel 6.8 ATTACINENT 8 FIELD WELD VERIFICATION PUBLIC SERVICE INDIANA MARELE HILL NUCLEAR CENERATING STATION, UNITS 162 VERIFICATION OF IN-PLACE SAFETT CATECORY I STRUCTURAL STEEL WHICH HAS BEEN INSPECTED /ACCEPTT BLDC: TEAM LEADER ELEV PSI QA ENCR/ LEVEL II INSP "EET OF PSI LEVEL I INSP**
' DATE OF VERIF.: REV. N-M11 LEVEL I INSP**
ERICTION DWC:
~~As required per Team Leader S&L DWC(S):~~
I r
VISUAL INSPECTION 0F FIELD WELDS Member Piece Approximate Description of Inspection Findings with regard Mark and/or l
Location of to AWS D1.1-80 article 8.1$.1 Connection Field Weld Number on member (e.g.L8 conn-ection)
I I
e I
I 1
a :-
=
A i
2 2 e
MARBLE HILL GENERATING STATION Date 5-13-80 l .PUBLIC SERVICE
~~Title:~~
SPECIAL PROCESS PROCEDURE e se r2 I INDIANA SPP-3 Category I Structural Steel I 6.9 ATTACINENT 9 (CONTINUED)
I NOT INSPECTED / ACCEPTED STEEL PUBLIC SERVICE INDIANA MAR 312 HILL NUCLEAR CENERATING STATION 1&2 VERIFICATION OF IN-PLACE SAFETY CATEGORY I STRUCTURAL STEEL NOT INSPECTED /ACCEITED I
BLDC: TEAM LEADER ELEV: PSI QA ENCR/ LEVEL II INSP SHEET OF PSI LEVEL I INSP**
DATE OF VERIF. REY.: N-!GI LEVEL I INSPa*
ERECIION DIG:
S&L EJG(S): ** As required per Tem Leader 1 2*
I Member Sire & Piece mk. as indicated on Erection deg.
Member Sizo & Piece ri. in-placs I I
I l
t h.
t O
O I O A
e t
I A 4
th 8 5 I s cn O
g Cr O
L4-
If the net.ber size and piece nk. in-place conforms with that shcvn on the Esection c.wg enter the . cord "SN:I" in colu=n (2). If ncn-ccafor mcc a: tis ts . further documen t the non-contoreanceon form SPP-3-3.3.0-2 I
a # Also, If theenpiece mark is inaccessible, physically measure nember dimensions to determine size.
" te r le t te r "?f' f - !! c 3 e t n - ek ir tha etu i. e ~ 2e ~ t
Date 5-13-80 I
MARBLE HILL GENERATING STATION
.PUBLIC SPECIAL PROCESS PROCEDURE ease 2 or 2 SERVICE 7m,.
INDIANA g
- SPP-3 Category I Structural Steel 5 6.9 ATTACHMENT 9 I NOT INSPECTED / ACCEPTED STEEL _
PCULIC SERVICE INDIN:A MMU;i.C llII,L NUCLEAP, CC:."JRATING STATION 152 VERIFICATION OF IN-PLACE SAFETY CATECORY I STRUCTURAL ST::EL NOT INSPECTED /ACCERTED
~~BLDC: TEAM LEADER ELEV: PSI QA ENCR/ LEVEL II INSP l 1~~
S!!EET OF PSI LEVEL I INSP**
ERECTIO;I D'4G: N-F01 LEVEL I INSP**
S&L D:lC:
DATE OF VERIF. REV.. ** As required per Team Leader I
I I
I a
I I
I I
t-n$bbsIze ((s$['"""'"*"N""' "'"' "i'"" " " " conf or=anc e of
_"a t o : "I" denotes in-p la ce ; "i;" ,1,.
~~. . t e s d;.La sh < r.in on e re c t i an Wa sin g e~~
e U
I S
I MARBLE HILL GENERATING STATION Date 5-13-80 l PUBLIC SPECI AL PROCESS PROCEDURE SERVICE
~~Title:~~
l INDIANA SPF-3 Category I Structural Steel I 6.10 ATTACHMENT 10 MISSING MEMBER VERIFICATION FOR g
I -
NOT INSPECTED / ACCEPTED STEEL PUJLIC SERVICE 1:;DIR A EUG;LE IIILL Nt: CLEAR C";;ERATI: C STATIC:!, If.2 I
~ VERIFICATION OF IN-PMCE SAFETY CATEC0KY I STRUCTURAL STEEL NOT INSPECTED / ACCEPTED BLDC: . TEAM LEMER I
ELEV: PSI QA ENCR/ LEVEL II IIISP
$11EET OF PSI LEVEL I INSP**
DATE OF VERIF. REV., -101 LEVEL I INF *
~~As required per Tea:n Leader I The following member piece marks have been identified as ris::ing cachers.~~
I PIECE !! ARK ERECTION IAIG. S&L INC.
CL 3) l l l
.. j l 4 s
I I I
e I '
~~I l~~
,l ?, I I t*% i.
I I m
M I
I i
a l
l l
I @ _ . _ -
I ' '
Q
MARBLE HILL GENERATING STATION o te 5-13-80 I
.PUBLIC SPECIAL PROCESS PROCEDURE
""'
~~f' SERVICE 7, ,,, .~~
INDIANA SPP-3 Category I Structural Steel 6.11 ATTACINENT 11 DESIGNATION OF CONNECTION NUMBEPS Connection number by shop drawings are to be designated as follows:
I p
l l l ,
I PLANT NORTH
E
-s I g 3027 B1 3027 B4S* '".
OM G
? i i
Shop Dwn. No.
l B1 [3 A "
p %) q
~
J e. .
a ,
3020 C1 $ $ $
l6 R R R *d R E R _b_
3027 B1 3027 B4N*
3o27 B2 3027 B1 3027 B3 2 a 3 B4 GortM ;
i.e. Connection at Beam 3027 B1, with 3027 B2, 3027 B3.
~~N, S, E. W can be alternatively used as a prefix. =~~
o
[
INRYCC ERECTION DRAWINGS S & L DRAWINGS NO. REV. DATE NO. REV. DATE E-685-AB D 07-26-79 S-685 K 05-08-79 I E-699 E-704 E-706 G D
E 05-02-79 06-12-79 06-12-79 S-699 S-704 S-706 0
H E
01-02-79 05-08-79 03-09-79 l
E-707 E 01-30-79 S-707 G 08-15-78 I E-1137 E-1138 E-1140 AB D
C A
10-31-78 06-12-79 05-02-79 S-1137 S-1138 S-1140 G
E D
05-31-79 09-27-78 03-09-79 I E-1141 E-1142 AB E-1143 B
G H
04-24-79 10-04-79 06-12-79 S-1141 S-1142 S-1143 K
G H
09-22-78 11-21-78 05-18-79 E-1144 AB A 12-14-78 S-1144 11-21-78 I
E E-1146 C 06-12-79 S-1146 G 05-18-79 E-1149 AB C 06-12-79 S-1149 D 03-09-79 E-1287 E 04-13-79 S-1287 D 03-27-79 I E-1288 AB E-1289 AB E-1292 F
G G
09-25-79 01-07-80 01-17-80 S-1288 S-1289 S-1292 H
K H
07-06-79 12-10-79 07-06-79 E-1293 G 06-14-79 S-1293 H 04-10-79 E-1296 AB D 10-04-79 S-1296 F 09-12-79 E-1297 AB D 12-14-78 S-1297 E 09-01-78 E-1297 B D 04-13-79 S-1297 F 02-09-79 I E-1301 E-1302 E-1306 B H
F H 01-07-80 06-14-79 06-21-79 S-1301 S-1302 S-1306 J
E K 10-26-79 05-08-79 11-21-78 E-1309 N 11-13-79 S-1309 J 09-12-79 E-1310 L 01-07-80 S-1310 G 09-12-79 E-1313 AB C 02-12-79 S-1313 C 12-22-78 E-1317 AB D 10-29-79 S-1317 D 09-12-79 I E-1318 B E-1320 AB E-1325 D
D C*
02-13-79 02-12-79 05-02-79 S-1318 S-1320 S-1325 C
C 01-02-79 01-02-79 D 01-22-79 I E-1326 E-1329 AB E-1332 AB D
D E
05-02-79 02-13-79 06-21-79 S-1326 S-1329 S-1332 C
D E
01-22-79 01-22-79 01-22-79 E-1333 B D 06-12-79 S-1333 I 05-08-79 B
E-1333 AB C 06-12-79 S-1333 B 05-08-79 E-1335 B F 09-25-79 S-1335 D 06-29-79 E-1335 AB D 06-12-79 S-1335 C 04-10-79 I E-1568 B E-1568 AB C
F 05-02-79 05-02-79 S-1568 S-1568 C
C 04-10-79 04-10-79
~~NOTE: E-1325, Rev. D, is shown as Attachment 3.6.6. The only difference between Rev. C and Rev. D is the addition of one metber - Piece Mark 2146Bl.~~
ll ATTAcHsEmT 3.e.2 e.Ee 1 ,, 1 LIST OF DRAWINGS USED FOR SPP-3 I 1 1
11 i
(1) The following connections could be neither visually I
inspected nor torque tested because they are embedded in concrete:
7072C2 - 7034B4 7034B7 - M-Lina 7072C2 - 7034B5 7072Cl - Ceiling 7072C1 - 7034B5 7072C2 - Ceiling 7072Cl - 7034B7 (2) The following members could not be visually inspected I
because they are embedded in concrete:
7072C2 7072C1 7034B7 (3) The following connections could not be visually inspected because they are temporarily covered:
1016C1 - baseplate 2010C1 - baseplate 1009C1 - baseplate 1010C1 - baseplate l 2006C1 - baseplate 1013C1 - baseplate 5 2002Cl - baseplate 1008B2 - 1013C1 1083B4 - 1083Bl(E) 1017B2 - 1013C1 1083B4 - 1083Bl(W) 1013Cl - 1007B2 (4) The following connections could not be visually inspected because the inspectors could not safely gain access to both sides of the connection:
3035B2 - 3013C1 - 3035B1 2070B2 - 2039B2 2071B2 - 2039B2 I
I I
I
, ATTACHMENT 3.6.3 Page 1 of 3 g l L?ST OF INACCESSIBLE STRUCTURAL MEMBERS AND CONNECTIONS E
l I
I
(5) The following connections could be neither visually inspected nor torque tested because the inspectors could not safely gain access to these connections:
1051B3 - 1064B1 2021D3 - 2061G1(S)
I 1053D1 - 1069D1 1053D2 - 1069D1 2021D3 - 2061G1(N) 1068D1 - 1004C1 I (6) The following connections could not be torque tested because the inspectors could not safely gain access to apply a torque wrench to these ccnnections:
3019D3 - NWGP .3019D4 - 3019D4(N) 207471 - 1045B4 3019D3 - 3019D3 1049B4 - 1049B2 3019D2 - 3019D2 I 2019D6 - NEGP 2019D6 - 1019D6 2019D5 - 2019D5 3019D2 - NEGP 3019D6 - 3019D6 3019D7 - 3019D7(S)
I 2019D5 - SWGP 3019D3 - 3019D3 1047B2 - 1043B1 3019D7 - 3019D7(N) 3007C1 - 3056G1 3070B18 - 3067B2 1047B4 - 1044B1 2023D7 - 2023D7 I 1047B1 - 2060G1 2023D1 - SWGP 2023D8 - 2023D8 3020D2 - 3020D2 2023D1 - 2023D1 3021D5 - NWGP I 2023DL - NEGP 2023D2 - SEGP 2023D3 - 2053B1 3021D5 - 3021D5 3021D2 - 3021D2 3021D6 - 3021D6 2023D3 - NEGP 3026D3 - NEGP 2023D4 - SEGP 2026D3 - 2026D3 2023D4 - NWGP 2026D3 - 2093B3 2024D4 - NEGP 2024D2 - NWGP 2024D4 - 2024D4 2024D6 - 2024D6 2024D3 - SEGP 2024D5 - 2024D5 2024D1 - NWGP 2024D4 - 2025D4 I 2024D2 - SEGP 2024D2 - 2024D2 2024D3 - SWGP 2025D3 - 2105B1 1035D3 - hWGP I
I I
ATTACHMENT 3.6.3 (Cont'd) Page 2 of 3 I .
LIST OF INACCESSIBLE STRUCTURAL MEMBERS AND CONNECTIONS I
I I
Il (7) The following connections could not be visually inspected
. because of interferences with other in place structural ,
steel members:
2023D2 - NEGP 2024D1 - SEGP g 2023D2 - 2053B1 2024Di - 2024D1 g 2023D2 - 2102B1 2025D3 - 2048C1 2023D3 - 2102B1 I
(8) The Collowing connections could not be torque tested due to interferences with metal decking:
2019D2 - 2019D2 1028D1 - SEGP 2019D3 - 2019D3 1030.05 - 1030D5 3019D3 - SEGP 1030D5 - NEGP 3019D4 - SEGP 1031D4 - SEGP 3019D4 - 3019D4(S) 1034D6 - 1034D6 g 3019D4 - NWGP 1034D5 - NWGP g 3019D4 - SWGP 1034D5 - 1034D5 1028D3 - NWGP 1034D3 - NWGP 1028D3 - 1028D3 1034D3 - SWGP 102JD2 - NWGP 1034D2 - NWCP "
1028D2 - SEGP 1034D1 - 1073B4 1028D2 - 1048BA 1005C1 - 1073B1 1028D1 - 1028D1 I
I.
I .
I ATTACHMENT 3.6.3 (Cont 'd) Page 3 of 3 LIST OF INACCESSIBLE STRUCTURAL MEMBERS AND CONNECTIONS I
l I I
,- a = @
"' p 9
,.i.
I
= @
= @
=
= o s +/. .
,5
. . = 8 r1 . . -
= 5 h.
2
- = _
3 n= 2
.- = @
= _ .
.: 9. = .
(4 . -
a N g
=
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~
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I
= ,
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9 a
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I ERECTED ERECTED ERECTED BY AB ELEV. BY BY LOOSE NOT INSPECTED NOT INSPECTED DIV. (FT.) N-MH AB BOLTED ERECTED UNDER SPP-3 UNDER SPP-3 1 414 X X 1 426 X X 1 439 X X 1 442 X X 1 451 X X 1 457 X X 1 460 X X 1 463 X X 1 477 X X 2 414 X X 2 426 X X 2 439 X X 2 451 X X 2 463 X X 2 477 X X 2 496 X X 3 426 X X 3 439 X X 3 451 X X 3 477 X X 463 X X R I
3 6 410 X X 6 426 X X 6 439 X X 6 451 X X 6 463 X 10% Only 6 477 X X r 6 485 X X l
7 346 X X 7 355 X X E 7 394 X X E 7 426 X X 7 439 X X 7 451 X X-7 463 X X ,
7 477 X X ;
7 485 X X !
l l
ATTACilMENT 3.6.4 Page 2 of 5 SCOPE OF ERECTION AND INSPECTION
I ERECTED ERECTED ERECTED BY AB ELEV. BY BY LOOSE NOT INSPECTED NOT INSPECTED DIV. (FT.) N-MH AB BOLTED ERECTED UNDER SPP-3 UNDER SPP-3 4
8 346 X X 8 355 X X 8 383 X X 8 394 I
X X 8 426 X X 8 439 X X l 8 451 X X g 8 463 X X g 8 477 X X 8 496 X X f
9 414 X X 9 426 X X 9 439 X X l
l 9 451 X X E 9 457 X X 9 460 X X i
I 9 9
463 477 X
X X
X 41 383 X X
, I 41 41 41 401 414 426 X
X X
X X
X j 41 451 X X 42 383 X X 42 401 X X l
42 414 X X 42 416 X X 42 439 X X
!g 42 451 X X I
3 42 459 X X i 42 467 X X 42 477 X X 42 485 X X 43 387 X X jl 43 401 X X l 3 43 414 X X 43 426 X X i g 43 451 X X g 43 459 X X 43 467 X X 43 477 X X
{
I ATTACHMENT 3.6.4 SCOPE OF ERECTION AND INSPECTION Page 3 of 5 o
I
I ERECTED ERECTED ERECTED BY AB ELEV. BY BY LOOSE NOT INSPECTED NOT IN5PECTED DIV. (FT.) N-Mil t.B BOLTED ERECTED UNDER SPP-3 UNDER SPP-3 44 364 X X 44 375 X X 46 383 X X 44 387 X X g 44 394 X X g 44 409 X X 44 414 X X g 44 44 426 X X g 439 X X 44 451 X X 44 459 X X 44 467 X X 44 475 X X 44 477 X X 44 485 X X 51 383 X X l
51 414 X X 51 426 X X 51 451 X X 52 383 X X 52 414 X X 52 426 X k 52 451 X X 52 459 X X l
=
52 467 X X 52 477 X X 52 485 X X 53 387 X X 53 414 X X l 53 426 X X l 53 451 X X 53 439 X X 53 967 X X 53 477 X X I
ATTAC101ENT 3.6.4 Page 4 of 5 SCOPE OF ERECTION AND INSPTCTION j
ERECTED ERECTED ERECTED BY AB ELEV. BY BY LOOSE NOT INSPECTED NOT INSPECTED DIV. (FT.) N-Mit AB BOLTED ERECTED UNDER SPP-3 UNDER SPP-3 i
54 364 X X 54 375 X X i 54 383 X X
!g 54 387 X X g 54 394 X X 54 409 X X 54 414 X X jl 54 426 X X
,m 54 439 X X l 54 451 X X t
54 459 X X l 54 467 X X 1 54 475 X X 54 477 X X 54 485 X X l
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l ATTACllMENT 3.6.4 Page 5 of 5 SCOPE OF ERECTION AND INSPECTION I
PC-0220
PC-0267 PC-0307 PC-0563 PC-0616 PC-0359 0221 0268 0308 0564 0617 0360 0222 0269 0322 0565 0618 0361 0223 0270 0323 0566 0619 0362 0224
0271 0324 0567 9620 0363 0235 0272 0325 0364 0568 0621 0236 0273 0328 0365 0569 0622 I 0237 0274 0329 0366 0570 0623 0238 0275 0330 0538 0571 0624 0239 0276 0331 0539 0572 0625 0240 0277 0332 0573 0626 0547 0241 0278 0333 0574 0627 0548 0242 0279 0334 0575 0628 0549 0243 0280 0335 0576 0629 0550 0244 0290 0336 0577 0630 0551 0245 029L 0337 0579 0631 0552 0246 0292 0340 0583 0632 0553 0247 0293 0341 0554 0586 0633 0248 0294 0342 0596 0634 0555 0249 0295 0348 0556 0597 0635 0250 0296 0349 0557 0598
~~0636 025L 0297 0350 0558 0599 0656 0252 0298 0355 0559 0600 0698 0261~~
~~0304 0356 0601 0723 0560 0262 0305 0357 0609~~
~~0725 0561 0263 0306 0358 0562 0615 ATTACllMENT 3.6.5 LIST OF SPP-3 CARS~~
~~(R)-Revision~~
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s EXAMPLE OF ERECTiohl CRAWIMG
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. 13. : s 1 "j ' JSED FOR INSPECTiO83 nV/s*41 \
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PUBLIC SERVICE INDZANA MARSLE IIILL NUCLEAR GENERATING STATION A&2 I . VERIFICATION OF IN-PLACE S AFETY CATECORY I STRUCTURAL STEEL MIIGI HAS BEEN INSPECTED /ACCEPTE BLDG: All xI Lt JA,ptY 7g33 tg33gg gici< gt;ggag l
5 (-
ELEV: fE.CPC F PSI QA ENCR/ LEVEL II INSP srw wn. wire
_ 7ostan wsgr SHEET "7 OF 12. PSI LEVEL I INSP** N/A DATE OF VERIF: 6 8 0 REV.: N-MH LEVEL I INSP** M/A ERECTION DWG. E - l 3'2.6 REV.C S f 1 DW4: S -152.5 REV. D
~~As required per Team Leader L-M ;6-10 The following member piece mks. have been identified as having evidence of unauthorized alterations to member configurations:~~
PIECE MK. SIZE MEMBER TYPE (BEAM, COLUKi, DESCRIPTION OF UNAUTHORIZED BRACE) ALTERATION TO CONFIGURATION MEMBER is WARPEp p 2fC282 W21 x44 BEAM fwisTao 'rowAno THE sur_
N 21c3Bl Wt285S B6A.M BENTT*F Ft Awga-wasTano l (
I 8
~
~~I :~~
a 7
9 ATTACHMENT 3.6.7 h TYPICAL INSPECTION FORMS W k PAGE 1 of 8 l
l 1
PUBLIC SERVICE INDIMIA MARDLE !!KLL NUCLEAR GENERAT2NC STATION, A&2 VERIFICATION OF IN-PLACE SAFETY CATECORY I STRUCTURAL STEEL WilIQI IIAS BEEN I?ISPECTED/ACCEPTE:
BLDc: A t.3 )< t LiAfE.Y M MER RIM NMM GTAh! WILH RTE I
i gg p PSI QA ENCR/ LEVEL II INSP Roc,sst west SHEET l OF l ^
DATE OF VERIF. : 6-9-80 REV. : N-MH I.EVEL I INSP** N/A ERacTtoN own. g-IS25 Rav.c
& $ L. Dvddi . S -1926 REV. o
~~As required per Team Leader P--<q : 7. 7 - Io The following member piece marks have been identified as missing members.~~
I PIECE MARK MEMBER TYPE (BRACE, BEAM, OR ERECTIO'i DWG. S&L IUC. COLUMN) 2114 E;,3 EE- 432.5 5-1325 BMM E
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E 7
9, d
4 0;
s R - I ATTACllMENT 3.6.7 TYPICAL INSPECTION FORMS E PAGE 2 of 8
~
PUBLZC SERVICE INDZMIA MARBLE HILL NUCLEAR GE!.ERATING STATZON 1&2 I VERIFICATION OF IN-PLACE SANTY CATECORY I STRUCTURAL STEEL WHIQ1 HAS 3EEN INSPECTED /ACCEPTE BLDG: AtJx t L 1A R Y- TEAM LEADER RICl4 5U074 AR d
gtgy, 477 '. c PSI QA ENGR / LEVEL II INSF ROGIER WEST ,
SHEET /6 0F So PSI LEVEL I INSP** N/A DATE OF VERIF.: 6-7-80 REV: N-MH LEVEL I INSP** W, pal 2* At45 I
EREctIo; uta: 2 ~/B2B REV.' C S&L dig (S): S * /gq q ggv p ** As required per Team Leader 8-ic y L-M i 2*
Me4er Size & Piece mk. as Member Size & Piece ek. in-pla.e f indicated on Erection dwg. .
2123B4 W e xl3 SA ME l 2118lB7 (c)
Zo *l2 Bd w to x 2.(, sA Me W14w54 Fw: 7": D : 23 '// P'T '/2 (M)
I 2129 st W to
~~2G 2129 S7 s 212387 We v. t 3 SAM e I '~~
21298 l CN) Wlox26 2129 8 2 i 2023D1 L Sh S1h 8646 s A u se
! -! 2o2SD2 L 3'/2 x2'/2 dit, *hA.ME g
2023DB L4 83'z / y'2 / SAue e 2023D4 ,
L a. w s'/z x t/2 SAve g B Zo24D4 LA x3 x #AG sAue 2o24D3 LA 83 x #/O / SA.M E I TI I
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~
S ATTACHMENT 3.6.7 I -
)
enter the word *[
conformance on f.
8 ~f the D. : r TYPICAL INSPECTION FORMS n the Erection dwg trther docu=en t the non-PACE 3 of 8 ansions to det**M s '. : .
1.*t.o, enter letter n inuicating tuat one size was ==4=uieu.
I
PUBLIC SERV 8CE INDIANA MARELE IlfLL NUCf. EAR CENERAT8NC STATION, UN1TS l&2 VERZF8 CAT 80N OF L:-PLACE SAFETY CATECORY Z STRUCTURAL STEEL WiiECH HAS BEEN ENSPECTED/
. ACCEPTED BLDC: M1 X t Ll ARY TEAM LEADER R.I C M BUONAR.
'! ELEV: IEC CD r-c rA w w it.H er a E PSI QA ENCR/ LEVEL II INSP MtoG 5R WES'T' E SHEET l"7 0F 40 PSI LEVEL I INSP** M/A DATE OF VERIF.: 8-9-84REV.: N-HH LEVEL I INSP** M/A g ERfr.c1"loM OWdg. E.-1325 REv.c. uSTCO BOLT INSP TECHNICAN
~~O~ IU '~~
~~As required per Team Leader Torque Inspection Results Connection Number .~~
(See Attachment 11) " PASS" " FAIL" 2105B1 - 2o53B1 $ # .
g 2f o3Bt - 2o5381 N /
21o181 - 2c53B1 v- g P-
~~b. 111181 212183-2to2B1-11U84 21o3B1-11U83 7 l~~
212181 - 2103B1 ~111181 V
$ 2.1 0 3 81 - 2l0 2 B 2 s P n -
4 2lo381 - Zio2B2 N / . _ _ _
21o2B2. - Zlo2Ebt #
, 2102 B 3 - 2.10 2 B1 v-2l02B1 - Zo%B3-Zo9ZB4- t, -
E Notes: 1. Use new bolts for each TORQUE WRENCH CALIBRATION calibrr. tion
2. Re-calibrate Torque Wrench N 1)_G 0 0 ftJ1b. 1) 1 6 (s C Ft-lb as necessary to reflect 4 . g changes in ambient conditioru 4 2) G 2. 0 ft-lb 'A Id A O- 8. 16 3._Re-calibration of Torque M Wrench is necessary if the
~~3) 6 3 0 ft-lb ATTACHMENT 3.6.7 wrench is accidentally dropped hit or jarred.~~
l l k Ave. 6 8 3 ft-lb TYPICAL INSPECTION FORMS Size O c
D A g 2,3 PACE 4 of 8 'O FT*
~~LS.~~
i
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g .
Et:3LIC SERVICE ZNDIANA MARBLE HILL NUCLEAR CENERATING STATION, L:N8TS I&2 I -
YERIFICATION OF IN-PLACE S AFETY CATECORY I STRUCTURAL STEEL WIIICI HAS BEEN INSPECIED/ ACCEPT
(- BLDc: At_1xtLIA5FY TEAM LEADER Rici< BOON AR E d.'J Y- C ,. PSI QA ENGR / LEVEL II INSP JERoME. A.V/ELLG ELEV:
SHEET l OF 3 PSI LEVEL I INSPA* hl /A l DATE OF VERIF. : 8'"30'8dlEY' N-M11 LEVEL I INSP** M/A arm a c, J tgEcIIOu Dua: 2-/926 . .
E . .
S&L IL'c(S): 9 - /.3 2.6 R.R V. D
~~ggiggr jegLegdjr s o f r o w h ter wousse or sTues matAt. Leo STUD BEND TOTAL NO. STUD NO. OF FLUTES NO. OF STUDS PER PIECE S&L DRAWING.~~
TESTS. STUDS PATTERN IN SECTIONS FLUTE PER SECT.
.p , g ,
, P S FAIL C* N* C N C N C N y v v v 10(oS85 9Asl o I4, 8 l c7&S3 9AB2 lor:
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I I 1073B4 9AS ATTACHMENT 3.6.7
- jol3%C)Ag I 1073 84 9AB TYPICAL INSPECTION FORMS PAGE 5 of 8 3 ,
~~C denotes conformance with design requirements~~
~~N denotes non-conformance with design requirements~~
. PUBLIC SERUZCZ ZNDIANA MARELE HILI .UCLEAR GENERATZNG STATZON, UNZTS 1&2 VERIFICATION OF IN-PLACE SAFETY CATEGORY I STRUCTURAL STEEL WHICH HAS BEEN INSPECTED /ACCEPTE
( BLDG: A U X1 L.l AWN TEAM LEADER Rld K BODh1AR ELEV: _gLEV. 476'-O +
PSI QA ENGR / LEVEL II INSP JERoue A. WELLS SHEET / OF M PSI LEVEL I INSP** N/A DATE OF VERIF. : 4 -6 80 REV.: N-MH LEVEL I INSP** N/A ERECTION DWG: 8 - /32 de AirKV. O
~~As required per Team Leader S&L DWG(S): 5 -/92 4r AiEEV.c _~~
VISUAL INSPECTION OF FIELD WELDS Member Piece Approximate -Description of Inspection Findings with regard E Mark and/or Location of to AWS D1.1-80 article 8.15.1 E Connection Field Weld Number on member (e.g.@ conn-ection)
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$ TYPICAL INSPECTION FORMS 2 4,LcN4,uwonecut PAGE 6 of 8 I I l
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PUBLZC SLRVICE INDINIA MARSLE !!ILL NUCLEAR GENERATING STATIONo 10 LITS 162
, VERIFICATION OF IN-PLACE SAFETY CATECORY I STRUCTURAL STE :L UlIICI !!AS BEEN INSPECTED /ACCEPTE^
I BLDC: AU X tLI AE2Y TEA!! LEADER RICK SUDNAR I
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~~As required per Team Leader L - M ; .83, - l o i~~
CONN. BOLT MAT'L BOLT SIZE BOLT COUNT IIARDENED PLATE # VISUAL CIEC; NUMBER WASilER WASi!ER FOR BOLT ,
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$ TYPICAL INSPECTION FORMS y-g EL-PACE 7 of 8 u ueno urs I # For long slotted connections only conrormance with design requirements AN denotes non-conformance with design requiremer I '
PUBLIC SERVICE INDINTA MARSLE HILL NUCLE.\R GENERATING S VERIFICAT20N OF Di-PLACE SAFETY CATEGORY I STRUCTURAL f, TEEL WilIQI HAS BEEN INSPECTED / tCCEPTEI BLDG: AU X i t ! A)llR,Y TEAM LEADER R l'C K SUDNAR -
ELEV: 4"7 7'- C# PSI QA ENCR/ LEVEL II INSP goGee., weg SIIEET l[# OF_.3 0 PSI LEVEL I UiSP** N/A ERECTION DL'G: 6 -13'l6 REV.C N-Mll LEVEL I INSP** N.PARANG S&L DwG: S-1376 REV. G DATE OF VERIF.:_ S-7-AcREV: ** As required per Ten:s Leader g
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e No,te,: "I" denotes in-place; "E" denotes data shown on erectjsn drawing ATTACHMENT 3.6.7 TYPICAL INSPECTION mRMS i
PAGE 8 of 8 I I
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I 4.0 ,IN-PLACE CATEGORY I PIPING & HANGERS 4.1 ABSTRACT This section describes the methods of inspection, controls, findings, and results of an extensive physical inspection and l I verification program conducted by Public Service Company of Indiana, Inc. (PSI) and Cherne Contracting Corporation (Cherne) on In-Place Category I pipe spools and pipe hangers at the Marble Hill Nuclear Generating Station. This section also includes the conclusions of the inspection and the proposed follow-up actions to be taken in assuring t.he appropriate corrective actions are identified.
This program consisted of a documented visual inspection, conducted by a qualified and specially trained team in accordance with the special process procedure, SPP-4. The visual inspection included a in place pipe spools, completely installed hangers, 100% of hanger welds and a statistical sample of pipe welds which provide for 95%
reliability with 95% confidence factor.
Based on the results of these examinations, PSI will take corrective measures to assure that appropriate repairs are conducted, following restart of Category I Construction activities.
~~4.2 INTRODUCTION~~
This report summarizes the measures taken to identify discrepancies I of In-place Category I piping and hangers. These steps consisted of the following items.
4.2.1 Preparation and approval of a Special Process Procedure (SPP-4)
Attachment 4.6.1 for physical inspection and verification of In-Place Safety Category I piping and hangers.
4.2.2 Establishment and qualification / training of a Physical Survey Team.
4.2.3 Compilation of survey data (see Paragraph 4.3.3).
4.2.4 Selection of the random sample welds to be inspected.
I 4.2.5 Physical inspection of Category I In-Place pipe, completely installed hangers and pipe and hanger welds.
I 4.2.6 Examination of traveller packages to assure inclusion of documents required. (A detailed review of documents included in the traveller packages is being performed as part of Special Process I Procedure SPP-12).
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I 4.2.7 Documentation of inspection results on the appropriate forms.
4.2.8 Physical flagging with a " fail ribbon' of In-Place Category I pipe spools and hangers not conforming to design configuration, to aid B in future location identification. 5 4.2.9 Preparation of Corrective Action Requests (CARS) to procedurally identify discrepancies and/or nonconformities. To establish corrective actions and actions to prevent recurrence.
4.3 DISCUSSION 4.3.1 Procedure Preparation and Approval Special Process Procedure SPP-4, entitled " Physical Inspection and Verification of In-Place Safety Category I Piping & Hangers" was prepared by S&L, reviewed and approved by the PSI Project Engineering Manager and the PSL Quality Assurance Manager. This procedure established written criteria and instructions for:
4.3.1.1 Physically inspecting In-Place Category I piping and hangers for g correctness of the installed configuration. E 4.3.1.2 . Visually examining separate statistical samples of the completed piping and hanger attachment field welds. The separate statistical samples provide for 95% reliability with 95% confidence level.
4.3.1.3 Identifying locations of items requiring corrective actions.
4.3.1.4 Verifying that traveller packages for In-Place Pipe and completely installed hangers contain the required documentation.
4.3.2 Establishment of the Physical Survey Teams The Physical Survey Team (PST) was established by the PSI l Construction Manager with the concurrence of the PSI Project W Engineering and Quality Assurance Managers. The Physical Survey Team performed the inspection under the supervtsion of the Team Leader. The Team Leader was a PSI Construction Engineer experienced in piping related work.
The Physical Survey Team membership consisted of:
4.3.2.1 The Team Leader, with a B.S. Degree and one year of experience in piping related work or a high school graduate with five years g experience in piping related work. g 4.3.2.2 At least one PSI Quality Assurance (QA) Engineer / Inspector qualified as a Level II Mechanical Welding Inspector under ANSI N45.2.6-1973.
4.3.2.3 A Cherne Quality Control (QC) Engineer qualified to Level I ( ANSI E N45.2.6-1973). 3 I
I In addition, each member of the Physical Survey Team attended a documented training session which dealt specifically witn the SPP-4 Procedure.
4.3.3 Compilation of Survey Data I
In addition to documents outlined in SPP-4, the following S&L letters were used by the PST during the inspection:
4.3.3.1 S&L letters dated 5/2, 5/19, 5/23/1980, documenting S&L review of Cherne isometrics against the corresponding S&L design drawings for I conformity of the information required for the installation of piping.
4.3.3.2 S&L letter dated 4/29/1980, documenting S&L review and acceptance of the attached Cherne Weld Procedure / Pipe Design Table Cross Reference List, marked " Attachment 4.6.2".
I 4.3.3.3 S&L letter dated 4/29/1980, defining the sample size required to estsblish overall weld quality of 95% reliability with 95%
confidence factor for pipe welds.
4.3.4 Physical Inspection The PST performed the Physical Inspection'between April 30, 1980 and June 4, 1980. The inspection included the following:
4.3.4.1 Configuration and cleanliness it;spection of In-Place Category I I piping.
4.3.4.2 Configuration inspection of completely installed hangers.
4.3.4.3 Visual examination of Category I Hanger Field Welds.
l 4.3.4.4 Visual examination of a sample of Category I Piping. Field Welds u (see Paragraph 4.3.3.3, this report).
I 4.3.4.5 Verification that Cherne traveller packages contain the required documentation.
4.3.5 _ Inspection Results and Documentation The results of the inspections were recorded under the direction of the PSI Level II Quality Assurance Engineer / Inspector team member.
The results were recorded as follows:
4.3.5.1 The inspection of traveller packages for In-Place pipe and completely installed hangers was documented on a unique F(>rm !
SPP-4.4.2.2-1 and assigned a unique number based on Cherne's l structure key for isometric drawing and hanger drawing. A sample i Form SPP-4-4.2. 2-1 is attached and marked " Attachment 4.6.3". It I
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I should be noted that in performing the traveller packages review, all packages were found to be complete.
4.3.5.2 Completely installed Category I Hangers examined for correct g configuration were documented on Form SPP-4-4.2.3.1-1 with a discrapancies noted. The hanger number served as a unique traceable identification based on Cherne structure key. A sample Form SPP-4-4.2.3.1-1 is attached and marked " Attachment 4.6.4". It should be noted that no physical hanger configuration discrepancies were found.
4.3.5.3 In-Place Category I spools inspected for correct configuration and cleanliness were documented on Form SPP-4-4.2.3.2-1 with discrepancies noted. Spools associated with a single isometric drawing were documented on the same form and assigned a un. ue number based on Cherne's structure key for each isometric drawing.
A sample Form SPP-4-4.2.3.2-1 is attached and marked " Attachment
. 4.6.5". It should be noted that no physical pipe configuration discrepancies were Sund and no generic cleanliness problem was found.
4.3.5.4 The drawings used (i.e., hanger drawings, isometric drawings, etc. ) to inspect Category I In-Place pipe and completely installed hangers as well as visual examination of pipe and hanger field welds are documented on Form SPP-4-4.2.3.3-1. The form was assigned a unique number cased on Cherne's structure key for each hanger or isometric drawing. A sample Form SPP-4-4.2.3.3-1 is attached and marked " Attachment 4.6.6".
4.3.5.5 Pipe field welds inspected were documented on Form SPP-4-4.3.3-1.
Discrepancies were noted and exact location of discrepancy was noted on the form. Forms were assigned a unique number based on Cherne's structure key for the isometric drawing and the weld number on that drawing. A sample Form SPP-4-4.3.3-1 is attached and marked " Attachment 4.6.7". It should be noted that out of 52 pipe field welds orginally inspected, only 1 weld was determined to require repair. The pipe weld sample size was in reased to 79 and no additional defects were found, thus achieving the required 95% g reliability with 95% confidence factor. g 4.3.5.6 Hanger field welds inspected were documented on Form SPP-4 .3.3-2.
Discrepancies were noted and exact location of discrepancy was noted by reference to the weld ID number. Forms were assigned a unique number based on Cherne's structure key for hanger drawing.
llanger field welds inspected on a single hanger were documented on E one form. A sample Form SPP-4-4.3.3-2 is attached and uarked g
" Attachment 4.6.8". It should be noted that hanger attachment welds were examined to criteria set in the following eight categories as outlined in Attachment 4.6.8; namely, undercuts, cracks, linear indications, reinforcement, lack of, fusion, piping l porosity (AWS welds), weld type, size and location, arc strikes and gouges. Discrepancies were found in the following categories:
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I undercuts, are strikes and field velds which do not conform to I hanger drawings. No discrepancies were found in the other categories specified in Attachment 4.6.8.
4.3.6 Physical Marking Concurrent with the recording activity of Category I In-Place I spools and completely installed hangers inspected for configuration, in place spools and completely installed hangers were flagged with a pass ribbon or fail ribMn. These measures will assure easy reference in the future to spools and hangers with I noted configuration discrepancies.
4.3.7 Preparation of Corrective Action Requests (CARS)
Using the documentation obtained during the inspections, PSI has generated eight (8) CARS to identify nonconformances, establish corrective actions for the specific discrepancies, establish action I required to prevent recurrence, identify probable cause and actions taken to assure the quality of items effected prior to discovery of adverse condition. Contractor's proposed corrective actions were reviewei and approved by Sargent & Lundy, PSI, and PSI Authorized Nuclear Inspector where required.
I Of the eight (8) CARS, one was determined not to be a dis ~crepancy.
The balance of these CARS written may be divided into three groups involving pipe hanger configurations, pipe welds, and hanger R
welds. Two CARS involved a discrepancy on two (2) Cherne isometric I drawings which left out a field weld and spool number. Cherne will correct their isometrics to include the missing field weld and spool number. It should be noted that the subject pipes are inscalled :orrectly per the S&L design drawings.
One CAR involved a pipe weld discrepancy on a burn-through and lack of penetration of a single weld. The weld will be repaired per approved Cherne procedures.
Four CARS involved hanger field weld discrepancies in the I categories of undercuts, are strikes, and weld configuration to S&L drawings. Some weld configurations are acceptable as is, other welds will be repaired per approved Cherne procedures.
~~4.4 CONCLUSION~~
l Of the five categories examined (i.e., traveller packages, hanger I configuration, pipe configuration, pipe field welds and hanger '
field welds), the majority of discrepancies were found in the hanger attachment welds, 100% of which were inspected. The I applicable CARS address the corrective actions required. The recommended action to prevent recurrence will be additional training to be conducted for welding inspectors, foremen, l
pipefitters, and welders.
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I In summary, Category I In-Place pipe, completely installed hangers, pipo field welds and hanger field welds were inspected.
Discrepancies were documented on CARS with corrective actions agreed on. These future corrective actions will assure that Category I In-Place pipe, completely installed hangers, pipe field l
W welds and hanger field welds installed to date will meet the requirements of the applicable specifications, codes and standards.
In addition, PSI is rcviewing 100% of the Contractor's Category I Work Procedures. Thic review, together with additional training of the Contractors inspectors, fo reme n, pipefitters and welders prior l to restart of Category I work, should assure an acceptable level of =
quality on future field piping work.
~~4.5 REFERENCES~~
4.5.1 SPP-4, " Physical Inspection and Verification of In-Place Safety Category I Piping and llangers, Revision 4, Special Process Procedures, Marble 11i11 Nuclear Generating Station, Public Service Indiana.
4.6 ATTACilMENTS 4.6.1 SPP-4, Revision 4 4.6.2 Cherna Weld Procedure / Pipe Design Table Cross Reference List 4.6.3 Traveller Package Worksheet 4.6.4 Itanger Verification Worksheet 4.6.5 Spool Verification Worksheet 4.6.6 Documentation Worksheet 4.6.7 Piping Weld Inspection Worksheet 4.6.8 Hanger Weld Inspection Worksheet 4.6.9 List of 11 anger Drawings Used to Inspect llangers 4.6.10 List of Drawings Used to Inspect Piping I
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~~SUMMARY~~
OF REVISIONS Attachment 4.6.1 PROC. NO. SUBJECT PHYSICAL INSPFCTION & VERIFICATION OF IN-PLACE I SPP-4 REVISION NUMBER SAFETY CARCORY I Pit'ING AND MANCFR9 REVISION DESCRIPTION
. 1 2 Major Revision:
I - 1.0 Purpose;
- 3.0 Definitions; Section 4.2.3.4, added k, 1 and m; Added Section 4.3.4 pertaining to AWS DI.1,1980 Welds ;
I Expanded Section 4.4; Added Attachments A and B; Changed all dates to 04-23-80; and Changed Revision number from 1 to 2.
3 Page 6, Changed Section 4.3 Page 8, Changed Section 4.3.3 h I Changed all dates to 05-08-80 Changed Revision from 2 to 3.
Added Note to page 4, Section 4.2.2 C 4 Revised Definition Relevant Arc Strike I Revised Paragraph 4.5 Revised Section 5.0 & 6.0.
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I REVISION AUTHORIZATION REVISION NUMBER 4 I
DATE 05-19-80 ISSUED $ ,
PREPARED d /Ahk BY 83t % h[h l '"*'hkd/wl eY APPROVED {
Jrnu -l SECTION MGR l ,
, APPROVED Im 7 l
Q.A.MGR y I
APPROVED '
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MARBLE HILL GENERATING STATION Date 05-19-80 PUBLIC SPECIAL PROCESS PROCEDURE Revision 4 SERVICE ""' * '
~~SPP-4 l~~
INDIANA PHYSICAL INSPECTION AND VERIFICATION 0F IN-PLACE SAFETY CATECORY I
, PIPING AND HANGERS TABLE OF CONTENTS TITLE SECTION 1.0 PURPOSE I,
i 2.0 APPLICABILITY ,
3.0 DEFINITIONS
~4.0 INSTRUCTIONS
~~5.0 REFERENCES~~
6.0 ATTACHMENTS ATTACHMENT A EXCESSIVE REINFORCEMENT ASME Section III, NB 4426 NC 4426, ND 4426 and NF 4426 ATTACHMENT B REQUIREMENT 3 FOR VISUAL INSPECTION OF FIELD WELDS l (AWS D.1.1 - 1980)
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I MARBLE HILL GENERATING STATION D:te 05-19-80 PUBLIC SPECIAL PROCESS PROCEDURE Revision 4
l SERVICE
~~Title:~~
SPP-4 PHYSICAL INSPECTION AND VERIFICATION INDIANA 0F IN-PLACE SAFETY CATEGORY I PIPING AND HANGERS i
I l.0 PURPOSE l
This document establishes the procedure for inspecting, by physical I verification, in place safety Category I piping and hangers for agreement with the latest design requirements ; or, where discrepancies I exist, to document the deviations in accordance with existing PSI procedures.
Dimensions of piping and hangers as well as relative loca'sn in the building, are not included in the Scope of SPP-4. Pipint, and hangers I are generally adjusted during installation, and these in place adjusted conditions are taken into acccunr. in the development of a Final Stress Report. Therefore, verificaticn of location and dimensions shall be I performed during normal construction activities.
2.0 APPLICABILITY This procedure is applicable to the work performed by the Mechanical Piping Contract (Cherne Contracting Ccrporation).
3.0 DEFINITIONS s
Traveller Packages - Assembled documentation containing Process I Sheets / Weld Data Records, Cherne Hanger Drawings, Isometric Drawings and Field Requisitions assembled in accordance with Section 12 of Cherne Contracting Corporation's Quality Assurance Manual.
I Structure Keys - Alpha - Numeric Code numbers assigned to Cherne Construction documents for internal Document Control.
I In-Place Spools - Any spools hung temporarily or permanently in their intended location.
In-Place Hangers - Any hangers attached in their designated locatior. in accordance with S&L hanger drawings.
Completely Installed Hangers - In place hangers supporting in place s pool s.
Pasa Ribbon - A ribbon of a green color which denotes that the flagged item was inspected and found to be acceptable.
Fail Ribbon - A ribbon of a white color which denotes that the flagged item was inspected and found to be questionable or rejected.
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MARBLE HILL GENERATING STATION Date 05-19-80 PUBLIC SPECIAL PROCESS PROCEDURE Revision 4
~3 of 11 p",
SERVICE
~~gg g SPP-4 PHYSICAL INSPECTION AND VERIFICATION OF IN-PLACE SAFETY CATEGORY I PIPING AND HANGERS E~~
3 Relevant Arc Strike:
(a) An Arc Strike pit whose depth is 1/32" or greater.
(b) An Arc Strike which results in weld deposit (s) on the base metal of 1/32" height or greater.
(c) An Arc Strike on the internal surface of sta nless steel piping.
8 (d) An Arc Strike which results in cracking.
Latest S&L Design Drawings - Latest as of April 14, 1980.
PST - Physical Survey Team PSI - Public Service Indiana S&L - Sargent & Lundy Engineers 4.0 INSTRUCTIONS 4.1 Establishment of Physical Survey Teams I The establishment of the Physical Survey Team shall be the 5 responsibility of the Public Service Indiana (PSI) Construction W Area Manager with the concurrence of the PSI Project Engineering Manager. The team shall consist of, as a minimum, a PSI Quality g Assurance Engineer / Inspector, a Cherne Quality Control Engineer and a PSI Construction Engineer who will serve as the Team Leader. The Q' Team Leader shall have at least a B.S. degree and one year of experience in piping related work or a high schcol graduate with g five years experience in piping related work. The Quality 3 Assurance Engineer / Inspector from PSI shall be a qualified Level II Mechanical Welding Inspector under ANSI N45.2.6 - 1973 (Ref. 6.3).
l The Cherne Quality Control Engineer shall be qualified to Level I as a minimum. Note: If required, additional PSI Level II Mechanical Inspectors qualified under ANSI N45.2.6 - 1973 may be used to support the Physical Survey Teams. Each Team Leader shall be under the supervision of the PSI Construction Area Manager for E g
the performance of the physical survey in his area, who in turn is responsible to the Construction Manager for the overall performance of work. The PSI Project Engineering Manager is responsible for providing technical support to the entire program. The recording of data shall be under the direction of the PSI Level II Quality Engineer / Inspector. The PSI Superintendent of Mechanical Quality g h Engineering is responsible for randomly selecting the statistical g a-weld sample numbers required in Paragraph 4.3.1.
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I MARBLE HILL GENERATING STATION cate 05-19-80 PUBLIC SPECIAL PROCESS PROCEDURE 4 t
Revision l SERVICE ""' 4 of 11
~~SPP-4 PHYSICAL INSPECTION AND VERIFICATION l~~
lNDIANA 0F IN-PLACE SAFETY CATECORY I l
l PIPING AND HANGERS l
l I 4.2 Physical Survey Team Verification and Inspection Activities I
I 4.2.1 The Physical Survey Team shall obtain a list of Safety Category I in place hangers and a list of the Cherne I Isometric drawings which show in place work for Safety Category I piping, from which installation was performed, The Physical Survey Team shall organize the list by l
i elevation and system, and establish a schedule for l completing the verification and inspection based on a 100%
I review of all in place spools and completely installed ;
hangers.
Oaly the latest issue of S&L drawings shall be used.
4.2.2 The Cherne Traveller Packages for in place pipe and I completely installed hangers shall be examined by the Physical Survey Team in Cherne's Field Construction Of fice for the items listed below. Note: The Physical Survey Team may, at their option, call on Quality Engineering personnel I for assistance.
a. Verification that .111 documentation required to be I in the Traveller Package in accordance with Cherne's Bulletin 12.3 has been included. This includes Process Sht:et/ Weld Data Records, Isometric Drawings, Field Requisitions, and Hanger Drawings.
b. Verification that the Isometric Drawings used for joining and installation activities were updated to I re flec t the latest applicable Sargent and Lundy (S&L) Mechanical Design drawings, and Field Change Requests (Sargent and Lundy shall assist by i
I reviewing each Isometric for configuration accuracy to the latest Design Drawings). If a discrepancy appears to exist, the Physical Survey Team shall uso the latest S&L drawings to verify the l initallation. Cherne's ISO / Single Line Cross m Reference Log shall also be reviewed to verify drawing correlation.
~~c. Verification that the weld procedure indicated for each weld is the correct procedure based on S&L's piping design tables and that the correct piping I f a~~
design tables are used. S&L Piping and Instrumentation Diagrams (P& ids) shall be used for verification of correct piping design tables.
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I MARBLE HILL GENERATING STATION cat. 05-19-80 4
PUBLIC SPECIAL PROCESS PROCEDURE Revision 5 of 11 SERVICE
~~Title:~~
SPP-4 PHYSICAL INSPECTION AND VERIFICATION OF IN-PLACE SAFETY CATEGORY I PIPING AND HANGERS Note: S&L shall review cross reference lists supplied by Cherne Contracting Corporation for concurrence *that the correct veld procedures are used in conjuction with the correct piping design tables.
The Physical Survey Team shall use Form SPP-4-4.2.2-1 to document the inspection of each Traveller Package and assign a number to the form based on Cherne's Structure Key for each Isometric Drawing.
4.2.3 A physical inspecton of the installed piping and hangers shall be conducted by the Physical Survey Team based on each S&L Hanger drawing, Cherne's Isometric drawings and associated Traveller Package examined in Paragraph 4.2.2.
4.2.3.1 The Physical Survey Team shall obtain the latest l S&L Hanger drawings for each completely installed 3 hanger and shall physically inspect each of those hangers to verify that the installed configuration is consistent with the Design drawings, and all spring type hangers are temporarily locked compressed. Hangers installed to the structure only, and not attached to the pipe, shall be g inspected for proper attachment only as outlined in 3 4.3. Each hanger inspected by the Physical Survey Team shall be listed on Form SPP-4-4.2.3.1-1 along with the S&L Hanger drawing used to verify the installation. The Form shall be completed by the Physical Survey Team to document the inspection and note any discrepancies. Hangers which pass the inspection shall be flagged with a " pass ribbon" g
3 and those failing the inspection shall be flagged with a " fail t ibbon".
4.2.3.2 The Physical Survey Team shall inspect each spool to insure that the correct configuration is as I
shown on the Isometric drawings. Each spool E correctly installed shall be flagged with a " pass 3 ribbon". Any spools found to be incorrectly installed shall be flagged with a " fail ribbon".
Form SPP-4-4.2.3 .-l shall be used by the Physical Survey Te.m to indicate which spools have been inspected and any discrepancies observed.
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g 4.2.3.3 The Physical Survey Team shall list all documents and drawings used in the physical inspection and verification on Form SPP-4-4.2.3.3-1.
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I MARBLE HILL GENERATING STATION Date 05-19-80
- PUBLIC SPECIAL PROCESS PROCEDURE hision 4 6 of 11 t SERVICE p
D 8: SPP-4 PHYSICAL INSPECTION AND VERIFICATION INDIANA I 0F 1N_ptiCg siggry cargcogy 1 PIPING AND HANGERS I 4.2.3.4 The following documents will be required by the Physical Survey Team in order to perform the I activities in 4.2:
]
~~a. Cherne Isometric Drawings~~
~~b. Cherne Traveller Packages~~
~~c. Cherne Bulletin 9.1, 12.3, 15.17, '~~
~~15.18~~
~~d. Cherne ISO / Single Line Cross Reference Log~~
~~e. S&L P & ids~~
~~f. S&L Single Line Drawings~~
~~g. S&L I 3 er Drawings~~
~~h. S&L Drawing List~~
~~i. S&L dpecification Y-2739 and appropriate ECNs~~
~~$ vield Change Requests~~
~~k. S&L letters of review of Isometric drawing~~
~~1. Cherne Hanger drawings~~
m. S&L letters defining the sample I size required to establish over-all weld quality of 95% reliability with 95% confidence for two I populations, namely, pipe welds and hangers.
4.2.4 The Physical Survey Team shall sign-off each Form used in I l the physical inspection and forward all Forms, grouped by elevation, to the Project Engineering Manager for input the final report.
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r MARBLE HILL GENERATING STATION Date 03-19-80 PUBLIC SPECIAL PROCESS PROCEDURE Revision 7
SERVICE Titla: SPP-4 l PHYSICAL INSPECTION AND VERIFICATION INDIANA 0F IN-PLACE SAFETY CATEGORY I PIPING AND HANGERS 4.3 Visual Field Weld Inspection by Statistical Sample A Level II Mechanical Welding Inspector, qualified under ANSI N45.2.6-1973, shall be assigned by the Construction Area Manager to inspect separate statistical samples of the completed piping and hanger attachment field welds. The separate statistical samples shall provide 95% reliability with a 95% confidence factor.
When the surface condition of the weld precludes meaningful visual examination, cleaning shall be performed. Acceptable methods of cleaning include solvent cleaning and brushing. The method of l cleaning shall be recorded in the remark column of Forms, W SPP-4-4. 3. 3-1 a nd SPP-4-4. 3. 3-2. Note: Grinding and polishing of the welds is prohibited.
4.3.1 The Team Leader shall establish a list of all piping field welds and all in place hangers for use in selecting a random sample. These pipe welds and hangers shall be given a l unique number by the Team Leader. A random sample table 5 shall be used to establish the weld sample number to be inspected for both the piping welds and hangers. The weld g sample number shall be selected by the PSI Superintendent of Mechanical Quality Engineering from the random sample 5 table. From these established lists and selected sample numbers, the Mechanical Welding Inspector shall inspect the l designated welds. W 4.3.2 The number of welds to be inspected will be determined by the following formula: (Ref. 6.2) r Np Nq x n-x C=1-8 l
3 x=0
[N )
(n/
N = total number of welds ""
n = number of welds to be inspected C = 0.95 Confidence Level p = 0.05 q=1p
{. r=0 N k N!
e (nf_- n. (n-n n l
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I I MARBLE HILL GENERATING STATION cate 05-19-80 PUBLIC SPECIAL PROCESS PROCEDURE RevWon 4 I SERVICE INDIANA M SPP-4
""' 8 of 11 PHYSICAL INSPECIION AND VERIFICATION 0F IN-PLACE SAFETY CATECORY I PIPING AND HANGERS I 4.3.3 The Welding Inspector shall visually inspect each ASME Section III weld in the random sample for the following items:
~~a. Undercut: Not to exceed 1/32" at any point.~~
~~b. Cracks: Are not acceptable.~~
~~c. Linear Indications: Not to exceed 1/16".~~
~~d. Excessive Reinforcement: (See Attachment A).~~
. e. Lack of Fusion: Not acceptable.
=
~~f. For pipe 42" diameter and larger, check pipe ID for veld defects as stated in a - e and h. Lack of penetration is unacceptable.~~
~~g. Weld Type, Size (L4g & Throat) and Location (hanger welds per S&L Drawings, piping welds per Weld Data Record). Note: Minimum throat & leg size is per S&L~~
~~Drawing or Weld Data Record. No maximum. Throat size is cosine of leg.~~
~~h. Following cleaning and brushing of area to be inspected, gouges and relevant Arc Strikes are not acceptable.~~
I Each weld examined shall be documented pssa or fail far each of the above items on Forms SPP-4-4.3.3-1 and SPP-4-4.3.3-2 for piping and hangers, respectively. The acceptance
'g criteria shall be as stated in "a" through "h" above. The
'g inspection shall continue until the required number of welds are inspected as outlined in Paragraph 4.2.3.4-M.
l Where a weld defect is identified, the exact location of the um defect along the circumference of the pipe shall be identified by the Time Clock Method. When facing the clock, the Inspector shall be facing Plant North, Plant West or up.
4.3.4 The Welding Inspector shall visually inspect each hanger field weld in the random sample of the selected hanger as fo llows :
~~a. Fielu welds undet jurisdiction of ASME Section III - NF:~~
I f e
Field Welds shall be inspected for the same requirements outlined in Paragraph 4.3.3.
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1 MARBLE HILL GENERATING STATION cats 03-19-80 4
PUBLIC SPECIAL PROCESS PROCEDURE Revision 9 of 11
- SERVICE
~~Title:~~
~~SPP-4 PilYSICAL INSPECTION AND VERIFICATION OF IN-PLACE SAFETY CATECORY I PIPING AND llANGERS~~
~~b. Field welds under jurisdiction of AWS D.1.1:~~
Field welds shall be visually inspected according to Article 8.15.1 of AWS D.1.1-80. For conve nience , the requirements of this Article are specified in Attachement B.
The Inspector shall assign a unique number to each AWS field weld. The assigned hanger veld shall be l sequentially numbered as follows: =
lhnger Number - AWS - Sequential Number.
Each unique field weld number shall be identified and recorded by the PST on the E g
Cherne llanger drawing.
~~c. For the purpose of the random sample weld inspection, a hanger will be considered to have passed the inspection =~~
only if all of its field welds have passed.
4.3.5 Upon completion of the inspection, the Welding Inspector shall sign each form used to document the weld inspection and forward them to the Taam Leader for input to the final report for the Safety-Category I Piping and I! angers.
4.4 Verification of Installation Cleanliness The Physical Survey Team shall visually inspect for cleanliness, the internal surface of each accessible in place pipe which has been field welded. For size 42" diameter and larger, the inspection shall include the complete length of the pipe.
For pipe smaller than 42" diameter, the inspection shall include only that section of pipe which can be visually inspected without g crawling inside the pipe. Examples of items to be checked are weld g splatter, oil, grease, paint, slag, chalk abrasive carbon deposits, t
coatings, and other foreign matter.
1
! Should the PST determine at the conclusion of the verification l program that a generic cleanliness problem exists, a generic nonconformance will be initiated to address all cleanliness g pro bletes . The cleanliness shall be documented for each pipe g checked by the PST on the Spool Verification Worksheet, Forn SPP-4-4.2.3.2-1.
4.5 Processing of Nonconformances with Design Requirements It shalt be the responeibility of the P.S.T to originate any g 0 deficiencies with design requirements in accordance with PMP 1.07 E on a Corrective Action Request (CAR). The PSI Level II Inspectors 5
3 are re s ponsib le for assuring that the nonconformances are I.
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MARBLE HILL GENERATING STATION cate 03-19-80
, PUBLIC SPECI AL PROCES3 PROCEDURE Revision 4
10 of 11 p'S' I SERVICE
~~Title:~~
l SPP-4 PHYSICAL INSPECTION AND VERIPICATION !
INDIANA 0F IN-PLACE SAFETY CATEGORY I PIPING AND HANGERS documented accurately wh the findings of the P.S.T and are responsible for signing the signature block labeled " Initiator".
NOTE: For SPP-4 deficiencies it shall be noted in the " Method of Discovery" block on the CAR Form that the deficiencies were discovered by SPP-4 P.S.T. The control of the nonconformances (CARS) shall be in accordance with PMP 1.07 af ter the origination I of the CAR by the P.S.T. Numbers for the CARS shall be obtained by the PSI Superintendent of Mechanical Quality Engineering from the Nnconformance Computer Coordinator.
4.6 Records Checklists and marked-up drawings for this inspection are quality records. In addition to their being maintained as quality I documents, the complete set shall be maintained separately until the resulcs of the reinspection have been evaluated and authorization for construction has been received.
5.0 REFERENCIS 5.1 PMP 5.16, "Special Process Procedures", Rev. O, March 5,1980.
5.2 A. 'l-S. Aug and W. H. Tang, Probability Concepts in Engineering Pla ming and Design, Volume I, "Bacic Concepts," John Wiley & Sons, Inc., New York, New York, 1975, p. 361 5.3 ANSI N45.2.6-1973, " Qualifications of Inspection, Exawnation, and I Testing Personnel for the Construction Phase of Nuclear Power Plants,"ASME, New York, New York.
5.4 PMP 1.07, " Control of Nonconformance", Rev.0, March 6,1980 6.0 ATTACHMENTS EFFECTIVE DATE I 6.1 Figure 1 - Flowchart for the inspection ard verification of piping and hangers.
05-08-80 6.2 F' gure 2 - Flowchart for the visual 05-08-80 I insection of piping and hanger attacheent walds.
6.3 Attachment A (2 pages) 05-08-60 6.4 Attachment B (4 pages) 05-08-80 I $
k 6.5 Form SPP-4-4.2.2-1 6.6 Form SPP-4-4. 2. 3.1-1 05-08-80 05-08-80 I i -
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MARBLE HILL GENERATING STATION Date 03-19-80 PUBLIC SPECIAL PROCESS PROCEDURE Revision p
SERVICE
~~Title:~~
SPP-4 PHYSICAL INSPECTION AND VERIFICATION l INDIANA Or IN-PUCE SAFEU CAECORY I PIPING AND HA!CERS 6.7 Form SPP-4-4.2.3.2-1 05-08-80 6.8 Form SPP-4-4.2.3.3-1 05-08-80 6.9 Form SPP-4-4.3.3-1 05-08-80 6.10 Form SPP-4-4. 3. 3-2 05-08-80 I
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MARBLE HILL GENERATING STATION Dew 05-08 90 l / .PUBLIC SPECIAL PROCESS PROCEDURE SERVICE I INDIANA
~~Title:~~
spp.4 PHYSICAL INSPECTION AND VERIFICA ON Or IN-PtACE Sigtry Cayecoay 1 PIPING AND MANGERS PEM,- PSI PROJECT ENGINEERING MANAGER 1
I PST - PHYSICAL SURVEY TEAM CAM - CONSTRUCTION AREA MANAGER I 4.1 CAM Select PST and assign TL
~~4. 2.1 . Develop schedule to complete PST inspection of piping & hangers I~~
'.2.2 4 , Review Cherne Traveller package PST
. 2. 3
~~Physically inspect installed~~
, I PST e
4.4 PST piping and hangers Visually Inspect Cleanliness I - .
SSP-4-4.2.2-1 i
PP-4-4.2.3.1-1[/SPP-4-4.2.3.2-1[dPP-4-4.2.3.3-l[ Fill forms out PFM and forward to PEM PEM PEM PEM by elevation I Process 4.5 l
2 I Nonconformance with control in accordance PST& PSI Review for Input to Final Report with PMP 1.07 l
I I u-e 1 - PI- ~~ +ns P -d veri fi-i- o f PiP in. - -s I , l e
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I MARBLE HILL GENERATING STATION Date 05-08-80 PUBLIC SPECIAL PROCESS PROCEDURE SERVICE D' SPP-4 PHYSICAL INSPECTION AND VERIFICATION OF IN-PLACE SAFETY CATECORY I PIPING AND HANGERS CAM - CONSTRUCTION AREA MANAGER PEM - PSI PROJECT ENGINEERING MANAGER WI - Level II Welding Inspector 4.3 Select WI ,
CAM l 4.3.1 From an established list of all :. elds and a selected random sam;de, perform up WI inspection.
4.3.3 Visually inspect desipated piping I
_ and hanger attachment welds.
WI I
SPP-4-4.3.3-1 SPP-4-4.3.3-2 Complete form and Forward to
/ PEM
/ / PEM
/ PEM.
I I Process 4.5 4.3.4 Noncon formance PST& PSI PEM Review for Input to With Control in Final Report Accordance with PMP 1.07 .
Figure 2 - Flowchart for the visual inspection of piping and hanger attachment l welds. g e
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I SPP-4 05-08-80 Page 1 of 2 I ATTACHMENT A I EXCEh1VE REINFORCEMENT Per ASME .setion III, NB, NC, ND 1977 Edition with Winter '77 Addenda I
ND-4426 Reinforcement of Welds ND-4426.1 1hickness of Weld Reinforcement for Vessels, Pumps, and 1alves. The surface of the reinforcement of all I butt velded joints in vessels, pumps and valves may be flush with the base material or u.ay have uniform crowns. The height of reinforcement on each face of the weld shall not exceed the following thickness tabulation:
i Nominal Maximum I _
Thickness, in.
Reinforcement, in.
I 3/32 Up to 1, incl.
Ove r 1 to 2, i e 1. 1/8 over 2 to 3, incl. 5/32 over 3 to 4, incl. 7/32 I over 4 to 5, incl.
over 5 1/4 5/16 I ND-4426.2 Thickness of Weld Reinforcement for Piping.
For double welded butt joints, the limitation on the I reinforcement given in column 1 of the following tabulation shall apply separately to both inside and outside surfaces of the joint. For single welded butt joints, the reinforcement given in column 2 shall apply to the inside surface and the I reinforcement given in column 1 shall apply to the outside surface. The reinforcement shall be determined from the Higher of the abutting surfaces involved.
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~~Requirements of NB-4426 and NC-4426 are identical to the requirements of ND-4426.~~
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SPP-4 05-nR-80 Page 2 of 2 ATTACHMENT A (Cont'd)
EXCESSIVE REINFORCEMENT Per ASME Section III, Subsection NF l
W 1977 Edition with Winter '77 Addenda
~~ND-4426.2 (Continuation)~~
Maximum g Reinforcement g Material Thickness, in.
Nominal Thickness, Column Column
.n . 1 2 Up to 1/3, incl. 3/32 3/32 over 1/3 to 3/16, incl. 1/8 3/32 over 3/16 to 1/2, incl. 5/32 1/8 Over 1/2 to 1, incl. 3/16 5/32 Over 1 to 2, incl. 1/4 5/32 Over 2 The greater of 1/4 in. or 1/8 times 5/32 the width o f the weld , in.
NF-4426 Keinforcement of Butt Welds I
The surface of the reinforcement of all butt welded joints may be flush with the base material or may have uniform crowns. The height of reinforcement on each face of the weld shall not exceed the following thickness:
Nominal Maximum Thickness, Reinforcement, in. in.
Up to 1 incl. 3/~a 2 Over 1 to 2, incl. 1/8 l Oser 2 to 3, incl. 5/32 over 3 to 4, incl. 7/32 Over 4 to 5, incl. 1/4 Over 5 5/16
~~Requirements of NB-4426 and NC-4426 are identical to the g requirements of ND-4426.~~
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Dsta 05-08-80 SPP-4 I Page 1 of 4 1
1 ATTACHMENT B AWS D1.1 - 80 REQUIREMENTS FOR VISUAL INSPECTION OF FIELD WELDS
,I 8.15 Quality of Welds 8.15.1 Visual Inspection. All welds shall be visually inspected. A wc!d shall be acceptab!c by visual inspec-I tion ifit shows that 8.15.1.1 The weld has no cracks.
8.15.1.2 Thorough fusion exists between* adjacent layers of we:d metal and between weld metal and base I metal.
of the weld.
8.15.1.4 Weld profiles are in accordance with 3.6.
8.15.1.3 All craters are filled to the full cross section (This Attachment A also I 8.15.1.5 Irrespective of length. undercut shall not ex- includes the requirements cced the value shown . Fig. S.15.1.5 for the primary of 3.6. See Page 3 of stress direction category applic.ible to the area containing of this attachment) the undercut. Further. the undereut may be Iwice the value I permitted by Fig. 8.15.l.5 tfor the appheable stress cate.
gory) for an accumul ted length of 2 in. in any 12 in. (51 mm in 305 mm) length of weld. but in no case may
~~undercut on one side be greater than 1/16 m. (1.6 mm). For I weld lengths less than 12 in. (305 mm). the pennitted length should be proimrtional to the actual length.~~
8.15.1.6 The sum of diameters of piping porosity in fillet wc!ds does not exceed 3/* in. (9.5 mm) in any lin'earinch of weld and shall not exceed 3/4 in,(19.0 mm)
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in any 12 in. (305 mm) length of weld.
8.15.1.7 A fillet weld in any single continuous weld shall be per. .itted to underrun the nominal fillet size
'l, required by 1/16 in. (1.6 mm) without correction. pro-W vided t!ut the undersize portion of thq wc!d does not execed 10% of the Icngth of the weld. On web-to-flange welds on girders, no underrun is permitted at the ends for a length equal to iwice the w idth of the fl.mge.
'I 8.15.1.8 Complete joint penetration groove weids in butt joints transserse to the direction of computed tensile I
stress shall have no piping porosity. For all other groove v.cids. piping pornsity sha!' not exceed 3/3 in. (9.5 mm) in any linear inch of weld and shall not exceed 3/4 in.
(19 mm)in any 12 in. (305 mm) length of wcid.
8.IS.I.9 Visual inspection of welds in all steels may begin immediately after the comp!:ted welds have cooled to amEent temperature. Acceptance criteria for ASTM A514 and A517 steels shall be based on visualinspection I performed not less than 48 hours5.555556e-4 days 0.0133 hours 7.936508e-5 weeks 1.8264e-5 months aftet completion of the weld.
l g The reqtirements on this page have been takes. from page 133 of j g AWS DJ.1-80, "1980 Structural Welding Code - 5 cel",1979, Aracrican
! Welding Society, Miami, Florida.
l3 I- --- -- --
E Date G.)-os-80 t SPP '4 Fage 2 of 14 l
ATTACEL%T 3 I
~
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g No calculated stress a07
/ L _ _ _I_ _ _ _
(1/161 0.05 Primary Tensde Stress
" 0.04 Paret'ei to undercut;
@ . shear, compressen in j 0.03 7 any crection -
i , , ._ _7.
=
r .r _ :f x Primary Tensile Stress Tranwerse to undercut a01 II ESR 1 2 3 4 5 6 NE Member thickness, in.
Fig. 8.15.1.5-Perntissible undercup,alues for buildings ,
I l The requirements on this page have been taken from page 134 of l AWS D1.1-80, "1980 Structural Welding Code - Steel", 1979 American Welding Society, Miami, Florida.
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I I Date 05-08-80 -
I S00 14 P'he a 3 of 4 effTACHEUT B ,
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3.6 Weld Profiles l
3.6.1 The faces of fillet wc!ds may be slightly convex, I
flat, or slightly concave as shown in Fig. 3.6 (A), end (B), with none of the unacceptable profiles shown in Fig.
3.6(C). Except at outside corner joints, the convexity shall a not exceed 0.1 times actual leg size, or thd longer leg in the I case of an unequal leg fillet weld, plus 0.06 in. (1.5 mm).
See Fig. 3.6(B).
3.6.2 Groove welds shall preferably be made with slight or minimum reinforcement except as may be otherwise provided in the case of butt and comerjoints, the rein-forcement shall not execed I/8 in. (3.2 mm) in height and shall have gradual trr.ntition to the plane of the base I metal surface. See Fig. 3.6(D). They shall be free of the discontinuities shown for buttjoints in Fig. 3.6(E).
3.f.3 Surfaces of butt joints required to be flush shall be I fahished so as not to reduce the thickness of the thinner base snetal or wcid metal by more than 1/32 in. (0.8 mm) or 57c of the thickness, whichever is smaller, nor leave reinforcement that exceeds 1/32 in. However, all rein-I '
forcement must be removed where the weld fonns part of a faying or contact surface. Any reinforecuent must blend smoothly into the plate surfaces with transition areas free from edge weld , undercut. Chipping may be I- used provided it is followed by grinding. Where surface finishing is required, its roughness value' shall not ex-cced 250 pin. (6.3 m). Surfaces finished to values I
of over 125 pin. (3.2 pm) through 250 gin. sh J1 be finished parallel to the direction of primarv stress. Sur-faces finished to values of 125 gin. or less may be fin-ished in any direction.
I 3.6.3.1 Ends of butt joints required to be flush shall be finished so as not to reduce the width beyond the de-tailed width or the actual width furnished, whichever is greater, by more than I/8 in. (3.2 mm) or so as not to I leave reinforcement at each end that exceeds 1/8 in. (3.2 mm). Ends of butt welds shall be faired to adjacent plate -
or shape edges at a slope not to exceed I in 10.
I 3.6.4 Welds shall be free from overlap.
The requirements on this page have been taken fr'om pages 39, 40 and 41 of AWS Dl.1-80, "1980 Structural Welding Code - Stecl", 1979, American Welding Society, Miami, Florida.
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I Date Q5-08-60 SPP 4 Pace '4 of 'e ATTACHME'T B ,
'. f f l l\ '
Site ,
45* e 'N Sin Site I Si8'
. .y._::, LQL
+-53:e-+ - Sit e - C
.L 4':.).,.':
_ s;,,- C ._ S;,, _ c l
, Note: Convesity C shall not exceed 01 times actual leg
si,e. or the longer leg in the case of an uncqual leg fillet weld, plus 0 06 in. (0.3 mm). *
(A) Desirable fillet weld prof.iee (B) Acceptable fillet weld profiles I %
, j' 's, 'l 's , i N, f 'g
~~N, \' i L; ; N~~
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1 _ __ _'2 4 $ E
_L..__ ___'_'
l - Si,e- }._. Si,e- - Si,e- - S; e-
}+- Sim- }- Si,e- g i insufficient Excessive Excessive Overlap Insuffecient Inadequate' j throat convesity undercut leg penetration (C) Unacceptat,.e fillet weld grofiles .
. lR y ( ,/ j
, t
. 1 /~s N 1 lR Note: fleinforcement R sharl not exceed 1/8 in. (3.2 mm). See 3.6.2.
(D) Acceptable butt weld profile 1
/
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y _ <' W! , ' -'
/~-s'\
\ / \
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Ereessive intufficient Excessive Cverlap corwezity throat undercut See 3.6.4 See 3.6.2 . See 3.6.3 See 8.15.1.5. 0.25.1.5 or 10.17.1.5 (E) Unacceptable butt weld profsfes Mg. 3.6-Acceptable and unacceptable weld p refiles The requirements on this page have been taken from page 40 of AUS D1.1-80, "1980 Structural Welding code - Steel",1979 Americ ::. Welding Society, Miami, Florida.
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I I PUBLIC SERVICE INDIANA MARBLE HILL NUCLEAR GENERATING STATION UNITS 1 & 2 B
Elevation: _
INSPECTION AND VERIFICATION OF PIPING AND HANGERS CONS . ENGR.
TRAVELLER PACKAGE WORKSHEET l
]CHERNEQCENGR. _
I 1. Cherne's Traveller Package contains the following information in accordance with their Bulletin 12.3:
Process Sheet / Weld Data Record (Hanger)
Process Sheet / Weld Data Record (Pipe)
YES D
NO D
M C
O O O l I Isometric Drawing Field Requisition Cherne Hanger Drawing C
G O
Q O
O I 2. Cherne's Isometric drawing reflects the latest approved S&L Mechanical design drawings at time of installation (the PST shall review t$e latest revisions of S&L lingle line drawings I
for applicability to the Isometric drawing.) -
0 O List of S&L Drawings Reviewed I
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~~3. The correct piping design table and pipe class was utilized O D D tI 4. The weld procedure used for eacn weld is correct for the class and type of material telded.~~
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! FORM SPP-4-4.2.2;1, 1 05-08-80 l 1
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PUBLIC SERVICE INDIANA Sheet No.
MARBLE IIILL NUCLEAR GENERATING STATION Building: Elevation:
~
PSI QA INSP.
INSPLCTION & VERIFICATION OF PIPING AND HANGERS PSI CONSTR. ENGR.
HANGER VERIFICATION WORKSHEET CHERNE QC ENGR, INSTALLED COMPLETELY HANGER S&L DRAWING REV. DATE CONFIGURATION INSTALLED HANGER DISCREPANCIES OR NUMBER NUMBER IS CORRECT (YES/NO) COMME! TIS FORI!
SPP-4-4.2.3.1.-l 05-08-8C l
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I PUBLIC SERVICE INDIANA Structure Key No.
I MARBLE HILL NUCLEAR GENERATING STATION UNITS 1 & 2 INSPECTION AND VERIFICATION OF PIPING AND HANGERS Building:
^
Elevation:
CONS .' ENGR.
SPOOL VERIFICATION WORKSHEET CHERNE QC ENGR.
SPOOL CLEANSINESS CONFIGURA-
-TION DISCREPANCIES NOTED
, I NLEBER COMMENTS COFREcT I
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~~8. FORM SPP-4-4.2.3.2.-1, 05-08-80 I~~
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l-PUBLIC SERVICE INDIANA Structure Key No.
MARBLE HILL NUCLEAR GENERATING STATION Building i Elevation:
UNITS 1 & 2 PSI QA INSP. 1 INSPECTION AND VERIFICATION OF PIPINC & HANGERS PSI CONSTR. ENCR. i DOCUMENTATION WORKSIEET g REV.
I DOCUMENTS REVIEWED DATE COMMENTS I
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f PUBLIC SERVICE INDIANA MARBLE IIILL NUCLEAR CENERATING STATION TS 1 & 2 FORM SPP-4-4.3.3.-2 05-08-80 INSPECTION & VERIFICATION OF PIPING AND FLANGERS WELD INSPECTOR IIANGER WELD INSPECTION WORKSliEET WELD ID/ LINEAR ED ARG UNDERCUT CRACKS REINFORCE- LACK OF l PIPING INDICA- HENT FUSION POROSITY TYPE & STRIKES. REM BK
/ WELDER ID TIONS we m n SIZE. LOC. & COUCES
ATTACHMENT 4.6.2 Page 1 of 2 CHERNE WELD PROCEDURE / PIPE DESIGN TABLE CROSS REFERENCE LIST SYSTE{i DESIGN CLASS DETAIL PROCEDURE I AF 907BB C MF-270.8.5 101B021-2.25 I ECN-M-55 l
CC 105BB C MF-270.8.4 101BR11-0.50 CC 105BB C MF-270.8.4 101BR11-1.875 CS 140BB B MF-270.8.3BB 808B021-1.0 (CT)
I &
ECN-M-55 I CS 140BB B MF-270.8.3BB ECN-M-55 808B022-0.56 I CS 340BB B MF-270.8.3BB 808B021-1.0 (CT)
I ECN-M-55 9
I CS 340BB B MF-270.8.3BB ECN-M-55 808B022-0.56 I SX 105BB C MF-270.8.4 101BR11-0.50 M-534 I SX 105BB C MF-270.8.4 M-534 101BR11-1.875 I
I I
I
ATTAC10iENT 4.6.2
~
Page 2 of 2 I
I WPS MATRIX FOR HANGERS Y-2739 I
System Class Type Weld Material WPS AF C Fillet P1 101BR11-0.50 CC C Fillet P1 101BR11-0.50 SX C Fillet P1 101BR11-0.50 CS B Fillet P1 101BR11-0.50 CS B Grove P1 101BR11-1.25 (IT)
I CS B Tack, Fillet P1 & P8 108B021-1.728 I
I.
I, I
I:
I' I
I
I ATTACHMENT 4.6.3 Structure Key No. IAFC 006 PUBLIC SERVICE INDIANA Aux.Fd.
MARBLE HILL NUCLEAR GENERATING STATION Elevation: Tunnel #1 UNITS 1 & 2 I
signed PSI QA INSP INSPECTION AND VERIFICATION OF PIPING AND HANGERS PSI CONSTR. ENGR. signed CHERNE QC ENGR. signed TRAVELLER PACKAGE WORKSHEET
~~1. Cherne's Traveller Package contains the following information YES NO M in accordance with their Bulletin 12.3:~~
Procese Sheet / Weld Data Record (Hanger) X Process Sheer / Weld Data Record (Pipe) X '
Isometric Draw 4 X Field Requisition X Cherne Hanger Drawing 1
W 2. Cherne's Isometric drawing re.tlects the latest approved S&L Hechanical design drawings at time of installation (the PST shall review the latest revisions of S&L single line drawings for applicability to the Isometric drawing.)
~I per S&L letter #4808/4923-00 (5-2-30) -
x - -
List of S&L Drawings Reviewed P&ID M 37-01 Rev. G i
i I Entered in error 5'8-80 l
3.
I x The correct piping design table and pipe class was utilized Class C 907BB
~~4. The veld procedure used for each weld is correct for the I~~
~~class and type of material velded. X Per S&L letter #4808/4923-00 WPS Matrix I~~
I
!I iI i
FORM SPP-4-4.2.2 1, I
05-08-80
I
.I i
ATTACIDfENT 4.6.4 PUBLIC SERVICE INDIANA Sheet No. I HARBLE 11111 NUCLEAP. CENERATING STATION Building: AUX. FD. #1 Elevation: TUNNEL PIPE UNITS - 1 & 2
' - PSI QA INSP. Signed CL 366' 2" INSPECTION & VERIFICATION OF PIPING AND HANGERS PSI CONSTR. ENCR. Signed HANGER VERIFICATION WORKSilEET CHERNE QC ENCR. Signed INSTALLED COMPLETELY
' DANGER S&L DRAWING REV. DATE CONFIGURATION INSTALLED RANGER DISCREPANCIES OR NUMBER NUMBER IS CORRECT (YES/NO) COMMENTS lAF04014R 1AF04014R A 5-2-80 YES YES #1 ALL !"JTS NOT INSTALLED PER DRAWING l
FORM SPP-4-4.2.3.l.-l 05-08-80 l
M e m W W W m m m m m m
. ATTACHMENT 4.6.5 PUELIC 'ERVICE INDIANA Structure Key No. IAFC002 I MAR 3LE HILL NUCLEAR CFNERATING STATION UNITS 1 & 2 INSPECTION AND VERIFICATION OF PIPING AND ILU;CERS Building: AUX. FD.dl Elevation: TUNNEL PSI QA INSP. Signed PSI CONSTR. E;GP.. Signed SPOOL VERIFICATION k'ORKSHEET Signed I. SF00L CLEANLINESS CHERNE QC ENCR.
CONFIGURA-NQ1BER -TION DISCREPANCIES FOTED I
COMd.ENTS enn Er '-
MH-05-16X SURFACE RUST YES NONE MH-05-17X NOT ACCESSIBLE YES NONE MH-05-18X NOT ACCESSIBLE YES NONE MH-05-19X NOT ACCESSIBLE YES NONE MH-05-20X NOT ACCESSIBLE YES NONE MM-05-21X UOT ACCESSIBLE YES NONE MH-05-22X NOT ACCESSIBLE YES NONE MH-05-23X SURFACE RUST YES NONE i
I 7 ed E 4 .
e; E
4 5
4 5
3 I 2 FORM SPP-4-4.2.3.2.-1, 05-08-80 I
I
ATTACHMENT 4. 6.6 PUBLIC SERVICE INDIANA Structure Key No. IAFC04014R HARBLE HILL NUCLEAR GENERATING STATION Building : Aux.Fd. Elevation: lunne1#1 $
g UNITS 1 & 2 signed
,, PSI QA INSP.
! PSI CONSTR. ENGR. signed INSPECTION AND VERIPICATION OF PIPING & HANGERS CIT.RNE QC ENCR. s12ned i
i DOCUMENTATION WORKSHEET t
REV. DATE COMMENTS I
DOCUMENIS REVIEWED l
1AF04014R A 5-7-80 NONE I
I I
l I
l l
l I
I 1 I!l I!
i t
FORM SPP-4-4.2.3.3.-1, 05-08-80 l
I.
ATTACIIMENT 4.6.7 PUBLIC SERVICE' INDIANA 7840 1AFC003 Rev. 1 Sheet No*
MARBLE HILL NUCLEAR GENERATING STATION UNITS 1 & 2 EURM SPP-4-4.3.3.-1, *
-- 05-08-80 INSPECTION & VERIFICATION OF PIPING AND HANGERS WELD INSPECTOR. signed Dated Page 32 PIPING' WELD INSPECTION WORKSilEET LACK OF WELD ARG KgLurd REINFORCE- LACK OF WELD I.D. UNDERCUT CRACKS -
MENT FUSION 'ENETRATIOI TYPE & STRIKES 1.D. NO. REMARK TIONS (ID) SIZE, IDC'. & COUCES (YES NO) 7 AD PASS IIAND 4 BRUSil TO CLEAN
. i i
l I
ATTACilMENT 4.6.8 PUBLIC SERVICE INDIANA MARBLE HILL HUCLEAR CENERATING STATION Sheet No. IAB0100R Rev. C UNITS 1 & 2 FORM SPP-4-4.3.3.-2 05-08-80 PAGE 379 INSPECTION h VERIFICATION OF ' IPING P AND HANGERS WELD INSPECTOR Signed and Dated IIANGER WEI.D INSPECTION WORKSilEET WEI.D ID/ LINEAR' REINFORCE- LACK OF l PIPING W I.D E UNDERCITT CRACKS INDICA- MENT FUSION POROSITY TYPE & STRIKES. REMARK
/ WELDER ID TIONS SIZE, LOC.
Ausunn & COUCES 1 BG PASS 2 BG FASS WIRE e
BRUSil I
g g g m e e m e M M M M M M M M
LIST OF HANGER DRAWIMGS Page 1 of 15 USED TO INSPECT HAPL;ERS Ilanger No. Rev. Class Date Installed Remarks 5-7-79 I 1AB0100lR B C 1AB01002R A C 5-2-79 Not installed 1AF01004R A C 5-31-79 1AF01007X B C 6-20-79 I 1AF01010X 1AF01012R 1AF01013X B
A B
C C
C 4-26-79 5-31-79 4-26-79 Reject 1AF01014R A C 4-26-79 Reject 1AF01018R A C 5-31-79 1AF01024X B C 4-26-79 FCR #129 1AF01026R A C 5-31-79 1AF01028R A C 4-26-79 1AF01030R B C 7-10-79 .
1AF01031X A C 4-26-79 1AF01032X A C 7-6-79 1AF02001R B C 7-9-79 1AF02002R B C 4-26-79 1AF02004R A C 4-26-79 1AF02006X B C 4-26-7a IAF02009X B C 4-26 ,.
lAF02010R A C 7-9-79 1AF02016X B C 4-26-79 1AF02021X C C 6-13-79 1AF02025X C C 5-25-79 1AF02030R A C 4-26-79 1AF02031X A C 6-5-79 1AF02032R B C 5-30-79 1AF02033R A C 5-30-79 1AF04003V A C 6-15-79 Reject IAF04004R A C 6-15-79 1AF04007R A C U-15-79 I 1AF04008R 1AF04013X 1AF04014R A
B A
C C
C 7-5-79 4-26-79 6-7-79 Reject 1AF04015R A C 6-7-79 1AF04016R A C 6-7-79 1AF04017X A C 6-7-79 1AF04018X B C 4-26-79 1AF04019R B C 4-26-79 Reject IAF04020X B C 4-26-79 Not installed 1AF04021R A C 6-8-79 .
lAF04022R A C 6-7-79 Reject lAF04023X B C 4-26-79 1AF04024R A C 6-7-79 Reject l 1A;04025X A C 5-8-79 li; c.026R A C 6-7-79 1AF04031X A C 6-15-79 Reject lAF04033V A C 6-15-79 1AF40434R A C 6-15-79 i l
Attachment 4.6.9
Page 2 oc 15 llanger No. Rev. Class Date Installed Remarks l
1AF04037R A C 6-15-79 L
l 1AF04038R A C 6-15-79 1AF04044X A C 4-26-79 Reject ,
IAF04045R A C 4-26-79 Reject 1AF04046R A C 4-26-79 Reject 1AF04047X A C 4-26-79 1AF04048R A C 4-26-79 1AF04049R A C 4-26-79 1AF04050X A C 4-26-79 1AF04051R A C 4-26-79 1AF04052X A C 4-26-79 1AF04053R B C 4-26-79 1AF04054R A C 6-14-79 l 1AF04055X B C 4-26-79 . E lAF04056R A C 4-26-79 Reject lAF04057R A C 6-14-79 g 1AF04058X A C 4-26-79 g lAF04059R A C 4-26-79 1AF04064X A C 4-26-79 Reject IAF04065R A C 4-26-79 1AF05006R A C 6-15-79 1AF05007R A C 6-15-79 1AF05011X B C 5-8-79 1AF05013X B C 4-26-79 Re jec t lAF05014K A C 4-26-79 1AF05015R A C 4-26 '/9 1AF05016X B C 4-26-79 1AF05017R A C 4-26-79 1AF05018R A C 4-26-79 Reject 1AF05019X B C 4-9-79 NCR #01691 (6.141) 1AF05021R A C 4-26-79 1AF05022X B C 4-11-79 NCR #01619 (6.141) 1AF05023R B c 4-11-79 1AF05024X B C 4-11-79 NCR #01619 (6.141) 1AF05025R B C 4-11-79 NCR #01619 (6.141) 1AF05026R A C 4-26-79 1AF05027X B C 4-11-79 NCR #01619 (6.141) 1AF0502dR A C 4-26-79 1AF05034R B C 6-15-79 1AF05036R A C 6-15-79 1AF05037X B C '6-5-79 1AF05038X B C . 5-8-79 1AF05041X B C 4-26-79 Reject 1AF05042R A C 4-26-79 1AF05043R A C 4-26-79 1AF05044X B C 4-26-79 1AF05046R A C 4-26-79 1AF05047X B C 4-26-79 1AF05048R A C 4-26-79 l
l l
I
Page 3 of 15 Hanger No. Rev. Class Date Installed Remarks 1AF05049R A C 4-26-79 LAF05050X A C 4-26-79 1AF05051R A C 4-26-79 1AF05052X B C 4-26-79 Reject 1AF05053R A C 4-26-79 I 1AF05054R 1AF05055X 1AF05056R A
A B
C C
C 6-14-79 4-26-79 4-26-79 I 1AF06008X 1AF06009X 1AF06010R B
B A
C C
C 7-6-79 6-14-79 6-18-79 NCR #01546 (6.132)
Reject 1AF06012X A C 7-6-79 I 1AF06015R lAF06014R 1AF06015X A
A B
C C
C 6-19-79 6-19-79 6-13-79 Reject Reject 1AF06016X B C 6-13-79 1AF06017R A C 6-18-79 1AF06018R A C 5-8-79 1AF06019X A C 6-21-79 I 1AF06020X 1AF06021R A
A C
C 6-20-79 4-26-79 1AF06022R A C 4-26-79 I 1AF06023R 1AF06024R 1AF06025X A
A A
C C
C 4-26-79 4-26-79 5-2-79 I
1AF06027R B C 6-14-79 1AF06028X A C 5-1-79 1AF06029X B C 5-1-79 1AF06030R A C 4-26-79 I 1AF06032R 1AF06033R 1AF06034R A
B B
C C
C 5-2-79 6-14-79 6-14-79 I 1AF07002X 1AF07003R 1AF07004R A
A B
C C
C 7-2-79 6-18-79 6-14-79 1AF07006R A C 4-12-79 Reject NCR #01798 (6.45)
I 1AF07007R 1AF07008R 1AF07009X A
A A
C C
C 4-26-79 4-26-79 5-1-79 Reject I 1AF070llR 1AF07012R 1AF07013R A
A A
C C
C 4-26-79 4-26-79 4-26-79 .
lAF07015X A C 7-2-79 1AF07016R A C 6-18-79 5 1AF07017R A C 4-11-79 1AF07018R A C 4-26-79 I 1AF07019R 1AF07020R lAF07021R A
A A
C C
C 4-26-79 4-26-79 4-26-79 1AF07022X B C 5-7-79 l
I 1AF07023X 1AF07024X B
A C
C 5-10-79 4-30-79 1AF07026X A C 6-1-79 Reject I
I
l Page 6 of 15 llanger No. Rev. Class Date Installed Remarks 1AF09002X B C 4-9-79 NCR #01619 (6.141) 1AF09003X B C 4-9-79 Cannot locate E
1AF09005X B C 4-19-79 NCR #01561 (6.136) 3 1AF09008R B C 4-11-79 1AF09009X B C 4-11-79 E 1AF09010R B C 4-12-79 1AF09011X B C 4-11-79 E
1AF09012R B C 4-11-79 1AF09014X B C 4-30-79 l 1AF09015R B C 4-25-79 E 1AF09017X B C 4-30-79 1AF09018X B C 4-30-79 1AF09020R B C 4-25-79 1AF10001R C C 8-1-79 WCR #01762 .
1AF10002X B C 4-12-79 1AF10003X B C 4-26-79 1AF10005X B C 4-11-79 1AF10008R B C 4-11-79 1AF10009X B C 3-26-79 3 1AF10010R B C 4-11-79 g 1AF10013R B C Cannot locate 1AF100i4X B C 7-17-79 1AF10015R B C 4-24-79 1AF10017X B C 5-1-79 1AF10018X B C 4-27-79 1AF10019R B C 4-24-79 E 1AF11014X B C 4-27-79 5 1AF11008R B C 4-9-79 NCR #01619 (6.141) 1AF11009X B C 3-26-79 NCR #01619 (6.141) 1AF11011R B C 4-9-79 Reject NCR#01619 (6.141) 1AF11016R B C 4-25-79 Reject 1AF11017X B C 5-1-79 1AF11018X B C 4-2,7-79 l 1AF11019R B C 4-25-79 E 1AF11020R B C 5-7-79 1AF12003X A C 4-9-79 NCR #01619 (6.141) 3 1AF12008R B C 4-11-79 g 1AF12009X B C 6-21-79 1AF12010R B C 4-11-79 Reject 1AF2011R B C 4-11-79 l 1AF12012X B C 4-11-79 E 1AF12013R B C 4-12-79 .
1AF12014X B C 4-27-79 NCR #C1727 (6.44) 1AF12015R B C 4-24-79 1AF12017X B C 4-27-79 1AF12018X B C 8-7-79 1AF12019R B C 6-1-79 l
! 1AF12020R B C 5-9-79 W
, IBR04004X A C 6-4-79 l
1BR04009X A C 5-4-79 g 1BR04013R B C 5-22-79 5
Page 5 of 15 Hanger No. Rev. Class Date Installed Remarks 1BR04014X A C Not installed I 1BR04015X 1BR04016X 1BR04017X B
B A
C C
C 5-22-79 5-22-79 5-22-79 1BR04022R A C 5-22-79 1BR04025X B C 7-20-79 1BR04028X A C 5-14-79 Reject 1BR04030X A C 5-4-79 Reject I 1BR04037X 1BR04044X 1BR04052X A
A A
C C
C 5-14-79 5-16-79 5-9-79 1BR04057X B D 7-17-79 Cat. II Delete 1BR04058R B D 5-29-79 Cat. II Delete 1BR06001R A C 5-8-79 FCR #046 1BR06002R A C 5-16-79 CRC #246 Not installed 1BP.06005R A C 5-16-79 CRC #247 i 1BR08003R B C 7-31-79 Reject 1BR080064 B C 5-16-79 Reject I 1BR08009X 1BR09001X 1BR09007R B
B A
C C
C 7-17-79 7-18-79 6-1-79
~
1BR11001X A C 7-16-79 IBR11002X t. C 6-5-79 Reject
= 1BR11003V A C 7-31-79 Reject ICC01002X A C 5-11-79 I 1CC01003R ICC01007R 1CC01011X A
B A
C C
C 5-24-79 5-24-79 7-19-79 Reject Reject 1CC01012V A C 5-20-79 Reject I ICC01014R 1CC01015V A
A C
C 5-30-79 5-24-79 1CC01019R A C 5-25-79 I 1CC01021X ICC01023X 1CC01024R A
A A
C C
C 5-25-79 5-11-79 5-23-79 Reject 1CC01026V 5-24-79 I Rej ec t B C ICC01033R A C 5-24-79 1CC01035V A C 5-30-79 Installed wrong elevat.
ICC0200lV B C 7-25-79 I ICC02003R 1CC02005R 1CC02014R B
B B
C C
C 7-18-79 5-23-79 7-19-79 I 5-14-79 1CC02015X A C 1CC02016R A C 5-14-79 1CC02017R B C 5-11-79 1CC02019R B C 7-11-79 Reject NCR#01707 (6.140)
I ICC02023X ICC02024X 1CC02028X B
B A
C C
C 5-14-79 R-1-79 6-4-79 Reject Reject ICC02032X B C 5-14-79 ICC0'035X
. B C 5-17-79 I
I l
Page 6 of 15 llanger No. R e. v . Class Date Installed Remarks ICCO2036R B C 7-20-79 1CC02038X A C 5-14-79 l ICC02041X A C 6-5-79 E 1CC02042R A C 6-5-79 1CC02043X B C 5-11-79 Reject g ICC02044R B C 5-14-79 g ICC02055X A C 5-31-79 1CC02058X A C 5-31-79 1CC02059R A C 6-5-79 1CC02060X A C 5-14-79 Reject ICC02061R A C 5-11-79 Reject ICC02066R A C 5-11-79 1CC02067X A C 6-11-79 1CC02072X A C 7-5-79 1CC02074R A C 6-4-79 1CC02076X A C 7-5-79 1CCO2082X A C 6-12-79 1CC02086X B C 6-13-79 1CC02087R B C 7-19-79 neject 1CC02089X A C 6-4-79 E c
3 1CC02090R A 6-11-79 CRC #369 1CC02091X A 3 6-8-79 FCAR #180-79 (5.20)
ICC02093R A C 6-11-79 1CC02095X A C 6-1-79 "
1CC02097X B C 5-30-79 1CCO2099X A C 6-11-79 E ICC02100R B C 6-11-79 3 1CC02103X B C 7-19-79 1CC02107X A C 5-2-79 g ICC02108R ICC02109R A
A C
C 5-29-79 5-8-79 Reject g
ICC02111R A C 6-1-79 1CC02113R A C 5-30-79 1CC02114X A C 5-23-79 1CC02116R B C 8-3-79 1CC02117X B C 7-9-79 3 1CCO2118R ICC02119X A C 5-29-79 Reject g A C 6-11-79 Reject ICCO2120X A C 5-31-79 FCAR #180-79 (5.20)
ICC0212R A C 6-20-79 1CC02122X A C 6-7-79 l
E ICC02125X A C 6-8-79 Reject -
ICC02127X A C 6-7-79 E ICC02128R A C 7-6-79 g 1CC03014R A C 5-16-79 Reject i
ICC03015X A C 5-7-79 NCR #01707 (6.140) 1CC13017X A C 7-5-79 l ICC03018X A C 5-31-79 m ICC03021X A C 5-2 '/9 1CC03022V A C 7-11-79 Reject NCR#01707 (6.140)
ICC03024R A C 6-7-79 I
I
Page 7 of 15 Hanger No. Rev. Class Date Installed ' 'tema rks ICC03027X A C 6-1-79 I 1CC03028R ICC03030X 1CC03032X A
A A
C C
C 5-2-79 6-4-79 6-20-79 Reject PSI /FCAR #427 1CC03034R A C 7-10-79 I 1CC03047X 1CC03048X 1CC03053X A
A B_
C C
C 5-7-79 5-2-79 6-5-79 Reject g ICC03055R B C 7-24-79 g ICC03057X B C 5-21-79 1CC03058R A C 6-5-79 1CC05059X A C 5-1-79 Reject 1CC03061R A C 6-8-79 Reject ICC03069R A C 5-29-79 1CC03070X A C 5-2-79 1CC03071R A C 5-29-79 5 ICC03072R 1CC03074V A C 5-2-79 B C 5-14-79 1CC03078X A C 5-25-79 I 1CC03079R ICC03087X 1CC03089X A
A C
C 5-2-79 6-4-79 Reject A C 5-23-79 Reject g
g ICC03094V A C 5-24-79 Reject ICC03095X A C 5-23-79 1CC03097X A C 7-12-79 FCAR #155-79 1CC03104X A C 5-2-79 1CC03109X A C 6-4-79 Reject NCR#01310 (6.103)
ICC03115X A C 5-2-79 1CC03118X A C 5-23-79 I 1CC03122R 1CC03123R 1CC03128V A
A A
C C
C 5-15-79 5-23-79 5-24-79 I ICC03132X ICC04014X 1CC06003R A
A A
C C
C 7-26-79 7-30-79 6-12-79 Cannot locate 1CC06004R A C 6-12-79 l 1CC06005R A C 6-12-79
! W 1CC06016X A C 7-18-79 1CC06017R A C 7-25-79 Reject I 1CC06020R ICC06022X 1CC06026X A
A A
C C
C 7-26-79 7-6-79 7-18-79 1CC06028X A C 8-1-79 Re jec t I 1CC06029X 1CC09002R 1CC09008X A
B C
C 7-3-79 7-11-79 A C 7-5-79 ICC09009R ^ C 7-30-79 Il ICC09014X ICC09015R A C 6-1-79 Rej ec t A C 5-10-79 Reject ICC10001R A C 6-5-79 Reject i
I
Page 8 of 15 Hanger No. Rev. Class Date Installed Remarks ICC10004R B C 7-25-79 1CC10005X A C 6-1-79 g ICC10006X A C 6-1-79 Reject g ICC10007R A C 6-5-79 1CC14001X B C 6-1-79 1CC14002R A C E-3-79 Reject 1CC14004R A C 5-21-79 Reject 1CC14006X A C 6-1-79 1CC14007R A C 5-11-79 g ICC14012X A C 5-31-79 m ICC15002X A C 7-6-79 Reject ICC15010X A C 6-5-79 1CC18003R A C 5-7-79 1CC18004X A C 6-19-79 1CC18006R A C 6-5-79 FCR #166 1CS01023V 1CS01024R B
B B
B 4-26-79 3-16-79 l
5 1CS01025R B B 3-16-79 1CS01026R B B 3-16-79 1CS01027R B B 3-16-79 Reject ICS01028R B B 3-16-79 1CS01029R B B 3-16-79 1CS01030R B B 3-16-79 l 1CS01031R B B 3-16-79 =
ICS01032R B B 3-16-79 Reject ICS01033R B B 3-16-79 Reject 1CS01034R 3-16-79 E
B B E
1CS01035R B B 3-16-79 1CS01036R B B 3-16-79 1CS01037R B B 3-16-79 Reject ICS01038R B B 3-16-79 Reject ICS01039V B B 5-12-79 1CS01042C B B 5-12-79 g ICS01050C B B 5-12-79 3 1CS02023V B B 5-12-79 ICS02024R B B 7-6-79 Not complete ICS02025R B B 7-6-79 1CS02026R B B 7-6;-79 l
1CS02027R B B 7-6-79 ICS02028R B B 7-6-79 l 1CS02029R B B 7-18-79 E 1CS02030R B B 7-18-79 1CS02031R B B 7-18-79 E ICS02032R ICS02033R B
B B
B 7-16-79 7-16-79 g
1CS02034R B B 5-12-79 1CS02037C B B 5-12-79 ,
ICS02042C B B 5-12-79 1CS03041X A L 8-1-79 Cat. II Delete ICS06007X A B 5-8-79 Reject I
I
l Page 9 of 15 llanger No. Rev. Class Date Installed Remarks ICS06008X A B 5-8-79 Reject I 1CS06009R 1CS06017R 1CS06018R A
B B
B B
B 5-8-79 5-9-79 7-12-79 Reject ICS06020R B B 5-31-7/
ICS08002X C B 5-7-79 Reject ICS08008X A B 5-7-79 1CS08009X B B 5-3-79 Cannot locate j ICS08010R A B 5-4-79 3 1CS08011X A B 5-3-79 Cannot locate CRC #242 1CS08012X A B 5-7-79 1CV08003X B B 8-2-79 1CV18032X Not installed ICV 18035V B B 5-18-79 1CV44013R A C 6-1-79 1CV44016R A C 8-7-79 Heject 5 ICV 44018R A C 8-7-79 1CV44021X A C 7-13-79 Reject I 1CV45005X 1CV45007R 1CV45008R A
B B
C C
C 5-30-79 7-10-79 5-31-79 CRC #344 CRC #350 1CV45010X A C 6-1-79 CRC #314 I ICV 47005X 1CV47010X 1CV47035X A
A A
B B
B' 7-12-79 7-13-79 7-13-79 1CV47040X B B 7-12-79 5 1CV53005X 1CVS1008X A B 7-3-79 A B 8-2-79 1CV53011X B B 8-3-79 I ICV 59019X 1FPO4014R IFP04016X A
A B
C 7-16-79 6-11-79 FCR #141 A C 6-7-79 I 1FPO4026X 1FPO4028X 1FPO4035X A
A A
C C
C 6-7-79 6-7-79 6-7-79 1FP04038X A C 6-7-79 CRC #175 Deleted 4
1FP06002R A C 6-7-79 1FP06005R A C 6-7-79 Cannot ins pec t CRC #306 1FP06009X A C 6-7-79 I 1FP06012X 1FP06014X IFP06017X A
A A
C C
C 6-7-79 6-7-79 6-7-79 Re jec t IFP06021R A C 8-7-79 1FP06022X A C 6-29-70 Reject 1FP06025R A C 6-8-79 1FP06027R A C 6-8-79 1FP06029X A C 6-7-79 8 IFP06033R A C 8-7-79 1FP06034X A C 6-12-79 I 1FP06049X IFP011001R A
B C
C 6-7-79 6-8-79 Reject il 1
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Hanger No. Rev. Class Date Installed Remarks IFPi1005X A C 7-5-79 1FP11009X C C 7-10-79 1FP11010R B C 6-11-79 1FP13003X A C 6-11-79 1FP13005X A C 6-29-79 g IFP13006X A C 7-30-79 Reject g IFP13011X A C 7-25-79 1FP15004R A C 7-16-79 Re j ec t 1FP15006R A C 6-11-79 1FP15007R A C 6-11-79 Reject 1FP15008V A C 6-11-79 1FP15009X A C 6-11-79 g IFP15011R A C 5-17-79 E l' R A C 7-13-79 Reject
__R A C 6-11-79 1Fra0'1R 4 A C 7-24-79 1RIIO1002X A B 6-13-79 Reject =
1RH05007R A B 5-9-79 Reject 1RH05008X B B 6-20-79 E 1RH05009V B B 7-6-79 3 1RH05010X B B 7-3-79 Reject 1RIIO5011X B B 6-22-79 g 1R1106001X A B 6-20-79 1R1106006V B B 7-5-79 NCR #01560 (6.134) 5 1RH08004X A B 6-20-79 ISIO5018X A B 7-6-79 1SIO5023X A B 8-1-79 l3 ISIO5024X A B 7-31-79 ISIO5030X A B 7-31-79 g ISX01012X B C 3-26-79 g ISX01014R A C 6-15-79 ISX02005X B C 6-10-79 Reject ISX02008X A C 6-11-79 ISX02041X A C 7-6-79 ISX02044R B C 6-12-79 Reject ISX02048X A C 5-14-79 E ISX02057R A C 6-14-79 Reject g ISXO400$X A C 7-6-79 ISXO400 7X B C 3-26-79 ISX21001R A C 6-20-79 Reject ISX23002R A C 6-22-79 =
ISX23004R A C 6-22-79 ISX2400SX ISX26002X A C 6-13-79 7-5-79 g
A C g ISX26003X A C 5-9-79 8
l.
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Page 11 of 15 Hanger No. Rev. Class Date Installed Remarks 2AF01002R A C 5-15-79 I 2AF01004R 2AF01006R 2AF01007R A
A A
C C
C 5-10-79 5-10-79 5-10-79 2AFG1009X A 5-10-79 Reject I
C 2AF01011R A C 5-10-79 2AF01012X A C 5-10-79 2AF01015X A C 5-10-79 j 2AF01016R A C 5-10-79 3 2AF01017R A C 5-10-79 Rejec t 2AF01022X B C 5-14-79 Rejact 2AF01024X A C 5-15-7
2AF01025R A C 5-16-73 Reject 2AF01026R A C 5-16-79 2AF01028R A C 5-17-79 2AF01029R A C 5-16-79 1 2AF01033R A C 5-17-79 2AF01034R A C 5-18-79 2AF01036R A ,
5-18-79 2AF01037R A C 5-18-79 2AF01038X A C 5-18-79 2AF01040X A C 5-18-79 2AF02001X A C 5-17-79 Reject I 2AF02002X A C 5-18-79 Reject 2AF02003R A C 5-18-79 I 2AF02005R 2AF02008R 2AF02012X A
A A
C C
C 5-18-79 5-22-79 5-22-79 2AF02014R A C 5-22-79 I 2AF02016X 2AF02017R 2AF02019R A
A A
C C
C 5-22-79 5-22-79 5-22-79 Reject I 2AF02021X 2AF02023R 2AF02024X A
A A
C C
C 5-30-79 6-21-79 5-22-79 2AF02025X A C 5-22-79 I 2AF02027X 2AF02032R 2AF04014R A
A C
C 5-22-79 7-26-79 A C 6-6-79 Reject 2AF04016R A C 6-6-79
.I 2AF04017R A C 6-6-79 2AF04018X A C o-6-79 Reject 2AF04019R A C 6-6-79 2AF04020X A C 6-6-79 2AF04021R A C 6-6-79 2AF04022R A C 6-6-79 I 2AF04023X 2AF04024R 2AF04025X A
A A
C C
C 6-6-79 6-6-79 6-6-79 I 2AF04026R 2AF04027R A
A C
C 6-6-79 7-2-79 l
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Page ;2 of 13 Ilanger No. Rev. Class Date Installed Remarks 2AF04045R A C 5-15-79 3 2AF04046R A C 5-16-79 g 2AF04047X A C 6-12-79 2AF04048R A C 5-16-79 2AF04049R A C 5-15-79 2AF04050X A C 6-12-79 2AF04051R A C 5-15-79 2AF04052X A C 6-12-79 g 2AF04053R A C 5-15-79 g 2AF04054R A C 5-15-79 Reject 2AF04056R A C 5-15-79 Reject 2AF04057R A C 5-15-79 2AF04058X A C 6-26-79 2AF04059R A C 5-15-79 Reject 2AF04064X A C 6-12-79 g 2AF04065R A C 5-16-79 3' 2AF05014R A C 5-16-79 2AF05015R A C 5-16-79 2AF05016X A C 6-12-79 2AF05017R A C 5-16-79 =
2AF05018R A C 5-18-79 2AF05019X 2AF05020R A
A C
C 6-12-79 5-18-79 g
m 2AF05021R A C 5-16-79 2AF05022X A C 6-12-79 2AF05023R A C 5-17-79 2AF05025R A C 5-17-79 2AF05026R A C 5-17-79 2AF05027X A C 6-12-79 Reject 2AF05028R A 5-16-79 l
C 3 2AF05042R A C 5-16-79 Reject 2AF05043R A C 5-24-79 g 2AF05044X 2AF05045R A C 6-12-79 g A C 5-16-79 2AF05046R A C 5-16-79 2AF0504 7X A C 6-12-79 l 2AF05048R A C 5-16-79 5 2AF05049R A C 5-18-79 2AF05050X A C 6-12-79 3 2AF05051R 2AF05052X A C 5-18-79 g A C 6-12-79 2AF05053R A C 5-18-79 2AF05054R A C 5-18-79 Reject 2AF05055X A C 6-12-79 2AF05056R A C 5-18-79 2AF00008X 2AF06019X A C 7-2-79 6-29-79 g
A C g 2AF06020X A C 6-29-79 2AF06021R A C 8-7-79 Cannot locate 2AF06025X A C 6-29-79 ll A
Pege 13 of 15 Hanger No. Rev. Class Date Installed Remarks 2AF06026X A C 6-29-79 I 2AF06028X 2AF07002X 2AF07009X A
A A
C C
C 6-29-79 8-7-79 6-29-79 2AF07022X A C 6-29-79 I 2AF07023X 2AF07024X 2AF07026X A
A A
C C
C 6-29-79 6-28-79 6-28-79 j 2AF07027X A C 6-28-79 3 2AF09005X A C 8-7-79 2AF09006X A C 8-7-79 2AF09009X A C 6-28-79 2AF09011X A C 6-28-79 2AF09014X A C 6-29-79 2AF09017X A C 6-28-79
.)
W 2AF09018X 2AF11012X A
A C
C 6-28-79 6-28-79 2AF11013R A C 7-2-79 2AF11014X 6-29-79 I
A C 2AF11015R A C 7-2-79 2AF11016R A C 6-28-79 2AF11017X A C 6-28-79 I 2AF12001X 2AF12002X 2AF12006X A
A A
C C
e 7-9-79 7-9-79 8-7-79 2AF12010R A C 6-28-79 8 2AF12011R 2AF12012X A
A C
C 6-28-79 6-28-79 2AF12014X A C 6-29-79 a 2AF12017X 2AF12018X A
B C
C 6-29-79 6-29-79 2BR04005R A C 7-18-79 I 2BF04008R 2BR04010R 2BR04011R A
A A
C C
C 7-29-79 7-19-79 7-19-79 2BR04013R A C 7-5-79 I 2BR04015R 2BR04016R 2BR04022R A
A A
C C
C 7-5-79 7-5-79 7-5-79 I 2BR04023R 2BR04038R 2CC10001R A
A A
C C
C 7-5-79 7-23-79 6-25-79 Reject FCR #164 2CC10002R A C 7-24-79 I 2CC10004X B C 5-10-79 Reject 2CC10008R A C 6-22-79 Reject ,
2CC1.8001X A C 6-21-79 )
I 2CC18002k 2CC18003X 2CC18005X B
A A
C C
C 7-18-79 5-11-79 5-10-79 Reject l
2CC18006X A C 6-25-79 2CC18007R A C 5-11-79 I
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Pcgn 14 of 15 '
Hanger No. Rev. Class Date Installed Remarks 2CS06017R B B 7-23-79 2CS06019X A B 7-12-79 2CS08002X A B 7-10-79 2CS08003X A B 7-11-79 Reject 2CS08008X A B 7-10-79 2CS08009X A B 7-11-79 2CV08031X A B 6-21-79 NCR #015."6 (6.135) 2FP03037R A C 5-21-79 2FP03038R 2FP03039X A
A C
C 5-21-79 5-21-79 [i 5
2FP03040X A C 6-22-79 Tacked only NCR #01666 (6.149) 2FP03042G A C 5-21-79 Reject 2FP03045X A C 5-21-79 2FP0304 7X A C 5-21-79 2FP03048X A C 5-21-79 2FP03049X A C 5-21-79 l m
2FP03051X A C 5-21-79 2FP03053X A 5-21-79 2FP03058R A C
C 6-1-79 Rejec t g 2FP03062R g
A C 6-28-79 2FP03063R A C 6-26-79 2)703065R ,; C 6-25-79 Tr'P03072R A C 6-26-79 2FP03074X A C 7-9-79 2FP03078X A C 6-25-79 2FP03080X A C 6-25-79 E 2FP03088X A C 6-21-79 3
2FP03091X A C 6-25-79 2FP03098R A c 6-27-79 2FP03099R A C 6-27-79 2FP03100X A C 6-22-79 Re jec t 2FP03104X A C 6-22-79 2FPO4007X A C 6-25-79 l
2FPO4012X 5
A C 6-26-79
'2FP05001R A C 7-25-79 2FP05006X A C 6-21-79 2FP05010X A C 6-21-79 2FP05012R A C 6-21-79 2FP18023X A C 6-26-79 2RH05008X A B 6-27-79 l
3 2RH05009V A B 6-29-79 2RH05011X A B 7-24-79 2RH07005R g
A B 7-23-79 g 2RH07007R A B 7-20-79 1RH06007X A B 7-12-79 2SXO4001R B C 7-12-79 2SXO4002X B C 6-27-79 i 2SX04003X B C 7-12-79 Rejec t
) 2SX04004R B C 7-10-79 Reject 3 l 2SX04006X 2SX04010X A
B C
C 7-16-79 6-27-79 g
i 2SX04012R A C 7-16-79 I
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I Page 15 of 15 Hanger No. Rev. Class Date Installed Remarks 2SX04014X B C 6-27-79 I 2SX22001R 2SX22002X 2SX23003X A
A A
C C
C 8-7-79 6-27-79 7-13-79 Reject 2SX24004X A C 7-16-79 I 2SX24007X A C 7-24-79 2SX24008X A C 6-15-79 2SX24009R A C 7-10-79 I 2SX25002R 2SX42012X B
A C
C 8-3-79 6-15-79 NOTE: These hangers were found during inspection, and were not included in the original pack.sge.
I ICC01022V ICV 45009X Reject I 2FP03050X 2FF03086X I
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I LIST OF DRAWINGS USED TO INSPECT PIPING Page 1 of 2 7840 1AF 003 Rev. 1 7840 1AF 006 Rev. 1 7840 1AF 015 Rev. 0 7840 1AF 016 Rev. 1 3 7840 1AF 018 Rev. 1 5 7840 2AF 025 Rev. 1 7840 2AF 036 Rev. 1 7840 10C 001 Rev. 1 7840 1CC 002 Rev. 2
~~7840 1CC 003 Rev. 2 7840 ICC 006 Rev.~~
E 7840 ICC 008 Rev. I g 7840 1CC 009 Rev. 2 7840 1CC 010 Rev. 1 7840 1CC 011 Rev. 1 7840 1CC 012 Rev. 2 7840 1CC 013 Rev. 1 7840 2CC 001 Rev. 1 7840 2CC 003 Rev. 1 E
3 7840 2CC 005 Rev. 2 7840 2CC 008 Rev. 1 7840 2CC 014 Rev. 1 7840 2CC 015 Rev. 0 7840 2CC 017 Rev. 1 7840 2CC 028 Rev. 2 l 7840 ISX 002 Rev. 1 W 7840 ISX 003 Rev. 3 7840 ISX 004 Rev. I g 7840 ISX 005 Rev. 0 7840 ISX 006 Rev. 3 5 7840 ISX 007 Rev. 0 7840 ISX 008 Rev. 1 l 78/ ~ ISX 029 Rev. 1 W 7840 ISX 031 Rev. 0 7840 ISX 032 Rev. 1 7840 ISX 033 Rev. 1 7840 ISX 034 Rev. 1 7840 2SX 048 Rev. 1 7840 2SX 051 Rev. 2 7840 2SX 064 Rev. 1 l'
=
7640 2SX 066 Rev. 2 -
7840 2SX 069 Rev. 0 7840 2SX 076 Rev. O E g
"840 1CS 001 Rev. 1 7840 1CS 002 Rev. 0 ,
7840 ICS 003 Rev. 0 7840 1CS 004 Rev. 1 "
7840 1CS 005 Rev. 2 '
7840 ICS 010 Rev. 1 l
Attachment 4.6.10 l
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I I Page 2 of 2 I 7840 MH-07-B-056 Rev. 0 E 7849 MH-07-B-102 Rev. 1 5 78'o ""-o7-8-o87 7840 MH-07-B-084 "ev- o Rev. 2 7840 MH-07-B-088 Rev. 1 I 7840 MH-07-B-086 7840 MH-07-B-101 7840 MH-02-C-034 Rev. 1 Rev. 1 Rev. O I 7840 1RC500 7840 1RC501 Rev. 1 Rev. 1 I
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I I 5.0 CATEGORY I CONCRETE SURFACE IRREGULARITIES 5.1 ABSTRACT This section des:ribes the completion and results of an extensive I inspection program conducted by Public Service Company of Indiana Inc. (PSI) and Newberg-Marble Hill (N-MH) on accessible wrfaces of Category I cencrete structures at the Marble Hill Nucla Generating Station, and the resulting conclusions and progased follow-up action to be taken in assuring the appropriate removal and repair of unsound concrete. This program consisted of documented visual examinations conducted by specially qualified and I trained teams in accordance with the approved Special Process Procedure, SPP-5. The visual examinations were documented on drawings and by physically marking the actual concrete surfaces as described in Paragraphs 5.3.5 and 5.3.6.
Based on the results of these examinations, PSI will take corrective measures to remove and replace existing patches and I unsatisfactory concrete upon restart of safety-related construction activities. In addition to the immediate corrective action to replace concrete patches and repair unsound concrete, PSI and I Newberg-Marble Hill will conduct a training program for production and inspection personnel. This training program will be structured to identify the probable causes which directly or indirectly led to I surface irregularities and honeycomb, and to instruct personnel how to eliminate or minimize conditions which lead eo unsound concrete (Reference, Paragraph 5.3.9.3).
~~5.2 INTRODUCTION~~
The information discussed in this section summarizes the measures I taken to identify surface irregularities of the in place Category I concrete and to determine the necessary corrective measures. These measures consisted of the following steps which are described in subsequent paragraphs of this section:
5.2.1 Preparation and approval of a procedure for physical inspection and verification of Category I concrete surface irregularities.
I 5.2.2 Establishment and Qualification / Training of Physical Survey Teams.
I 5.2.3 Compilation of Sargent & Lundy (S&L) structural drawings for use in mapping irregularities.
5.2.4 Physical inspection of visible Category I concrete surfaces.
5.2.5 Documentation of results consisting of reports, appropriate forma I and mapping of surface irregularities. l I
5.2.6 Physical marking and identification of accessible surface irregularities to assure traceability to documentation and aid in future location.
5.2.7 Identification of inaccessible formed areas which will require detailed inspection when authorization to resume safety-related activities is obtained.
5.2.8 Preparation of Corrective Action Requests (CARS) to procedurally identify and record surface irregularities and to disposition the CARS to identify corrective action, probable cause and action to prevent recurrence.
5.3. DISCUSSION 5.3.1 Procedure Preparation Special Process Procecure, SPP-5, entitled " Category I Concrete Surface Irregularities" was prepared by S&L and reviewed and approved by the PSI Project Engineering Manager and the PSI Quality Assarance Manager. This procedure established written criteria and instructions for the systematic identification, location, and documentation of concrete patches and unrepaired concrete surface irregularities located in visible Category I areas.
The criteria used for identifying concrete patches and repair areas are as follows:
5.3.1.1' Repair Area A repair area was defined as a concrete surface area containing a void, rock pocket, or other indications of unsound concrete, or observed deleteritas materials such as wood, paper, or mud. Small surface voids, 4" or less in diameter and less than 1/2" in depth, l which were surrounded by satisfactory concrete were not identified W as repair areas.
5.3.1.2 Concrete Patch Area A concrete patch was defined as any locat. ion which has been re' aired with dry pack or grout. In additicm, patched areas'4" or less in diameter and locations where fill has been provided to smooth out mismatched formwork or champhers were sounded with a hammer. If the hammer sound was similar to the surrounding l concrete, this indicated solid material and these locations were E not identified as patches. However, if the area seemed suspect because of questionable circumstances such as an adjacent rock g pocket, then the Physical Surveyors marked the area as a concrete 3 patch. Obvious form-tie patches were not considered as concrete patches. A copy of the procedure (SPP-5) is contained in Attachment 5.6.1.
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I 1 5.3.2 Establishment of Physical Survey Teams Physical Survey Teams were established by the PSI Construction I Manager with the concurrence of the PSI Project Engineering Manager and the PSI Quality Assurance Manarer. Physiccl Survey Teams worked under the supervision of a Team Leader. Each Team Leader I was a PSI Engineer experienced in concrete construction. Physical Survey Team membership consisted of at least one PSI QA Engineer / Inspector qualified to Level II and a N-MH QA/QC Inspector I qualified to Level I in acccedance with the requirements of ANSI N45.2.6-1973, as defined by PSI Project Management Procedure (PMP) 3.01. In addition, each member of the Physical Survey Team attended a documanted training session which dealt specifically I, with the SPP-5 procedure.
5.3.3 Compilation of Survey Data Prior to starting inspections, a plan print of each S&L structural drawing of in place Category I concrete was obtained for use in the I survey. Developed elevation drawings were used for the containment exterior and primary and secondary shield walls. These prints were used as the basis for dividing areas into survey units.
5.3.4 Physical Inspection once prints were obtained, the teams conducted the physical I inspection of visible areas. This activity was performed between February 6,1980 and April 18, 1980.
The visual surface examination included the folicwing:
5.3.4.1 The bottom and side surfaces of accessible beams ard slabs indicated on the plan drawings.
5.3.4.2 The vertical surfaces of accessible walls and columns were indicated on the plan drawing, and extended from the top of the I slab on the plan drawing to the bottom of the slab / beam directly above.
5.3.5 Documentation of Results The results of the inspections were recorded under the direction of the PSI Level II member of each team. The results were recorded as I follows:
5.3.5.1 Each area that had been visually inspected was clearly indicated by marking the drawing.
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I 5.3.5.2 Any areas which could not be visually inspected were noteu en the .
drawing and the reason for inaccessibility was clearly indicated, such as formwork-in-place or backfill. (Re ference Sections 5.2.7 and 5.3.7.)
5.3.5.3 Surface irregularities were located on the plan drawings using the following notation:
- Concrete Patch
- Repair Area 5.3.5.4 Each surface irregularity was given a unique identification number, g which was recorded adjacent to the code notation shown in 5.3.5.3 g above.
5.3.5.5 In addition to locating the surface irregularities on the drawings, either a Concrete Patch Data Sheet or Repair Area Data Sheet form was prepared in detail. An example of each of these forms is included in Attachments 5.6.3.2 and 5.6.3.3 of this section. These forms were used to record dimensional and descriptive information regarding surface irregularities.
5.3.5.6 All marked-up drawings were annotated with the names of the Survey Team members who performed the inspection and the date the inspection was performed. An example of a marked-up drawing is included in Attachment 5.6.3.1.
5.3.5.7 A report summarizing the type and number of irregularities encountered during each survey was also prepared by the Team Leader and filed with the drawings and checklists. Documention produced during this inspection will be filed in QA Records.
5.3.6 Marking and Identification C^ncurrent with the recording activity, the perimeter of each patch / repair area was physically marked . These measures will assure that surface irregularities can be readily located for repairs in the future by using the marked-up drawir.g and corresponding data sheets.
5.3.7 Identification of Inaccessible Areas Formed areas which remain inaccessible for visual inspection were recorded as described in Subsection 5.5.5 and have been reported to the NRC. Locations covered by formwork will be examined as formwork is removed af ter the resumption of safety-related construction act ivitie s.
PSI plans to address surfaces which are inaccessible due to l backfilling in the following manner: 5 l
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I I Upon the Nuclear Regulatory Commission's authorization to resume Category I concrete work, patched areas shall be removed to sound I concrete. The inspection of each patch will be documented in accordance with approved procedures. Patches will be grouped into separate categories to enable PSI Project Engineering to evaluate the effect of each category of patch on the integrity of the I structure to perform as designed. Based upon the inspection of patches and the evaluation of these categories of patches, PSI Project Engineering will evaluate areas which were inaccessible for I surface inspection due to engineered backfills or other physically inaccessible surface areas. -
5.3.8 Preparation of Corrective Action Requests (CARS)
Using the documentation obtained during the inspections, PSI has generated CARS to procedurally identify the presence of surface I irregularities for evaluation, repairs and to establish corrective actions to prevent recurrence. These CARS are grouped into three categories as follows:
5.3.8.1 Concrete patches (See Figure 5.6.2-1)
I 5.3.8.2 Potential repair areas except those located on exposed construction joints (See Figure 5.o.2-2)
Potential repair areas located on exposed construction joints (See I 5.3.8.3 Figure 5.6.2-3)
Note: Separate CARS, as defined in 5.3.8.3, were written as an added precaution to assure that repair areas located on an exposed I- construction joint will not be covered by a subsequent concrete placement before corrective action can be completed,.
5.3.9 Concrete Patches PSI has made the commitment that previously completed concrete I 5.3.9.1 patches will be removed whether or not it is evident that the patches had been correctly installed. Patched areas have been identified and will be removed to sound concrete. Conditions found I will be evaluated and repaired in accordance with procedures reviewed and approved by the Contractor and PSI.
N-MH QC will inspect these repairs under PSI QA surveillance.
5.3.9.2 Potential Repair Areas Repair Areas shall be divided into two categories; " Cosmetic ,
De fects" and " Structural De fec ts". l I
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Due to che scrutiny of the visual examination, many areas of sand streaking, small localized air and water pito, and localiz d areas of bonded but expoced coarse aggregate, where identified as " Repair Areas" in accordar.ce with procedure SPP-5. For the purpose of this report, these areas are termed " Cosmetic Defects". These surface irregularities are not aesthetically appealing, but are not detrimental to the integrity of the concrete structure nor are they l indications of internal voids. Each " Repair Area" will be further 5 examined to determine if it is a " Cosmetic Defect." For areas which are eventually identified as " Cosmetic Defects", no repair is g necessary for structural adequacy. For an example of a " Cosmetic g De fec t", a photograph of sand streaking is shown in Figure 5.6.2-2.
5.3.9.3 Actions to Prevent Recurrence
" Cosmetic Defects" are common to concrete construction, and it is extremely difficult to totally prevent their occurrence. However, l by taking added precautions, the number of " Cosmetic Defects" can M be reduced. Sand streaking can be reduced by tightening formwork so that grout and/or water loss is minimized. Even with perfectly g sealed formwork, some sand streaking will occur due to the upward 5 movement of the bleed water at the formed surface.
Small localized air and water pits are caused by air and water bubbles adhering to the form surface. These bubbles are driven to the forms by the vibrators used to consolidate the concrete. The occurrence of these pockets cannot be eliminated, but may be minimized by the use of form vibrators. However, since water and air pits are not detrimental and the use of form vibrators is not practical for large scale construction, corrective action to prevent occurrence is not necessary.
Localized areas of exposed coarse aggregate which are bonded together by a coating of grout are caused by the insertion of a vibrator at a distance too far from the formed surface. Care ful "
insertion of the vibrator as close as practical to the formwork, making sure that the previous layer of concrete is penetrated, will l 5
reduce the number of this type of surface irregularity. However, due to the large amount of reinforcing steel required in nuclear power plant structures, insertion of a vibrator suf ficiently close g to the form is, at times, physically impossible. Consequently, the g l
occurrence of this localized unconsolidated concrete cannot be eliminated, but can be minimized.
l The occurrence of rock pockets and honeycombs is caused by a lack Due to the large amount of I
of vibration in these areas.
l reinforcing steel, proper vibrator insertion and vibration duration is extremely important to force the plastic concrete through and I around the reinforcing curtain to the fonn surface. Again, the occurrence of honeycomb and rock pockets can be minimized, but not eliminated, by careful vibration.
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l I Further steps to be used in combination with or in addition to those discussed above are as follows:
5.3.9.3.1 Supplementation of Quality Assurance /.ontrol, Construction, Engineering, and Production staffs wit. personnel qualified in concrete-related work for nuclear power plants.
5.3.9.3.2 Revision of existing procedures and development of additional procedures.
5.3.9.3.3 Addition of procedural " Hold Points" to allow ef fective inspection of work-in-progress.
5.3.9.3.4 Development and implementation of an extensive indoctrination and training program in concrete-related work for inspection and production personnel.
~~5.4 CONCLUSION~~
S Through this extensive visual concrete surface examination at the Marble Hill Nuclear Generating Station, concrete patches and potential rSpair areas on visible concrete surfaces have been I identified and located. Potential repair areas such as honeycomb, rock pockets, and other voids which expose reinforcing steel will be repaired. These future repairs, combined with the engineering evaluation to be performed on the inaccessible surfaces, will I assure that the in-plcce safety-related concrete is structurally adequate and meets the requirements of applicabic codes and standards.
In addition, training of personnel in concrete work, augmenting of staf fs with more qualified personnel, provision of new and improved I procedures to govern such work, and increased controls through witness and hold points to assure proper preparation for and performance of work will improve the quality cf future concrete placement.
~~5.5 REFERENCES~~
5.5.1 SPP-5, " Category I Concrete Surface Irregularities," Rev. 7, Special Process Procedures, Marble Hill Nuclear Generating Station, Public Service Indiana.
5.5.2 Concrete Manual, U.S. Department of the Interior, Bureau of Reclamation, Eighth Edition, 1975, pp. 353-354.
5.5.3 ACI Standard, " Preparation of Notation for Concrete," (ACI 104-71).
5.5.4 " Guide for Making a Condition Survey of Concrete in Service," ACI I Committee 201, Title No. 65-67, 1968.
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5.6 ATTACIU4E!rrS II SPP-5, " Category I Concrete Surf ace Irregularities" i
5.6.1 5.6.2 Photographs of Concrete Patches and Potential Repair Areas !
Figure 5.6.2 Concrete Patch i Figure 3.6.2 Repair Area not on a Construction Joint l Figure 5.6.2 Repair Area on a Construction Joint 5.6.3 Examples of Generated Documentation I 5.6.3.1 Example of a Marked-Up Drawing 5.6.3.2 Example of a Concrate Patch Data Sheet f 5.b.3.3 Example of a Repair Area Data Sheet i 5.6.4 List of Drawings Used to Document Inspection I: ,
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~~SUMMARY~~
OF REVISIONS PROC NO. SU BJECT I SPP-5 CATEGORY I CONCRETE SURFACE IRREGULARITIES A 5 ON REVISION DESCRIPTION l
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I 1 Reviseo paint requirements , Paragraph 3.2-6. ,
2 Revised responsibility of team assignment, Paragraph 3.2.
I Revised responsibility of PSI Project Engineering Manager, Paragraph 3.1.
Revised PSI /NRC communication channels, Paragraph 3.1.
3 Revised supervision responsibility of Team Leader, Paragraph 3.1.
Re'ised drawing requirements, Paragraph 3.2.
4 Revised " Repair Area" and " Concrete Patch" definitions, Paragraph 3.2.
5 Revised qualification requirements of Team Leader, Paragraph 3.1.
I 6 Revised paint requirements, Paragraph 3.2-6.
I 7 Revised responsibility of team assignment, Paragraph 3.1.
Revised issuance of nonconformances, Paragraph 3.2-6.
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I ATTACIDfENT 5.6.1 I REVISION AUTHORIZATION I R EVISION NUMBER 7 I DATE ISSUE D BY 05-22-80 I I CHECKED BY APPROV E
. (
j SECTION MGR i APPR OV E D E Q. A. MGR g ., $(h[h I
APPROV E D PRCJ. DIR.
PutWec Servce indens LF 61175 2/80
MARBLE HILL GENERATING STATION oate 05-22-80 7
PUBLIC SPECIAL PROCESS PROCEDURE Revision SERVICE 7;,,, .
l INDIANA see-5 cATEc0av I c0NcRETE SURFACE IRREGULARITIES I
TABLE OF CONTENTS Secu0N T1m I
1.0 ECOPE 2.0 DEFINITIONS AND ABBREVIATIONS 3.0 INSTRUCTIONS 4.0 FLOWCHART
~~5.0 REFERENCES~~
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I MARBLE HILL GENERATING STATION Date 05-22-80 Revision 7 PUBLIC SPECI AL PROCESS PROCEDURE I
9
~ of 8
"*S' ]
SERVICE Tit!e:
INDIANA SPe-5 CATECORY I CONCRETE SURFACE I IRREGULARITIES I 1.0 SCOPE This procedure establishes a systematic method for the identification, location, and documentation of all concrete patches and unrepaired concrete surface irregularities located in all visible Category I areas.
2.0 DEFINITIONS AND ABBREVIATIONS N-MH - Newberg - Marble Hill NRC - Nuclear Regulatory Commission PSI - Public Service Indiana I
Physical Surveyor - An individual who performs the inspection work involved in the verification procedure.
PST - Physical Survey Team - A group of individuals, including a Team I Leader and Physical Surveyors, who are responsible for the performance of the visual inspection and documentation.
S & L - Sargent & Lundy Engineers Surface Irregularity - A concrete patch or repair area.
Team Leader - An individual who is a member of the Physical Survey Team and supervises the work of the Physical Surveyors.
3.0 INSTRUCTIONS 3.1 Establishment of Physical Survey Team The establishment of the Physical Survey Teams shall be the responsibility of the PSI Construction Manager with the concurrence of the PSI Project Engineering and Quality Assurance Managers. All I Pnysical Survey Teams shall work under the supervision of a Team Leaders. Each Team Leader shall be a PSI engineer who satisfies one of the following qualifications.
~~1. BS degree plus one year experience in concrete related work.~~
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MARBLE HILL GENERATING STATION Date 05-22-80 .
PUBLIC SPECIAL PROCESS PROCEDURE Revision 7
"*" 3 '8 SERVICE
~~Title:~~
l INDIANA SPP-5 CATEGORY I CONCRETE SURFACE IRREGULARITIES Each Physical Survey Team will contain at least one PSI QA Engineer / Inspector qualified to Level II under ANSI N45.2.6-1973.
Other inspectors from PSI or N-Mit qualified to Level I may be assigned to the Physical Survey Team as necessary. Each Team Leader shall be under the supervision of the PSI Construction Area Manager for the performance of the physical survey, who in turn is responsible to the PSI Construction Manager for the performance of g
g the work. The PSI Project Engineering Manager is responsible for providing technical support to the entire program. The recording of data shall be under the direction of the PSI Level II Inspector.
3.2 Verification Activities All visible Category I concrete surfaces shall be visually examined in a systematic manner for the location and identification of all cor. crete patches (excluding form tia holes) and unrepaired surface g irregularities. The visual examination shall be conducted by the 3 Physical Survey Teams in the following manner. A plan print of each S & L structural drawing where Category I concrete is in place shall be obtained for use in the survey. Each drawing shall constitute a survey unit. 'ihe visual surface examiaation shall include the following.
~~1. The bottom and side surfaces of all beams and slabs indicated on the plan drawing.~~
~~2. T1 2 vertical surfaces of all walls and columns indicated on the plan drawing. These surfaces shall extend from the top of the slab on the plan drawing to the bottom of the 3~~
slab / beam directly above. g All inspections shall take place und : adequate lighted conditions.
Ladders or scaffolding shall be utilized where required. Each visible surface shall be illuminated using construction floodlights when raquired. Surfaces shall be examined for the following surface defects:
1. Repair Area - Surface area containing a void, rock pocket, other indications of unsound concrete, or observed deterious materials such as wood, paper, or mud. Small surface voids, 4" or less in diameter and less than 1/2" in depth, which are surrounded by satisfactory concrete shall not be identified as repair areas.
I 2. Concrete Patch Area - Any location which has been repaired o with dry pack or grout. Patched areas 4" or less in diameter E
!$ and locations where fill has been provided to smooth out 3
@ mismatched formwork or champhers shall be sounded with a lU 5
I MARBLE HILL GENERATING STATION Date 05-22-80 Revision 7 PUBLIC SPECIAL PROCESS PROCEDURE I SERVICE y ,.
INDIANA I SPP-5 CATEORY I CONCRETE SURFACE IRRECULARITIES I hammer. If the hammer sound is similar to the surrounding concrete, this indicates solid material and these locations shc11 not be identified as patches. However, if the area seems suspect be:ause of questionable circumstances such as an adjacent rock pocket, then the Physical Surveyors shall mark the area as a concrete patch. Obvious patch form-tie I locations shall not be considered as concrete patches As the inspection progresses, the plan drawing defining the area I shall be marked in the following manner:
~~1. Any area that has been visually inspected shall be clearly I 2.~~
indicated by marking the drawing.
If any area cannot be visually inspected, then a note I describing the area and the reason for inaccessibility shall be clearly indicated on the drawing, e.g., formwork-in place, backfill, bottom surface of a grade slab, etc.
When formwork prohibits the visual inspection of a concrete surface, the Team Lecder sna11 notify the PSI Construction Fbnager (or his delegate),
who in turn will communicate with the PSI Project Engineering Manager.
I It is intended that all PSI /NRC communications associated with implementation of the verification program go through the PSI Project Engineering Manager. The removal of formwork shall be handled on a I case-by-case basis with the exception that the formwork for the 9th lift of the Containment Exterior - Unit 1, shall not be removed until required in the normal course of events following the resumption of work. This surface area shall then be inspected using normal QA surveillance as the I formwork is removed.
~~3. Surface irregularitics shall be approximately located on the I plan drawings using the following notation:~~
- Concrete Patch (1/4" diameter)
- Repair Area (each leg 1/4" in length)
Developed Elevation drawings shall be used for the I Note:
containment exterior, secondary shield wall and primary shield wall.
~~4. Each surface irregularity shall be given a unique identification number using the following format:~~
ID - X where ID !ECP for Concrete Patch
MARBLE HILL GENERATING STATION Dan 05-22-80 PUBLIC SPECIAL PROCESS PROCEDURE Revision 7 5 of 8
" 'S' SERVICE Titis' INDIANA SeP-5 CATecoRv i Concrete SeRrAce IRREGUIAR'IIES EE RA for Repair Area X:2 Sequential Number Starting with ]
"1" for each drawing W For example, if on drawing S-673 five concrete patches and ten repair areas have been found. then the first and last identification number for each type would be CP-1 and CP-5 for concrete patches and RA-1 and RA-10 for repair areas.
In addition, when the next drawing is used for inspection, the first concrete patch discovered shall be labelled CP-1, etc. All marked up drawings shall contain the names of the Physical Surveyors and Team Leader and the date of the l 5
inspeccion.
~~5. ,In addition to locating the surface irregularities on the drawing, the following forms shall be completed at the time that the inapection is being conducted:~~
Form SPP 3.2-1 Concrete Patch Data Sheet Form SPP 5-3.2-2 Repair Area Data Sheet I
The dimensions input on the above forms shall be to the approxicate center of the surface irregularity. The accuracy l 5
of the location dimensions shall be such that any surface irregularity can be readily located by using the marked up g drawing and the corresponding data sheets. g
6. The perimeter of each concrete patch shall be clearly marked using red spray paint; whereas, the perimeter of each repair area shall be clearly marked using yellow spray paint. The yellow and red spray paints shall be used for all Category I areas except for the exterior of the Containment Building. l For the exterior of the Containment Building, the perimeters 5 of repair areas shall be marked using a light gray spray paint and the perimeters of concrete patches shall be marked using a dark gray spray paint. All spray paints shall be an exterior enamel type.
l It shall be the responsibility of the P.S.T to originate any
) deficiencies with design requirements in accordance with PMP l 1.07 on a Corrective Action Request (CAR). The PSI Level II Inspectors are responsible for assuring that the nonconformances are documented accurately with the findings of the P.S.T and are responsible for signing the signature block labeled " Initiator". NOTE: For SPP-5 deficiencies it
@ shall be noted in the " Method of Discovery" block on the CAR E Form that the deficiencies were discovered by SPP-5 P.S.T.
3 The control of the nonconformances (CARS) shall be in e
MARBLE HILL GENERATING STATION Date 05-22-80 l Il 7
PUBLIC SPECIAL PROCESS PROCEDURE Revision
" 6 of 8 SERVICE
~~Title:~~
I SPP-5 CATEGORY I CONCRETE SURFACE IRREGULARITIES I accordance with PMP 1.07 after the origination of the CAR by the P.S.T.
Numbers for the CARS shall be obtained by the PSI Superintendent of I Mechanical Quality Engineering from the Nonconformance Computer Coordinator.
3.3 Records Checklists and marked-up drawings for this reinspection are quality In addition to their being maintained as quality I
records.
documents, the complete set shall be maintained separately until the results of the reinspection have been evaluated and authorization for construction has been received.
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MARBLE HILL GENERATING STATION Date 05-22-80 PUBLIC SPECIAF ROCESS PROCEDURE Revision 7 l
i SERVICE Titfe:
l lNDIANA See-s CATEcGay 1 C0sCaETE SuarACE IRREGULARITIES l
=.
4.0 FLOWCl! ART 3.1 Establish PSTs PSI 3.2 Obtain Reduced Prir.ts of I PST Category I Areas Y
3.2 Visually Examine Concrete Surfaces, Mark Prints to PST Indicate Surveyed Areas and to Indicate Concrete Surface Irregularities, Complete Data Forms
[ 3.2 [ Output Document (Typ.)
/ eS
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3.2 Process Nonconformances PST l h
3.3 Maintain File of All Documents PSI I'
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I MARBLE HILL GENERATING STATION Date 05-22-80 7
PUBLIC SPECIAL PROCESS PROCEDURE Revision 4
I SERVICE
~~Title:~~
"'S' 8 of 8 INDIANA SPP-5 CATEGORY I CONCRETE SURFACE i
I IRREGULARITIES i
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~~5.0 REFERENCES~~
~~1. SPP-1 " Preparation of procedures for Physical Construction Verification," Rev. O, Special Process Procedures, Marble Hill I Nuclear Generating Station, Public Service Indiana.~~
~~2. ANSI N45.2.6-1973, " Qualifications of Inspection, Examination, and~~
~~l Testing Personnel for the Constuction Phase of Nuclaar Power~~
~~]= Plants," ASME, New York, New York.~~
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CONCRETE PATCll DATA SilEET REV. DATE 1
Signats.. _s of Physical Surveyors S&L D67.. No.:
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Concrete' Dimensions From Column Lines 1 Approximate Approximate
, Patch Comment I.D. No.
North - South ,-
East - West 2 Elevation Size,SQ.FT. -
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M M M M M M M M M M . _M_ _M__ _ .M M M M M __.M M REPAIR AREA DATA SILLET REU. DATE Sir,nat, e of Physical Surveyors S&L Dwg. No.: .
Building:
l Repair Dimensions From Column Lines 1 Approximate Approximate Comment Area I.D. No. North - South 2 East - West 2 Elevation Size,SQ.FT.
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? Dimer:sicos shall be indicated ao counterclockwisc-CCW and clockwise-CH uhen Azir.inthr. are osol for raf..rence
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4 ATTACPJENT 5.6.3.2 ,
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l Example of a Concrete Patch Data Sheet
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a I enerorTr paTrst NATA wrr+
Signatures of Physical Surveyors PFV. O S & L Dwg. No..
DA?F %A PC S-709 Fev. G
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Building: Auxiliary Tunnel i
I Cencrete Patch pt m ,gops Prom Colurn Lines 1 \pproximate Approximate Cc:::'ent
~~f. D. 'In . North - % uth 2 Fast - West 2 Elevation 11:e.Sn.FT.~~
N. face of wall ia.' ' 3' W. or race or wall j
_ CP-1 of 10 line 6" tJ. o f N . line 363 It'hx2"V Patch at ter of wall on N. face t f ace of wall 14' S 1 CP-2 of 1011ee P line -
363 9'Hx2"V Patch at ten of ull on M. face N. face of waAl 14' S CP-3 of 10 line a' W. of P line 360 6"Vxl"H Patch next to erbed N. face -
2'4" 5. of 10 line wall W. face on N. line wal: 360 6'Vx4"H Vertical patch in face CP-4 ratches aros.nc e-e- ata eter S. face of 10 line CP-5 vall 8' W. of N line 358 1" vide pipe sleeves CP-6
' ~ "
8' W. of N line 363 11"Exl"V Patch alcng top of wall W. f a:e o f wal) 5' e'nx; V-n ratcn along ten o: wall anc CP-7 8' S. of 6 line W. of P 373 2'Vx2"H-V vertically along embed Lene norizontal raten Irem e Arne CP-8 6 line 370 10'Hx3"Y tc 7 line 4
g Cp o 8' 2. of 7 line 368 2'Hy6"V Patch alent conduit E " " Horizontal patch in form seam CP-10 6' S. of 8 line 367 12'Ex2"Y CP-ll 6' S. o f 8 lir.e 365 '2'Hx2"V Horizental patch in fer- seam in corner or wati - u ster cown CP-12 13' S. of 8 line 364 3'Vxl"H in slab North face of step on L. tace or step cesn norizontal CP-13 devn in slab 13' E. of 0 line 365 12'Ex2"V patch in form sen In corner oI wail anc step ccs 4 E. f ace o f wall 7' A CP-14 13' S. of 8 line E. of 0 line 363 4'Vx2"H in slab O " " Horizontal patch in form seam I
d CP-15 6' S. of 8 line 367 12'Hx2"V h 7' E. of Q line en E. ,
4 CP-16 8 line face of wall 363 l'Hx6"V Patch en E. face 1 For Centainment Exterior Wall, Secondary Shield Wall, and Primary Shield Vall use Azinths 2
Dimensions shall be indicated as counterclockwise-CCW and clocWise-C'! whcp Azimutbs are used for reference I
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- . _ _ _ _ _ _, _ _ _ _. _. ._ _. l
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ATTACHMENT 5.6.3.3 Exaeple of a Repair Area Data Sheet I
I PEPAIR AREA OATA FHEET I
prv 0 DATE 3-6-80 f'gnatures of Physical Surveyors S 5 L Dwg. No. S-709. Fa . C Buildina: Auxiliary Tunnel Fepair Dirensions From Colurn Lines 1 Approximate Apprcxicate Corrent =
Area :
~~7. p. No. North - South 2 East - West 2 Elevation S t:e ,50. FT .~~
N. face at vail 1*' s RA-1 of 10 li.e 6' W. o f " line 357-6" l'Hx4"v InterriM nent - urcon. are en N. face Rock pocket in term seam on RA-2 10' W. o f N line 358 4'Vxl"H N. face PA-3 3' S. of 10 W. face of N. Ifne val 362 2'Hx!'V incen, area en V. face S. face of 10 line PA-4 vgli 2'-6" W. of N 36 1 3"Fxl'V Vncen. area en S. face I Rock pocket in horizental form seam RA-5 "
8' W. of N line - 361 It'Fx]'V and includes uncen, area Pock rocket aleng forn sea at top RA-6 . 12' W. of N line 36 3 3'Hxl"V of wall j Rock rocket along e=ted on S. .
RA-7 4' N. of 6 line 7' F. of 0 line 369 2-l'Vxl"H f ace of vall RA-8 7' N. of 5 line 7' L. of 0 line 373 l'Hx4' V Veid at top of vall S. face of vall I c RA-9 4' N of $ line 372 l'Hx6"V Vncen. ares en C. face of vall l T Suspect areas on slab step-down
~~', RA-10 5 line 5' E. of 0 line ?60 W. face~~
.. W. f ace o f vall 5' W. g RA-Il 4 ' S . o f ' line of P line 369 l'Fx6"" Suspect area around conduit W. face of vall 5' W. ,
PA-12 3' N. of 5 line of P line 369 l Ix l "V Pock pocket alone bottee of vall ,
PA-13 9' N. of 5 line 371 3'Hx2'V Bue hole area gp 7 " "
"I RA-14 13' S. of 8 line 369 2'Ex2'V Pur hole area l
l 7 E. face of vall 7' E.
T u- 15 13' S. oi 8 line of 0 line 370 3'Vx1'M Bue hole area I
~~12' S. of 8 line " "~~
2 'lixl"V RA-16 366 Rock recht alcee form seam ;
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E I For Containment Exterior Wall, Secondary Shield Wall, and Primary Shield Wall use Ari uths 2
Dimensions snall be indicated as counterclockvise-CCW and clockwise CW when Azimuths are used for reference Il .
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LIST OF DRAWINGS USED TO DOCUMENT INSPECTION DRAWING DRAWING DRA4ING I
~~Rev. # Rev. # Rev.~~
A-324 D S-683 R S-892 L I A-325 A-326 A-327 C
F B
S-664 S-683 S-689 H
M L
S-895 S-896 S-899 R
K H
A-328 S-690 S-900 L I
C P A-329 B S-691 P S-904 N A-330 D S-692 J S-905 N A-331 A S-693 G S-906 L I S-387
~~S-549 S-550 K~~
K H
S-694 S-695 S-696 0
L W
S-952
~~S-965 S-966 K~~
K K
S-697 S-969 L I S-551 J W S-552 H S-700 L S-970 M S-670 K S-702 F S-973 J S-67' F S-705 G S-974 K I S-672 S-673 S-674 W
H G
S-708 S-709 S-710 K
G C
S-1402 S-1471 S-1472 H
L K
I S-711 S-1473 S-675 N F K S-676 G S-712 E
~~S-1474 K S-677 E S-810 K S-1479 G S-678 G S-812 S S-1480 J I S-679 S-680 S-681 V~~
T N
S-878 S-891 B
M S-1481 S-1482 G
F I S-682 M
~~Revision 1:~~
- S-549 Rev. K Added to list 695 Rev. K Changed to S-965 Rev. K
- S-1474 Rev. F Changed to S-1474 Rev. K
- All drawing numbers put in increasing order l
!I l
ATTACHMENT 5.6.4 I
I I
I I 6.0 MECHANICAL (CADWELD) SPLICES 6.1 ABSTRACT This section describes the results of an inspection program conducted by Public Service Company of Indiana, Inc. (PSI) and Newberg-Marble I Hilt (N-MH) on accessible mechanical Cadweld splices at the Marble Hill Nuclear Generating Station. Also included are proposed corrective actions to assure the adequacy of the in place splices and actions to prevent recurrence of questionable splices in the future.
This program consisted of visual examinations conducted by qualified I and trained teams in accordance with an approved Special Process Procedure, SPP-6, and the follow-up testing program described herein to determine the acequacy of the splices which did not meet the visual examination acceptance criteria.
Upon completion of the reinspection of accessible mechanical Cadweld R splices PSI developed an extensive testing program which included radiograph examination and tensile testing of visually rejected splices to determine the structural acceptability of the in place Cadweld splices.
In addition to the testing program, PSI further evaluated existing Cadweld data, ta determine adequacy of Category I Cadwelds. This evalue. tion is presented in Attachment 6.6.9.
It was concluded from the investigation performed that the mechanical Cadweld splices at Marble Hill meet the specified strength R requirements.
To emphasize PSI's quality commitment on the Marble Hill Project, PSI R has elected to remove and replace or repair, visually rejected splices with physical defects identified during the inspection of Cadwa.1ds under the Construction Verification Program. This is over and above commitments of the PSI Construction Verification Program.
Fifty (50) type 'T' vertical Cadweld splices will be removed and replaced and fourty-seven (47) type 'B' vertical will be repaired.
The list of splices to be removed and replaced or repaired is in Attachment 6.6.9.
~~6.2 INTRODUCTION~~
6.2.1 Commitments PSI committed to a verification program for Cadweld splices in Article III.A.2. vi. of the " Description of Licensee Activities Addressing Order Confirming Suspension of Construction". This verification program was to consist of inspecting a statistical sample to provide 95% reliability with a 95% confidence factor of exposed Cadweld splices. The inspection commitment required the fellowing:
-l-l
I (1) A visual check for poro"*ty and inclusions in the surface of the I
Cadweld material.
(2) A eneck for recess at the ends of the Cadweld sleeves.
I To meet these commitments a random sampling was adopted and successfully implemented. This inspection examined and documented the following:
(1) Distance between gage lines used during production, (2) Void area of filler metal in the sleeve ends, (3) Distance of filler metal recess in the sleeve ends, (4) Presence of slag in the sleeve tap hole, (5) Tap hole burnout and (6) Porous filler metal or slag visible in the sleeve ends.
6.2.2 Procedure Outline The steps taken to perform the visual inspection, testing and R documentation were as follows:
(1) Preparation and approval of a procedure for the visual inspection and verification of Category I mechanical Cadtreld splices, SPP-6 (Attachment 6.6.1).
(2) Establishment and qualification / training of the Physical Survey Teams (P3T).
(3) Visual inspection of accessible Category I mechanical Cadweld splices.
(4) Documentation of visual examination results in reports, detailed forms and the mapping of the splice locations.
(5) Identification by marking and tagging the splices which did not meet the visual examination ac eptance to assure traceability and documentation.
l (6) Performance of additional physical tests, including both l nondestructive and destructive tests, to further evaluate the l splices which did not meet the visual examination acceptance criteria.
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(7) Preparation of Corrective Action Requests (CARS) to procedurally l identify any deficiencies associated with the production and I inspection of the splices and to establish corrective actions to l prevent recurrence. m '
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.2-
6.3 ' DISCUSSION 6.3.1 Procedure Special Process Procedure, SPP-6, entitled " Mechanical (Cadweld)
Splices" was prepared by Sargent & Lundy (S&L) based on S&L Form BY/BR/MCS which forms part of Specification Y-2722 and Y-2850 (Reference 6.5.4). This procedure was reviewed and approved by the PSI Project Engineering Manager and the PSI Quality Assurance Manager. It established written criteria and instructions for the I systematic identification, location, visual examination and documentation of the visual examination results of the mechanical Cadweld splices.
6.3.2 Establishment of Physical Survey Team The survey teams were established, organized and staffed with I. qualified personnel as described in Section 4.1 of SPP-6. The commitments made in Section III.A.2.b. of the " Description of Licensee Activities Addressing Order Confirming Suspension of I Construction" were incorporated into SPP-6. In addition, survey team members attended documented training sessions which dealt with the SPP-6 procedure.
6.3.3 Compilation of Survey Data Prior to starting inspections, copies of the contractor prepared I Cadweld splice mapping drawings, which show the relative location of the splices, were obtained for use in the survey. Each visible splice was given a unique identification label which was written adjacent to its location on the Cadweld splice mapping drawing.
Labeling and review of the mapping drawings were done in accordance R with Section 4.2 of SPP-6.
6.3.4 Visual Examination Once the mapping drawings were marked with the identification labels, I the teams conducted the visual examination of the accessible Cadweld splices. This activity was performed between May 16, 1980 and June 27, 1980.
' I 6.3.4.1 Technical Requirements The visual examination included the following technical requirements:
1 (1) Presence of gage marks on the spliced bars, (2) Physical measurement of the distance between the 7, age marks for l "T" splice or the measurement of the distance 5etween the a type gage mark and the structural plate or shape attached to a type "B" splice, (3) Measurement of the distance between the centerline of the gage marks and the center of the tap hole for type "T" splices, I ....
(4) Examination of the sleeve ends and tap hole to verify that filler metal and not slag was present at these locations, (5) Examination of the sleeve ends and tap hole to verify that the filler metal was not porous in texture, (6) Measurement of the filler metal recess from the edges of the ,
M sleeve, (7) Measurement of spot void maximum depths and widths and the calculation of the total void area at each sleeve end and (8) Examination of tap hole for " burnout".
6.3.4.2 Documentation of Visual Examination Results The results'of the inspections were recorded under the direction of a PSI Level II inspector as follows:
(1) A "Cadweld Visual Examination Chart", shown as Attachment 2 of E SPP-6, was used for documenting the results of the visual g inspection of each splice. This form contained the visual accept / reject criteria for each item inspected.
(2) The visual acceptance or rejection of each inspected splice was documented by denoting " accept" or " reject" appropriately along-side the splice identification label on the Cadweld splice mapping drawing.
(3) Visual examination charts were annotated with the names of the survey team members who performed the inspection and the date l the work was performed. Cadweld splice mapping drawings were E annotated with the names of the individuals and dated as the splice number I.D. was assigned. The drawings were subsequently E marked accept or reject at the completion of the inspection by g the Physical Survey Teams. Those splices identified as inaccessible were marked as such on the Cadweld splice mapping drawings.
t Refer to Attachment 6.6.5 for an example of the marked up inspection drawing and Attachment 6.6.6 for examples of the "Cadweld Visual '
Examination Chart".
6.3.4.3 Marking and Identification 1 c Inspected Cadweld splices were marked in accordance with SPP-6. A =
weatherproof tag was attached to visually rejected splices to assure that they could be identified for testing, cnd repair or removal. R 6.3.5 Discussion of Visual Examination Results A total of 2,431 Cadweld splices were visually examined. This total included 1,244 type "B" splices made in a vertical oosition, L,131 '
4 I'
I type "T" splices made in a vertical position, and 56 type "T" splices made in a horizontal position. Of these 2,431 splices, 1,794 were R visually acceptable.
6.3.5.L Visual Rejection g 504 individual splices were identified as not conforming to visual 3 acceptance criteria. 576 separate nonconforming conditions were identified on these 504 individual splices. Sixty-six individual R splices were identified to have had more than one nonconforming I condition based on visual inspection.
The visual rejection of a Cadweld splice does not mean that the I splice will not satisfy the strength requirements; it is only an indication that these particular splices must be examined further.
This is because the accept / reject criteria for visual examinations I were conservatively chosen to cover a wide range of situations while being relatively easy to perform.
The basic types of visual rejections addressed in SPP-6, their potential consequences and the type of further examinations used to evaluate them are listed and discussed below.
(1) Gage Mark Related Rejection - These rejections indicated tnat either the gage mark was not visible, the gage mark distances were outside specified tolerances or more than one gage mark was I used. Gage marks are totally unrelaced to the splicing operation and therefore, they do not affect the quality of the finished splice. Gage marks are used for the visual inspection I after the splice is completed to determine if the reinforcing br. is sufficiently embedded into the Cadweld sleeve. Gage mark deficiencies documented during the visual examination are described below.
(A) "No Gage Marks" - There were 203 cases for which R there were no visible gage marks. Each piece of I seinforcing steel in a Cadweld splice should have had a mark placed 12 inches from its end.
Note 1: It is noted that the Marble Hill Specification R does not require a permanent marking system to be used to identify the gage mark. It is PSI's I conclusion that many of the marks faded away or were washed away during the shutdown which attributed the majority of the gage mark visual rejections.
Note 2: Included in the 203 is One splice having two R gage marks on che bar. Although this is not one I of the rejection criterion, it was macKed for further examiaation because there was no positive way to visually determine how far the bar is embedded into the sleeve.
I Ill l
(B) "Out of-Tolerance Gage Marks" - Ihere were 106 cases where R the location of the gage marks was out of tolerance. For a type "T" splice, the distance between the gage marks should E have been 24 1/2 inches + 1/2 inch and the centerline of
_ E this distance should have been within the diameter of the tap hole to pass the visual examination. Likewise, for a type "B" splice, the distance between the structural steel plate or shape and the gage mark should nave been 12 inches
+ 1/2 inch.
(C) Centerline of Gage Marks not Within Diameter of Tap Hole" -
There were ill cases where the centerline of the distance R between the gage marks did not fall within the diameter of the tap hole.
The embedded length of the reinforcing bar into the Cadweld sleeve is the ultimate question in all gage mark related g rejections, because there is a potential pullout of the bar in E tension at loads lower than the specified strength requirements if adequate embedment is not provided.
l Sixty-six visually rejected splices for gage mark deficiencies R were radiographed according to the Radiograph Test Procedure I described in Subsection 6.3.6.1 to assure the splices were E E
I installed in accordance with the manufacturer's recommenda-tions. Sixty of these were acceptable. The six that did R not pass the radiograph test were then removed and tensile g tested in accordance with the Tensile Test Procedure described E in Subsection 6.3.6.3. The results of this tensile test, given in Attachments 6.6.4.8 and 6.6.9, shows that the splices exceed R the strength requirement.
Based on these results and the conclusions reached in Attachment R 6.6.9, the sleeves that were visually rejected due to gage mark deficiencies, are capable of meeting the strength requirements of Regulatory Guide 1.10 " Mechanical Splices in Reinforcing Bars of Cstegory I Structures" (Ref erence 6. 5.3).
The one case which had two gage marks on the bar was radiographed and found acceptable.
(2) Excessive Void Area - There were 103 cases where the calculated R l void area exceeded the allowable void limits for a visual l examination. When the calculated void area exceeds the limits, there may not be sufficient filler metal present between the bar and the sleeve to transfer the tensile load from the bar to the sleeve.
Tensile tests were performed on selected splices in accordance
! with the Tensile Test Procedure described in Subsection 6.3.6.3. The splices that were selected were the two cases with the largest calculated void areas for each bar size used in each type of splice. The tensile test results are given in l
Attachment 6.6.4.1. The results show that the splices tested exceed the strength requirements of Regulatory Guide 1.10. This ensures that the sleeves with lower calculated void areas will ;
exceed the strength requirements.
(3) Excessive Recess of the Filler Metal - There were seven cases for which there was an excessive recess of the filler metal at R j the sleeve ends. Enen the recess does not satisfy the visual 3
acceptance criterion there may be insufficient filler metal present to transfer the minimum s trength requirements.
Tensile tests were performed in accordance with the Tensile Test Procedure described in Subsection 6.3.6.3, on the two splices which had the largest recess. These test results are given in Attachment 6.6.4.2. These results show that the splices tested exceeded the strength requirements of Regulatory Guide 1.10.
Since the splices with the largest recess, which are potentially the least capable of fulfilling the strength requirements, g exceeded the strength requirenents, the splices with smaller recess will also meet the strength requirements.
g (4) Slag Penetrations Beyond the Sleeve at the Tap Hole - There were I 26 cases for which evidence of some slag was found beyond the thickness of the Cadweld sleeve at the tap hole. The slag may have displaced too much of the filler metal inside the sleeve, R
causing a potential reduction in the capacity of the splice.
I Tensile tests were performed in accordance with the Tensile Test Procedure described in Subsection 6.3.6.3 on at least one splice for each size used in each type of sleeve. A total of eight splices were tested. The results of these tests are given in I Attachment 6.6.4.4. The results of these tensile tests show that the splices exceeded the strength requirements of Regulatory Guide 1.10.
(5) Tap Hole Burnout - There vere three cases of tap hole burnout during the inspection activities. Tap hole burnouts are caused R 1 when the hot molten filler metal hits the sleeve wall before entering tne inside of the sleeve. This causes some of the outside surface of the sleeve wall to be melted and eroded. The I tap hole is irregularly enlarged, usually taking an elliptical shape. The net crot s-sectional area of the sleeve may be reduced to such an extent that the sleeve may not be capable to l meet the strength requirement.
All three splices were removed and tensile tested in accordance with the Tensile Test Procedure described in Subsection
! I 6.3.6.3.
6.6.4.5.
The results of these tests are given in Attachment They show that the splices exceeded the strength requirements of Regulatory Guide 1.10.
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I (6) Porosity in the Sleeve Ends - There were 14 cases where R a porous textured filler metal was located in one of the sleeve ends. The quality of the filler metal may be such that it is not sufficient to transfer the loads. Tensile tests were l performed in accordance with the Tensile Test Procedure W described in Subsection 6.3.6.3 on one splice for each size used for each type of sleeve. A total of four splices were tested. g The results of these tests are given in Attachment 6.6.4.3. g' These results show the splicer exceeded the strength requirements af Regulatory Guide 1.10.
(7) No Filler Metal Visible at the Sleeve Ends - There was one case R where there was no filler metal visible at one of the sleeve ends. The concern for visual rejection was that there may not be sufficienc filler metal to transfer the tensile loads.
This case was removed and tensile tested in accordance with the Tensile Test Procedure described in Subsection 6.3.6.3. The result of this test is given in Attachment 6.6.4.6. This tensile test shows it exceeded the strength requirements of Regulatory Guide 1.10.
(8) More Tnan One Tap Hole - Two type "B" splices had two tap holes i in the sleeve. This was not one of the rejection criteria, but
! it is a concern because there is a possibility of a reduction in i the net cross-sectional area of the sleeve, and therefore, the sleeve .nay not be able to withstand the specified tensile loads.
A mock up sleeve was made with a similar cap hole configuration and was tensile tested in accordance with the Tensile Tes Procedure described in Subsection 6.3.6.3. The results of the test is given in Attachment 6.6.4.7. This tensile test shows it exceeds the strength requirements of Regulatory Guide 1.10.
Because of the similar characteristics between the production l sleeves and the mock up sleeve, it was concluded that the two E questionable production sleeves will act similarly under loaded conditions to the mock up sleeve.
6.3.5.2 Sleeves Not Fully Verifiable l Because of physical conditions that existed in the field, 141 exposed R l splices were totally or partially inaccessible and therefore not E fully verifiable. These splices were visually inspected as much as l was physically possible. Splices which were found to be unacceptable g for any of the visual inspection criteria are addressed in tne g appropriate subsections described above.
1 6.3.6 Follow-Up Testing Program, Results, and Conclusions
{ Fucher testing of the visually rejected sp1. ices was performed af ter
! the inspection determined them to be inadequate. See Attachment R 6.6.9, Section 1, Paragraph III, CADWELD TESTING PROGRAM.
I I I l 6.3.6.1 Radiograph Test Procedure After completion of the visual examination and after the data on I these rejected splices was compiled, s. review of the results and the splice accessibility for the radiographic equipment was made to select the splices which should be radiographed.
j The camera was operated by a Level II RT Examiner who was qualified W
under ASNT-TC-1A. The technique used in this procedure is outlined in Attachment 6.6.2.
The radiographs were interpreted by a Level III RT Examiner who was qualified under ASNT-TC-1A. The radiographs showed the positioning of the tap hole and the relative location of the ends of the bar to the tap hole.
/
The accept / reject criterion for the radiograph test was as follows: R
~~1. For Type B splice, there should be evidence in the radiograph that the bar extends beyond the tap hole towards the welded end I of the sleeve.~~
For Type T splices, there should be evidence in the radiograph 2.
that the end of the bars are within a 3/4" diameter centerr.d at the center of the tap hole. For transition splices, there should be evidence that the end of the bars are within + 3/d" of the I.D. transition of the sleeve.
~~3. The interpretation of the radiographs shall be limited to the location of the bar ends.~~
Any splices which were rejected by the radiograph test were subjected to a tensile test in accordance with the Tensile Test Procedure described in Subsection 6.3.6.3.
6.3.6.2 The Radiograph Test Results Sixty-six splices with gage mark deficiencies were radiographed to R provide 95% reliability with a 95% confidence that the splices will perform as required, even though only 54 were required. Thus the R I confidence level exceeds 95% at a 95% reliability.
A passing splice is defined as one which was produced as per manufacturer's specifications or one that will meet the strength re c,uirements . Sixty of the 66 splices tested were shown by the R radiograph test to be produced properly. The six splices that did not pass the radiograph test were removed and tensile tested u-I the Tensile Testing Procedure and exceeded the strength reqe trew cs of Regulatory Guide 1.10. See Attachments 6.6.4.8 and 6.6 R 6.3.6.3 Tensile Test Procedure Af ter completion of the visual examination and af ter the data on I these visually rejected splices was compiled, a review was made to choose which splices should be tensile tested.
I I
The splices which were selected te have tensile tests performed on them were cut from the structure. A listing of the splices tested is given in Attachment 6.6.4. Type "T" splices were removed by cutting the bars on both ends; type "B" splices were cut from the structural steel plate or shape on one end and from the bar on the opposite end.
~~Areas where the splices were removed were tagged. Cut splices will [~~
be evaluated and replaced where required by engineering evaluation. 3 Photographs were taken of each splice prior to the tensile testing. .
The photographs were made to provide a permanent record of the reason for rejection.
The tensile test was performed in accordance with the applicable g provisions of Form BY/BR/MCS. 5 Photographs were again taken to illustrate the mode of failure for
~~each splice.~~
Refer to Attachment 6.6.4 for the tensile test results.
The acceptance criteria used for these tensile tests are more stringent than those required in Regulatory Guide 1.10 which requires that each splice must develop at least a tensile strength of 125% of g.
yield of the reinforcing bar (75,000 psi) and the average of any 15 g individual splices tested must not be less than 90,000 psi.
6.3.6.4 Tensile Test Results The results of the tensile tests showed that the splices tested exceeded the 125% of yield requirements with the lowest two splices g breaking at 76,500 and 84,445 psi respectively. Also, when the 15 R E lowest individual tests were averaged, the resulting value is 92,356 psi.
6.3.7 Statistical Approach In order to meet the commitment contained in the " Description of Licensee Activities Addressing Order Confirming Suspmion of h
3 Construction", 59 Cadweld splices were randomly selected and included in the inspection program described in this Subsection. Attachment 6.6.7 contains 59 random numbers for a population of 2434, representing the exposed splices. Three splice numbers were assigned but not used. This is why the 59 random numbers were generated for a population of 2,434 instead of the 2,431 visually [
inspected splices. E Attachment 6.6.8 contains a listing of all accessible Cadweld splices. The statistical sample of 59 is identified by circling the appropriate splice number.
l All 59 splices met the required acceptance criteria for either l
! visual, radiograph or tensile test. This provides 95% reliability a with a 95% confidence factor that the exposed Cadweld splices are adequate.
I 6.3.8 Corrective Action 6.3.8.1 Preparation of Corrective Action Requests (CARS) l E Using the documentation obtained during the inspection program, PSI j has generated two CARS PC0603 and 281 PSI 0018 to identify the R l individual splices which did not meet the visual acceptance criteria, I to identify further testing requirements, and to identify the program problems which led to the deficiencies in the production and i
inspection of the Cadweld splices.
Note: CAR 281 PSI 0018 replaced CAR PC 0602. R 6.3.8.2 Proposed Corrective Action on Rejected Splices The visually rejected Cadweld splices discovered during the
,g inspection of the accessible Cadweld splices have been subjected to
'g further evaluation using both nondestructive and destructive test methods. No corrective action is required other than the replacement, where required by engineering evaluation, of the splices that were cut out for testing.
6.3.9 Actions to Prevent Recurrence The primary cause for the existence of the questionable Cadwelds splices was the lack of adequate inspection. The intent of the production and visual inspection procedures is to prevent substandard I eplices from Leing p.oduced. The general contractor should have produced the Cadweld splices and then an independent testing agency should have inspected the splices to determine if they are If the inspection had been adequately conducted at the I acceptable.
time of production, the problems in production would have been immediately detected and could have been rectified at that time.
(
EW Because the inspection was not as intense as intended, the production personnel were not made aware of the deficiencies as they occurred and they continued to happen. If the production and inspection i procedures available at the time of the splice installation had been properly implemented, then the quality of the existing splices would have never been in question.
I In order to prevent the recurrence of questionable splices, additional training of production and inspecting personnel will be conducted prior to the resumption of work. In addition, the PSI l
E 9^/qC organizations will monitor both of these activities more E thoroughly than in the past.
~~6.4 CONCLUSION~~
S Visual examination of Cadweld splices during production i' a conservative test to detect any substandard conditions that maf affect the quality of the finished splice. Due to inadequate I production inspection, an extensive visual reinspection program was initiated. This program consisted of a visual inspection of all the accessible Category I mechanical Cadweld splices at the Marble Hill I job site.
I Follow-up testing programs were implemented on selected samples to =
further evaluate the splices which did not meet the visual inspection acceptance criteria. This program showed that these splices met the strength requirements of Regulatory Guide 1.10.
A statistical sample of 59 randomly selected splices was investigated. All 59 of these selected splices meet the acceptance criteria for visual acceptance or for tensile strength. With this =
verification, a 95% reliability is provided with a 95% confidence factor. This meets the commitment in the " Description of Licensee Activities Addressing Order Confirming Suspension of Construction".
The generic problems in the inspection of mechanical Cadweld splice; have been identified and evaluated. Since similar production methods were utilized for the inaccessible splices as for the accessible splices, the evaluacion conducted on the accessible Cadwelds splices has been extrapolated to those which remain inaccessible, indicating statistical acceptability of buried and inaccessible splices.
~~1. No substandard splices exist at Marble Hill.~~
~~2. Gage mark rejects are not true rr,jects in accordance with specification or code, th.o the evaluation program eliminated 358 of the 504 individual sp'. ices as visur.1 rejects.~~
~~3. 146 out of 2431 or 6% were err.e visual rejects. R It is noted that the industry average has been as high as 7.6% ,~~
~~for substandard splices. Marble Hill tested worst cases of visual rejects and had 0_% substandard splices. See Reference 6.5.5.~~
~~4. The Marble Hill Project has had no substandard in process sirter or production splice test results.~~
~~5. Unit 1 Cadweld splices do not exhibit the type of visual rejection identified inder SPP-6. See Attacheent 6.6.9, Se. tion 1, Paragrap.. V. Page 7.~~
In place Cadweld splices are therefore capable of satisfying the W strength requirements.
Training of personnel involved in the production and inspection of Cadweld splices, and the supplementing of staffs with qualified personnel, will prevent recurrence of the deficiencies described in this report.
~~6.5 REFERENCES~~
6.5.1 Public Service Indiana Marble Hill Project Corrective Action Request R
No. 281 PSI 0013 6.5.2 Public Service Indiana Marble Hill Project Corrective Action Request No. PC0603 I
I
I
~~6. 5. 3 " Mechanical Splices in Reinforcing Bars of Category I Structures,"~~
Regulatory Guide L.LO, U.S. Nuclear Regulatory Commission, Washington, D.C., 1971.
6.5.4 Sargent & Lundy Form BY/BR/MCS, Revision 7, " Specification for Making and Inspecting Mechanical (Cadweld) Splices," part of Sargent & Lundy Specification Y-2722 and Y-2850.
6.5.5 Journal of the Construction Division, A.S.C.E., September 1979, R
" Quality Control of Cadweld (Mechanical) Splicec, H. Randolph Thomas, J:. .
6. 6 ATTACHMENTS 6.6.1 SPP-6 " Mechanical (Cadweld) Splices" 6.6.2 Radiograph Technique for Cadweld Splices I 6.6.3 Summary of Gage Mark Rejections and Radiograph Locations 6.6.4 Summary of Tensile Test Results 6.6.4.1 Splices Failing Visual Inspection Due To Voids 6.6.4 2 Splices Failing Visual Inspection Due To Excessive Recess 6.6.4.3 Splices Failiag Visual Inspection Due to Porosity of Filler Metal 6.6.4.4 Splices Failing Viaual Inspection Due To Slag at Tap Hole 6.6.4.5 Splices Failing Visual Inspection Due To Burned-Out Irregularly Shaped Tap Hole 6.6.4.6 Splices Failing Visual Inspection Due To Absence of Filler Metal 6.6.4.7 Splices Failing Visual Inspection Due To Two Tap Holes 6.6.4.8 Splices Failing Radiograph Test 6.6.5 Example of Marked Up Inspection Drawing 6.6.6 Example of Marked Up Inspection Forms 6.6.7 Random Numbers 1 6.6.8 Statistical Verification of Splice Acceptability 6.6.9 Supplement 1, Mechanical Cadweld Splices, January 23, 1981 R B
3
~~SUMMARY~~
OF REVISIONS PR c.ggP-6 """
MECHANICAL (CADWELD) SPLICES
( REVISION REVISION DESCRIPTION NUMBER i
0 Initial Issue.
1 Changed Paragraph 4.2 to uniquely identify horizontal, vertical g and diagonal positions. -
g 2 Revised splicing identification system, Paragraph 4.2.
Revised method of identifying nonconformances, Paragraph 4.3.
Revised Paragraph 4.3 E.
3 Revised first paragraphh in Section 4.1.
Revised Section 4.2.
Revised Paragraph 4.3.C-2.
Revised Paragraph 4.3.D and Subparagraph 4.3.D.b.
Revised Paragraph 4.3.E.
Revised Attachment 2.
I g,
c' =
5 I
I, i
REVISION AUTHORIZATION REVISION NUMBEP 0^
,33UED 06-04-80
'""^"%
sv A6./,4L l i l g c"'::'*All&/d
/ SECTION
^"= hd. air o !
APPROVED PR OJ. DIR.
Pubsec Seewee Indiana LF 61-175 2/80 3
I -
l MARBLE HILL GENERATING STATION Date 06-04-80 Revision 3 5 PUBLIC SPECIAL PROCESS FROCEDURE i, SERVICE ritie-
!5 INDIANA SPP-6 MECHANICAL (CADWELD) SPLICES
~~I i~~
TABLE OF CONTENTS
, SECTION TITLE 1.0 PURPOSE f 2.0 APPLICABILITY
! 3.0 DEFINITIONS AND i ABBREVIATIONS 4.0 INSTRUCTIONS 1
~~5.0 REFERENCES~~
'W 6.0 ATTACHMENTS
\
1
~~I 4~~
I l5
!l!,
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i I MARBLE HILL GENERATING STATION Date 06-04-80 3
PUBLIC SPECIAL PROCESS PROCEDURE Revision
""' 2 # ' "
SERVICE y ,.
INDIANA SPP-6 MECHANICAL (CADWELD) SPLICES 1.0 PURPOSE I
This procedure establishes a method for determining whether or not the in place Category I mechanical cadweld splices satisfy design requirements.
2.0 APPLICABILITY This procedure is applicable to Category I mechanical cadt .o splices g only. g 3.0 DEFINITIONS AND ABBREVIATIONE, N-MH - Newberg-Marble Hill NRC - Nuclear Regulatory Commission Physical S ;veyor - An individual who perfoms anj work involved zu the verifica t an procedure.
PST - Physical S"rvey Teart - A group of individuals, including a Team Leader and Physical Surveyors, who perform all work involved in the verification procedure.
PSI - Public Service Indiana PSI /CM - Public Servica Indiana Construction Manager PSI /PEM - Public Service Indiana Project Engineering Manager S&L - Sargent & Lundy Engineers Team Leader - An individual who is a member of the Physical Survey Team and supervises the world of the Physical Surveyors.
l 4.0 INSTRUCTIONS 4.1 Establishment of Physical Survey Team Establishment of the Physical Survey Tean shall be the tesponsibility of the PSI Construction Manager with the concurrence i of the PSI Project Engineering and Quality Assurance Managers. All Physical Survey Teams shall work unde.r the supervision of a Team Leader. One Team Leader, may supervise more than one Physical Survey Team. Each Team Leader shall be a PSI Engineer who satisfies l
one of the following qualifications:
Fe s
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I MARBLE HILL GENERATING STATION Date 06-04-80 3
PUBLIC SPECIAL PROCESS PROCEDURE Revklon Page 3 of 7 I SERVICE
~~Title:~~
~~INDIANA I SPP-6 MECHANICAL (CADWELD) SPLICES l~~
~~1. BS degree plus one year experience in concrete-related work.~~
~~2. Five years experience in concrete-related work.~~
Each Physical Survey Team will contain at least one PSI QA Engineer /
I Inspector qualified to Level II under ANSI N45.2.6-1973. Other Inspectocs from PSI or N-MH qualified to Level I may be assigned to the Physical Survey Team as necessary. Each Team Leader shall be under the supervision of the PSI Construction Area Manager for the I performance of the Physical Survey Team, who in turn is responsible to the PSI Construction Manager for the performance of the work.
The PSI Project Engineering Manager is responsible for providing I technical support to the entire program. The recording of data shall be under the direction of the PSI Level II Inspector.
4.2 Labelling of Splices Using Whalen-Chilstrom cadweld splice mapping drawings, the Physical I Survey Team shall consecutively number all accessible Category I cadweld splices. Type "B" splices made in a horizontal position shall be labelled BH-1, BH-2, etc. Likewise, each Type "B" splice I
made in a vertical position shall be consecutively numbered BV-1, BV-2, etc., and those made in inclined position shall be labelled BI-1, BI-2, etc. For Type "T" splices, the labelling shall be TH-1, TH-2, etc for horizontal splice; TV-1, TV-2, etc. for vertical splices; and TI-1, TI-2, etc. for inclined splices. The names of I the Physical Survey Team members who perform the numbering and the date of the work, shall be placed on the mapping drawings. All accessible cadweld splices shall be visually examined in accordance I with Section 4.3 of this procedure.
4.3. Visual Examination E Each visible completed cadweld splice shall meet all of the i following requirements in order to satisfy the acceptance I requirement. It shall be the responsibility of the PST to originate any deficiencies vith design requirements in accordance with PMP 1.07 on a Corrective Action Request (CAR). The PSI Level II Inspectors are responsible for assuring that the nonconformances are I documented accurately with the findings of the PST and are responsible for signing the signature block labelled " Initiator".
NOTE: For SPP-6 deficiencies, it shall be noted in the " Method of I Discovery" block on the CAR Form that the deficiencies were discovered by SPP-6 PST. The control of the nonconformances (CARS) shall be in accordance with FMP 1.07 af ter the origination of the CAR by the PST. Numbers for the CARS shall be obtained by the PSI Ilg Superintendent of Civil Quality Engineering from the Nonconformance Computer Coordinator.
I;
MARBLE HILL GEN 2 RATING STATION D:te 06-04-80 PUBLIC SPECIAL PROCESS PROCEDURE Revkion Page 4 of 3
7 SERVICE
~~Title:~~
l lNDIANA '
SPP-6 MECHANICAL (CADWELD) SPLICES A. Filler metal shall be visible at the end(s) of the splice I.
sleeve and at the tap hole in the center of t.he sleeve. l Filler metal shall not be recessed more than 1/2 :r.ch from the end of the sleeve.
B. Splices shall not contain slag or porous metal in the tap hole or at the end(s) of the sleeves. If there is any doubt as to whether filler metal or slag is in the tap hole, scratch the material with a punch or file, filler metal will shine while slag will remain dull. If slag is found, the Inspector shall remove slag at the tap hole and search for filler metal. If the slag does not penetrate beyond the wall thickness of the sleeve, it shall not be cause for rejection. If slag penetrates beyond the wall thickness of the sleeve, the splice shall be rejected. A single bubble, widely dispersed bubbles, l pinholes, cracks, fissure-seams or cold joints present in the filler metal in the tap holes or the sleeve ends need not be construed as failing to satisfy the acceptance criteria.
Areas with porous texture simulating the appearance of a sponge or honeycomb with sharp edges and projections around the porosity at the end of the spliced sleeve, shall be considered as general porosity and cause for rejection.
Should the Physical Survey Team notice a tap hole " burnout" (irregular shaped tap hole), and some filler metal spill from the tap hole onto the outside of the sleeve, the PSI Project Engineering Group should be contacted for a disposition on the acceptance or rejection. Acceptance or rejection shall be noted on the cedweld Visual Examination Chart (Attachment 2).
C. The total void area at each end of the sleeves shall not exceed the following limits (for splicing bars up to grade 60):
a) for #18 bars - 2.65 sq. inches l
b) for #14 bars - 2.00 sq. inche s i c) for #11 bars - 1.5 sq. inches
! d) for #10 bars and splice Catalog Number RBT-10101 (H) - 1.58 sq. inche=
e) for #10 bars in general and Or bars #9, #8, #7, and #6 - 1.03 sq. inches il l
f) for #5 bars - 0.53 sq. inches g) for #4 bars - 0.47 sq. inches Il '
,y .
l
I l 5 MARBLE HILL GENERATING STATION Date 06-04-80 l PUBLIC SPECI AL PROCESS PROCEDURE Revision 3 (
I '- ' '
sesvice m e.
INDIANA SPP-6 MECHANICAL (CADWELD) SPLICES l
~~1. The total void area at each end of the sierves when transition sleeves are used shall not exceed the limits in 4. 3.C above , except that 30 sq.~~
inches shall be used for #18 oars instetz ' 2.65 I sq. inches for #14 to ft18 and #11 to #18 .rensition splices. The total void area for #10 to #18 trans-itio. splices shall not exceed 2.65 sq. inches at I each end. Should the calculated void area not satisfy the above requirements, the cadseld shall be rejected. The rejection shall be noted on the Cadweld Visual Examination Chart (Attachment 2).
j I 2. The recession and area of spot void is indicated in Figure 1 on Attachment 1. The area of void shall be computed using the fol; awing fomula:
V= W(D-a) + P(a-3/16) where W(D-a) = area of a spot void greater than 1/2
! inch.
W(D-a) = summation of the area of all spot voids at the end under coasideration.
p(a-3/16) = average weld area of filler metal
~~recessed more than 3/16 inch.~~
! V = total void area a = filler metal recession is defined as the average depth of the filler metal determined f rom at least four approximately equally spaced probe measurements, excluding spot voids greater than 1/2 inch, and rounded to the nearest ./16 'och.
Note: When a, is calculated to be less than 3/16",
'I the value 3/16" shall be used for a in the void area computation.
D = spat void maximum depth greater than 1/2 inch,
'I rounded to the nearest '/16 inch.
W = spot void maximun width measured on bar surface at a depth a,from the edge of the sleeve, rounded to the I c aearest 1/16 inch.
R-P = nominal bar perimeter as indicated in Attachment 2.
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I MARBLE HILL GENERATING STATION cate 06-04-80 w PUBLIC SPECIAL PROCESS PROCEDURE Revision 6 of 3
7 lPage SERVICE
~~Title:~~
l lNDIANA SPP-6 MECHANICAL (CADWELD) SPLICES D. If the splice to be examined does not have visible gage marks, the Physical Survel Team shall make an applicable comment on +
the Cadweld Visual Examination Chart. The minimum embedment of the reinforcing bars shall be verified in the following manner:
a. The distance between the Cage Marks for a type "T" splice shall be 24 1/4 inches + 1/2 inch. (In cases l where the 12" Gage length was not prsctical, dif ferent E dage lengths may be used following the procedure specified in Paragraph 3.5 and 5.3.6a of Sargent &
Lundy Specification Form BY/BR/MCS, Rev. 7).
The centerline of the distance between the Gage Marks shall fall within the diameter of the tap hole (See Figure 2 on Attachment 1).
~~b. The distance between the Gage Line and the structural steel plate or shape for a type "B" splice l shall be 12 + 1/2 inches.~~
, m E. The Physical Survey Team shall attach a weatherproof tag to each splice which is visually inspected and rejected. The tag shall contain the signature (s) of the person (s) who actually inspected the splice, the date of the inspection, and the splice number. If the splice is rejected, then a spot of red enamel paint shall be sprayed on the splice and the word
" Reject" shall be written on the splice mapping drawing. If the splice meets the requirements of Section 4.3, it shall be considered acceptable and the splice shall be sprayed with a spot of yellow enamel paint. In addition, the word " Accept" shall be written on the cadweld splice mapping drawing. The acceptance or rejection shall be noted on the Cadweld Visual Examination Chart (Attachment 2). ,
l 4.4 Documentation ,
Visual cadweld inspection data shall be recorded on the Cadweld Visual l Examination Chart (Attachment 2).
4.5 Records Forms for this reinspection are quality records. In addition to their being mair.tained as quality documents, the complete set shall be j maintained separately until the results of the reinspection have been j ,
evaluated and authorization for :onstruction has been received. W R '
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l 5 MARBLE HILL GENERATING STATION Date 06-04-80 3
l PUBLIC SPECI AL PROCESS PROCEDURE Revision
" 7 at 7 \
, SERVICE Title.
INDIANA SPP-6 MECHANICAL (CADWELD) SPLICES 5.0 .IFERENCES 5.1 PMP 5.16, "Special Process Procedures", Rev. O. Marble Hill Nuclear Generating Station, Public Service Indiana.
5.2 ANSI N45.2.6-1973, " Qualifications of Inspection, Examination, and Testing Personnel for the Construction Phase of Nuclear Power Plants,"
ASME, New York, New York.
5.3 Sargent & Lundy Specification Y-2722, " Concrete Structures and Site Work," Marble Hill Nuclear Generat ng Station - Units 1 and 2, Amendment 4, 10-30-74, Public Service Indiana.
5.4 Sargent & Lundy Form BY/BR/MCS, Rev. 7, " Specification for Making and Inspecting Mechanical (Cadweld) Splices".
6.0 ATTACH.W NTS EFFECTIVE DATE 6.1 Attachmeat 1 - Figure 1, " Void Area Computation" 05-09-80 I - Figure 2, " Type "T" Splice Embedment Dimensions" 05-09-80 6.2 Attachment 2 - Cadweld Visual Examination Chart 06-04-80 I
I i l I l I
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l 3 5
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~2 MAnBLE HILL GENEnATING STATION cete o g,9_g,
'" O .PUBLIC srEciAt enocEss enccEoune Page 1 of 1
--- _!7 / - SERVIC:I
~~Title:~~
(O d INDIANA SPP-6 !!EtilA!.!LAL (CAD'.4 ELD) S P LI CE.S ATTACliMENT 1 fit.;URE 1, "*.'01D AREA CC:tPUTAT10:;"
FICtfRE 2 " TYPE "T" SPLICE EMLED::EMT DIMENSIONS" g Except for voids, "a" shall not bc
, more than is (see 4.3.C.2)
Tap Hole -
17/ thin rinir,'mr?'im d
~
=
,//, 's .;. I7//Mdj '
(
?/,('.,, 't ,
b' . 'ik p['- * [ f ' V
,fi .,0
' , %g --
4 o
7s, pa'( 3 ; m, ' -
\rcinforcing bar l 8 P ' #E " E"" "# "
Filler !!etal r 3
'h ~
_D. ~
Y3/16" = ::orr.al filler catal recession due to l packi:.g c.aterial l
VOID AREA CC:!PUTATION FIG'JRE 1 l
@ of distance between Cage Marks shall f all within the diarcter of the tap hc>1e 241" t + 1" I
t Tap Hole Cadweld Sleeve I s . 4 i
% _ s. ' ' ' , . it - ,
t .
h \ \_\_, / , ~/ -
i l l l,
"E" "# Sleeve Length (in) (""E#
Reinforcing Bar Reinforcing 1:ar
' E-3 ,
(T TYPE "1" SPL!CE C3ED:':';I D1:!E::SIO:;S :
[
FIGURE 2 ,,
l tu - .. . _ . _ _ _ . . _ __ _ . _ _ _ j l
I
I MARBLE HILL GENERATING STATION Date 06-04-80 j;g PUBLIC SPECIAL PROCESS PROCEDURE ,
SERVICE
~~g. c p, _~~
~~Title:~~
v'4 a
" INDIANA SPP-6 MECHANICAL (CADWELD) SPLICES I
ATTACl21EST 2 I CADUELD VISUAL EXA!!INATICN CILGT I !!arble Hill Nuclear Generating Station Report 50.
Splice No.
Splice Location Buildin3 Location:
I Splice Type "T" Distance 3etween Cage Lines.
0"5" O vertical O :w" +.5" O norizontal O 1:" t.5" Got=<enat Docher Otraas I
, Center line of sleeve centered between gage lines Yes CNo N/A X UDS Filler !:etal visible Yes O!:0 TAP HOLES O Y*= ::
.h
Slag visible.'Fourous !!etal INDS C Yes CNo TAP HOLES Cyes O so Filler recess in execss of inch C Yes O No (if ve=. reject ta)
'I o ( of Tap Hole- tm ;_ } (Place as-neasured vabes
! $g N ,
wma 1 on these sketches) 4 F" i k ,, J, , ) ' i cal'"'.ATIO:: OF VOID AREA TOR CNE SLEEVE ESD al= ia.
~~in. Perineter P =~~
a2= in. "a" avg. = al + a + a3 + a4 4 .
, a3= in. W= in. "a" avg. = in, aver. depth W a4 = in. V=
?(D-a] + P("a" - 3/16)
Depth of Void D= V=
I in. D= in. sq. it.ches Width of said W= in. k'=_ in.
, Bar Peri eter Acceptable Criteria Acc. Criteria for Trans. Srlices
= 0 810 aar - 3 99 in- O #ti nar 1.50 ss. in. OriotoisBar2.6ssq. in.
~~11 3ar = 4.43 in. C#14Dar=2.00sq. in. '~~
Oetttolarar2oo=9- in.
^
C#14Bar=5.32in. O*2asar-2.6s=9- in- *i to is nar 2.00 sq. in.
I VISC!L CX/JtI;ATIO:: R ES ULTS O Accret O outs sot ::ttT sr'ctrtc^T tex SICNAIURES OF P;t'l';ICAL SUPVf.YURS
_ _ DATE DATE
_DA;E w DA!L h.
c
' 2.".Cd 5 l:a
I I
Source: Iridium 192 Source Strength: 35 to 50 curies I
Source Size: .1" x .1" Exposure Time: 4 to 9 minutes depending on geometric factors.
I Film Type and Manufacturer: Eastman Kodak AA (Class II)
Film Size: 7" x 17" Radiographic Screens: .010 Lead Front and Back Film Density: L.0 to 4.0 Materist Thickness: 2-l/2" to 3-3/4" Processing: Automatic Processor Film Identifiction: Film is identified with the unique ident- g ification for each splice, e.g., TV-101 or ,g BV-101. This identification is permanently marked on the film, and the unique ident-ification is on a tag affixed on the splice.
I ATTACHMENT 6.6.2 RADIOCRAPHIC TECHNIQUE FOR CADWELD SPLICES j I
I l I
m W W m m m- m a m m m m' a m mmm W .m REJECTION CRITERIA SLEEVE GAUGE MARKS GAUGE MARKS SPLICE NO GAUGE NOT EXCEED LESS T lN RT NO. MARK TYPE SIZE MARK CENTERED TOLERANCE TOLERANCE PERFORMED 1 TV 9 T #18-#10 X 2 TV 14 T #18-#10 X 3 TV 15 T #18-#10 X 4 TV 18 T #18-#10 X 5/8" 5 TV 20' T #18-#10 X 6 TV 21 T #18-#10 X 7 TV 23 T #18-#10 X '
8 TV 26 T #18-#10 X 9 TV 28 T #18-#10 X 10 TV 31 T #18-#10 X 11 TV 32 T #18-#10 X 12 TV 36 T #18-#10 X 13 TV 37 T #18-#10 5/8" 14 TV 39 T #18-#10 5/8" 15 TV 40 T #18-#10 X 1 1/4" 16 TV 41 T #18-#10 3/4" X 17 TV 42 T #18-#10 X 18 TV 44 T #18-#10 X 19 TV 48 T #18-#10 X 20 TV 49 T #18-#10 X 21 TV 50 T #18-#10 X 22 TV 51 T #18-#10 1 1/8" X 23 TV 52 T #18-#10 X 24 TV 54 T #18-#10 X 25 TV 55 T #18-#10 X 3 1/2" X 26 TV 59 T #18-#10 X 1 1/8" 27 TV 65 T #18-#10 5/8" 28 TV 66 T #18-10 3/4" 29 TV 68 T #18-#10 X 30 TV 73 T #18-#10 X X 31 TV 74 T #18-#10 X ATTACllMENT 6.6.3 Page 1 o f 14
~~SUMMARY~~
OF GAUGE MARKS REJECTIONS AND RADIOGRAPil LOCATIONS
REJECTION CRITERIA SLEEVE GAUGE MARKS GAUGE MARKS SPLICE NO GAUGE NOT EXCEED LESS THAN RT NO. MARK TYPE SIZE MARK CENTERED TOLERANCE TOLERANCE PERFORMED 32 TV 75 T #18-10 3/4" X 33 TV 77 T #18-#10 X 1 1/4" X 34 TV 78 T #18-#10 3/4" 35 TV 79 T #18-#10 x 6 1/4" X 36 TV 80 T #18-#10 3/4" 37 TV 81 T #18-#10 X 38 TV 82 T #18-#10 X 3/4" X R 39 TV 85 T #18-#10 X X 40 TV 87 T #18-#10 X 41 TV 88 T #18-#10 X 42 TV 92 T #18-#10 -X 43 TV 93 T #18-#10 X 3/4" 44 TV 94 T #18-#10 X 45 TV 96 T #18-#10 X 46 TV 97 T #18-#10 X 47 TV 102 T #18-#10 X 48 TV 104 T #18-#10 3/4" 49 TV 105 T #18-#10 X 50 TV 107 T #18-#10 X 51 TV 110 T #18-#10 3/4" 52 TV 155 T #18-#10 X 53 TV 159 T #18-#10 X 54 TV 160 T #18-#10 X 55 TV 161 T #18-#10 X 56 TV 171 T #18-#10 X X 57 TV 184 T #18-#10 Y 1 1/8" 58 TV 192 T #18-#10 X 1 1/2" 59 TV 193 T #18-#10 3/4" 60 TV 194 T #18-#10 1 5/8" 61 TV 196 T #18-#10 3/4" 62 TV 198 T #18-#10 X ATTACHMENT 6.6.3 (Cont'd) Page 2 of 14
~~SUMMARY~~
OF GAUGE MARKS CEJECTIONS AND RADIOGRAPil LOCATIONS mM M M W m W M M M M M M mW m M M
U M M M M M M M' M M M M M M M W W W M REJECTION CRITERIA SLEEVE GAUGE MARKS GAUGE MARKS SPLICE NO GAUGE NOT EXCEED LESS TilAN RT NO. MARK TYPE SIZE MARK CENTERED TOLERANCE TOLERANCE PERFORMED 63 TV 211 T #18 X 64 TV 212 T #18 3/4" 65 TV 213 T #18 X X 66 TV 215 T #18 X 67 TV 216 T #18 X 68 TV 224 T #18-#10 1" 69 TV 230 T #18-#10 X 70 TV 235 T #18-#10 X X 71 TV 237 T #18-#10 3/4" 72 TV 238 T #18 X 73 TV 242 T #18-#14 X 74 TV 245 T #18 X 75 TV 251 T #18 X 7i TV 254 T #18-#14 X 77 TV 258 T #18-#14 1" 78 TV 269 T #18 X 79 TV 271 T #18 X 80 TV 275 T #18 X 81 TV 283 T #18-#14 3/4" 82 TV 284 T #18-#14 3/4" 83 TV 295 T #18 X 84 TV 297 T #18 X 85 TV 301 T #18 X 86 TV 303 T #18 X 87 TV 305 T #18 X 88 TV 307 T #18 X 89 TV 317 T #18-#11 X 90 TV 327 T #18-#11 X 9L TV 334 T #18-#11 X 92 TV 339 T #18-#10 X 3/4" X 93 TV 341 T #18-#10 5/8" X ATTACllMENT 6.6.3 (Cont'd) Page 3 of 14
~~SUMMARY~~
OF GAUGE MARKS REJECTIONS AND RADIOGRAPil LOCATIONS
REJECTION CRITERIA SLEEVE GAUGE MARKS GAUGE MARKS SPLICE NO GAUGE NOT EXCEED LESS TIIAN RT NO. MARK TYPE SIZE MARK CENTERED TOLERANCE TOLERANCE PERFORMED 94 TV 343 T #18-#10 3/4" X 95 TV 349 T #18-#10 1 1/8" 96 TV 351 T #18-#10 X 3/4" 27 TV 352 T #18-#10 X 98 TV 354 T #18-#10 X 13/16" 99 TV 356 T #18-#10 X 100 TV 358 T #18-#10 3/4" X 101 TV 360 T #18-#10 3/4" X 102 TV 364 T fl8-#10 3/4" 103 TV 365 T #18-#10 3/4" 104 TV 366 T #18-#10 3/4" X 105 TV 370 T #18-#10 X L 1/8" X 106 TV 375 T #18-#10 X 107 TV 377 T #18-#10 X 108 TV 379 T #18-#10 X 109 TV 401 T #18-#10 X 110 TV 403 T #18-#10 X 111 TV 417 T #18 3/4" 112 TV 425 T #18 X 113 TV 436 'a #18-#14 X 114 TV 437 T #18 X 1" 115 TV 440 T #18-#14 X 3/4" X 116 TV 441 T #18 X 117 TV 454 T #18-#14 1 1/4" X 118 TV 459 T #18 X 1" 119 TV 461 T #18 X 120 TV 471 T #18 X 121 TV 473 T #18 X 1" 122 TV 480 T #18-#14 5/8" 123 TV 501 T #18-#10 X 124 TV 506 T #18 X (See Note 1)
~
ATTACHMENT 6.6.3 (Cont'd) Page 4 of 14 SUHMARY OF GAUGE MARKS REJECTIONS AND RADIOGRAPH LOCATIONS m M M M W W W M- M m M M M M M W W M M
M M M M M M M M M M M M M M M M W W M REJECTION CRITERIA SLEEVE GAUGE MARKS GAUGE MARKS SPLICE No GAliGE NOT EXCEED LESS THAN RT NO. MARK TYPE SIZE MARK CENTERED TOLERANCE TOLERANCE PERFORMED 125 TV 532 T #18 X 126 TV 533 T #18 X 3/4" 127 TV 535 T #18 X 12d TV 536 T #18 X 129 TV 548 T #18 X 130 TV 550 T #18 X 131 TV 551 T #18 X 132 TV 552 T #18 X 133 TV 555 T #18 X 134 TV 558 T (18 X 135 TV 561 T #18 X 136 TV 563 T #18 X 137 TV 565 T #18 X 138 TV 580 T #18 3/4" 139 TV 581 T #18 X 140 TV 587 T #18 X 141 TV 590 T #18 X 142 TV 604 T #18 X 143 TV 607 T #18 X 3/4" 144 TV 613 T #18 X 145 TV 614 T #18 X 146 TV 615 T #18 X 147 TV 618 T #18 X 148 TV 624 T #18 X 149 TV 626 T #18 X 150 Tv 629 T #18 x 151 TV 632 T #18 X 1 1/4" 152 TV 635 T #18 X 153 TV 648 T #18 X 154 TV 652 T #18 X 155 TV 654 T #18 X (See Note 1)
ATTACHMENT 6.6.3 (Cont'd) Page 5 of 14
~~SUMMARY~~
OF GAUGE MARKS REJECTIONS AND RADIOGRAPH LOCATIONS
REJECTION CRITERIA SLEEVE GAUGE MARKS GAUGE MARKS SPLICE NO GAUGE NOT EXCEED LESS TilAN RT NO. MARK TYPE SIZE MARK CENTERED TOLERANCE TOLERANCE PERFORMED 156 TV 668 T #18 X 157 TV 670 T #18 X L58 TV 679 T #18 X 159 TV 680 T #18 X 160 TV 681 T #18 X 161 TV 684 T #18 X 162 TV 695 T #18 X 163 TV 700 T #18 X 164 TV 712 T #18 X X 165 TV 717 T #18 X 166 TV 721 T #18 X 167 TV 723 T #18 X 168 TV 725 T #18 X 169 TV 729 T #18 1 1/4" X 170 TV 741 T #18 1" 171 TV 742 T #18-#14 X 172 TV 743 T #18 5/8" 173 TV 745 T #18 L" 174 TV 751 T #18 1 1/4" 175 TV 752 T #18-#14 X 176 TV 753 T #18 X 177 TV 757 T #18 X R 178 TV 759 T #18 X 179 TV 76L T #18 X 180 TV 768 T #18-#14 X 18L TV 769 T #18 X 182 TV 771 T #18 X 183 TV 773 T #18 X 3/4" 184 TV 775 T #18 X 185 TV 777 T #18 X 1 1/2" (See Note 1) 186 TV 779 T #18 X ATTACllMENT 6.6.3 (Cont'd) Page 6 o f 14
~~SUMMARY~~
OF GAUGE MARKS REJECTIONS AND RADIOGRAPil LOCATIONS
W W W M M M M W M W W W m M M M M W W REJECTION CRITERIA SLEEVE GAUGE MARKS GAUGE MARKS SPLICE NO GAUGE NOT EXCEED LESS THAN RT NO. MARK TYPE SIZE MARK CENTERED TOLERANCE TOLERANCE PERFORMED 187 TV 781 T #18 X 188 TV 785 T #18-#14 X 189 TV 791 T #18 X 190 TV 795 T #18 X 191 TV 797 T #18 X 192 TV 799 T #18 X 193 TV 801 T #18 X 194 TV 807 T #18 X 195 TV 809 T #18 X 196 TV 811 T #18 X 197 TV 813 T #18 X 198 TV 817 T #18 X 199 TV 820 T #18 X 200 TV 821 T #18 X 201 TV 824 T #18 X 202 TV 829 T #18 X 203 TV 831 T #18 X 204 TV 833 T #18 K 205 TV 838 T #18 X ..s 206 TV 839 T #18 X -
207 TV 840 T #18 X 3/4" 208 TV 842 T #18 X 209 TV 843 T #18 X 210 TV 845 T #18 X (See Note 1) 211 TV 847 T #18 X 212 TV 848 T #18 X 213 TV 849 T #18 X 214 TV 853 T #18 X 215 TV 854 T #18 X 216 TV 857 T #18 X 217 TV 860 T #18 X ATTACl! MENT 6.6.3 (Cont'd) Page 7 of 14
~~SUMMARY~~
OF GAUGE MARKS REJECTIONS AND RADIOGRAPH LOCATIONS
REJECTION CRITERIA SLEEVE GAUGE HARKS GAUGE HARXS SPLICE NO GAUGE NOT EXCEED LESS TilAN RT NO. HARK TYPE SIZE HARK CENTERED TOLERANCE TOLERANCE PERFORMED 218 TV 863 T #18 X 219 TV 867 T #18 X 220 TV 869 T #18 X 7/8" 221 TV 879 T #18 X 222 TV 887 T #18 X 223 TV 890 T #18 X 224 TV 893 T #18 X 225 TV 902 T #18 x 226 TV 910 T #18-#14 X 227 TV 911 T #18 X 228 TV 912 T #1E -#14 X X 229 TV 913 T #18 X 230 TV 914 T #18-#14 X 1" 231 TV 915 T #18 X 232 TV 917 T #18 X 233 TV 922 T #18-#i4 X 234 TV 924 T #18-#14 X 235 Tv 926 T #18-#14 X 236 TV 928 T #18-#14 X 237 TV 930 T #18-#14 X 238 TV 932 T #L8-#14 X 239 TV 934 T #18-#14 X 240 TV 939 T #18-#14 X 241 TV 940 T #18-#14 X 3/4" 242 TV 941 T #18-014 X 243 TV 943 T #18 3/4" 244 TV 945 T #18 7/8" 245 TV 947 T #L8 X 246 TV 957 T #18 X 247 TV 958 T #18-#14 X 248 TV 959 T #18-#14 X 1" X ATTACHMENT 6.6.3 (Cont'd) Page 8 o f 14
~~SUMMARY~~
OF GAUGE MARKS REJECTIONS AND RADIOGRAPil LOCATIONS M W W M W M M M M .M M M W W W W wM M W
M M M M M M M M M M M m M M M M M M M REJECTION CRITERIA SLEEVS GAUGE MARKS GAUGE MARKS SPLICE NO GAUGE NOT EXCEED LESS TilAN RT NO. MARK TYPE SIZE MARK CENTERED TOLERANCE TOLERANCE PERFORMED 249 TV 965 T #18 3/4" 250 TV 967 T #L8 X 3/4" 251 TV 971 T #18 X 3/4" 252 TV 975 T #18 x 253 Tv 983 T #18 x 254 TV 986 T #18-#14 X 255 TV 989 T #18-#14 X 256 TV 990 T #13 X 257 TV 993 T P13 X 258 TV 10lt T #18 1" 259 TV 1015 T #t8-#10 X 260 TV 1017 T #18-#10 X X 261 TV 1024 T #18-#10 15/16" 262 TV 1025 T #18-#10 X 2 1/4" 263 TV 1029 T #18-#10 X X 264 TV 1052 T #18-#10 8 1/4" X 265 TV 1053 T #18-#10 L 1/4" 266 TV 1054 T #;8-#10 3/4" 267 TV 1055 T #t8-#10 1 3/8" 268 TV 1057 T #18-#10 3/4" 269 TV 1064 T #18-#10 X L 1/4" 270 TV 1066 T #L8-#10 X 271 TV 1068 T #18-#10 X 272 TV 1069 T #18-#10 X 273 TV 1072 T #18-#10 3/4" 274 TV 1073 T #18-#10 X 275 TV 1083 T #18-#10 X 276 TV 1084 T #18-#LO X 277 TV 1091 T #18-#10 13/16" 278 TV 1095 1 #18-#10 X 279 TV 1096 T #18-#10 X ATTACitMENT 6.6.3 (Cont' d) Page 9 of 14
~~SUMMARY~~
OF GAUGE MARKS REJECTIONS AND RADIOGRAPil LOCATIONS
REJECTION CRITERIA SLEEVE GAUGE MARKS GAUGE MARKS SPLICE NO GAUGE NOT EXCEED LESS THAN RT NO. MARK TYPE SIZE MARK CENTERED TOLERANCE TOLERANCE PERFORMED 280 TV 1100 T #18-#10 3/4" 281 TV 1101 T #18-#10 1" 282 TV 1102 T #18-#10 3/4" 283 TV 1103 T #18-#10 1" 284 TV 1105 T #18-#10 1 1/4" 285 TV 1106 T #18-110 1" 286 TV ILO7 T #18-#10 X 287 TV IL16 T #18-#10 5/8" 288 TV 1117 T #18-#10 11/16" 289 TV 1121 T #18-#10 3/4" X 290 TV 1131 T #18 8 1/4" (See Note 1) 291 TV 1132 T #18 7 5/8" 292 TV 1133 T #18 8 1/4" (See Note 1) 293 TV 1134 T #18 X 4 1/4" X 386 TV 467 T #18 3/4" R ATTACHMENT 6.6.3 (Cont'd) Page 10 of 14
~~SUMMARY~~
OF GAUGE MARKS REJECTIONS AND RADIOGRAPH LOCATIONS M M M M M M M M M W W W M M M M M M M
W W M M M M M M M M M M M M M M W M M REJECTION CRITERIA SLEEVE GAUGE MARKS GAUGE MARKS SPLICE NO GAUGE NOT EXCEED LESS TilAN RT NO. MARK TYPE SIZE MARK CENTERED TOLERANCE TOLERANCE PERFORMED 294 Til 26 T #9 X X 295 Til 28 T #9 X X 296 Til 29 T #11 X 297 Til 31 T #11 X 298 Til 33 T #11 X 299 Til 41 T #L1 X 300 Til 43 T #11 X X 301 Til 47 T #LL X 302 Til 49 T #11 X 303 Til 53 T #11 X NOTE: Til-23 was not rejected but was radiographed as a control test for inaccessible splices. R ATTACilMENT 6.6.3 (Cont'd) Page 11 of 14
~~SUMMARY~~
OF GAUGE MARKS REJECTIONS AND RADIOGRAPil LOCATIONS . . .
i REJECTION CRITERIA SLEEVE GAUGE MARKS GAUGE MARKS SPLICE NO GAUGE NOT EXCEED LESS TilAN RT NO. MARK TYPE SIZE MARK CENTERED TOLERANCE TOLERANCE PERFORMED 304 BV 62 B #18 X X 305 BV 74 B #18 X
306 BV 98 B #11 3/4" 307 BV 133 B #1L X X 308 BV 175 B #11 X 309 BV 2L5 B #LL X 310 BV 219 3 #1L X 31L BV 220 B #11 X 312 BV 222 B #11 X 313 BV 236 B #11 X X 314 BV 339 B #18 X 315 BV 350 B #18 X X 316 BV 356 B #18 X X 317 BV 361 B #18 X 318 BV 366 B #18 X 319 BV 377 B #1L X X 320 BV 378 B #1L X 321 BV 389 B #1L X 322 BV 410 B #1L . X 323 BV 421 B #11 X 324 BV 462 B #11 X 325 BV 483 B #11 X 326 BV 485 B #11 X X 327 BV 488 B #1L X X 328 BV 506 B #11 X 329 BV 507 8 #11 X 330 BV 508 B #11 X 331 BV 530 B #LL X 332 BV 533 B #11 X 333 BV 536 B #11 3/4" 334 BV 539 3 #11 X X ATIACllMENT 6.6.3 (Cont'd) Page 12 of 14
~~SUMMARY~~
OF GAUGE MARKS REJEr? IONS AND RADIOGRAPil LOCATIONS M M M M M M M M M M M M W W W W W M M
m W W W ma m M M M M M M m m M M W M REJECTION CRITERIA SLEEVE GAUGE MARKS GAUGE MARKS SPLICE N0 GAUGE NOT EXCEED LESS THAN RT NO. MARK TYPE SIZE MARK CENTERED TOLERANCE TOLERANCE PERFORMED 335 BV 587 B #11 X 336 BV 605 B #11 X X 337 BV 606 B #1L 3/4" 338 BV 614 B #11 X 339 BV 633 B #L8 X 340 BV 638 8 #18 X 341 BV 640 B #L8 X 342 BV 655 8 #11 X -
343 BV 66L B #LL X 344 BV 665 B #11 X X 345 BV 667 n #1t X 346 BV 668 B #11 X 347 BV 669 8 #11 X 348 BV 670 B #11 X X 349 BV 675 B #LL X 350 BV 683 8 #11 X 351 BV 706 B #11 X 352 BV 7L3 8 #11 X 353 BV 714 B #L1 X 354 BV 719 B #11 X 355 BV 720 B #11 X 356 BV 721 B #11 X 357 BV 722 B #11 X 358 BV 724 8 #11 X 359 BV 755 B #11 X X 360 BV 757 B #LL X X 361 BV 759 8 #11 5/8" X 362 BV 760 B #11 X 363 BV 761 B #11 X 364 BV 765 B #11 X 365 BV 767 B #11 X ATTACHMENT 6.6.3 (Cont'd) Page 13 of 14
~~SUMMARY~~
OF GAUGE MARKS REJECTIONS AND RADIOGRAPH LOCATIONS
REJECTION CRITERIA SLEEVE GAUGE MARKS GAUGE MARXS SPLICE NO GAUGE NOT EXCEED LESS TRAN RT NO. HARK TYPE SIZE HARK CENTERED TOLERANCE TOLERANCE PERFORMED 366 BV 768 B #11 X X 367 BV 816 B #ll X X 368 BV 820 B #11 1" X 369 BV 823 B #ti 5/8" X 370 BV 827 B #11 X X 371 BV 828 B #l1 3/4" X 372 BV 837 #11 X X 373 BV 848 B #1L X 376 BV 883 B #11 X 375 BV 884 B #11 X 376 BV 885 B #11 X 377 BV 886 B #11 X 378 BV 911 B #11 X X 379 BV 920 B #11 2 1/2" X 380 BV 92L B #11 X 381 BV 930 B #11 X 382 BV 958 8 #11 5/8" 383 BV 1035 B #L1 X 386 BV 1122 8 #18 1 1/4" X 385 BV 549 8 #11 9/16" R NOTE 1 - This splice was subjected to radiographic testing (RT) and failed to meet the criteria. This splice was subsequently tensile tested. The tensile test shows that it is acceptable. Refer to Attachment 6.6.4.8 for tensile test results.
NOTE - BV-63 was radiographed (RT) because it had two gage marks, one in tolerance and one exceeding tolerance. R The RT met the embedment criteria.
4 ATTACHMENT 6. 6. 3 (Cont' d) Page 14 of 14
~~SUMMARY~~
OF GAUGE MARKS REJECTIONS AND RADIOGRAPH LOCATIONS e W W W W m M M M M M M M M M M m mW
I I TENSILE I VOIL AREA TEST NO. MARK NO. TYPE SIZE (SQ. INCH) RESUL'i 1 BV 742 B ell 4.91 92,564 1si ,
2 BV 796 B #11 4.49 102,308 psi l 3 BV 266 B #11 4.38 I 4 5
6 BV 814 BV 694 BV 580 B
B P
11
11
~~11 4.13 4.12 3.45 l~~
I 7 8
9 BV 730 BV 855 BV 861 B
B B
11
11
~~11 3.05 3.05 3.05 10 BV 788 B #11 2.97 5 11 BV 1053 B #11 2.96 12 BV 299 B #11 2.92 13 BV 268 #11 2.91 I~~
B 14 BV 579 B #11 2.88 15 BV 256 B #11 2.82 16 BV 419 B #11 2.62 17 BV 296 B #11 2.58 5 18 BV 1014 B #11 2.45 19 BV 298 B #11 2.39 20 BV 308 B #11 2.38 I 21 BV 255 B #11 2.34 22 BV 476 B #11 2.27 BV 844 #11 2.25 I
23 B 24 BV 932 B #11 2.10 25 BV 431 B #11 2.05 26 BV 378 B #11 2.01
, 27 BV 1013 B #11 2.00
'
28 BV 1023 B #11 2.00 29 BV 743 B #11 2.00 30 BV 449 B #11 2.00 5 31 BV 601 B #11 1.99 32 BV 257 B #11 1.97 BV 527 #11 1.83 I
33 B 34 BV 460 B #11 1.82 35 BV 724 B #11 1.81 36 BV 591 B #11 1.78 37 BV 720 B #11 1.75
=
38 BV 976 B #11 1.73 39 BV 1019 B #11 1.73 40 BV 4 B #11 1.72 5 41 BV 512 B #11 1.70 42 BV 510 B #11 1.66 1.63 I 43 BV 854 #11 B
44 BV 543 B #11 1.62 ATTACHMENT 6.6.4.1 )
SUMARY OF TENSILE TEST RESULTS SPLICES FAILING VISUAL INSPECTION DUE I
TO EXCESSIVE VOIDS I Page 1 of 3 1
I I l
I TEN 3ILE VOID AREA TEST NO. MARK NO. TYPE SIZE (SQ. INCH) RESULT 45 BV 158 B #11 1.62 46 BV 517 B #11 1.62 47 BV 511 B #11 1.61 48 BV 691 B #11 1.60 49 BV 961 B #11 1.59 50 BV 965 B #11 1.59 51 BV 541 B #11 1.57 105,000 psi E 52 BV 544 B #11 1.56 3 53 BV 374 B #11 1.56 54 BV 590 B #11 1.55 g 55 BV 262 B n1 1.55 5 56 BV 304 B #11 1 53 57 BV 428 B #11 1.53 58 BV 307 B #11 1.52 59 BV 744 B #11 1.50 60 BV 178 B #11 1.50 61 BV 626 B #18 3.59 101,000 psi 62 BV 68 B #18 2.97 99,750 psi 63 TV 174 I #18-#10 14.44 87,402 psi 64 TV 68 T #18-#10 5.91 99,591 psi 65 TV 91 T #18-#10 5.84 102,835 psi 66 TV 84 T #18-#10 5.46 67 TV 97 T #18-#10 4.75 68 TV 392 T #18-#10 4.68 69 TV 50 T #18-#10 4.49 g 70 TV 356 T #18-#10 4.42 3 71 TV 66 T #18-#10 4.30 72 TV 355 T vi8-#10 4.16 g 73 TV 373 T #18-#10 4.13 g 74 TV 177 T #18-#10 3.98 75 TV 230 T #18-#10 3.91 76 TV 494 T #18-#10 3.85 77 TV 367 T #18-#10 3.77 78 TV 378 T #18-#10 3.72 79 TV 1122 T #18-#10 3.71 3.56 3
g 80 TV 369 T #18-#10 81 TV 496 T #18-#10 3.56 82 TV 61 T #18-#10 3.51 3 83 TV 502 T #18-#10
~~18-#10 3.38 3.33 103,937 psi 5~~
~~84 TV 155 T~~
S TV 1062 T #18-#10 3.30 86 TV 1045 T #18-#10 3.28 ATTACINENT 6.6.4.1 'g SUMARY OF TENSILE TEST RESULTS m SPLICES FAILING . VISUAL INSPECTION DUE TO EXCESSIVE VOIDS Pbge 2 of 3 I
I l TENSILE W VOID AREA TEST NO. MARK NO. TYPE SIZE (SQ. INCH) RESULT 87 TV 1079 T #18-#10 3.26 88 TV 110 T #18-#10 3.19 TV 59 #18-#10 3.12 I 89 T 90 TV 340 T #18-#10 3.10 91 TV 56 T #18-#10 3.10 92 TV 384 T #18-#10 3.00 I 93 94 95 TV 338 TV 99 TV 46 T
T T
~~18-#10~~
~~18-#10~~
~~18-#10 2.90 2.86 2.75 I 96 97 98 TV 78 TV 65 TV 403 T~~
~~T T~~
~~18-#10~~
~~18-#10~~
18-#10 2.71 2.70 2.67 TV 401 #18-#10 2.66 I 99 T 100 TV 153 T #18-#10 2.87 100,787 psi 101 TV 433 T #18-#14 2.44 99,556 psi 102 TV 285 T #18-#14 2.38 84,445 psi 103 TV 560 T #18 3.52 97,500 psi i
. I
)
!I 1
'I
}
I i
I I
ATTACHMENT 6.6.4.1
,I SUMARY OF TENSILE TEST RESULTS SPLICES FAILINC VISUAL INSPECTION DUE TO EXCESSIVE VOIDS Page 3 of 3 I
I I EXCESSIVE TENSILE NO. MARK NO. TYPE SIZE RECESS TEST i (DEPTH IN.) RESULTG 1 TV 80 T #18-#10 0.95 102,205 psi 2 TV 153 T #18-#10 0.73 100,787 psi 3 TV 77 T #18-#10 0.73 4 TV 79 T #18-#10 0.73 l 5 TV 485 T #18-#10 0.69 5 6 TV 73 T #18-#10 0.59 7 TV 1041 T #18-#10 0.59 I
I I
I I
I I
E I
I I
g ATTACllMENT 6.6.4.2
~~SUMMARY~~
OF TENSILE TEST RESULTS 5 I SPLICES FAILING VISUAL INSPECTION DUE TO EXCESSIVE RECESS I
I TSNSILE
]I TYPE SIZE TEST RESULT NO. MARK NO.
~~18-#10 1 TV 7 0 T 95,276 psi 2 TV 93 T #18-#10 ;~~
j 3 TV 97 T #18-#10 l 4 TV 1020 T #18-#10 t
! 5 TV 434 T #18-#14 89,333 psi 6 TV 446 T #18-#14 l 7 TV 729 T #18 95,500 psi
, I 8 9
TV 856 TV 863 T
T
18
~~18 10 3V 519 B #11 4~~
I 11 12 BV 541 BV 571 BV 736 B
B
11
11
~~11 105,000 psi i 13 B j 14 TV 46 T #18-#10 R 1~~
~~I i~~
i I
!I
~~I 4~~
~~I i~~
~~I I _~~
ATTACRMENT 6.6.4.3
]'
~~SUMMARY~~
OF TENSILE TEST RESULTS SPLICES FAILING VISUAL INSPECTION DUE TO PCROSITY OF FILLER METAL I
I TENSILE g TEST g NO. MARK NO. TYPE SIZE RESULT 1 BV 22 S #11 l 2 BV 242 B #11 100,641 psi 3 BV 525 B #11 4 BV 1025 B #11 5 BV 757 B #11 94,872 psi 6 BV 635 B #18 100,000 psi 7 BV 1095 B #18 8 TV 19 T #18-#10 9 TV 34 T #18-#10 10 TV 70 T #18-#10 95,276 psi 11 TV 382 T #18-#10 12 TV 408 T #18-#14 92,444 psi 13 TV 410 T #18-#14 14 TV 412 T #18-#14 g 15 TV 416 T #18-#14 g 16 TV 432 T #18-#14 17 TV 433 T #18-#14 99,556 psi 18 TV 434 T #18-#14 89,333 psi l 19 TV 446 T #18-#14 l 20 TV 926 T #18-#14 21 TV 684 T #18 22 TV 873 T #18 23 TV 874 T #18 g 24 TV 890 T #18 97,500 psi 3 25 TV 979 T #18 26 TV 983 T #18 I
I I
I I
ATTACllMENT 6.6.4.4 g
~~SUMMARY~~
~~OF TENSILE TEST RESULTS g SPLICES FAILING VISUAL INSPECTION DUE TO SLAG AT TAP 110LE I~~
I
!g TENSILE 5 TEST NO. . iAR' . NO . TYPE SIZE RESULT 1 TV 729 T #18 95,500 psi 2 BV 742 B #11 92,564 psi
, 3 BV 1139 B #18 97,500 psi i
!I 1
i
!I
!E .
~~I i,I~~
!I 4
d 4
4 l
lI
I
~~,I ATTACllMENT 6.6.4.5~~
~~SUMMARY~~
OF TENSILE TEST RESULTS I SPLICES FAILING VISUAL INSPECTION DUE TO BURNED OUT IRREGULARLY I SHAPED TAP 110LES
1 I'
l TENSILE l I
TEST NO. MARK NO. TYPE SIZE RESULT 1 TV 87 T #18-#10 109,764 psi El l I
l ll E, i i
I l l
I Ii I I!
l, Il i Il l Il I l!
Ii i ATTACliMENT 6.6.4.6 E' 5j
~~SUMMARY~~
OF TENSILE TEST RESULTS
( SPLICES FAILING VISUAL INSPECTION l l DUE TO ABSENCE OF FILLER METAL
=l i
I TENSILE
W l TEST NO. MARK NO. TYPE SIZE RESULT 1 BV 1087 B #18 2 BV 1101 B #18 3 F -2* B #18 97,000 psi
!I I
iI
!I i
~I jI l 1
iI i
lI l
~~MU-2 is a mock up with two tap holes oriented similar to the as-built I condition found for BV 1087 and BV 1101 l~~
~~1 ATTACHMENT 6.6.4.7~~
~~SUMMARY~~
OF TENSILE TEST RESULTS l SPLICES FAILING VISUAL IN,SPECTION DUE l TO TWO TAP HOLES I
I TENSILE g TEST 5 NO. MARK NO. TYPE SIZE RESULT
~
1 TV 506 T #18 99,250 psi 2 TV 654 T #18 99,250 psi 3 TV 777 T #18 76,500 psi 4 TV 845 T #18 99,000 psi l 5 TV 1',31 T #18 89,750 pai L-6 TV 1133 T #18 97,750 psi I
I I
. I I
E I
I I
I I I I! l I!
ATTACHMENT 6.6.4.8 g ,
~~SUMMARY~~
OF TENSILE TEST RESULTS g SPLICES FAILING VISUAL INSPECTI0t: DUE i TO RADIOGRAPHIC TESTS S
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.1 I NSDECT[ON CAEWING U :se +~7e's~iLT . a n. ,,,u w .ar .rar . m ,,,,, . .., u.i t . - W,, . w., n,z ,n ese. , *~= = = = = - == 4 , j - I-l ,* tur. 4.sc4,Ta-_ - WHALEN / $ mL3,n ae , 1- ,o . n .a n a, . , ~ ,, - 1s , t 27. . : . , - CQwfAns'wansv T.As.4,4s,A.mtwr .. 8 eau g-,. w w.,r.aq .- - - . e e 4 o a 7. be 3 y e4 & * .l, T,;. ,,g g ,..

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1 M ,2 . _ _ . _ _ . * . , _ _ . ~ _ [" ,,,,,,,,,,, s t .,._m...,-. , . < , _ _m ,,, w . . .ua, .. ,- c.g , o ,n 2. .. L_,,, . . y r I I ; g 3 g g g g , y g g g g L, W3, .y . 4 lL T 3 I g 7 3 . . l- Ijg ,,<,.,,3 I . I MARBLE HILL GENERATING STATION cate 06-01.-80 I ( PUBLIC SERVICE Tit!e: SPECI AL PROCESS PROCEDURE Page 1 of 1 INDIANA I a SPP-6 MECHANICAL (CADL.TLD) SPLICES I ATTACRCT 2 CAWELD VIS1*AL EXNtINAT!CN CHART Marble Hill helear Generating Station Splice No.P/- Of T) Report !b.bkkh

lhl7 Splice Location h b Building Eneatten:4WT. % EM Vi M Splice Jype 2 *T" 0 " *" 2 veriscal O wartreatat Octa4a"=1 2 :raa=

m Distance Between Cage Lines @ 2 4'." +. '." O i:" + 'i Oot**r I .= Filler Y.etal visible Center line of sleeve centered between gare lines 1.:;cs @Yes Ow QYes rar i'o'c5 C Ns g v== va

a Slag visible /Pourous Metal I DCS O 'a Osa h t^r "ot:5 Ov== 2 .sa s

filler recess in excess of La inch 2 g O v'* C "a (tr re=. r 1 ci 'id) I2 Sir. jl o t, cf Tap Hole ' (Place as-reas red values 1 l'g ,9 N on these sketches) I I % ,, o , , _ i I,, ,p, ,, j h t e 4 ( , CALCtLA!!0N OF Vo!D AREA FOR ONE SLEEVE END al= $ in. De k in. Perimeter P = h* a2= $> in. "a" avg.

a1 + a2 + a3 + a4 a3= 2P in. W= in. "a" avg. = / in, aver. depts a4 = in. V* i(D.a + P("a" - 3/16)

~~Depth of Void Da n. D*N in. V= *hh sq. inches I~~

~~Width of Toid W=~~

~~fi a r Pe r J *e te r in. W= in. Acceptsble Criterit Acc. Criteria for TrAng. Solices @ f13 Bar = 3.99 in. C it! Dar~~

~~1.50 sq. in. @fl0to18Bar2.65sq. in.~~

O *ii nar '.41 in. ! O'ittoit. car 2.o0=9 0 8 ' nNfck. in. ta. Cd14Bar=3.32in. ; O'iaaar-2.65s,.sa. O < i '. t o la aar 2.00 sa. ta. I .. ... VISUAL CXA11 :Af!OM ftLLTS $1 Call RM Of hl7':! CAL M:RVF.YOKS Q ACCLM [ NI.S ;;0T ltCET S!'I CIFICATION JAM!Es D, CLGO4 _ _m:t 6 14 - Ro G.L. JODREY nur. 6-14-230 D. ISLACKwC.LL oAtt c,- u. 43o y _p at g - a p o" I . ATTACHM5hT G.G.C I EXAMPLE OF MARKED UP INSPECTION FORMS - I MARBLE HILL GENERATING STATION on. 06-04-80 C^ PUBLIC SPECIAL PROCESS PROCEDURE Page 1 of 1 SERVICE Titte: [ A INDIANA SPP-6 MECILU'ICAL (CAD'..T.LD) SPLICES ATTAC5.':UT 2 I CALUELD VIS: AL LWINATIC:4 CMART Mar,1e u ll suelear Ceeeratie, st. tion s, lice so. TV-lol- ( 20 Report W.6 PPG- 1311 A s,ttee tecation_ J $ M 1 But! ding teattom _(p h3 T. 2._ bY T* WbLt= Splice *ype $ i" Q"S" @ Vertical O dart >~ est Octavaat M ira '= m Distance Between Case Linet 8 24'." + 't O i: ' + 'i Oot,er - Center line of sleeve centered between sare lines 2Tes O sa :/A Osa :a Filler Metal vistble 1ACS @ Yes t^r "o'c5 Mv* 51as visibla'Pourous Metal DDS 05= Esa T^r "ot:5 05* 2 sa Filler recess in encess of 5 inch " O v*> O Sa (5' re . r=2 ce ta) ' I I D/A T I (Place as.reasured vales 4 fgo ' f~ ofTapHolelI m,f i on these sketches) { r i i ' !. 9, . J ' * (.- CALCLtAT!cN OF VCfD AREA TCR ONE SLEEVE D D a1= in. Da NN ta. Perineter P = 7' a2 l[o in. "a" avg. = at + a? + a1 + e4 a3a h in. We ,in. "a avg. * / _i n . ater. depts a4= jdp in. Va (D-a + P("a" . 3/16) Depthof'JoidDeh in. Da in. %a bk sq. inches i l Width of Ta14 Wa in. We in. v- 7 o9(%,- %) l R4e Perleeter /cceptable Criteria Acc. Criteri.i for Trus. Relice. O 'to mar 2 99 ta- Ostinar- .so =a ta- S'ioca 8 nar : 65 =a ta-k2h O *ii or 6 ') ta. O *i' , ia-l O 'ti ta in Ear : co =a ta. 0 8t' ear s 12 ia. - O 'ia aar - 2.65 9- : i-I O ri ta ia aar 2 co =a ia. @'16 para NC' sin. l -. --- .. . _ . . - - -. . - . . _ . . . . . . . . - . . \ V!FDL TXA ll* ATIU:1 p l_SLI.15 A Li.P1 1:Ut h *40T :!f.ET PICITICM 105 S !CAILht'. UT hl7'.! CAL : IPV F.YORN JAut:s O OLsoM nur 43; 14 _. S O 4 L. JopeEv__ _nui . A.iA.Ao D BLACKWELL _ nAic 6, - l 4. - f3Q _ g 3 _mL _ . g j m.m sjg.= o. D pac.6 2. o F 3 g ATTACHMENT G.G.G E'XAMPLE OF MARKED UP lt4SPECTioN FORMS I E I i MARBLE HILL GENERATING STATION cate 06-0!.-80 I (' PUBLIC SERVICE Titte: SPECI AL PROCESS PROCEDURE Page 1 of 1 C INDIANA I SPP-6 MECP.ANICAL (CADL EI.D) SPLICES I ATTACRICNT 2 CAOWELD *.*!$UAL E.V;t! NATION CHART Marble Hill Nuclear Cenerating Station Spitee No. W-f lO Cd Report No. S PPG-lb26 lO I Buildine teatten:. C O M T. 2. Splice Jype Z "T" Q " B" @ Verticat O Hartzoacal settce tocation EvT. WALC Octa4=,=1 A' M . Straa= Distance Between Cage Lines O i " i s" I Filler Metal visible A 2 : a" 1 %" Center line of sleeve centereJ between gage lines 4.505 @Yes Oso @Yes 2^c notts C No 3Y= Cosr ~ y/A

~~w I Slagvisib1[FourotsMetal h i Cit $ 0 v'= 8so T^r "ct s Ov== 8 so Filler recess in excess of inch e O ve=_ .~~

E no (if res. resect =*ta) /0 t, of Tap Hole ! t Il Y ! (Place as-reasured vakaes I I 8 on these sietebes) . 'l f ' % m,j b i ' t { > !. . P. . . ' (.- CALCULATION OF VOID AREA TCR CSE SLEI'.T. INO I 41* a2= a3-G IGP l dp in. in. in. D= W= l in. in. Perimeter P = "a" "a" avg. = a1 + a2 + a3 + at. avg. = l(:lP N in, aver. depth a4 = 10 in. V= 4(D-a} + P("4" - 3/16) Capth of Vo1J Da in. D= in. V= h' sq. inches l I

~~Width of "old !==~~

~~Pa* Perleeter _in. Ws_, in. Acceptable Criteria V= 1(1Yz- h)+1(l/c b)+l[l' b) Acc. Criteria for Trans. $rtices E d10 bar~~

~~3.99 in. O *11 nar - i.so =9 2n. Oriotoissar2.6539 in.~~

O *it P.ar ' 53 in. C#i'Nf:ba.ta. ! O*iitointar2.oosa.in. Cfi'Bar=$.32in. . O*isaar-2.65=a.sa. O<t ta ia nar : co sa. ta. I C'18Bar=7.03 in. VISUAL CLVt[:.ATIu:1 ut.sht.T5 5!f5Mt.kLS Of HlY:;lCAL SI'RVF. yod 5 Q ACCLM Q D01'S :.0T :ttET $N CIFICATION JAM'Es c OLGoM _ _9st 42 - I 4 - - 8 0 6 t . J C O R.G Y n.u E 6-I4.-80 D. G>L AC<vvELL. I cat: 42- M 6 0 ? -net g - E w~ +4a, E MARK _ MEA 9ygE}JEEh!T. Ov_T. aE.50L6g ArJgE th isMIVE Volo AREA. Blow HOLE IN TAF' HOLE I g - MhfAL OK ATTACHMENT 'G.G.o PAciE 3 cF 3 I EXAMPLE OF MARKED UP INSPIECTloM Fof?Ms _ Il I 59 Random Numbers of a Total 2434 Splice Population. I

~~1) 2047 19) 0212 36) 1999 52) 2135 g~~
~~2) 2145 20) 1193 *) 2356 53) 0287 g~~
~~3) 0178 21) 1317 37) 1929 54) 0254~~
~~4) 0579 22) 0543 38) 1140 55) 0070~~
~~5) 1039 23) 1979 39) 0634 *) 2389 l~~

=

~~6) 1646 24) 1406 40) 0045 56) 0643~~
~~7) 0484 25) 1180 41) 2161 57) 1224~~
~~8) 1428 *) 2295 42) 0628 58) 0881 3~~
~~9) 1279 26) 1138 43) 0552 59) 0154 5~~
~~10) 0573 27) 1894 44) 0819~~
~~11) 1443 28) 0280 45) 0783 g~~
~~12) 2157 29) 1854 46) 0433 g~~
~~13) 2413 30) 0489 47) 0089~~
~~14) 0990 31) 1178 48) 1765~~
~~15) 0972 32) 1989 49) 0939 l~~

=

~~16) 0985 33) 0322 50) 1472~~
~~17) 0222 34) 0932 *) 1567~~
~~18) 0127 35) 2269 51) 2064~~
~~Splice was exposed but inaccessible to any inspections or tests.~~

~~I I . 8 I I ATTACHMENT 6.6.7 RANDOM NUMBERS~~

I

M M M M M M M M M M M M M M M M M W M

SPLICE V* F** # S PLICE V* F** # SPLICE V* F** # SPLICE V* F**

NUMBER NUMBER NUMBER NUMBFR 00G1 fV-1 A . 4 0T4 6 TV-26 R 0051 TV-51 R RT 0076 TV-76 A 0002 TV-2 A 0027 TV-27 A 0052 TV-52 R 0077 "V-77 R RT 0003 TV-3 A 0028 TV-28 R 0053 TV-53 A 0078 TV-78 R 0004 TV-4 A 0029 TV-29 A 0054 TV-54 R 0079 TV-79 R RT 0005 TV-5 A 0030 TV-30 A 0055 TV-55 R RT 0080 TV-80 R T 0006 'TV-6 A 0031 TV-31 R 0056 TV-56 R 0081 TV-81 P 0007 TV-7 A 0032 TV-32 R 0057 TV-57 A 0082 TV-82 R RT 0008 TV-8 A 0033 TV-33 A 0058 TV-58 A 0083 TV-84 R 0009 TV-9 R 0034 TV-34 R 0059 TV-59 R 0084 TV-85 R RT 0010 TV-10 A 0035 TV-35 A 0060 TV-60 A 0085 TV-86 A 0011 TV-11 A 0036 TV-36 R 0061 TV-61 R 0086 TV-87 R T 0012 TV-12 A 0037 TV-37 R 0062 TV-62 A 0087 TV-88 R 0013 TV-13 A 0038 TV-38 A 0063 TV-63 A 0088 TV-89 A 0014 TV-14 R 0039 TV-39 R 0064 TV-64 A (0089 TV-90 A) 0015 TV-15 R 0040 TV-40 R 0065 TV-65 R 0090 TV-91 R T 0016 TV-16 A 0041 TV-41 R RT 0066 TV-66 R 0091 TV-92 R 0017 TV-17 A 0042 TV-42 R 0067 TV-67 A 0092 TV-93 R 0018 TV-18 R 0043 TV-43 A 0068 TV-68 R T 0093 TV-94 R 0019 TV-19 R 0044 TV-44 R 0069 TV-69 A 0094 TV-95 A 0020 TV-20 R (0045 TV-45 A) (0070 TV-70 R T) 0095 TV-96 R 0021 TV-21 R 0046 TV-46 R 0071 TV-71 A 0096 TV-97 R 0022 TV-22 A 0047 TV-47 A 0072 TV-72 A 0097 TV-98 A 0023 TV-23 R 0048 TV-48 R 0073 TV-73 R RT 0098 TV-99 R 0024 TV-24 A 0049 TV-49 R 0074 TV-74 R 0099 TV-100 A 0025 TV-25 A 0050 TV-50 R 0075 TV-75 R RT 0100 TV-101 A ( ) Random splices given in Attachment 6.6.7

~~V-Visual Examination - A-Accept, R-Reject, I-Inaccessible~~
~~F-Follow-Up Testing Acceptance - T-Tensile Test, RT-RadioEraph Test ATTACHMENT 6.6.8 STATISTICAL VERIFICATION OF SPLICE ACCEPTABILITY Page 1 of 25~~
SPLICE V* F** # SPLICE V* F** # SPLICE V* F** # SPLICE V* F**

NUMBER NUMBER NUMBER NUMBER 0101 TV-102 R 0126 TV-127 A 0151 TV-152 A 0176 TV-177 R 0102 TV-103 A (0127 TV-128 A) 0152 TV-153 R T 0177 TV-178 A 0103 TV-104 R 0128 TV-129 A 0153 TV-154 A (0178 TV-179 A) 0104 TV-105 R 0129 TV-130 A (0154 TV-155 R T) 0179 TV-180 A 0105 TV-106 A 0130 TV-131 A 0155 TV-156 A 0180 TV-181 A 0106 TV-107 R 0131 TV-132 A 0156 TV-157 A 0181 TV-182 A 0107 TV-108 A 0132 TV-133 A 0157 TV-158 A 0182 TV-183 A 0108 TV-109 A 0133 TV-134 A 0158 TV '59 R 0183 TV-184 R 0109 TV-110 R 0134 TV-135 A 0159 TV-160 R 0184 TV-185 A 0110 TV-111 A 0135 TV-136 A 0160 TV-161 R 0185 TV-186 A 0111 TV-112 A 0136 TV-137 A 0161 TV-162 A 0186 TV-187 A 0112 TV-113 A 0137 TV-138 A 0162 TV-163 A 0187 TV-188 A 0113 TV-114 A 0138 TV-139 A 0163 TV-164 A 0188 TV-189 A 0114 TV-115 A 0139 TV-140 A 0164 TV-165 A 0189 TV-190 A 0115 TV-116 A 0140 TV-141 A 0165 TV-166 A 0190 TV-191 A 0116 TV-117 A 0141 TV-142 A 0166 TV-167 A 0191 TV-192 R 0117' TV-118 A 0142 TV-143 A 0167 TV-168 A 0192 TV-193 R 0118 TV-119 A 0143 TV-144 A, 0168 TV-169 A 0193 TV-194 R 0119 TV-120 A 0144 TV-145 A 0169 TV-170 A 0194 TV-195 A 0120 TV-121 A 0145 Tv-146 A 0170 TV-171 R RT 0195 TV-196 R 0121 TV-122 A 0146 TV-147 A 0171 TV-172 A 0196 TV-197 A 0122 TV-123 A 0147 TV-148 A 0172 TV-173 A 0197 TV-198 R 0123 TV-124 A 0148 TV-1s A 0173 TV-174 R T 0198 TV-199 A 0124 TV-125 A 0149 TV-150 A 0174 TV-175 A 0199 TV-200 A 0125 TV-126 A 0150 TV-151 A 0175 TV-176 A 0200 'TV-201 A ( ) Random splices given in Attachment 6.6.7

~~V-Visual Examination - A-Accept, R-Reject, I-Inaccessible~~
~~F-Follow-Up Testing Acceptance - T-Tensile Test, RT-Radicgraph Test ATTACHMENT 6.6.8 (cont.)~~

STATISTICAL VERIFICATION OF SPLICE ACCEPTABILITY Page 2 of 25 E E E E E E E E E E E E E E E E E E E W W W W W W W W W W W W m W W W W W

SPLICE V* F** # SPLICE V* F** # SPLICE V* F** # SPLICE V* F**

NUMBER NUMBER NUMBER NUMBER 0201 TV-202 A 0226 TV-227 A 0251 TV-328 A 0276 TV-353 A 0202 TV-203 A 0227 TV-228 A 0252 TV-329 A 0277 TV-354 R 0203 TV-204 A 0228 TV-229 A 0253 TV-330 A 0278 TV-355 R 0204 TV-205 A 0229 TV-230 R (0254 TV-331 A) 0279 TV-356 R 0205 TV-206 A 0230 TV-231 A 0255 TV-332 A (0280 TV-357 A) 0206 TV-207 A 0231 TV-232 A 0256 TV-333 A 0261 TV-238 R 0207 TV-208 A 0232 TV-233 A 0257 TV-334 R 0282 TV-239 A 0208 TV-209 A 0233 TV-234 I 0258 TV-335 A 0283 TV-240 A 0209 TV-210 A 0234 TV-235 R RT 0259 TV-336 A 0284 TV-241 A 0210 TV-211 R 0235 TV-236 I 0260 TV-337 A 0285 TV-242 R 0211 TV-212 R 0236 TV-237 R 0261 TV-338 R O286 TV-243 A (0212 TV-213 R RT) 0237 TV-314 A 0262 TV-339 R RT (0287 TV-244 A) 0213 TV-214 A 0238 TV-315 A 0263 TV-340 R 0288 TV-245 R 0214 Tv-215 R 0239 TV-316 A 0264 TV-341 R RT 0289 TV-246 A 0215 TV-216 R 0240 TV-317 R O265 TV-342 A 0290 TV-247 A 0216 TV-217 A 0241 TV-318 A 0266 TV-343 R RT 0291 TV-248 A 0217 TV-218 A 0242 TV-319 A 0267 TV-344 A 0292 TV-249 A 0218 TV-219 A 0243 TV-320 A 0268 TV-345 A 0293 TV-250 A 0219 TV-220 A 0244 TV-321 A 0269 TV-346 A 0294 TV-251 R 0220 TV-22; A 0245 TV-322 A 0270 TV-347 A 0295 TV-252 A 0221 TV-?22 A 0246 TV-323 A 0271 TV-348 A 0296 TV-253 A (0222 TV-223 J) 0247 TV-324 A 0272 TV-349 R 0297 TV-254 R 0223 T V-224 R 0248 TV-325 A 0273 TV-350 A 0298 TV-255 A 0224 TV-225 A 0249 TV-326 A 0274 TV-351 R 0299 TV-256 A 0275 TV-226 A 0250 TV-327 R 0275 TV-352 R 0300 TV-257 A ( ) Random splices given in Attachment 6.6.7

~~V-Visual Examination - A-Accept, R-Reject, I-Inaccessible~~
~~F-Follow-Up Testing Acceptance - T-Tensile Test, RT-Radiograph Test ATTACPJ1ENT 6.6.8 (cont. )~~

~~STATISTICAL VERIFICATION OF SPLICE ACCEPTABILITY Page 3 of 25~~

SPLICE V* F** # S PLICE ~ V* F** # SPLICE V* F** # SPLICE V* F**

NUMBER NUMBER NUMBER NUMBER 0301 TV-258 R 0326 TV-283 R 0351 TV-309 A 0376 TV-377 R 0302 TV-259 A 0327 TV-284 R 0352 TV-310 A 0377 TV-378 R 0303 TV-260 A 0328 TV-285 R T 0353 TV-311 A 0378 TV-379 R 0304 TV-261 A 0329 TV-286 A 0354 TV-312 I 0379 TV-380 A 0305 TV-262 A 0330 TV-287 A 0355 TV-313 A 0380 TV-381 A 0306 TV-263 A 0331 TV-288 A 0356 TV-1128 A 0381 TV-382 R 0307 TV-264 A 0332 TV-290 A 0357 TV-358 R RT 0382 TV-383 A 0308 TV-265 A 0333 TV-291 A 0358 TV-359 A 0383 TV-384 R 0309 TV-266 A 0334 TV-292 A 0359 TV-360 R RT 0384 TV-385 A 0310 TV-267 A 0335 TV-293 A 0360 TV-361 A 0385 TV-386 A 0311 TV-268 A 0336 TV-294 A 0361 TV-36% A 0386 TV-387 A 0312 TV-269 R 0337 TV-295 R 0362 TV-363 A 0387 TV-388 A 0313 TV-270 A 0338 TV-296 A 0363 TV-364 R 0388 TV-389 A 0314 TV-271 R 0339 TV-297 R 0364 TV-365 R 0389 TV-390 A 0315 TV-272 A 0340 TV-298 A 0365 TV-366 R RT 0390 TV-391 A 0316 TV-273 A 0341 TV-299 A 0366 TV-367 R 0391 TV-392 R 0317 TV-274 A 0342 TV-300 A 0367 TV-368 A 0392 TV-393 A 0318 TV-275 R 0343 TV-301 R 0368 TV-369 R 0393 TV-394 A 0319 TV-276 A 0344 TV-302 A 0369 TV-370 R RT 0394 TV-395 A 0320 TV-277 A 0345 TV-303 R 0370 TV-371 A 0395 TV-396 A 0321 TV-278 A 0346 TV-304 A 0371 TV-372 A 0396 TV-397 A (0322 TV-279 A) 0347 TV-305 R 0372 TV-373 R 0397 TV-398 A 0323 TV-280 A 0348 Tv-306 A 0373 TV-374 A 0398 TV-399 A 0324 TV-281 A 0349 TV-307 R 0374 TV-375 R 0399 TV-400 A 0325 TV-282 A 0350 Tv-308 A 0375 TV-376 A 0400 TV-401 R I l ( _) Random splices given in Attachment 6.6.7

~~V-Vir, .1 Examination - A-Accept, R-k j ec t , I-Inaccessible~~
~~F-Follow-Up Testing Acceptance - T-Tensile Test, RT-Radiograph Test l~~

i ATTACllMENT 6.6.8 (cont.) l STATISTICAL VERIFICATION OF ( SPLICE ACCEPTABILITY Page 4 of 25 m M M M M M M M M M M M M M M M M m W W W W W W W W W W W W M M M M W W

SPLICE V* F** # SPLICE V* F** # SPLICE V* F** # SPLICE V* F**

NUMBER NUMBER NUMBER NUMBER 0401 TV-402 A 0426 TV-503 A 0451 TV-1102 R 0476 TV-1078 A 0402 TV-403 R 0427 TV-504 c. 0452 TV-1101 R 0477 TV-1077 A 0403 TV 404 A 0428 TV-1126 A 0453 TV-1100 R 0478 TV-1076 A 0404 TV-4c1 A 0429 TV-1125 A 0454 TV-1099 A 0479 TV-1075 A 0405 TV-482 A 0430 TV-1124 A 0455 TV-1098 A 0480 TV-1074 A 0406 TV-483 A 0431 TV-1123 A 0456 TV-1127 A 0481 TV-1073 R 0407 TV-484 A 0432 TV-1122 R 0457 TV-1097 A 0482 TV-1072 R 0408 TV-485 R (0433 TV-1121 R RT) 0458 TV-1096 R 0483 **<1071 A 0409 TV-486 A 0434 TV-1120 A 0459 TV-1095 R (0484 TV-1070 A) 0410 TV-487 A 0435 TV-1119 A 0460 TV-1094 A 0485 TV-1069 R 0411 TV-488 A 0436 TV-1118 A 0461 TV-1093 A 0486 TV-1068 R 0412 TV-489 A 0437 TV-1117 R 0462 TV-1092 A 0487 TV-1067 A 0413 TV-490 A 0438 TV-1116 R 0463 TV-1091 R 0488 TV-1066 R 0414 TV-491 A 0439 TV-1115 A 0464 TV-1090 A (0489 TV-1065 A) 0415 TV-492 A 0440 TV-1114 A 0465 TV-1089 A 0490 TV-1064 R 0416 TV-493 A 0441 TV-1113 A 0466 TV-1088 A 0491 TV-1063 A 0417 TV-494 R 0442 TV-1112 A 0467 TV-1087 A 0492 TV-1062 R 0418 TV-495 A 0443 TV-1111 A 0468 TV-1086 A 0493 TV-1061 A 0419 TV-496 R 0444 TV-1110 A 0469 TV-1085 A 0494 TV-1060 A 0420 TV-497 A 0445 TV-1109 A 0470 TV-1084 R 0495 TV-1059 A 0421 TV-498 A 0446 TV-1108 A 0471 TV-1083 R 0496 TV-1058 A 0422 TV-499 A 0447 TV-1107 R 0472 TV-1082 A 0497 TV-1057 R 0423 TV-500 A 0448 TV-1106 R 0473 TV-1081 A 0498 TV-1056 A 0424 TV-501 R 0449 TV-1105 R 0474 TV-1080 A 0499 TV-1055 R 0425 TV-502 R 0450 TV-1103 R 0475 TV-1079 R 0500 TV-1054 R ( ) Random splices given in Attachment 6.6.7

~~V-Visual Examination - A-Accept, R-Reject, I-Inaccessible~~
~~F-Follow-Up Testing Acceptance - T-Tensile Test, RT-Radiograph Test ATTACHMENT 6.6.8 (cont.)~~

~~STATISTICAL VERIFICATION OF SPLICE ACCEPTABILITY Page 5 of 25~~

S PLIt.2 V* F** # SPLICE V* F** # SPLICE V* F** # SPLICE V* F**

NUMEER NUMBER NUMBER NUMBER 0501 TV-1053 k 0526 Tv-1025 R 0551 TV-920 A 0576 TV-945 R 0502 TV-1040 A 0527 TV-1026 A (0552 TV-921 A) 0577 TV-946 A 0503 TV-1041 R 05'28 TV-1027 A 0553 TV-922 R 0578 TV-947 R 0504 TV-1042 A 0529 Tv-1028 A 0554 TV-923 A (0579 TV-948 A) 0505 TV-1043 A 0530 TV-1029 R RT 0555 TV-924 R 0580 TV-949 A 0506 TV-1044 A 0531 Tv-1030 A 0556 TV-925 A 0581 TV-950 A 0507 TV-1045 R 0532 TV-1031 A 0557 TV-926 R 0582 TV-951 A 0508 TV-1046 A 0533 TV-1032 A 0558 TV-927 A 0583 TV-952 A 0509 TV-1047 A 0534 TV-1033 A 0559 Tv-928 R 0584 TV-953 A 0510 TV-1048 A 0535 TV-1034 A 0560 TV-929 A 0585 TV-954 A 0511 TV-1949 A 0536 TV-1035 A 0561 TV-930 R 0586 TV-955 A 0512 Tv-1050 A 0537 TV-in16 A 0562 TV-931 A 0587 TV-956 A 0513 TV-1051 A 0538 TV-1037 A 0563 TV-932 R 0588 TV-957 R 0514 Tv-1052 R RT 0539 TV-1038 A 0564 TV-933 A 0589 TV-958 R 0515 TV-1014 A 0540 TV-1039 A 0565 TV-934 R 0590 TV-959 R RT 0516 TV-1015 R 0541 TV-910 R 0566 TV-935 A 0591 TV-960 A 0517 TV-1016 A 0542 TV-911 R 0567 TV-936 A 0592 TV-961 A 0518 Tv-1017 R RT (0543 TV-912 R RT) 0568 TV-937 A 0593 TV-962 A 0519 TV-1018 A 0544 TV-913 R 0569 TV-938 A 0594 TV-963 A 0520 TV-1019 A 0545 TV-914 R 0570 TV-939 R 0595 TV-964 A 0521 TV-1020 R 0546 TV-915 R 0571 TV-940 R 0596 TV-965 R 0522 TV-1021 A 0547 TV-916 A 0572 Tv-941 R 0597 TV-966 A 0523 TV-1022 A 0548 TV-917 R (0573 TV-942 A) 0598 TV-967 R 0524 TV-1023 A 0549 TV-918 A 0574 TV-943 R 0599 TV-968 A 0525 TV-1024 R 0550 TV-919 A 0575 TV-944 A 0600 TV-969 A ( ) Random splices given in Attachment 6.6.7

~~V-Visual Examination - A-Accept, R-Reject, I-Inaccessible~~
~~F-Follow-Up Testing Acceptance - T-Tensile Test, RT-Radiograph Test ATTACllMENT 6.6.8 (cont.)~~

~~STATISTICAL VERIFICATION OF SPLICE ACCEPTABILITY Page 6 of 25 m m m e e m M m m e m e e e m M M M M W W~~

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~~V AAAAAAAAAAAARAAAAAARRRARA 5 2~~

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SPLICE V* F** # SPLICE V* F** & SPLICE V* F** # SPLICE V* F**

NUMBER NUMBER NUMBER NUMBER 0701 TV-747 A 0726 TV-772 A 0751 TV-796 A 0776 TV-725 R 0702 TV-748 A 0727 TV-773 R 0752 TV-797 R 0777 TV-726 A 0703 TV-749 A 0728 TV-774 A 0753 TV-798 A 0778 TV-727 A 0704 TV-750 A 0729 TV-775 R 0754 TV-799 R 0779 TV-728 A 0705 TV-751 R 0730 TV-776 A 0/55 TV-800 A 0780 TV-729 R T&RT 0706 TV-752 R *** 0731 TV-777 R T&RT 0756 TV-801 R 0781 TV-720 A 0707 TV-753 R 0732 TV-778 A 0757 TV-802 A 0782 TV-731 A 0708 TV-754 A 0733 TV-779 R 0758 TV-803 A (0783 TV-732 A) 0709 TV-755 A 0734 TV-780 A 0759 TV-804 A 0784 TV-733 A 0710 TV-756 A 0735 TV-781 R 0760 TV-805 A 0785 TV-734 A 0711 TV-757 R 0736 TV-1129 A 0761 TV-806 A 0786 TV-735 A 0712 TV-758 A 0737 TV-782 A 0762 TV-807 R 0787 TV-736 A 0713 TV-759 R 0738 TV-783 A 0763 TV-808 A 0788 TV-814 A 0714. TV-760 A 0739 TV-784 A 0764 TV-809 R 0789 TV-815 A 0715 TV-761 R 0740 TV-785 R 0765 TV-810 A 0790 TV-816 A 0716 TV-762 A 0741 TV-786 A 0766 TV-611 R 0791 TV-817 R 0717 TV-763 A 0742 TV-787 A 0767 TV-812 A 0792 TV-818 A 0718 TV-764 A 0743 TV-788 A 0768 TV-813 R 0793 TV-819 A 0719 TV-765 A 0744 TV-789 A 0769 TV-718 A 0794 TV-820 R 0720 TV-766 A 0745 TV-790 A 0770 TV-719 A 0795 TV-821 R 0721 TV-767 A 0746 TV-791 R 0771 TV-720 A 0796 TV-822 A 0722 TV-768 R 0747 TV-792 A 0772 TV-721 R 0797 TV-823 A 0723 TV-769 R 0748 TV-793 A 0773 TV-722 A 0798 TV-824 R 0724 TV-770 A 0749 TV-794 A 0774 TV-723 R 0799 TV-825 A 0725 TV-771 R 0750 TV-795 R 0775 TV-724 A 0800 TV-826 A ( ) Random splices given in Attachment 6.6.7

~~V-Visual Examination - A-Accept, R-Reject, I-Inaccessible~~
~~F-Follow-Up Testing Acceptance - T-Tensile Test, RT-kadiograph Test~~
~~Revision 1~~

. ATTACHMENT 6.6.8 (cont.) STATISTICAL VERIFICATION OF SPLICE ACCEPTABILITY Page 8 of 25 m M M M M O M M M M M M M M M M M M m i M M M M M M M M M M M M e m M W W 1 l

SPLICE V* F** # SPLICE V* F** # SPLICE V* F** # SPLICE V* F**

NUMBER NUMBER NUMBER NUMBER , 0801 TV-827 A 0826 TV-852 A 085L TV-639 A 0876 TV-623 A l 0802 TV-828 A 0827 TV-853 R 0852 TV-640 A 0877 TV-624 R 0803 TV-829 R 0828 TV-854 R 0853 TV-641 A 0878 TV-625 A 0804 TV-830 A 0829 TV-855 I 0854 TV-642 A 0879 TV-652 R 0805 TV-831 R 0830 TV-856 R 0855 TV-643 A 0880 TV-653 A 0806 TV-832 A 0831 TV-857 a/I 0856 TV-644 A ***(0881 TV-654 R T&RT) 0807 TV-833 R 0832 TV-858 A 0857 TV-645 A 0882 TV-655 A 0808 TV-834 A 0833 TV-859 I 0858 TV-646 A 0883 TV-656 A 0809 TV-835 A 0834 'rV-860 R 0859 TV-647 A 0884 TV-657 A 0810 TV-836 A 0835 TV-861 A 0860 TV-648 R 0885 TV-658 A 0811 TV-837 A 0836 TV-862 A 0861 TV-649 A 0886 TV-659 A 0812 TV-838 R 0837 TV-863 R 0862 TV-650 A 0887 TV-660 A 0813 TV-839 R 0838 TV-626 R 0863 TV-651 A 0888 TV-661 A 0814 TV-840 R 0839 TV-627 A 0864 TV-611 A 0889 TV-662 A 0815 TV-841 I 0840 TV-628 A 0865 TV-612 A 0890 TV-663 A 0816 TV-842 R 0841 TV-629 R 0866 TV-6L3 R 089L TV-664 A 0817 TV-843 R 0842 TV-630 A 0867 TV-614 R 0892 TV-665 A 0818 TV-844 A 0843 TV-631 A 0868 TV-615 R 0893 TV-666 A

(0819 TV-845 R T&RT) 0844 TV-632 R 0869 TV-616 A 0894 TV-667 A 0820 TV-846 A 0845 TV-633 A 0870 TV-617 A 0895 TV-668 R 0821 TV-847 R 0846 TV-634 A 087L TV-618 R 0896 TV-669 A 0822 TV-848 R 0847 TV-635 R 0872 TV-619 A 0897 TV-670 R 0823 TV-849 R 0848 TV-636 A 0873 TV-620 A 0898 TV-671 A 0824 TV-850 A 0349 TV-637 A 0874 TV-62l A 0899 TV-672 A 0825 TV-851 I 0850 TV-638 A 0875 TV-622 A 0900 TV-673 A

~~( ) Random splices given in Attachment 6.6.7~~

~~V-Visual Examination - A-Accept, R-Reject, I-Inaccessible~~
~~F-Follow-Up Testing Acceptance - T-Tensile Test, RT-Radiograph Test~~
~~Revision 1 ATTACilMENT 6.6.8 (con. /~~

~~STATISTICAL VERIFICATION OF SPLICE ACCEPTABILITY Page 9 of 25~~

SPLICE V* F** # SPLICE V* F** # SPLICE V* "** # SPLICE V* F**

NUMBER NUMBER NUMBER NUMBER 0901 TV-674 A 0926 TV-699 A 0951 TV-573 A 0976 TV-598 A 0902 TV-675 A 0927 TV-700 R 0952 TV-574 A 0977 TV-599 A 0903 TV-676 A 0928 TV-701 A 0953 TV-575 A 0978 TV-600 A 0904 TV-677 A 0929 TV-702 A 0954 TV-576 A 0979 TV-601 A 0905 TV-678 A 0930 TV-703 A 0955 TV-577 A 0980 TV-602 A 0906 TV-679 R 0931 TV-704 A 0956 TV-578 A 0981 TV-603 A 0907 TV-680 R (0932 TV-705 A) 0957 TV-579 A 0982 TV-604 R 0908 TV-681 R 0933 TV-706 A 0958 TV-580 R 0983 TV-605 A 0909 TV-682 A 0934 TV-707 A 0959 TV-581 R 0984 TV-505 A 0910 TV-683 A 0935 TV-708 A 0960 TV-582 A ***(0985 TV-506 R T6RT) 0911 TV-684 R 0936 TV-709 A 0961 TV-583 A 0986 TV-507 A 0912 TV-685 A 0937 TV-710 A 0962 TV-584 A 0987 TV-508 A 0913 TV-686 A 0938 TV-711 A 0963 TV-585 A 0988 TV-509 A 0914 TV-687 A (0939 TV-712 R RT) 0964 TV-586 A 0989 TV-510 A 0915 TV-688 A 0940 TV-713 A 0965 TV-587 R (G990 TV-511 A) 0916 TV-689 A 0941 TV-714 A 0966 TV-588 A 0991 TV-512 A 0917 TV-690 A 0942 TV-715 A 0967 TV-589 A 0992 TV-513 A 0918 TV-691 A 0943 TV-716 A 0968 TV-590 R 0993 TV-514 A 0919 TV-692 A 0944 TV-717 R 0969 TV-591 A 0994 TV-515 A 0920 TV-693 A 0945 TV-567 A 0970 TV-592 A 0995 TV-516 A 0921 TV-694 A 0946 TV-568 A 0971 TV-593 A 0996 TV-517 A 0922 TV-695 R 0947 TV-569 A (0972 TV-594 A) 0997 TV-518 A 0923 TV-696 A 0948 TV-570 A 0973 TV-595 A 0998 TV-519 A 0924 TV-697 A 0949 TV-571 A 0974 TV-596 A 0999 TV-520 A 0925 TV-698 A 0950 TV-572 A 0975 TV-597 A 1000 TV-521 A ( ) Random splices given in Attachment 6.6.7

~~V-Visual Examination - A-Accept, R-Reject, I-Inaccessible~~
~~F-Follow-Up Testing Acceptance - T-Tensile Test, RT-Radiograph Test~~
~~Revision 1 ATTAC& TENT 6.6.8 (cont.)~~

STATISTICAL VERIFICATION OF SPLICE ACCEPTABILITY Page 10 of 25 E E E E - M M M M M M M M M M ~ # SPLICE V* F** # SPLICE V* F** # SPLICE V* F** # SPLICE V* F** NUMBER NUMBER NUM3ER NUMBER 1001 TV-522 A 1026 TV-547 A 1051 TV-289 A 1076 TV-427 A 1002 TV-523 I 1027 TV-548 R 1052 TV-1134 R RT 1077 TV-428 I 1003 TV-524 A 1028 TV-549 A *** 1053 TV-1133 R T6RT 1078 TV-429 A 1004 TV-525 A 1029 TV-550 E 1054 TV-405 A 1079 TV-430 I 1005 TV-526 A 1030 TV-551 R 1055 TV-406 1 1080 TV-431 1 1006 TV-527 A 1031 TV-552 R 1056 TV-407 A 1081 TV-432 R 1007 TV-528 A 1032 TV-553 A 1057 TV-408 R/I T 1082 TV-433 R T 1008 TV-529 A 1033 TV-554 A 1058 TV-409 A 1083 TV-434 R T 1009 TV-530 A 1034 TV-555 R 1059 TV-410 R/1 1084 TV-435 A 1010 TV-531 A 1035 TV-556 A 1060 TV-411 A 1085 TV-436 R 1011 TV-532 R 1036 TV-557 A 1061 TV-412 R/I 1086 TV-437 R 1012 TV-533 R 1037 TV-558 R 1062 TV-413 A 1087 TV-438 A 1013 TV-534 A 1038 TV-559 A 1063 TV-414 I 1088 TV-439 A 1014 TV-535 R (1039 TV-560 R T) 1064 TV-415 A 1089 TV-440 R RT 1015 TV-536 R 1040 TV-561 R 1065 TV-416 R/I 1090 TV-441 R 1016 TV-537 A 1041 TV-562 A 1066 TV-417 R 1091 TV-442 A 1017 TV-538 A 1042 TV-563 R 1067 TV-418 1 1092 TV-443 A 1018 TV-539 A 1043 TV-564 A 1068 TV-419 A 1093 TV-444 A 1019 TV-540 A 1044 TV-565 R 1069 TV-420 I 1094 TV-445 A 1020 TV-541 A 1045 TV-566 A 1070 TV-421 A 109 TV-446 R 1021 TV-542 A 1046 TV-606 A 1071 TV-422 1 10!s TV-447 A 1022 TV-543 A 1047 TV-607 R 1072 TV-423 A 1097 TV-448 A 1023 TV-544 A 1048 TV-608 A 1073 TV-424 A 1098 TV-449 A 1024 TV-545 A 1049 TV-609 A 1074 TV-425 R 1099 TV-450 A 1025 TV-546 A 1050 TV-610 A 1075 TV-426 A 1100 TV-451 A ( ) Random splices given in Attachment 6.6.7

~~V-Visual Examination - A-Accept, R-Reject, I-Inaccessible~~
~~F-Follow-Up Testing Acceptance - T-Tensile Test, RT-Radiograph Test~~
~~Revision 1 ATTACHMENT 6.6.8 (cont.)~~

~~STATISTICAL VERIFICATION OF SPLICE ACCEPTABILITY Page 11 of 25~~

S PL1CE V* Fx* # SPLICE V* F** # SPLICE V* F** # SPLICE V* F**

NUMBER NUMBER NUMBER NUMBER 1101 TV-452 A 1126 TV-477 A 1151 BV-20 A 1176 BV-45 A 1102 TV-453 A 1127 TV-478 A 1152 BV-21 A 1177 BV-46 A 1103 TV-454 R RT 1128 TV-479 A 1153 BV-22 R (1178 BV-47 A) 1104 TV-455 A 1129 TV-480 R 1154 BV-23 A 1179 BV-48 A 1105 TV-456 A 1130 TV-1132 R 1155 BV-24 A (1180 BV-49 A) 1106 TV-457 A *** 1131 TV-1131 R T6RT 1156 BV-25 A 1181 BV-50 A 1107 TV-458 A 1132 BV-1 A 1157 BV-26 A 1182 BV-51 A 1108 TV-459 R 1133 BV-2 A 1158 BV-27 A 1183 BV-52 A 1109 TV-460 A 1134 BV-3 A 1159 BV-28 A 1184 BV-53 A 1110 TV-461 R 1135 BV-4 R 1160 BV-29 A 1185 BV-54 A 1111 TV-462 A 1136 BV-5 A 1161 BV-30 A 1186 BV-55 A 1112 TV-463 A 1137 B$ -6 A 1162 BV-31 A 1187 BV-56 A 1113 TV-464 A (1138 BV-7 A) 1163 BV-32 A 1188 BV-57 A 1114 TV-465 A 1139 BV-8 A 1164 BV-33 A 1189 BV-58 A 1115 TV-466 A (1140 BV-9 A) 1165 BV-34 A 1190 BV-59 A 1116 TV-467 R 1141 Bk-10 A 1166 BC-35 A 1191 BV-60 A 1117 TV-468 A 1142 BV-11 A 1167 . 36 A 1192 BV-61 A 1118 TV-469 A 1143 BV-12 A 1168 BV-37 A (1193 BV-62 R RT) 1119 TV-470 A 1144 BV-13 A 1169 BV-38 A 1194 BV-63 R RT 1120 TV-471 R 1145 BV-14 A 1170 BV-39 A 1195 BV-64 A 1121 TV-472 A 1146 BV-15 A 1171 BV-40 A 1196 BV-65 A 1122 TV-473 R 1147 BV-16 A 1172 BV-41 A 1197 BV-66 A 1123 TV-474 A 1148 BV-17 A 1173 BV-42 A 1198 BV-67 A 1124 TV'-475 A 1149 BV-18 A 1174 BV-43 A 1199 BV-68 R T 1125 TV-476 A 1150 BV-19 A 1175 BV-44 A 1200 BV-69 A ( ) Random splices given in Attachrtent 6.6.7

~~V-Visual Examination - A-Accept, R-Reject, I-Inaccessible~~
~~F-Follow-Up Testing Acceptance - T-Tensile Test, RT-Radiograph Test~~
~~Revision 1 ATTACID1ENT 6.6.8 (cont.)~~

STATISTICAL VERIFICATION OF SPLICE ACCEPTABILITY Page 12 of 25 E E E E E E E E E E E E E E E E E M M M M M M M M M M M M M US M M

SPLICE V* F** # SPLICE V* F** # SPLICE V* F** # SPLICE V* F**

NUMBER NUMBER NUMBER NUMBER 1201 BV-70 A 1226 BV-95 A 1251 BV-120 A 1276 BV-145 A 1202 BV-71 A 1227 BV-96 A 1252 BV-121 A 1277 BV-146 A 1203 BV-72 A , 1228 BV-97 A 1253 BV-122 A 1278 BV-147 A 1204 BV-73 A 1229 BV-98 R 1254 BV-123 A. (1279 BV-148 A) 1205 BV-74 R 1230 BV-99 A 1255 BV-124 A 1280 BV-149 A 1206 BV-75 A 1231 BV-100 A 1256 BV-125 A 1281 BV-150 A 1207 BV-76 A 1232 BV-101 A 1257 BV-126 A 1282 BV-151 A 1208 BV-77 A 1233 BV-102 A 1258 BV-127 A 1283 BV-152 A 1209 BV-78 A 1234 BV-103 A 1259 BV-128 A 1284 BV-153 A 1210 BV-79 A 1235 BV-104 A 1260 BV-129 A 1285 BV-154 A 1211 BV-80 A 1236 BV-105 A 1261 BV-130 A 1286 BV-155 A 1212 BV-81 A 1237 BV-106 A 1262 BV-131 A 1287 BV-156 A 1213 BV-82 A 1238 BV-107 A 1263 BV-132 A 1288 BV-157 A 1214 BV-83 A 1239 BV-108 A 1264 BV-133 R RT 1289 BV-158 R 1215 BV-84 A 1240 BV-109 A 1265 BV-134 A 1290 BV-159 A 1216 BV-85 A 1241 BV-110 A 1266 BV-135 A 1291 BV-160 A 1217 BV-86 A 1242 BV-111 A 1267 BV-136 A 1292 BV-161 A 1218 BV-87 A 1243 BV-112 A 1268 BV-137 A 1293 BV-162 A 1219 BV-88 A 1244 BV-113 A 1269 BV-138 A 1294 BV-163 A 1220 BV-89 A 1245 BV-114 A 1270 BV-139 A 1295 BV-164 A 1221 BV-90 A 1246 BV-115 A 1271 BV-140 A 1296 BV-165 A 1222 BV-91 A 1247 BV-116 A 1272 BV-141 A 1297 BV-166 A 1223 BV-92 A 1248 BV-117 A 1273 BV-142 A 1298 BV-167 A (1224 BV-93 A) 1249 BV-118 A 1274 BV-143 A 1299 BV-168 A 1225 BV-94 A 1250 BV-119 A 1275 BV-144 A 1300 BV-169 A ( ) Random splices given in Attachment 6.6.7

~~V-Visual Examination - A-Accept, R-Reject, I-Inaccessible~~
~~F-Follow-Up Testing Acceptance - T-Tensile Test, RT-Radiograph Test ATTACllMENT 6.6.8 (cont.)~~

~~STATISTICAL VERIFICATION OF SPLICE ACCEPTABILITY Page 13 of 25~~

SPL1CE V* F** # SPLICE V* F** # SPLICE V* F** f SPLICE V* F**

NUMBER NUMBER NUMBER NUMBER 1301 BV-170 A 1326 BV-195 A 1351 BV-220 R 1376 BV-245 A 1302 BV-171 A 1327 BV-196 A 1352 BV-221 A 1377 BV-246 A 1303 BV-172 A 1328 BV-197 A 1353 BV-222 R 1378 BV-247 A 1304 BV-173 A 1329 BV-198 A 1354 BV-223 A 1379 BV-248 A 1305 BV-174 A 1330 BV-199 A 1355 EV-224 A 1380 BV-249 A 1306 BV-175 R 1331 BV-200 A 1356 BV-225 A 1381 BV-250 A 1307 ,BV-176 A 1332 BV-201 A 1357 BV-226 A 1382 BV-251 A 1308 BV-177 A 1333 BV-202 A 1358 BV-227 A 1383 BV-252 A 1309 BV-178 R 1334 BV-203 A 1359 BV-228 A 1384 BV-253 A 1310 BV-179 A 1335 BV-204 A 1360 BV-229 A 1385 BV-254 A 1311 BV-180 A 1336 BV-205 A 1361 BV-230 A 1386 BV-255 R 1312 BV-181 A 1337 BV-206 A 1362 BV-231 A 1387 BV-256 R 1313 BV-182 A 1338 BV-207 A 1363 BV-232 A 1388 BV-257 R 1314 BV-183 A 1339 BV-208 A 1364 BV-233 A 1389 BV-258 A 1315 BV-184 A 1340 BV-209 A 1365 BV-234 A 1390 BV-259 A 1316 BV-185 A 1341 BV-210 A 1366 BV-235 A 1391 BV-260 A (1317 BV-186 A) 1342 BV-211 A 1367 BV-236 R RT 1392 BV-261 A 1318 BV-187 A 1343 BV-212 A 1368 BV-237 A 1393 BV-262 R 1319 BV-188 A 1344 BV-213 A 1369 BV-238 A 1394 BV-263 A 1320 BV-189 A 1345 BV-214 A 1370 BV-239 A 1395 BV-264 A 1321 BV-190 A 1346 BV-215 R 1371 BV-240 A 1396 BV-265 A 1322 BV-191 A 1347 BV-216 A 1372 BV-241 A 1397 BV-266 R 1323 BV-192 A 1348 BV-217 A 1373 BV-242 R T 1398 BV-267 A 1324 BV-193 A 1349 BV-?l8 A 1374 BV-243 A 1399 BV-268 R 1325 BV-194 A 1350 BV-219 R 1375 BV-244 A 1400 BV-269 A ( ) Random splices given in Attachment 6.6.7

~~V-Visual Examination - A-Accept, R-Reject, I-Inaccessible~~
~~F-Follow-Up Testing Acceptance - T-Tensile Test, RT-Radiograph Test ATTACHMENT 6.6.8 (cont.)~~

STATISTICAL VERIFICATION OF SPLICE ACCEPTABILITY Page 14 of 25 m M M M M M M M M M M M M M M m m W W W m m m m m m m m M M M M l l [ l

S PLICE V* F** # SPLICE V* F** # SPLICE V* F** # SPLICE V* F**

NUMBER NUMBER NUMBER NUMBER 1401 BV-270 A 1426 BV-295 A 1451 BV-320 A 1476 BV-345 A 1402 BV-271 A 1427 BV-296 R 1452 BV-321 A 1477 BV-346 A 1403 BV-272 A (1428 BV-297 A) 1453 BV-322 A 1478 BV-347 A 1404 BV-273 A 1429 BV-298 R 1454 BV-323 A 1479 BV-348 A 1405 BV-274 A 1430 BV-299 R 1455 BV-324 A 1480 BV-349 A (1406 BV-275 A) 1431 BV-300 A 1456 BV-325 A 1481 BV-350 R RT 1407 BV-276 A 1432 BV-301 A 1457 BV-326 A 1482 BV-351 A 1408 BV-277 A 1433 BV-302 A 1458 BV-327 A 1483 BV-352 A 1409 BV-278 A 1434 BV-303 A 1459 P"-328 A 1484 BV-353 A 1410 BV-279 A 1435 BV-304 R 1460 BV-329 A 1485 BV-354 A 1411 BV-280 A 1436 BV-305 A 1461 BV-330 A 1486 BV-355 A 1412 BV-281 A 1437 BV-306 A 1462 BV-331 A. 1487 BV-356 R RT' 1413 BV-282 A 1438 BV-307 R 1463 BV-332 A 1488 BV-357 A 1414 BV-283 A 1439 BV-308 R 1464 BV-333 A 1489 BV-358 A 1415 BV-284 A 1440 BV-309 A 1465 BV-334 A 1490 BV-359 A 1416 BV-285 A 1441 BV-310 A 1466 BV-335 A 1491 BV-360 A 1417 BV-286 A 1442 BV-311 A 1467 BV-336 A 1492 BV-361 R 1418 BV-287 A (1443 BV-312 A) 1468 BV-337 A 1493 BV-362 A 1419 BV-288 A 1444 BV-313 A 1469 BV-338 A 1494 BV-363 A 1420 BV-289 A 1445 BV-314 A 1470 BV-339 R 1495 BV-364 A 1421 BV-290 A 1446 BV-315 A 1471 BV-340 A_ 1496 BV-365 A 1422 BV-291 A 1447 BV-316 A (1472 BV-341 A) 1497 BV-366 R 1423 BV-292 A 1448 BV-317 A 1473 BV-342 A 1498 BV-367 A 1424 BV-293 A 1449 BV-318 A 1474 BV-343 A 1499 BV-368 A 1425 BV-294 A 1450 BV-319 A 1475 BV-344 A 1500 BV-369 A ( ) Random splices given in Attachment 6.6.7

~~V-Visual Examination - A-Accept, R-Reject, 1-Inaccessible~~
~~F-Follow-Up Testing Acceptance - T-Tensile Test, RT-Radiograph Test ATTACitMENT 6.6.8 (cont. )~~

~~STATISTICAL VERIFICATION OF SPLICE ACCEPTABILITY Page 15 of 25~~

S PLICE V* F** # SPLICE V* F** # SPLICE V* F** # SPLICE V* F**

NUMBER NUMBER NUMBER NUMBER 1501 BV-370 A 1526 BV-395 1 1551 BV-420 A 1576 BV-445 A 1502 BV-371 A 1527 BV-396 A 1552 BV-421 R 1577 BV-446 A 1503 BV-372 A 1528 BV-397 1 1553 BV-422 A 1578 BV-447 A 1504 BV-373 A 1529 BV-398 I 1554 BV-423 A 1579 BV-448 A 1505 BV-374 R 1530 BV-399 I 1555 BV-424 A 1580 BV-449 R 1506 BV-375 A 1531 BV-400 I 1556 BV-425 A 1581 BV-450 A 1507 BV-376 A 1532 BV-401 1 1557 BV-426 A 1582 BV-451 A 1508 BV-377 R RT 1533 BV-402 1 1558 BV-427 A 1583 BV-452 A 1509 BV-378 R 1534 BV-403 I 1559 BV-428 R 1584 BV-453 A 1510 BV-379 A 1535 BV-404 1 1560 BV-429 A 1585 BV-454 A 1511 BV-380 A 1536 BV-405 1 1561 BV-430 A 1586 BV-455 A 1512 BV-381 A 1537 BV-406 1 1562 BV-431 R 1587 BV-456 A 1513 BV-382 A 1538 BV-407 I 1563 BV-432 A 1588 BV-457 A 1514 BV-383 A 1539 BV-408 I 1564 BV-433 A 1589 BV-458 A 1515 BV-384 A 1540 BV-409 I 1565 BV-434 A 1590 BV-459 A 1516 BV-385 A 1541 BV-410 R 1566 BV-435 A 1591 BV-460 R 1517 BV-386 1 1542 BV-411 A (1567 BV-436 I) 1592 BV-461 A 1518 BV-3S7 A 1543 BV-412 A 1568 BV-437 A 1593 BV-462 R 1519 BV-388 A 1544 BV-413 A 1569 BV-438 A 1594 BV-463 A 1520 BV-389 R 1545 BV-414 A 1570 BV-439 A 1595 BV-464 A 1521 BV-390 A 1546 BV-415 A 1571 BV-440 A 1596 BV-465 A 1522 BV-391 1 1547 BV-416 A 1572 BV-441 A 1597 BV-466 A 1523 BV-392 I 1548 BV-417 A 1573 BV-442 A 1598 BV-467 A 1524 BV-393 1 1549 BV-418 A 1574 BV-443 A 1599 BV-468 A 1525 BV-394 I 1550 BV-419 R 1575 BV-444 A 1600 BV-469 A ( ) Random splices given in Attachment 6.6.7

~~V-Visual Examination - A-Accept, R-Reject, I-Inaccessible~~
~~F-Follow-Up Testing Acceptance - T-Tensile Test, RT-Radiograph Test ATTACHMENT 6.6.8 (cont.)~~

STATISTICAL VERIFICATION OF SPLICE ACCEPTABILITY Page 16 of 25 m m m M M M M M M M M M 1 i

SPLICE V* F** # SPLICE V* F** # SPLICE V* F** # SPLICE V* F**

NUMBER NUMBER NUMBER NUMBER 1601 BV-470 A 1626 BV-495 A 1651 BV-520 A 1676 BV-545 A 1602 BV-4)L A 1627 BV-496 A 1652 BV-521 A 1677 BV-546 A L603 BV-472 A 1628 BV-497 A 1653 BV-522 A 1678 BV-547 A 1604 BV-473 A 1629 BV-498 A 1654 BV-523 A 1679 BV-548 A 1605 BV-474 A 1630 BV-499 A 1655 BV-524 A *** 1680 BV-549 R 1606 BV-475 A 1631 BV-500 A 1656 BV-525 R 1681 BV-550 A 1607 BV-476 R 1632 BV-50L A 1657 BV-526 A 1682 BV-551 A 1608 BV-477 A 1633 BV-502 A 1658 BV-527 R 1681 BV-552 A 1609 BV-478 A 1634 BV-503 A 1659 BV-528 A 1684 BV-553 A 1610 BV-479 A 1635 BV-504 A 1660 BV-529 A 1685 BV-554 A L611 BV-480 A 1636 BV-505 A 1661 BV-530 R L686 BV-555 A 1612 BV-481 A 1637 BV-506 R 1662 BV-531 A 1687 BV-556 A L613 BV-482 A L638 BV-507 R 1663 BV-532 A L688 BV-557 A 1614 BV-483 R 1639 BV-588 R 1664 BV-533 R 1689 BV-558 A 16L5 BV-484 A 1640 BV-509 A 1665 BV-534 I 1690 BV-559 A 1616 BV-485 R RT 1641 BV-510 R 1666 BV-535 A 1691 BV-560 A 16L7 BV-486 A 1642 BV-511 R 1667 BV-536 R 1692 BV-56L A 16L8 BV-487 A 1642 BV-5L2 R 1668 BV-537 A 1693 BV-562 A 1619 BV-488 R RT 1644 BV-513 A 1669 BV-538 A 1694 BV-563 A 1620 BV-489 A 1645 3V-514 A 1670 BV-539 R RT 1695 BV-564 A 162L BV-490 A (1646 BV-515 A) 167L BV-540 A 1696 BV-565 A 1622 BV-49L A 1647 BV-516 A L672 BV-541 R T 1697 BV-566 A 1623 BV-492 A 1648 BV-517 R 1673 BV-542 A 1698 BV-567 A 1624 BV-493 A 1649 BV-518 A 1674 BV-543 R 1699 BV-568 A 1625 BV-494 A 1550 BV-519 R 1675 BV-544 R 1700 BV-569 A ( ) Random splices given in A?.tachment 6.6.7

~~V-Visual Examination - A-Accept, R-Reject, I-Inaccessible~~
~~F-Follow-Up Testing Acceptance - T-Tensile Test, RT-Radiograph Test~~

~~'*** Revision 1~~

~~ATTACHMENT 6.6.8 (cont.)~~

~~STATISTICAL VERIFICATION OF SPLICE ACCEPTABILITY Page 17 of 25~~

S PLICE V* F** # SPLICE V* F** # SPLICE V* F** # SPLICE V* F**

NUMBER NUMBER NUMBER NUMBER 1701 BV-570 A 1726 BV-595 A 1751 BV-620 A 1776 BV-645 A 1702 BV-571 R 1727 BV-596 A 1752 BV-621 A 1777 BV-647 A 1703 BV-572 A 1728 BV-597 A 1753 BV-622 A 1778 BV-647 A 1704 BV-573 A 1729 BV-598 A 1754 BV-623 A 1779 BV-648 A 1705 BV-574 A 1730 BV-599 A 1755 BV-624 A 1780 BV-649 A 1706 BV-575 A 1731 BV-600 A 1756 BV-625 A 1781 BV-650 A 1707 BV-576 A 1732 BV-601 R 1757 BV-626 R T 1782 BV-651 A 1708 BV-577 A 1733 BV-602 A 2758 BV-627 A 1783 BV-652 A 1709 BV-578 A 1734 BV-603 A 1759 BV-628 A 1784 BV-653 A 1710 BV-579 R 1735 BV-604 A 1160 BV-629 A 1785 BV-654 A 1711 BV-580 R 1736 BV-605 R RT 1701 BV-630 A 1786 BV-655 R 1712 BV-581 A 1737 BV-606 R 1762 BV-631 A 1787 BV-666 A 1713 BV-582 A 1738 BV-607 A 1763 BV-632 A 1788 BV-657 A 1714 BV-583 A 1739 BV-688 A 1764 BV-633 R 1789 BV-658 A 1715 BV-584 A 1740 BV-609 A (1765 BV-634 A) 1790 BV-659 A 1716 3V-585 A 1741 BV-610 A 1766 bV-635 R T 1791 BV-660 A 1717 BV-586 A 1742 BV-611 A 1767 BV-636 A 1792 BV-661 R 1718 BV-587 R 1743 BV-612 A 1768 BV-637 A 1793 BV-662 A 1719 BV-588 A 1744 BV-613 A 1769 BV-638 R 1794 BV-663 A 1720 BV-589 A 1645 BV-614 R 1770 BV-639 A 1795 BV-664 A 1721 BV-590 R 1646 BV-615 A 1771 BV-640 R 1796 BV-665 R RT 1722 BV-591 R 1747 BV-616 A 1772 BV-641 A 1797 BV-666 A 1723 BV-592 A 1748 BV-617 A 1773 BV-642 A 1798 BV-667 R 1724 BV-593 A 1749 BV-618 A 1774 EV-643 A 1799 BV-668 R 1725 BV-594 A 1750 BV-619 A 1775 BV-644 A 1800 BV-669 R ( ) Random splices given in Attachment 6.6.7

~~V-Visual Examination - A-Accept, R-Reject, 1-Inaccessible~~
~~F-Follow-UF Testing Acceptance - T-Tensile Test, RT-Radiograph Test ATTACitMENT 6.6.8 (cont. )~~

STATISTICAL VERIFICATION OF SPLICE ACCEPTABILITY Page 18 of 25 m M M- m M M M M M m M M M M M M M M

SPLICE V* F** # SPLICE V* F** # SPLICE V* F** # SPLICE V* F**

NUMBER NUMBER NUMBER NUMBER 1801 BV-670 R RT 1826 BV-695 A 1851 BV-720 R 1876 BV-745 A 1802 BV-671 A 1828 BV-696 A 1852 BV-721 R 1877 BV-748 A 1803 BV-672 A 1828 BV-697 A 1853 BV-722 R 1878 BV-747 A 1804 BV-673 A 1829 BV-698 A (1854 BV-723 A) 1879 BV-748 A 1805 BV-674 A 1830 BV-699 A 1855 BV-724 R 1880 BV-749 A 1806 BV-675 R 1831 BV-700 A 1856 BV-725 A 1881 BV-750 A 1807 BV-676 A 1832 BV-701 A 1857 BV-726 A 1882 BV-751 A 1808 BV-677 A 1833 BV-702 A 1858 BV-727 A 1883 BV-752 A 1809 BV-678 A 1834 BV-703 A 1859 BV-728 A 1884 BV-753 A 1810 BV-679 A 1835 BV-704 A 1860 BV-729 A 1885 BV-754 A 1811 BV-680 A 1836 BV-705 A 1861 BV-730 R *** 1886 BV-755 R RT 1812 BV-681 A 1837 BV-706 R 1862 BV-731 A 1887 BV-756 A 1813 BV-682 A 1838 BV-707 A 1863 BV-732 A 1888 BV-757 R T&RT 1814 BV-683 R 1839 BV-708 A 1864 BV-733 A 1889 BV-758 A 1815 BV-684 A 1840 BV-709 A 1865 BV-734 A 1890 BV-759 R RT 1816 BV-685 A 1841 BV-710 A 1866 BV-735 A 1891 BV-760 R 1817 BV-686 A 1842 BV-711 A 1867 BV-736 R 1892 BV-761 R 1818 BV-687 A 1843 BV-712 A 1868 BV-737 A 1893 BV-762 A 1819 BV-688 A 1844 BV-713 R 1869 BV-738 A (1894 BV-763 A) 1820 BV-689 A 1845 BV-714 R 1880 BV-739 A 1895 BV-764 A 1821 BV-690 A 1846 BV-715 A 1881 BV-740 A 1896 BV-765 R 1822 BV-691 R 1847 BV-716 A 1882 BV-741 A 1897 BV-766 A 1823 BV-692 A 1848 BV-717 A 1883 BV-742 R T 1898 BV-767 R 1824 BV-693 A 1849 BV-718 A 1884 BV-743 R 1899 BV-768 R RT 1825 BV-694 R 1850 BV-719 R 1885 BV-744 R 1900 BV-769 A ( ) Random splices given in Attachment 6.6.7

~~V-Visual Examination - A-Accept, R-Reject, I-Inaccessible~~
~~F-Follow-Up Testing Acceptance - T-Tensile Test, RT-Radiograph Test~~
~~Revision 1 ATTACID1ENT 6.6.3 (cont.)~~

STATISTICAL VERIFICATION OF SPLICE ACCEPTABILITY Page 19 of 25 J SPLICE V* F** # SPLICE V* F** # S PI'It ' V* F** # SPLICE 1/* F** NUMBER NUMBER NUMBER NUMBER 1901 BV-770 A 1926 BV-795 A 1951 BV-820 R RT 1976 BV-1148 A 1902 BV-771 A 1927 BV-796 R T 1952 BV-821 A 1977 BV-838 A 1903 BV-772 A 1928 BV-797 A 1853 EV-822 A 1978 BV-839 A 1904 BV-773 A (1929 BV-798 A) 1854 BV-823 R RT (1979 BV-840 A) 1905 BV-774 A 1930 BV-799 A 1955 BV-824 A 1980 BV-841 A 1906 BV-775 A 1931 BV-800 A 1956 BV-825 A 1981 BV-842 A 1907 BV-776 A 1932 BV-801 A 1957 BV-826 A 1982 BV-843 A 1908 BV-777 A 1933 BV-802 A 1958 BV-827 R RT 1983 BV-844 R 1909 BV-778 A 1934 BV-803 A 1959 BV-828 R RT 1984 BV-845 A 1910 BV-779 A 1935 BV-804 A 1960 BV-829 A 1985 BV-846 A 1911 BV-780 A 1936 BV-605- A 1961 BV-830 A 1986 BV-847 A 1912 BV-781 A 1937 BV-806 A 1962 BV-831 A 1987 BV-848 R 1913 BV-782 A 1938 BV-807 A 1963 BV-832 A 1988 BV-849 A 1914 BV-783 A 1939 BV-808 A 1964 BV-833 A (1989 BV-850 A) 1915 BV-784 A 1940 BV-809 A 1965 BV-834 A 1990 BV-851 A 1916 BV-785 A 1941 BV-810 A 1966 BV-835 A 1991 BV-852 A 1917 BV-786 A 1942 BV-811 A 1967 BV-836 A 1992 BV-853 A 1918 BV-787 A 1943 BV-812 A 1968 BV-837 R RT 1993 BV-854 R 1919 BV-788 R 1944 BV-813 A 1969 BV-1141 A 1994 hV-855 R 1920 BV-789 A 1945 BV-814 R 1970 BV-1142 A 1995 BV-856 A 1921 BV-790 A 1946 BV-815 A 1971 BV-1143 A 1996 BV-857 A 1922 BV-791 A 1947 BV-816 R RT 1972 BV-1144 A 1997 BV-858 A 1923 BV-792 A 1948 BV-817 A 1973 BV-1145 A 1998 BV-859 A 1924 BV-793 A 1949 BV-818 A 1974 BV-1146 A (1999 BV-860 A) 1925 BV-794 A 1950 BV-819 A 1975 BV-1147 A 2000 BV-861 R ( ) Random splices given in Attachment 6.6.7

~~V-Visual Examination - A-Accept, R-Reject, I-Inaccessible~~
~~F-Follow-Up Testing Acceptance - T-Tensile Test, RT-Radiograph Test ATTAClelENT 6.6.8 (cont. )~~

STATISTICAL VERIFICATION OF SPLICE ACCEPTABILITY Page 20 of 25 W M M - M M M m m W W W W m W M M m m e m W m M

SPLICE V* F** # SPLICE V* F** # SPLICE V* F** # SPLICE V* F**

NUMBER NUMBER NUMBER NUMBER 2001 BV-862 A 2026 BV-887 A 2051 BV-912 A 2076 BV-937 A 2002 BV-863 A 2027 BV-888 A 2052 BV-913 A 2077 BV-938 A 2003 BV-864 A 2028 BV-889 A 2053 BV-914 A 2078 BV-939 A 2004 BV-865 A 2029 BV-890 A 2054 BV-915 A 2079 BV-940 A 2005 BV-86.. A 2030 BV-891 A 2055 BV-916 A 2080 bV-941 A 2006 BV-867 A 2031 BV-892 A 2056 BV-917 A 2081 BV-942 A 2007 BV-868 A 2032 BV-893 A 2057 BV-918 A 2082 BV-943 A 2008 BV-869 A 2033 BV-894 A 2058 BV-919 A 2083 BV-944 A 2009 BV-870 A 2034 BV-895 A 2059 BV-920 R RT 2084 BV-945 A 2010 BV-871 A 2035 BV-896 A 2060 BV-921 R 2085 BV-946 A 2011 BV-872 A 2036 BV-897 A 2061 BV-922 A 2086 BV-947 A 2012 BV-873 A 2037 BV-898 A 2062 BV-923 A 2087 BV-948 A 2013 BV-874 A 2038 BV-899 A 2063 BV-924 A 1988 BV-949 A 2014 BV-875 A 2039 BV-900 A (2064 BV-925 A) 1989 BV-950 A 2015 BV-876 A 2040 BV-901 A 2065 BV-926 A 2090 BV-951 A 2016 BV-877 A 2041 BV-902 A 2066 BV-927 A 2091 BV-952 A 2017 BV-878 A 2042 BV-903 A 2067 BV-928 A 2092 BV-953 A 2018 BV-879 A 2043 BV-904 A 2068 BV-929 A 2093 BV-954 A 2019 BV-880 A 2044 BV-905 A 2069 BV-930 R 2094 BV-955 A 2020 BV-881 A 2045 BV-906 A 2070 BV-931 A 2095 BV-956 A 2021 BV-882 A 2046 BV-907 A 2071 3V-932 R 2096 BV-957 A 2022 BV-883 R (2047 BV-908 A) 2072 BV-933 A 2097 BV-958 R 2023 BV-884 R 2048 BV-909 A 2073 BV-934 A 2098 BV-959 A 2024 BV-885 R 2049 BV-910 A 2074 BV-935 A 2099 BV-960 A 2025 BV-886 R 2050 BV-911 R RT 2075 BV-936 A 2100 BV-961 R ( ) Random splices given in Attachment 6.6.7

~~V-Visual Examination - A-Accept, R-Reject, I-Inaccessible~~
~~F-Follow-Up Testing Acceptance - T-Tensile Test, RT-Radiograph Test ATTACilMENT 6.6.8 (cont.)~~

~~STATISTICAL VERIFICATION OF~~

~~SPLICE ACCEPTABILITY Page 21 of 25~~

~

SPLICE V* F** # SPLICE V* F** # SPLICE V* F** # S PLICE V* F**

NUMBER NUMBER NUMBER NUMBER 2101 BV-962 A 2126 BV-987 A 2151 BV-1012 A 2176 BV-1037 A 2102 BV-963 A 2127 B,V-988 A 2152 BV-1013 R 2177 BV-1038 A 2103 BV-964 A 2128 BV-989 A 2153 BV-1014 R 2178 BV-1039 A 2104 3V-965 R 2129 BV-990 A 2154 B/-1015 A 2179 BV-1040 A 2105 BV-9i6 A 2130 BV-991 A 2155 BV-1016 A 2180 BV-1041 A 2106 BV-967 A 2131 BV-992 A 2156 BV-1017 A 2181 BV-1042 A 2107 BV-968 A 2132 BV-993 A (2157 BV-1018 A) 2182 BV-1043 A 2108 BV "69 A 2133 BV-994 A 2158 BV-1019 R 2183 BV-1044 A 2109 BV-970 A 2134 BV-995 A 2159 BV-1020 A 2134 BV-1045 A 2110 BV-971 A (?l35 BV-996 A) 2'.60 BV-1021 A 2185 BV- 1046 A 2111 BV-972 A 2136- BV-997 A (Y161 BV-1022 A) 2186 BV-1047 A 2112 BV-973 A 2137 BV-998 A 2162 BV-1023 R 2187 BV-1048 A 2113 BV-974 A 2138 BV-999 A 2163 BV-1024 A 2188 BV-1049 A 2114 BV-975 A 2139 BV-1000 A 2164 BV-1025 R 2189 BV-1050 A 2115 BV-976 R 2140 BV-1001 A 2165 BV-1026 A 2190 BV-1051 A 2116 BV-977 A 2141 BV-1002 A 2166 BV-1027 A 2191 BV-1052 A 2117 BV-978 A 2142 BV-1003 A 2167 BV-1028 A 2192 BV-1053 R 2118 BV-979 A 2143 BV-1004 A 2168 BV-1029 A 2193 BV-1054 A 2119 BV-980 A 2144 BV-1005 A 2169 BV-1030 A 2194 BV-1055 A 2120 BV-981 A (2145 BV-1006 A) 2170 BV-1031 A 2195 BV-1056 A 2121 BV-982 A 2146 BV-1007 A 2171 BV-1032 A 2196 BV-1057 A 2122 BV-983 A 2147 BV-1008 A 2172 BV-1033 A 2197 BV-1058 A 2123 BV-984 A 2148 BV-1009 A 2173 BV-1034 A 2198 BV-1059 A 2124 BV-985 A 2149 BV-1010 A 2174 BV-1035 R 2199 BV-1060 A 2125 BV-986 A 2150 BV-1011 A 2175 BV-1036 A 2200 BV-1061 A ( ) Random splices given in Attachment 6.6.7

~~V-Visu'l Examination - A-Accept, R-Reject, I-Inaccessible~~
~~F-Follow-Up Testing Acceptance - T-Tensile Test, RT-Radiograph Test ATTACHMENT 6.6.8 (cont.)~~

STATISTICAL VERIFICATION OF SPLICE ACCEPTABILITY Page 22 of 25 m M M M M M W W M M M M M M M M W W W W W W W M M M M M M M M M M M M

SPLICE V* F** # SPLICE V* F** # SPLICE V* F** # SPLICE V* F**

NUMBER NUMBER NUMBER NUP3ER 2201 BV-1062 A 2226 BV-1087 R 2251 BV-1112 A 2276 BV-1137 A 2202 BV-1063 A 2227 BV-1088 A 2252 BV-1113 A 2277 BV-1138 A 2203 BV-1064 A 2228 BV-1089 A 2253 BV-1114 A 2278 BV-1139 R T 2204 BV-1065 A 2229 BV-1090 A 2254 BV-1115 A 2279 BV-1140 A 2205 BV-1066 A 2230 BV-1091 A 2255 BV-1116 A 2280 BV-1149 I 2206 BV-1067 A 2231 BV-1092 A 2256 BV-1117 A 2281 BV-1150 I 2207 BV-1068 A 2232 BV-1093 A 2257 BV-1118 A 2282 BV-1151 1 2208 BV-1069 A 2233 BV-1094 A 2258 BV-1119 A 2283 BV-1152 I 2209 BV-1070 A 2234 BV-1095 R 2259 BV-1120 A 2284 BV-1153 I 2210 BV-1071 A 2235 BV-1096 A 2260 BV-1121 A 2285 BV-1154 1 2211 BV-1072 A 2236 BV-1097 A 2261 BV-1122 R RT 2286 BV-1155 1 2212 BV-1073 A 2237 BV-1098 A 2262 BV-1123 A 2287 BV-1156 1 2213 BV-1074 A 2238 BV-1099 A 2263 BV-1124 A 2288 BV-1157 I 2214 BV-1075 A 2239 BV-1100 A 2264 BV-1125 A 2289 BV-1158 A 2215 BV-1076 A 2240 BV-1101 R 2265 BV-1126 A 2290 BV-1159 A 2216 BV-1077 A 2241 BV-1102 A 2266 BV-1127 A 2291 BV-1160 A 2217 BV-1078 A 2242 BV-1103 A 2267 BV-1128 A 2292 BV-1161 A 2218 BV-1079 A 2243 BV-1104 A 2268 BV-1129 A 2293 BV-1162 A 2219 BV-1080 A 2244 BV-1105 A (2269 BV-1130 A) 2294 BV-1163 A 222P BV-1081 A 2245 BV-1106 A 2270 BV -1131 A (2295 BV-1164 I) 2221 BV-1082 A 2246 BV-1107 A 2271 BV-1132 A 2296 BV-1165 1 2222 BV'1083 A 2247 BV-1108 A 2272 BV-1133 A 2297 BV-1166 1 2223 BV-1084 A 2248 BV-1109 A 2273 BV-1134 A 2298 BV-1167 I 2224 BV-1085 A 2249 BV-1110 A 2274 BV-1135 A 2299 BV-1168 I 2225 BV-1086 A 2250 BV-1111 A 2275 BV-1136 A 2300 BV-1169 I ( ) Random splices given in Attachment 6.6.7

~~V-Visual Examination - A-Accept, R-Reject, I-Inaccessible~~
~~F-Follow-Up Testing Acceptance - T-Tensile Test, RT-Radiograph Test ATTACllMENT 6.6.8 (cont)~~

~~STATISTICAL VERIFICATION OF SPLICE ACCEPTABILITY Page 23 of 25~~

SPL1CE V* F** # SPLICE V* F** # SPLICE V* F** # SPLICE V* F**

NUMBER NUMBER NUMBER NUMBER 2301 BV-1170 1 2326 BV-1195 A 2351 BV-1220 A 2376 Til-1 1 2302 BV-1171 1 2327 BV-1196 A 2352 BV-1221 A 2377 Til-2 I 2303 SV-1172 1 2328 BV-1197 A 2353 BV-1222 A 2378 Til-3 I 2304 8V-1173 A 2329 BV-1198 A 2354 BV-1223 A 2379 Til-4 I 2305 BV-1174 A 2330 BV-1199 A 2355 BV-1224 I 2380 Til-5 I 2306 BV-1775 A 2331 BV-1200 I (7356 BV-1225 I) 2381 Til-6 A 2307 BV-1176 I 2332 BV-1201 I 2357 BV-1226 1 2382 Til-7 A 2308 BV-1177 I 2333 BV-1202 1 2358 BV-1227 1 2383 Til-8 A 2309 BV-1378 1 2334 BV-1203 1 2359 BV-1228 I 2384 T11-9 A 2310 BV-1179 I 2335 BV-1204 I 2360 BV-1229 I 2385 Til-10 1 2311 BV-1180 1 2336 BV-1205 1 2361 BV-1230 I 2386 Tli-11 1 2312 BV-1181 I 2337 BV-1206 I 2362 BV-1231 I 2387 Til-12 1 2313 BV-1182 1 2338 BV-1207 1 2363 BV-1232 I 2388 Til-13 1 2314 BV-1183 I 2339 BV-1208 I 2364 BV-1233 I (2389 TH-14 I) 2315 BV-1184 I 2340 BV-1209 1 2365 BV-1234 I 2390 Til-15 1 2316 BV-1185 A 2341 BV-1210 I 2366 BV-1235 1 2391 TH-16 I , 2317 BV-1186 A 2342 BV-1211 1 2367 BV-1236 I 2392 Til-17 A 2318 BV-1187 A 2343 BV-1212 I 2368 BV-1237 I 2393 Til-18 1 2319 BV-1188 I 2344 BV-1213 1 2369 BV-1238 1 2394 Tii-19 A 2320 BV-1189 I 2 34 ' BV-1214 1 2370 BV-1239 I 2395 Til-20 A 2321 BV-1190 1 2346 BV-1215 1 2371 BV-1240 1 2396 Til-21 A 2322 BV-1191 1 2347 BV-1216 I 2372 BV-1241 I 2397 TH-22 A 2323 BV-1192 I 2348 BV-1217 I 2373 BV-1242 A 2398 Tll-23 I RT 2324 BV-1193 I 2349 BV-1218 A 2374 BV-1243 A 2399 TH-24 I 2325 EV-1194 A 2350 BV-1219 A 2375 BV-1244 A 2300 Til-25 A ( ) Random splices given in Attachment 6.6.7

~~V-Visual Examination - A-Accept, R-Reject, I-Inaccessible~~
~~F-Follow-Up Testing Acceptance - T-Tensile Test, RT-Radiograph Test ATTACHMENT 6.6.8 (cont.)~~

STATISTICAL VERIFICATION OF SPLICE ACCEPTABILITY Page 24 of 25 M M M M W M D M M W W W W W W W M M M M M M M M M M M W W M M M W M M M W M P SPLICE V* F** # SPLICE V* F** # SPLICE V* F** # SPLICE V* F** NUMBER NUMBER NUMBER NUMBER 2401 Til-26 R RT 2426 Til-51 A 2451 2476 2402 Til-2 7 A 2427 Til-52 1 2452 2477 2403 Til-28 R RT 2428 Til-53 R 2453 2478 2404 Til-29 R 2429 Til-54 I 2454 2479 2405 Til-30 A 2430 Til-55 I 2455 2480 2406 Til-31 R 2431 Tii-56 I 2456 2481 2407 Til-32 1 2432 TV-83 Void 2457 2482 2408 Tit-33 R 2433 TV-1104 Void 2458 2483 2409 Til-34 I 2434 TV-1130 Void 2459 2484 2410 Til-35 1 2435 2460 2485 2411 Til-36 1 2436 2461 2486 2412 Til-37 I 2437 2462 2487 (2413 Tll-38 A) 2438 2463 2488 2414 Til-39 1 2439 2464 2489 2415 Til-40 A 2440 2465 2490 2416 Til-41 R 2441 2466 2491 2417 Til-4 2 A 24i2 2467 2492 2418 Til-43 R RT 2/.43 2468 2493 2419 Til-44 A 2444 2469 2494 2420 Til-45 A 2445 2470 2495 2421 Til-46 I 2446 2471 2496 2422 Til-4 7 R 2447 2472 2497 2423 Til-48 A 244S 2473 2498 2424 Til-49 R 2449 2474 2499 2425 Til-50 1 2450 2475 2500 ( ) Random splices given in Attachment 6.6.7

~~V-Visual Examination - A-Accept, R-Reject, I-Inaccessible~~
~~F-Follow-Up Testing Acceptance - T-Tensile Test, RT-Radiograph Test ATTACliMENT 6.6.8 (cont. )~~

STATISTICAL VERIFICATION OF SPLICE ACCEPTABILITY Page 25 of 25 . - - _A ._ _ i I - I I 3, I; I' SUPPLEMENT 1 l MECHANICAL CADWELD SPLICES JANUARY 23, 1981 I! , Il i l I 1 ATTACHMENT 6.6.9 81' l I' ll 1 I ' E f3 .2 R f,W PUBLIC l SERVICE INDIANA ' E January 23, 1981 E S. W. Sh elds Senior Vice President - Nuclear Division Mr. James G. Keppler, Director I U.S. Nuclear Regulatory Commission Docket Nos.: STN 50-546 Region III STN 50-547

I 799 Roosevelt Road Glen Ellyn, IL 60137 Construction Permit Nos.

CPPR-170 CPPR-171
~~SUBJECT:~~
~~Marble Hill Nuclear Generating Station - Units 1 and 2~~
~~Dear Mr. Keppler:~~
Pursuant to Public Service Company of Indiana, Inc. (PSI's) submittal of The Construction and Material Verification Program Final Report, PSI is enclosing a Supplement 1 (5 copies) to Section 6.0, " Mechanical Cadweld Splices".
Supplement 1 is based on additional information and engineering evaluation developed by PSI since the original report submittal on September 12, 1980.
This information was presented to the NRC in Bethesda, Maryland on January 8, 1981.
, Supplement 1 is divided into three sections. Section 1 discusses the SPP-6 inspection program and results, the Cadweld Radiography and Tensile Testing evaluation and the conclusions on the adequacy of Marble Hill Category I Cadwelds. Section 2 discusses strain in Cadweld Splices, in acordance with your verbal requests of October 31, 1980. Section 3 represents the slides and handout information presented and transmitted to the NRC in the Bethesda presentation on January 8, 1981.
The results of the testing program show conclusively that there are no substandard splices on the Marble Hill Project. Therefore, PSI is requesting NRC approval of Section 6.0 and Section 12.0 of The Constructio, and Material Verification Program.
In response to an NRC concern on possible future changes in the Marble Hill I Specification to include Radiography for accepting visual rejects or incorporating other less restrictive criteria for accepting visual rejects, PSI would like to reaffirm its position. It is PSI's present and future intent n'o t to make any changes in the Marble Hill Specification which would decrease the conservatism of the existing specification or regulatory guide.
I P. O. Box 190, New Washington, Indiana 47162 812. 289.1000
I PUBLIC SERVICE INDIANA Mr. James G. Keppler January 23, 1981 E
During production additional evaluations (i.e., Radiography) are neither practical u r economical. In the future visual rejects will be removed and replaced.
To emphasize PSI's quality commitment on the Marble Hill Project, PSI has elected to remove and replace or repair, visually rejected splices with physical defects identified during the inspection of Cadwelds under the Construction Verification Program. This is over and above commitments of the PSI Construction Verification Program. Fifty (50) type 'T' vertical Cadweld l Splices will be removed and replaced and fourty seven (47) type 'd' vertical =
will be repaired. The list of splices to be removed and replaced or repaired is shown on Attachment 1.
If there are any further quest' ions please let me know. PSI would appreciate your response by February 9, 1981, the date indicated to PSI by the NRC in ,
Bethesda on January 8, 1981.
Sincerely, I
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S.W. Shields DI/dks cc: Victor Stello, Jr., Director (5 copies) ~
Of fice of Inspection and Inforcement U.S. Nuclear Regulatory Commission Washington, D.C. 20555 H.-J. Wong J.J. Harrison g
W E.R. Schweibins, P.E.
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I ATTACHMENT 1 Page 1 of 2 List of B-Type Vertical Splices to be piggy-backed. This is the existing i method by Marble Hill Specification of repairing visually rejected B-Type Cadwelds.
EXCESSIVE VOIDS
~~SLAG POROSITY~~
~~1. BV-266 21. BV-844 41. BV-519 44. BV-22~~
~~2. BV-814 22. BV-932 42. BV-517 45. BV-525~~
~~3. BV-694 23. BV-431 43. BV-736 46. BV-1025~~
~~4. BV-580 24. BV-378 47. BV-1095~~
~~5. BV-730 5 6. BV-855~~
~~25. BV-1013~~
~~26. BV-1023~~
~~7. BV-861 27. BV-743~~
~~8. BV-788 28. BV-449 5 9. BV-1053 29. BV-601~~
~~10. BV-299 30. BV-257~~
~~11. BV-268 31. BV-527 I 12. BV-579 32. BV-460~~
~~13. BV-256 33. BV-724~~
~~14. BV-419 34. BV-591~~
~~15. BV-296 35. BV-720 1 16. BV-1014 36. BV-976~~
~~17. BV-298 37. BV-1019~~
~~18. BV-308 38. BV-4 5 19. BV-255 39. BV-512~~
~~20. BV-476 40. BV-510 t~~
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For the excessive void category of visual rejects this list includes all remaining in place splices in excess of 110 percent of the acceptable void criteria, rejected under the SPP-6 Inspection Program. BV#11 criteria for I allowable voids is 1.5 square inches. 110% is equal to 1.65 square inches.
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NOTE: 1 The above list (2 pages) accounts for all physical visual I rejected splices identified during the SPP-6 inspection program except those splices with excessive voids that are S,
within 10% of criteria. These splices are being accepted on LJ the basis of PSI':. engineering evaluation and testing program.
NOTE: 2 These lists were based on the appendices attached to PSI Corrective Action Request PC 0602. l l
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I ATTACID!ENT 1 Page 2 of 2 List of T-Type Vertical Splices to be removed and replaced. l EXCESSIVE VOIDS
~~EXCESSIVE RECESS SLAG~~
~~1. TV-84 27. TV-77 32. TV-93~~
~~2. TV-97 28. TV-79 (2) TV-97 (Voids)~~
~~3. TV-392 29. TV-485 33. TV-1020~~
~~4. TV-50 30. TV-73 34. TV-446 E~~
~~5. TV-356 3~~
~~31. TV-1041 35. TV-856~~
~~6. TV-66 36. TV-863~~
~~7. TV-355 37. TV-684~~
~~8. TV-373~~
~~9. TV-177~~
~~10. TV-230~~
~~11. TV-494 POROSITY '~~
~~12. TV-367~~
~~13. TV-378 38. TV-19 g~~
~~14. TV-1122 39. TV-34~~
~~15. TV-369 3~~
~~40. TV-382~~
~~16. TV-496 41. TV-410~~
~~17. TV-61 42. TV-412~~
~~18. TV-502 43. TV-416~~
~~19. TV-1062 44. TV-432~~
~~20. TV-1045 (34.)TV-446 (Slag)~~
~~21. TV-1079 45. TV-926~~
~~22. TV-110 46. TV- 46~~
~~23. TV-59 47. TV-873 g~~
~~24. TV-340 48. TV-874 3~~
~~25. TV-56 49. TV-979~~
~~26. TV-384 50. TV-983 3~~
For the excessive void category of visual rejects, this list includes all 3 remaining in place splices in excess of 110 percent of the acceptable void criteria, rejected under the SPP-6 Inspection Program. TV#18-10 criteria g
for allowable voids is 2.65 square inches. 110% is equal to 2.92 square inches.
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i l ces,1xec11es s sirestit vsm1,1c 110s emocaxx etsit azeoa
, ,ec 1c s c _ s,<1ces SECTION 6.0 SUPPLEMENT 1, JANUARY 23, 1981 I
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SECTION 1, INSPECTION AND TESTING PROGRAM .
AND ADEQUACY OF EMBEDDED CADWELDS l
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I. INTRODUCTION (Pages 1 through 4, Section 3)
On January 8,1981 Public Service Company of Indiana, Inc. (PSI) made a I presentation to various departments within the Nuclear Regulatory Commission at the Phillips Building, Bethesda, Maryland. The following is a report of that presentation, which was developed based on the NRC agenda for "Cadwelds -
Marble Hill", attached as page 4 of Section 3.
PSI discussed the chronological sequence of events which led to the presentation. (Pages 1 and 2, Section 3.)
PSI summarized the results of the program (page 3, Section 3) by stating that no substandard splices were found. The Cadweld (SPP-6) results met the I acceptance criteria and commitments required by PSI Construction Verification Program. The results of the program were conservatively biased by an evaluation and test program of the population of visual rejects which shows I that there is a 95% celiability with a 95% confidence factor that there are no substandard splices at Marble Hill.
g In addition PSI evaluated the strain effect of visually rejected physical 3 Cadwelds which shows that the strain effect on the Marble Hill Category I Structures is insignificant.
In summary PSI stated that it was PSI's opinion that no further testing or evaluation of the Cadweld Splices is required.
l II. INSPECTION PROGRAM (Pages 5 through 11 _Section 3)
Terms used throughout this report are defined on (Pages 5 & 6, Section 3),
along with the accept / reject criteria for SPP-6 and Marble Hill Specification I Y-2722. (Page 7 & 8, Section 3) There were nine (9) accept / reject critera for the SPP-6 procedure on visual inspection. Eight of these criteria were due to specification and regulatory requirements. The ninth criteria "No Gage Marks I Visible" was incorporated -into the procedure by PSI because the inspection program took place some ten (10) months after the Cadwelds were installed.
Although missing gage marks do not mean a splice is defective, PSI required inspectors to identify splices without gage marks as rejects for further evaluation by Engineering. It was also noted that there is no specification or regulatory requirement which requires that gage marks be permanent.
Page 9, Section 3 describes the summary of the overall inspection program.
The total number of Cadwelds inspected was 2431. Eight inspections were I performed on each of the 2431 splices, for a total of 19,448 inspections performed. There were 576 inspections performed which did not meet tne accept / reject criteria on 504 splices.
Page 11, Section 3, shows a plan view of the containment structure. Four hundred ninty-four (494) of the visually rejected splices are located in the primary and secondary shield walls, the refueling pool walls and the containment shell wall. The remaining ten (10) visually rejected splices are I
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located in the coastruction openings for the steam tunnels. These splices were rejected due to lack of gage marks. The containment shell wall 'T' type splices were staggered and located at elevations 390 and 394. The remaining B-type splices were all located at elevation 374, at the base of the 3 foot fill slab.
III. CADWELD TESTING PROGRAM (Pages 12 through 17, Section 3)
Page 11, Section 3 Describes the purposes of the Testing Program. It was stressed at this point that the only reason the accessible splices were tested was due to the necessity of evaluating the types of visual rejects in the accessible population to draw conclusions on the acceptability of the embedded Cadwelds. If there had been no embedded Cadwelds, PSI would have removed all the visually rejected splices prov.' Jing adequate reinstallation of splices was practical.
It is important to point out that the visual inspection requirements were l established to ensure adequate tensile strength. In other words, when splices "
are being nade, it is strength, not strain that one looks for.
The main objective behind the visual inspection criteria is to guarantee a "bar breaking" mode of failure with a simple non-destructive conservative procedure of inspection.
The interaction between inspection and production is the key element in achieving bar breaking splices.
Failure to meet the visual inspection criteria on a lot of finished splices
~~does not necessarily mean that:~~
A true visual rejection has occurred.
Substandard splices will result. .
A pullout or sleeve breaking mode will occur.
It means that more eleborate procedures need to be used to further evaluate the splices before they are rejected.
During production, this additional evaluation is neither practical nor g economical; and, therefore, splices that could be accepted are rejected W because it is economically expedient to do so.
Pages 12, 13 and 14, Section 3, describe the scope of the Testing Program.
Fifty nine rr- hmly selected splices from the entire population of inspected Cadwelds (243 vere evaluated on the basis of acceptable inspection, proper
. embedment in
Cadweld sleeve (verified by Radiography), or by tensile l testing of the 59 randomly selected splices. Forty-eight (48) splices passed the inspection criteria, 8 failed the gage mark inspection criteria and 3 l
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I failed the physical inspection criteria. The 8 gage mark visual rejects were radiographed with 3 radiograph failures. These 3 and the 3 physical visual rejects were tensile tested. All tensile test results passed the stress criteria of 75 KSI minimum. At this point the commitments of the overall program were met, providing a 95% reliabilty with a 95% confidence factor that there were no substandard splices in the completed work at Marble Hill. ,
l I PSI realized that the random selection prccess had not necessarily evaluated the worst cases of visually rejected splices it was therefore decided to g further evaluate worst cases where worst cases could be determined. In 3 addition PSI wanted to evaluate those splices with gage mark rejections to determine if the measured gage marks were in fact the actual gage marks and if the splices without gage marks were properly installed.
It must be noted again that the Marble Hill specification does not require a permanent marking system to be used to identify the gage mark. PSI, in I writing the accept / reject criteria for the (SPP-6) Cadweld Inspection Program, took a conservative stand in the inspection program by calling bars without gage marks rejects. Out of the 334 individual splices, 202, or approximately I 54%, of these splices were called visual rejects only under the SPP-6 program. They were not rejects due to noncompliance with Marble Hill specification or endorsed codes. The point of this conservatism was to identify any potential for substandard splices for subsequent evaluation by I PSI cagineering.
Upon review of the SPP-6 inspection findings and initial testit; program (59 random splices from the total population for a 95% reliability eith a 95%
I confidence factor), PSI utilized radiography test program to de. ermine and evaluate the following:
~~1. Location of bar ends in a sample size to provide 95%/95%~~
~~confidence / reliability that no bars had end embedments sufficiently reduced to pull test below 75 psi.~~
~~2. Reliability of marks inspected to be the " actual" gage mark.~~
I 3. Relationship of gage marks out of tolerance by visual inspection to actual bar embedments by radiograph interpretation.
4 I 4. Relationship of bar ends in sleeves with gage marks not centered to actual location of bar ends to sleeve centers by radiograph interpretation.
~~5. Determination of tensile strength of any splices not meeting the radiograph criteria.~~
In the random selection process, 8 splices were radiographed. An additional 58 (54 were required for 95%/95%) were selected from a conservatively biased statistical sampling of the remaining (379) gage mark rejects.
It is noted that the selection process uas biased by selecting worst cases from each Appendix or Category of rejection for each type of splice.
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I Results of the Radiography Test Program were:
~~1. 66 total radiographs taken and interpreted.~~
~~2. 60 RT showed bar ends within tolerances.~~
3. 6 RT's showed bar ends not within required tolerances. These 6 were g tensile tested in accordance with PSI procedures and results ranged from W 76,500-99,2*; psi Average 93,583 (Minimum 75,000 average 90,000 psi required' 3 were borderline cases and were tested to eliminate potential g argume.its over RT interpretation. g
~~4. All 6 RT rejects were 18/18 T-Vertical splices.~~
5. No direct relationship exists between excessiv gage marks greater than or less than allowable tolerances. No relationship exists between gage marks not centered and actual distances of f center as were seen in the E radiographs. 5 It is PSI's conclusion that these marks were not actual gage marks or that g gage distances other than 24" were used, but not documented. E Of the 6 RT rejects no exact pattern exists on the relationships of measured dimensiors of embedment actual measurements by RT Interpretation. The RT procedure conservatively chose worst cases for each splice type and size and these worst cases met the stress criteria.
It is PSI's judgement, there fore , that the visual rejects due to gage marks under the SPP-6 program are not truly rejects according to the specification or code and need no further analysis or evaluation prior to embedment in g concrete. 3 In addition to the 59 random sampling evaluation and the Radiography Test Program for gage mark rejects, the worst cases of the physical rejects were then chosen for each category of rejection and for each type and size of splice. Where worst cases could not be determined quantitatively, worst cases became those splices which had more than one category for rejection.
Twenty-one physical worst cases were chosen and tensile tested. All splices passed the tensile minimum stress requirement of 75 KSI and the lowest 15 results were in excess of 90 KSI.
IV.
~~SUMMARY~~
(Page 18, Section 3)
In summary of the overall inspection testing program 1794 splices were inspected and visually acceptable; 60 splices were radiographed and accepted and 30 splices were tensile tested and accepted. Thus 1884 splices of those examined were acceptable giving the overall program a 95% CONFIDENCE WITH A 99% RELIABILITY. Therefore the commitment for a 95% reliability with a 95%
confidence factor was surpassed due to the additional examination (radiography) and tensile testing of the worst cases of visual rejection over E and above the 59 randomly selected splices from the total population. 5 I
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I V. ADEQUACY OF EMBEDDED CADWELDS (Pages 44 through 50, Section 3)
In addition to the evaluation of data from the Cadweld Inspection Program (SPP-6), PSI also reviewed data available on Cadweld Operators, Cadweld
' I Inspectors and sister and production splice test results to evaluate the buried Cadwelds.
l Seven (7) handouts (Pages 44 through 50, Section 3) were developed from this l available Cadweld data.
Prior to the date of Category I work shutdown, 351 Category I sister and production splices were tensile tested on the Marble Hill Project. Since the shutdown, 30 additional production splices (27 of which were the worst cases of physical visual rejection) were tensile tested. All tensile tested splices to date on the Marble Hill Project have met the strength criteria of the l Project specifications and Regulatory Guide 1.10.
l It is noted that the industry average for tensile test failures is 2-8%, on similiar nuclear power plant projects.
l Another concern of the NRC was the potential for a similar number of visual l rejected Cadwelds to be buried in the Unit 1 containment structure. The Operator Distribution and Inspector Distribution handoucs, pages 48 & 49 I respectively, were developed to statistically estimate the potential for visual rejects in Unit 1. These tables were based on the actual percentages of visual rejects in Ur.it 2 for Operators and for Inspectors. The results of i
I the statistical estimate indicate a potential for 89 to 111 physical visual rejects. However, Unit 1 splices were reinspected between August, 1978 snd February, 1979. Reinspection of all Type B and T Cadwelds was performed for excessive voids and porosity. (Voids and porosity rejects made up 90% of th'e I total physical rejects for Unit 2). This item had been previously identified by Region III Inspectors in I.E. Repc-t 50-546/78-08-02; 50-547/ 78-08-02 and was closed by Region III I.E. Report 50-540/79-03; 50/547/79-03.
Therefore, it is PSI's conclusion that this second inspection of Unit 1 l Cadwelds eliminated the potential for buried visual rejects in Unit 1.
l VI. CONCLUSIONS
~~1. No substandard splices exist at Marble Hill.~~
~~2. Gage mark rejects are not true rejects in accordance with specification or l g code, thus, the evaluation program eliminated 358 of the 504 individual jg splices as visual rejects.~~
~~3. 146 out of 2431 or 6% were true visual rejects. .~~
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It is noted that the industry average is 2-8% substandard splices. Marble Hill tested worst cases of visual rejects and had 0_% substandard splices.
~~4. The Marble Hill Project has had no substandard sister or production splice test results.~~
~~5. Unic 1 Cadwelds do not exhibit the type of visual rejection identified under SPP-6.~~
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~~Journal of the Construction Division, A.S.C.E September 1979, " Quality Control of Cadweld (Mechanical) Splices, H. Randolph Thomas, Jr. l W~~
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MARBLE HILL CADWELD SPLICES - STRAIN EFFECT I. Strain in Cadweld Splices (Figure 1, Section 3)
The test program and test results on Cadweld splices at Marble Hill were described earlier. The results of the test program showed that these l
e splices met the strength requirements of the NRC Regulatory Guide 1.10.
In addition to these tests, the NRC requested that PSI evaluate the g effect of strain on the behavior of structural members with Cadweld 3 splices which did not meet the visual inspection acceptance criteria.
It seems that the NRC's main concern is (1) that the Cadweld splices whf.h did not meet the visual examination might show a "sof ter" stress-strain relationship than the splice which does meet the visual acceptance criteria and (2) the effect th a t this possible " softness" might have on the structural load-carrying characteristics and concrete cracking. We shall address this concern from three standpoints.
~~1. Code requirements.~~
~~2. Erico tests and comparison to Marble Hill case.~~
~~3. Stresses and crack widths at Marble Hill if visually rejected splices with physical defects were assumed non-existent in the structure.~~
II. Code Requirements (Figure 2, Section 3)
Strength, not strain is the ultimate criterion for acceptance of Cadweld splices for the following reasons:
~~1. ACI 318-71 & 77 require the Cadweld splice to meet 125% of the specified minimum yield strength.~~
Reg. Guide 1.10 and ASME,Section III, Division 2, (ACI-359)
CC-4333.3 require, in addition to the 125% fy strength criterion, that the average of 15 consecutive samples equal or exceed the tensile strength of the bar. Under the SPP-6 program, Marble Hill ,
splices met these criteria. No manufacturer's recommendation imposes a stress / strain criterion. '
ACI 349-76, which does not govern Marble Hill work, requires in Section 7.5.5 that splices be staggered if the strain measured over the length of the connector at .9 yield stress exceeds that of an unspliced bar by more than 50% and if the maximum computed design load stress in the bar equals or exceeds 0.5 f y. For Grade 60 bars, the strain at which splices should be staggered is
.9 x 60 1.5 = .0028.
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1 At Marble Hill, T-s eries splices in the Containment exterior shell l I wall and basemat are staggered and meet this ACI-349 criterion. This was done for crack control prior to the issuance of ACI-349. The only T-splices not staggered are the ones in conatruction openings.
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There were 52 T-splices in the construction opening in the steam l tunn21. Ten of them had no visible gage marks because of concrete j splatter. Three were radiographed and passed the radiography )
criteria.
2. The visual inspection requirements were established to ensure l adequate tensile strength. In other words, when splices are being I made, it is strength not strain that one looks for.
The main objective behind the visual inspection criteria is to guarantee a "bar breaking" mode of failure with a simple I non-destructive conservative procedure of inspection.
I The interaction between inspection and production is the key element in achieving bar breaking splices.
I Failure to meet the visual inspection criteria on a lot of finished splices does not necessarily mean that:
A true visual rejection has occurred.
Substandard splices will result.
t A pullout or sleeve breaking mode will occur.
It means that more eleborate procedures need to be used to further evaluate the splices before they are rejected.
During production, this additional evaluation is neither practical nor economical; and, therefore, splices that could be accepted are rejected because it is economically expedient to do so.
Marble Hill accessible splices were evaluated further by radiographic examination and/or tensile tests. All splices met the required I strength criteria..
III. Erico Tests (Figure 3 through 6, Section 3)
In 1967, at the University of Illinois, Urbana, Dr. C. P. Siess and Mr. A. F. Abbasi conducted tests on reinforced concrete beams with Cadweld reinforcing bar splices for Erico Products, Inc., Cleveland, Ohio (Ref. 1). One of the objectives of the test was similar to what the NRC is looking for in the case of the Marble Hill Cadweld I splices, i.e., an evaluation of the effects of stress-strain characteristics of the splices on the ultimate moment capacity and load deflection characteristics of the concrete members. Siess and Abbasi drew the following conclusions from these tests:
~~1. The presence of even very " soft" splices had no significant effect on ultimate moment capacity, mode of failure, crack pattern or, location of crushing of the beams.~~
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~~2. At service load levels , the presence of even very "sof t" splices g had no significant effect on either measured or computed g deflections.~~
~~3. At or near yield load, the deflections were increased 15% to 20%~~
for the beams with very "sof t" splices. Ilowever, at failure by crushing of concrete, the deflections were essentially the same for all beams.
Test Description Following is a summary of the Erico tests and their relation to the Marble Hill Cadweld splicas.
Tests were madei n four reinforced concrete beams 8-inch wide by 12-inch deep with 12-foot spans, loaded at two points to provide a constant moment over the central 5-foot of the span. All of the beams were reinforced longitudinally in tension only with two No. 8 bars which had the following splice conditions:
~~a. One beam (CAD-3) had unspliced bars.~~
b. Two beams (CAD-2, CAD-4) had both bars spliced at the mid span in such a way that very "sof t" stress-strain characteristics were produced. This was done by introducing a 1-1/2" " free" steel plug inside the splice sleeve between the two ends of the bars being spliced. The plug ef fectively reduced the embedded length of the bars in the sleeve and produced exaggerated " soft" stress-strain characteristics.
~~c. One beam (CAD-1) had bars with standard Cadweld splices.~~
Figure 4, Section 3 shows the stress-strain relationship for a standard Cadweld splice, the average curve for splices degraded by moistening of the bar ends and for splices degraded by introducing one and two inch rigid free plug as shown in Figure 3, Section 3. A comparison between these stress-strain curves shows that the moistened Cadweld splice lies between the standard splice and the degraded splices with a plug in the middle. These " plugged" splices show very " soft" stress-strain characteristics.
In the tests, all beams were loaded to failure. The deflections of the beams, steel strains, and concrete strains were recorded during each increment of the applied load.
Test Results The results of the Erico tests are summarized below:
All of the beams failed by yielding of the tensile reinforcement followed by crushing E of the concrete in the constant moment region 3
- i.e., all beams showed a ductile failure.
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The crack patterns of all stages of loading and I failure were generally quite similar for all beams.
The ultimate moment capacities were essentially I the same for all of the beams, irrespective of the characteristics of the splices. The measured ultimate moments are listed in Table 1. (Attached)
The measured load-deflection curves for all beams are shown in Figure 6, Section 3. For loads lower than 50%
of the ultiamte load, the deflections are essentially I the same for all beams. At the yield load the deflections for beams with very sof t splices (CAD-2, CAD-4) were 15% to 20% larger than for the beams with standard splices.
At failure by crushing of the concrete, the deflections were again essentially the same for all beams.
IV. Marble Hill Less Severe than Erico Tests (Figure 7, Section 3)
A review of the Marble Hill test results presented earlier for visually rejected splices with excessive voids, excessive recess, slag and porosity shows that the Marble Hill worst splices are not as " soft" as the ones tested by Abbasi & Siess for the following reasons:
1. In order to decide on a " degraded" splice for use in the concrete beam tests, bars were moistened to cause porosity. Moistening leads I to a release of gases which " blow out" when the molten filler material is poured. This also causes excessive porosity in the remaining filler metal. The stress-strain curves for these i " moistened" splices showed some increase in strain, which was judged insufficient and unrepeatable for the purpose of evaluating the effect of degraded splices on concrete beams. As a result, Abbasi and Siess chose the free plug to degrade the splices. Marble Hill I splices with porosity did not result in a blowout condition. This porosity was localized porosity typical of residual condensation or i locally entrapped gases. There fore , the porosity is less severe than i I those tested by Erico, where bars were purposely moistened.
5 Furthermore, out of thirteen splices with porosity, four splices which had, in addition to porosity, other visual rejections were !
tensile tested and the strengths ranged between 89, 333 psi and 105,000 psi. !
I 2. The 1-1/2" unstressed rigid plug used in Erico's beam tests prevented the sleeve from deforming and applying a tight grip on both bars. I This gripping effect (Poisson's ef fect) is not prevented in Marble
+I Hill since there are no rigid plugs. Gripping of the bars results in an overall improvement in strain behavior, as it reduces slippage
, between the bars and the sleeve. The importance of the gripping effect is shown in the Erico tests when two significantly dif ferent plug lengths (l" and 2") resulted in essentially identical stress / strain curves, because in both cases the grip was prevented.
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3. In Erico's tests the plug reduces the bar embedded length into the g sleeve and the gripping effect of the sleeve on both bars. Uance, g splices with voids resulting in a similar loss of embedded leagth and no loss in the gripping effect should behave as well or better than those tested by Abbasi and Siess. This is shown in the following table:
~~1 2 3 4 5 Equivalent void to Table 2~~
l-1/2 plug Correction Factor for Bar 0.75 x peri- Rela tive [ To tal Eq uiv . Worst Voids for Size meter Embedment Voids T-splices
~~in2 -~~
in2 in2 I
10 2.99 0.79 2.36+3.99=6.35 5.91 14 3.99 0.85 3.39 2.44 18 5.31 0.83 4.35 3.52
~~Table 2 Attached In the above table:~~
-Col.1 gives the bar sizes for splices exhibiting excessive voids.
-Col. 2 gives the void area for each bar size equivalent to 1 1/2" plug (or 3/4" per one side) by multiplying the bar perimeter by 3/4".
-Col. 3 gives a correction factor obtained as shown in Table 2 taking into account the relative embedment of the #8 bar used in Erico tests as compared Marble Hill bars.
-Col. 4 gives the total adjusted equivalent voids, and results from multiplying Col. 2 by Col. 3. Also in this Column, No. 10 bars occur I
in 18 to 10 transition splices. In these splices there is no void criterion for #10 to #18 transition splices. In SPP-6, a conservative allowable void of 2.65 in2 is given. This value is smaller than the 2.99 in2 recommended by Erico when consulted on ;
this subject. However, even 2.99 is a conservative value when #11 to
~~18 sleeves are used. That is when a #10 sleeve is used, the~~
~~embedded length is 2.5 inches, and when a #11 to #18 sleeve is used~~
( for #10 to #18 splices, the embedded length in the #10 bar side is 1 3.50 inches. An additional embedded length of 1.0 inch is provided.
l This additional length is equivalent to 1.0 x 3.99 = 3.99 in2 of void area.
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I Furthermore, At Marble Hill, the worst void area for No.18 to 10 are 14.44, 5.91, and 5.84 . These were tested and their tensile I strengths are respectively 87.4, 99.6, and 102.8 ksi.
ll -Col. 5 gives the worst case for voids in T-Splices at Marble Hill e identified during SPP-6 Inspection Program.
Type "B" splices have an additional 3" bar embedment which minimizes I the ef fect of voids at the top of the sleeves.
~~4. In Erico's tests,100% of the beam reinforcing was "sof tened".~~
~~I Marble Hill, a maximum of 8.2% of the primary shield wall splices were visually rejected due to physical defects. The worst cases were At tensile tested and passed the tests.~~
V. Stress and Crack Analysis (Figures 8 through 14. Section 3)
Figure 8 shows a plan view of the Containment showing the walls in question.
Figure 9 shows a section and a typical detail of the "B" splice used.
Figures 10 through 13 show the location of the visual physical rejections in Containment Unit #2.
= Figure 14 is a summary of percent rejected splices for each location.
Included in these percentages are the splices already removed and
~g tested. These would be replaced with standard visually acceptable
~~3 splices.~~
VI. Containment Internals (Figure 15, Section 3)
The type B Cadweld splices with excessive voids, excessive recess, slag and porosity are located inside the Unit 2 Containment. These splices
-lW are welded to embedded plates on the top of the base mat containment liner. The mat liner is covered with a three foot thick fill slab.
These Cadweld splices with excessive voids, excessive recess, slag and g porosity are located below the primary shield wall, secondary shield 5 wall or refueling pool walls at the bottom of the three foot thick fill slab.
These walls have been designed using the load combinations shown in Table 3.8-lb of the Marble Hill Preliminary Safety Analysis Report (PSAR). The governing load case is PSAR load case #6 (1.4 dead load +
l 1.7 live load + 1.3 thermal pipe reaction + 1.9 OBE = 1.3 operating
temperature). The primary function of these bars is to resist horizontal shear and overturning due to seismic loads. These sections g of walls are in compression during normal non-seismic operation. As
~~3 stated in Section 3.8.1.1.5.5 of the PSAR, the reinforcing steel stress has been limited to 48.6 ksi [=.9 X.9 (=g factor per ACI 318) X 60~~
~~g ksi]. The allowable steel stress as per ACI 318-71 is 54 kai (0.9 Fy).~~
~~5 The resulting steel stress ignoring all splices with excessive voids, excessive recess, slag and porosity is 52 ksi. This is based on 8.2%~~
(worst case) unavailable bars in the primary shield wall. (NOTE: This I percent includes some previously removea and tensile tested bars which will be replaced.) Any resulting increase in strain is not of concern 15-
I due to the physical location of these Cadwelds. These splices are g located at the bottom of very thick walls and confined within a three 5 foo t thick slab. Any cracks caused by excessive strain at the splices would occur at the bottom of the fill slab just above the mat liner as a separation. Since separations are due to seismic load cases, they sre of short duration and of no concern.
VII. Containment Shell (Figure 16, Section 3)
The type T cadwelds having visual " physical" rejections are located in the Unit 2 containment shell. The containment wall has been assessed I for the critical load combinations from PSAR table 3.8-1C assuming W Cadwelds labeled suspect for physical reason provided g rebac continuity (i.e., an infinite strain at zero stress). These cadwelds consist of #18 to #10 transition splices, #18 to #14.' transition splices and #18 splices.
For the service and factored load combinations of the PSAR, the bar attess was reanalyzed considering no continuity at suspect (physical) cadwelds. It was found that the steel stresses at the locations of the visually rejected splices as the excessive voids, recess, slags or E porosity are within the limits specified in the PSAR Section 3.8.2.4, 5 (the limit for sarvice level steel stress is 30 ksi, and for factored level steel stress is 54 ksi). Furthermore, the maximum rebar stress found in the assessment for the test and normal operating combinations was about 10 ksi.
The 10 kai steel stress corresponds to a calculated crack width at the reinforcing of approximately of 0.003" based on the method contained in Reference 2. We do not consider cracks of this size significant with regard to serviceability. The calculated crack width values for the containment are smaller than ACI 318-71 limits of .013" and an accepted limit for crack width in hydraulic structures of .01". Cracking is of no concern for factored loads because, a) the structure is designed to g remain within the elastic range, and b) the loads which produce cracking 3 are short term.
Therefore, the visually rejected cadwelds will have no deleterious effect on containment strength or servicability for the postulated loads.
VIII. Conclusion (Figure 17, Section 3)
It has been shown that consideration of strain behavior, taking in account the visually rejected Cadweld splices, does not lead to impairment of the structural integrity or serviceability of Marble Hill '
structures.
This conclusion was reached by addressing strain from the following three different aspects:
~~1. Code requirements l~~
~~l 2. Tests~~
~~3. Location of Cadweld splices at Marble Hill I '~~
IX. Additional Questions:
I A. Deflections:
I The NRC requested an assessment of the effect of rejected splices on the deflections. The following addresses this concern:
, 1. Containment Internals The primary shield wall, secondary shield wall and refueling pool walls have the following physical dimensions:
I LOCATION HEIGHT THICKNESS Primary Shield 26'-l 1/2" 8'-5 1/2" Wall Secondary Shield 78'-0" 4'-6" Wall I Refueling Pool 16'-0", 50'-0" 3'-6", 5'-0" Walls These physical sizes have been chosen based on shielding requirements, not strength requirements. Deflections of the above structures under the controlling load conditions will be I insignificantly affected by the presence of the visually rejected splices due to the excessive mass of these walls required to meet shielding requirements.
2. Containment Shell I The deflections for the test and normal conditions for the containment shell will be unchanged due to the presence of suspect cadwelds because the wall remains in membrane compression. The deflection for the LOCA and seisimic combinations remain essentially I unchanged because Cadweld effects are localized. Furthermore, these deflections are of no concern as long as stresses remain within allowables.
B. Containment Basemats The NRC requested an assesment of the buried Cadweld splices in I Containments #1 and #2 basemats. These splices a- 'naccessible.
I The cadweld splices in the containment basemats are #18 T type as required to provide splices betueen 60' long sections of hoop bars.
Adjacent cadwelds are staggered by a minimum of 6 in the basemats.
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The 12' thick containment basemat was poured on the foundation rock I and the top surface is almost completely covered by the containment liner.
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I The potentia, presence of cadweld splices which exhibit "sof t" strain behavior in ti e containment basemat will have no effect on the l
=
serviceability if the containment. Strength has already been demonstrated to be adequate through the tensile testing program E undertaken in conjunction with SPP-6. If the suspect cadwelds are 3 sof ter or have a lower ef fective modulus in comparison with cadwelds in general, any strain effects, bar slip and concrete cracks will be localized to the cadweld location due to the staggering employed.
Since the amount of steel provided is controlled by the earthquake and pressure load combination, the basemet cadwelds experience small stresses for the other load combinations and any local ef fect due to cadweld softness will result from earthquake and thus be short term.
Furthermore, the basemat rebar and cadwelds are noc subject to exterior exposure or a corrosive environment since they are protected g not only by the concrete but by rock and the liner. 3 I
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! -REFERENCES-
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~~1. Report for Erico Products, Inc., " Tests of~~
~~l Reinforced Concrete Beams with Cadweld Rein-I W forcing Bar Splices" by C. P. Siess and i A. F. Abassi, January, 1967.~~
~~!I i 2. " Determination of the Maximum Crack Width l g in Reinforced Concrete Members," by P. Desayi,~~
~~g ACI Journal, August 1976, Title No. 73-40.~~
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TABLE I (Reference 1)
MEASURED VS. COMPUTED ULTIMATE MOMENTS FROM ACI CODE I
I Measured Computed Beam f' c fy Ultimate Ultimate e Moment Moment psi psi Including as per ACI 3163 Measured (1) (2) In-kips In-kips Computed CAD-1 4770 48.0 646 650 0.995 CAD-2 3920 47.1 635 622 1.02 CAD-3 3660 46.5 620 608 1.02 CAD-4 3550 47.3 614 613 1.00 I
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I -TABLE 2-I Characteristics of the Splice Embedded Length as Per Table 1 of ASTM A-615 I
I BAR MINIMUM NUMBER OF EMBEDDED BAR SURFACE /BAR I SIZE DEFORMATIONS
EMBEDDED CROSS SECTIONAL AREA RATIO I 18 2.7 7.64 14 2.8 7.83 11 2.8 7.99 10 2.6 7.2C 9 2.9 E.19 8 3.3 9.2 7 4.4 10.6 6 4.1 12.4 5 5.2 11.5 4 5.2 14.2 I
,
~~Based on Maximum average spacing.~~
~~Assuming ef fectiveness ratio for #8 bars (tested by Erico) as 1, the I correction factor for other sizes are:~~
~~10 - 7.26/9.2 = 0.79 I #14 - 7.83/9.2 = 0.85~~
~~18 - 7.64/9,2 = 0.83 I~~
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SUPPIB ult 1 I
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I; Il Il I 1 SECTION 3 P [SENTATION # 0 HN FJR ll Il
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PRESENTATION
~~1. INTRODUCTION W. i3R0~~
~~2. SPP-6 PROGRAM D. INGMIRE~~
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3. EFFECT OF STRAIN A. M0RCOS l 4.
~~SUMMARY~~
W. PETR0 l
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CHRONOLOGICAL SEQUEtlCE OF EVENTS l RELATING TO CAD!!EL" PDFSFilTAT10tl PSI HALTS ALL CATEGORY I HORK, .AUG. 7.
I AuG. '79 flRC CONFIRMS CESSITATION OF CATEGOP.Y I WORK, AUGUST 15. NRC ISSUES NINE-POINT CONFIRMING ORDER.
FEB, '80 PSI SUBrilTS STEPWISE PROCESS TO RESUME g CATEGORY l WORK, FEBRUARY 28.
IlAY '80 NRC APPROVES PSI " BROWN BOOK," STEPWISE PROCESS TO RESUME CATEGORY I WORK, INCLUD-ING CONSTRUCTION VERIFICATI0rl PROGRAM, MAY 15.
JUNE '80 NRC CONCURS WITH PSI CONSTRUCTION VERIFI-I CATION PROCEDURE SPP-6, REVISION 3, JUNE 4. g July '30 NRC CONCURRENCE WITH TESTING PROGRArt.
AuG. '80 PSI SUBMITS CONSTRUCTION VERIFICATION FINAL REPORT (" INCLUDING TEST!tlG PROGRAM") TO REGION III, AUGUST 27.
I OCT. '80 NRC MEETS WITH PSI AT MARBLE HILL SITE Ort OCT. 31 TO PRESENT NRC DRAFT PROPOSAL FOR ADDITIONAL TESTING OF ACCESSIBLE CADWELDS.
N0v. '80 PSI-NRC HOLDS MEETING IN CHICAGO, TO MAKE PRESENTATION Oil CADWELD INSPECTION AND TESTING PROGRAM, AFTER 2 t10NTHS OF INFORMAL tiEETINGS AtlD CONFERENCE CALLS WITH REGION III, NOVEf1BER 10. I l I l
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- - - - - - - - - - - -w --a_.4 .._.a ma a.a.--a- - - - - - - - . _.e. %a.m.-m -w-.aeaM.e. ,.--.h*...ra.~M.e,--m...+ n. m m. w. w 4Aa a___Jb d-- *+ - + - -+- - - ---h--e - - + ---- - - -*m*--- -" A->.h- - - - --- .- - *-
~~SUMMARY~~
PROGRAM MET ACCEPTANCE CRITERIA SAMPLE SIZE EXCEEDED THAT REQUIRED FOR A 95/95 CONFIDENCE / RELIABILITY STRAIN EFFECT IS INSIGNIFICANT CONCLUSION NO FURTHER TESTING IS REQUIRED i
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AGENDA FOR MEETING ON "CADWELDS - MARBLE HILL" g 1/08/81 AGENDA A. BACKGROUND OF CADWELD DATA SPP-E VISUAL INS. RESULTS - PURPOSE & SCOPE
~~1. (CONSTRUCTION VERIFICATION PROGRAM AT MARBLE HILL)~~
I 2.
3.
RADIOGRAPHY RESULTS TENSILE IEST RESULTS l
B. PSI EVALUATION OF ADECUACY OF EMBEDDED AND ACCESSIBLE CADWELDS
~~l. PROGRAM - OvERALL COMMITMENTS AND RESuLTS !~~
~~2. ADEQUACY OF EMBEDDED CADWELDS~~
~~3. GAGE MARKS NOT IRUE VISUAL REJECTIONS~~
~~4. STRAIN EFFECT~~
~~5. CONCLUDING STATEMENT C. NRC CONCERNS /0UESTIONS g I~~
I HANDOUT INFORMATION l PRODUCTION AND SISTER SPLICE IEST RESULTS
' l SIMILARITIES AND DIFFERENCES BETWEEN ACCESSIBLE AND INACCESSIBLE CADWELDS
~~SUMMARY~~
OF LOCATIONS FOR CADWELD SPLICES - UNITS 1 & 2 I
a I
l DEFINITIONS g STANDARD SPLICE: -
A SPLICE WHICH MEETS ALL ACCEPT / REJECT CRITERIA (BOTH THE GAGE g ;
MARK AND CENTERIrlG CRITERIA AND THE PHYSICAL CRITERIA FOR VOIDS, RECESS, SLAG, POROSITY, ETC.) SEE FLIMSY ON ACCEPT / REJECT CRITERIA.
VISUALLY REJECTED SPLICE:
l
~~A SPLICE THAT FAILS ONE OR MORE OF THE ACCEPT / REJECT CRITERIA.~~
SUBSTANDARD SPLICE:
g A SPLICE THAT FAILS TENSILE TESTING (TEST LESS THAN 75,000 PSI).
g PHYSICAL VISUAL REJECT:
EXCESSIVE VOIDS, EXCESSIVE FILLER RECESS POROSITY, SLAG, LACK OF FILLER METAL, TWO TAP HOLES, TAP HOLE BURNOUT.
l GAGEMARK VISUAL REJECT:
NO GAGEMARKS, GAGEMARKS NOT CENTERED WITH TAP HOLE, GAGEMARKS EX-CEED TOLERANCE OR LESS THAN TOLERANCE.
TYPE "T" SPLICE (T-VERTICAL, TV OR T-HORIZONTAL TH):
~
I DEVELOP FULL POSITIVE ULTIMATE STRENGTH MECHANICAL CONNECTIONS BE-l TWEEN TWO REINFORCING BARS WITH A COMMON SLEEVE IN TENSION AND COM-PRESSION. TRANSITION SPLICES ARE USED WHEN BARS OF DIFFERENT SIZE 3
I ARE TO BE SPLICED.
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. DEFINITIONS,c0NT.
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TYPE "B" SPLICE (B-VERTICAL OR BYl: I PROVIDE A MECHANICAL MEANS OF CONNECTING REINFORCING BARS TO l STRUCTURAL STEEL PLATES AND SHAPES.
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I ACCEPT / REJECT CRITERI A FOR SPP-6 AND SPECIFICATION Y-2722
~~1. FILLER METAL MUST BE VISIBLE AT THE ENDS OF THE SPLICE SLEEVE.~~
~~2. FILLER METAL MUST BE VISIBLE AT THE TAP HOLE.~~
~~3. FILLER METAL SHALL NOT BE RECESSED MORE THAN 1/2 INCH AT SLEEVE ENDS.~~
>l 4. SPLICES SHALL NOT CONTAIN SLAG AT TAP HOLE OR SLEEVE ENDS.
l 5. SPLICES SHALL NOT CONTAIN POROSITY AT TAP HOLE OR SLEEVE ENDS.
l 6. VOID AREA SHALL NOT EXCEED 2,65 SQUARE INCHES FOR #18 2.00 " "
~~14 l~~
l 1.50 1,58 FOR #11 FOR #10 l 1.03 FOR #10,9,8, 7,6
<g 0.53 5 0.47 4 l 7, DISTANCE BETWEEN GAGE MARK AND STRUCTURAL STEEL PLATE OR SHAPE FOR TYPE B SPLICE 12 + 1/2 INCHES
~~8. A. DISTANCE BETWEEN GAGE MARKS l~~
FOR A TYPE I SPLICE SHALL BE 24 1/4 i 1/2 INCHES B. THE CENTERLINE OF THE DISTANCE BETWEEN GAGE MARKS SHALL FALL WITH THE DIAMETER OF THE TAP HOLE.
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~~9. N0 GAGE MARKS VISIBLE - WAS A REJECT CRITERIA EVEN THOUGH A PERMANENT MARKING SYSTEM IS NOT REQUIRED.~~
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24 k" t 1/2" or (:c+y+ k" ) t 1/2" l
. , -k" t k" ( s ee 3. 7 )
~~g,auge line TAP HOLE % fCA LD~~
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GAUGE MAS b GAUGE MARK REINFORCING BA REINFORCING BAR
= ; f SLEEVE LEtIGTH (IN) ,
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"CMark 12"+ k" or d + ",(Mark 12" + " or y + %" i from end of bar. (see 3.5)'* !
TtPE "T" SPLTCE IM5EDMEW DP. ENS IONS 3 ;URE 4 -
~~These r'equirements and tolerances '~~
i are independent to each other. .
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~~SUMMARY~~
OF INSPECTION PROGRAM I
I g TOTAL IlUMBER OF CADWELDS INSPECTED 2431 TOTAL NUMBER OF INSPECTED ITEMS 19448 g ,
TOTAL NUMBER OF VISUAL REJECTED ITEMS 576 g
(CASES OF REJECTION)
TOTAL NU".BER OF CADWELDS WITH VISUAL REJECTIONS 504 I
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THE BREAKDOWN OF VISUAL REJECTS INTO CATEGORIES (CASES) AS FOLLOWS: g
~~1. NO GAGE MARK (G.M.) 203 I~~
~~2. G.M. OUT OF TOLERANCE 106~~
~~3. CENTERLINE OF G.ft. il0T ll! THIN -~~
~~111 TAP HOLE DIAf'.ETER~~
~~4. EXCESSIVE VOID AREA 103~~
~~5. EXCESSIVE RECESS 7~~
~~6. SLAG AT TAP HOLE 26~~
~~7. TAP HOLE BURt10UT 3~~
~~8. POROSITY IN SLEEVE EtIDS 14 g;~~
~~9. NO FILLER f!ETAL VISIBLE AT 1 l THE SLEEVE EtlDS l!~~
10, 2 TAP HOLES INDETERMIflA"E 2 TOTAL 576 !
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I PURPOSE OF TESTING: 1. TO PROVE THAT THE TYPE OF VISUAL REJECT PRESENT IN THE ACCESSIBLE g
POPULATION OF CADWELDS AT MARBLE HILL ARE NOT SUBSTANDARD SPLICES.
g
~~2. TO ASSURE THAT VISUALLY REJECTED SPLICES MEET THE STRESS AND l AVERAGE STRESS REQUIREMENTS (75 KSI MINIMUM, 90 KSI AVERAGE FOR 15) AT A 95% RELIABILITY WITH A 95%~~
l CONFIDENCE FACTOR. g NOTE: THE ONLY REASON THE ACCESSIBLE SPLICES WERE TESTED WAS DUE TO THE NECESSITY OF EVALUATING THE TYPES OF REJECTS IN THE ACCESSIBLE POPULATION TO DRAW I CONCLUSIONS ON THE ACCEPTABILITY OF BURIED CADWELDS.
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SCOPE OF TESTING RANDOM SAMPLE TOTAL POPULATION SCOPE OF TESTING: 1. SELECT 59 RAND 0M NUMBERS FROM ENTIRE POPULATION OF ACCESSIBLE CADWELDS AND DETERMINE BY VISUAL INSPECTION, RADIOGRAPilY OR TENSILE TESTING TilAT Tile SPLICES MEET THE SPECIFIED VISUAL INSPECTION CRITERIA: THE RADIOGRAPH CRITERIA FOR GAGE MARK REJECTION OR Tile SPLICE MUST BE CUT OUT AND TESTED ACCORDIllG TO STRESS RE-QUIREMENTS.
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l SCOPE OF TESTil1G RAND 0M SAMPLE TOTAL POPULATI0li
~~2. FOR CONSERVATISM, GROUP ALL VISUAL GAGE MARK REJECTS AIID RADIOGPAPil SPLICES TO OBTAlfl A 95% CollFIDEilCE FACTOR TilAT TiiE REBARS ARE~~
-l lilSTALLED/ EMBEDDED CORRECTLY WITHiti THE SLEEVE OR IF RADIOGPAPilED OUTSIDE OF TOLERANCE TiiEN TENSILE TEST RT REJECTS.
1 e e e m e m M M m m m a m m m m en as e
ADDITI0I1AL WORST CASES PHYSICAL REJECTS
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~~3. FOR C0i1SERVATISM DETERMIllE WORST CASES OF ALL VISUAL PHYSICAL REJECTS AtlD TEllSILE TEST TO SHOW ACCEPTAllCE OF MittlfluM Af1D AVERAGE STRESS.~~
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~~SUMMARY~~
OF PilYSICAL TESTS VISUAL REJECTS METIIOD TENSILE TEST RESULTS (PSI)*
INSPECTED TOTAL NUMBER NUMBER OF ITEM NUMBER TESTED PASSED TEST liighest Lowest Average Excessive Void 103 13 13 T 105,000 84,445 98,206 Area **
Excessive Recess 7 2 2 T 102,205 100,787 101,496 Of The Filler Metal Slag Penetration 26 8 8 T 100,641 89,333 96,203 Beyond The Sleeve At The Tap liole Tap IIole Burnout 3 3 3 T 97,500 92,564 95,188 Porosity In The 14 4 4 T 105,000 89,333 96,277 Sleeve Ends No Filler Metal 1 1 1 T 109,764 Visible At The Sleeve Ends 2 Tap IIoles 2 1 1 T 97,000 (MU)
TOTAL $ 15 6* *
~~31 30 (T) 109,764 84,445 97,710 1(MU)~~
T = Tensile Test I
(MU) = Mockup
= Acceptance Criteria: < 75,000 psi for individual splice and average of any 15 test results had to meet or exceed 90,00 psi.
~~= Same splice TV-434; 8,9,3 3 3 TV-541 ; 105,000~~
~~= 2 splices which had "indeterminant" conditions:~~
l by TV-1087 & TV-1101 2 tap holes are included.
( E E E E E E E E E E E E E E E E E M E t
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~~SUMMARY~~
OF GAUGE MARK TESTS VISUAL REJECTS METIIOD TENSILE TEST RESULTS (PSI)*
INSPECTED TOTAL NUMBER NUMBER OF ITEM NUMBER TESTED PASSED TEST Ilighest Lowest Average No Gauge Marks 203*** 25 25 RT Out of Tdlerance 106 29 27 RT 97,750!89,750 93,75G Gauge Marks 2 T [
" Centerline Of 111 19 15 RT 99,250 76,500 93,500 Gauge Marks Not 4 T Within Diameter i Of Tap IIole i TOTAL 420 73 66 RT 99,250 76,500 93,583 6 T ,
RT = Radiograph T = Tensile Test
~~= Acceptance Criteria: < 75,000 psi for individual splice and average of any 15 test results had to meet or exceed 90,000 psi.~~
~~= Bar ends must be within the outline of the tap hole.~~
kd *** = Splice had " indeterminate" condition (nv-63, 2 gage marks) included,
l RELIABILITY OF TEST PROGRAM t
ACCESSIBLE CADWELDS TOTAL 2431 ,
CONFIDENCE RELIABILITY RAND 0M SAMPLE TOTAL POPULATION 59 95% 95%
(2431)
SAMPLE OF GAGE WORK 58 95%+ 95%+
VISUAL REJECT POPULATION (381)
ADDITIONAL WORST CASES 21 - -
PHYSICAL REJECTS (115)
TOTAL ACCEPTABLE SPLICES 95% 99%
INSPECTED & TESTED (1884) tEi e e m m m m m m m m m m M M M m a m m
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STRAIN IN CADWELD SPLICES NRC C0ilCERl1: SPLICES FAILIllG VISUAL EXAMI:1ATIOll COMPROMISE STRUCTURAL I?1TEGRITY
, RESP 0:1SE: CODE REQUIREMENTS ,
ERIC0 TESTS j STRESSES AND CRACK C0liSIDERATIO:iS AT MARBLE IIILL i
FIGilRE 1 i
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CODE REQUIREMEtLIS STRENGTH, NOT STRAllt IS CRITERI0l1 IN GOVER! LING CODES, REGULATORY GUIDES
' OR MANUFACTURER'S RECOMMENDATIO!1S.
ACI-349-76 110T GOVERNING - HOWEVER, MET FOR T-SPLICES Ili CONTAlllMENT SilELL AtlD BASEMAT.
FIGURE 2 l
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RElilFORCED C0ilCRETE BEAM 8" WIDE X 12" DEEP f
1 BEAN, UilSPLICED BARS SP 2 BEAMS, VERY SOFT UilSTAGGERED SPLICES (1 1/2" PLUG) 1 BEAM STAfIDARD CADWELD SPLICES mnm b ll 0 9 un---
9 FIGURE 3 lS
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/,. e' ---- CADWELD SPLICE WITH
/ I INCH PLUG 10 l//,
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CADWELD SPLICE WITH p 2 INCH PLUG l l l O
O 10 0 200 300 400 500 600 700 800 900 AVERAGE STRAIN OVER 5" SLEEVE LENGTH U STRESS -STRAIN CURVES FOR SPLICE BARS FIGljRE 11 ame uma mas em aus sus sus sua sus em sus e em ens e sus em W Ems
RESULTS OF ERIC0 TESIS BEAMS LOADED TO FAILURE DUCTILE FAILURE SIMILAR CRACK PATTERN SAME ULTIMATE MOMENT CAPACITY SAME DEFLECTIONS AT LOAD 50% OF ULTIMATE DEFLECTIONS AT YIELD 15% To 20% HIGHER FOR SOFT SPLICES SAME DEFLECTIONS AT POINT OF FAILURE FIGURE 5 i O ,
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. BLOW OUT (MOISTENED) C0ilDITI0il MORE CRITICAL THAN MARBLE IIILL.
. ERICO TESTS HAVE A RIGID PLUG PREVENTIllG THE SLEEVE FROM GRIPPING THE BAR.
. ERIC0'S PLUG WORSE THAN MARBLE HILL'S WORST CASE.
. Ifl ERIC0'S TESTS, 100% RElllFORCING IN THE BEAM WAS SPLICED WITH SOFTENED CADHELDS AT SECTION OF MAXIMUM ff0 MENT; WHILE AT MAP,BLE ilILL A [1AXIt10M 0F 8% OF BARS IN ONE WALL llAD PilYSICAL VISUAL REJECTIONS (THE WORST PASSED TENSILE TESTS).
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~~SUMMARY~~
OF VISUAL INSPECTION RESULTS OF SRLICES WITH PilYSICAL i< EJECTIONS (RECESS, VOIDS, SLAG, POROSITY)
PERCENT OF
LOCATION TOTAL PRIMARY SHIELD WALL 8.2 SECONDARY SHIELD WALL 6.6 REFUELING POOL WALLS 3.4 CONT. SHELL a EL. 378'-0" 1.3 CONT. SiiELL a EL. 382'-0" 0.7 CONT. SHELL a EL. 390'-0" 2.1 CONT. SHELL a EL. 394'-0" 2.1 CONT. SilELL a EL. 397'-0" 0.1 CONT. Si1 ELL a EL. 414'-0" 0.3 FIGURE 14
.W m m m m m m m m e m e m m Ele m m Ein m m
m e um W m m una e m em m mais e e m nu m m m STRESS AllD CRACK ANALYSIS - C0itTAlllBEllT_IllIERf!aLS.
ASSl' MING ALL SPLICES VISUALLY _ ACCEPTABLE A. WALL IS IN COMPRESSION FOR fl0RMAL, il0N-SEISMIC LOADING B. 118.6 KSI STEEL STRESS FOR THE MOST SEVERE LOADING ASSUMING VISilALLY_REJECIEILSELIfES_l1011-EXISTENT A. WALL IS IN COMPRESS 10N FOR liORMAL NON-SEISMIC LOAD B. 52 KSI STEEL STRESS FOR THE MOST SEVERE LOADIllG ALLOWABLE STRESS _PEILACJ 318-71_IS Sit KSI CRACK IllSIGilIF_IfaliI COVERED BY 3' CONCRETE SLAB OCCURS ONLY UllDER SEISMIC CONDITI0il, FOR A SHORT TIME FIGURE 15 Bi
STRESS AflD CRACK AflALYSIS - CONTAlllMEllT SilELL ASSUMING VISUALLY REJECTED SPLICES ARE 110f1EXISTEilT, STRESSES ARE WITillii
~~DESIGil ALLOWABLES FOR ALL LOADIllG CONDITIONS.~~
fi0 SIGilIFICAllT CRACKS EXIST Uf1 DER 110f1 SEISMIC SERVICE LOADS (DUE TO POST
' TEllSI0 fill 1G).
Al4Y CRACKS UilDER SEISMIC LOADS ARE CLOSED BY C0l'iPRESSI0li LOADS FROMlE
~~' POST TEllSIONING SYSTEM.~~
FIGURE 16 l W j m m m e m W aus e e m M use W m W B5 m m m
m m al su WE M mm was e e m m tems luiin m em m W m C0flCLilSI0tl STRAlff C0flSIDERATI0f! RF!.ATIflG TO PilYSICAL VISilAL REJECTI0tlS SliONS f!0
~~IMPAIRf1Ef!T OF Tile STRtlCTURAL lt!TEGRITY Af!D SERVICEABILITY AT MARBLE lilLL.~~
) i t I i FIGURE 17 j u 1
E HANDOUT INFORMATION TABLE OF CONTENTS I TOTAL CADWELD POPULATION - GENERAL RESULTS 1 PAGE;37 59 RANDOM NUMBERS OF A TOTAL 2,434 SPLICE POPULATION 2 PAGES;38, 39 1 PAGE;40 = TEST GROUP 2 - GAGE MARK VISUAL REJECTS TEST GROUP 3 - WORST CASES OF PHYSICAL REJECTS 1 PAGE;41 2 PAGES;42, 43
~~SUMMARY~~
TENSILE TESTING 1 PAGE;44 PRODUCTION AND SISTER TEST RESULTS 1 PAGE;45 CADWELD IN-PROCESS TENSILE TESTS RESULTS SIMILARITIES BETWEEN EMBEDDED & ACCESSIBLE CADWELDS 1 PAGE;46 SIMILARITIES AMONG OPERATORS REJECT DISTRIBUTION BY CATEGORY l PAGE;47 OPERATOR DISTRIBUTION 1 PAGE;48 INSPECTOR DISTRIBUTION - UNITS I AND 2 1 PAGE;49 1 PAGE;50 CADWELD SPLICE DISTRIBUTION SPLICES WITH MULTIPLE DEFECTS 1 PAGE;51 DISTRIBUTION OF REJECTS BY TYPE / SIZE AND VISUAL REJECT CATEGORY l PAGE;52 CADWELD SAMPLING & TESTING FREQUENCIES 1 PAGE;53 RADIOGRAPHIC EXAMINATION ACCEPTANCE CRITERIA FOR 1 PAGE;54 l g OFF CENTERED BAR ENDS 1 PAGE;55 DISTRIBUTION OF VISUAL REJECTS I l NOTE: The handout information pages 36 - 55 of Section 3 were developed from the following sources: Pages 37, 51, 52, 55....... Inspection Results Pages 38-43, 54............ Testing Program & Results l Pages 44-50................ Contractor & Inspection Records l M Page 53.................... Specification Y-2722 I 6 I
l t L , i l l ! TOTAL CADWELD POPULATION - GENERAL RESULTS l >
! 2434 TCTAL SPLICES AVAILAELE ; ,
FOR INSPECTION 3 v0iD (NOT INSTALLED) - V l . 1794 VISUALLY ACCEPTABLE -A 499 VISUALLY REJECTABLE -R , 133 INACCESSIBLE -I - i 5 REJECT / INACCESSIBLE -R/I !
. 2434 TOTAL l !
I e OF THE 2431 IN-PLACE SPLICES INSPECT 5D THERE WERE 502 SPLICES .
~~! WHICH DID NOT MEET THE VISUAL INSPECTION CRITERIA. IN ADDITION :~~
l
! TWO SPLICES EV-1007 AND BV-1101 WERE IDENTIFIED DURING THE ! ; liiSPECTION AS HAVING TWO TAP HOLES. BV-1087 AND BV-1101 HAVE . ! BEEN INCLUDED IN THE SC4 SPLICE TOTAL. j i 5C4 INDivlDUAL SPLICES WITH ONE OR MORE CASE CF REJECTICN -504 INCLUDING (2 INDETERMANENT CASES EV-1033 AND BV-1101 ; ; (2 TAP HOLES) (0) .
~~60 INDIVIDUAL SPLICES WITH TWO CASES OF REJECTION - 60 7 INDIVIDUAL SPLICES WITH THREE CASES OF REJECTION _l2~~
~~' TOTAL CASES OF REJECTION 576 fM 1~~
~~I 59 RANDOM NUMBERS OF A TOTAL 2,4 34 SPLICE POPULATION~~
1) 2047 BV-908 (A) 21) 1317 BV-186 (A) 41) 2161 BV-1022 (A)

2) 2145 BV-1006 (A) 22) 0543 TV-912 (R) 42) 0628 TV-870 (A)

3) 0178 TV-179 (A) 23) 1979 BV-840 (A) 43) 0552 Tv-921 (A)

4) 0579 TV-948 (A) 24) 1406 BV-275 (A) 44) 0819 TV-845 (R)

5) 1039 TV-560 (R) 25) 1180 BV-49 (A) 45) 0783 TV-732 (A)
~
6) 1646 BV-515 (A) *) 2295 BV-ll64 (I) 46) 0433 TV-ll21 (R)

7) 0484 TV-10',0 (A) 26) 1138 BV-7 (A) 47) 0089 TV-90 (A)

8) 1428 BV-297 (A) 27) 1894 BV-763 (A) 48) 1765 BV-634 (A)

9) 1279 BV-148 (A) 28) 0280 TV-357 (A) 49) 0939 TV-712 (R)

10) 0573 TV-942 (A) 29) 1854 BV-723 (A) 50) 1472 BV-341 (A) .

11) 1443 BV-312 (A) 30) 0489 TV-1065 (A) *) 1567 BV-436 (I)

12) 2157 BV-1018 (A) 31) 1178 BV-47 (A) 51) 2064 BV-925 (A)

13) 2413 TH-38 (A) 32) 1989 BV-850 (A) 52) 2135 BV-996 (A)

14) 0990 TV-511 (A) 33) 0322 TV-279 (A) 53) 0287 TV-244 (A) i 15) 0972 TV-594 (A) 34) 0932 TV-705 (A) 54) 0254 TV-331 (A)

16) 0985 TV-506 (R) 35) 2269 BV-ll30 (A) 55) 0070 TV-70 (R)

17) 0222 TV-223 (A) 36) 1999 BV-860 (A) *) 2389 TH-14 (I)

18) 0127 TV-128 (A) *) 2356 BV-1225 (1) 56) 0643 TV-885 (A)

19) 0212 TV-213 (R) 37) 1929 BV-798 (A) 57) 1224 BV-93 (A) ,

20) 1193 BV-62 (R) 38) 1140 BV-9 (A) 58) 0881 TV-654 (R) m l
gl
39) 0634 TV-876 (A) 59) 0154 TV-155 (R) ;

40) 0045 TV .5 (A)
I.
~~Splice was exposed but inaccessible to any inspections or tests.~~
5
l I I Note 1: 48 splices inspected as acceptable 3 splices rejected due to physical visual defects I (TV-70; TV-155; TV-560) 8 splices rejected due to gage mark visual defects 8 (BV-62; TV-506; TV-654; TV-712; TV-845; TV-912; TV-213; TV-1121) I 59 Total rarAom nic.bers I Note 2: Three gage mark visual rejects did not pass the radiography procedure and were tensile tested. TV-654 and TV-845. These were TV-506, Note 3: Tensile Test Results: Splice I.D. I Tensile Strength Tvoe of Failure TV-70 95,276 Bar railure TV-155 103,937 Dar Failure TV-560 97,500 Dar Failure TV-506 99,250 Sleeve railure TV-654 99,250 Pullout TV-845 99,000 Dar Failure I I I I ~I I I
I l I TEST GROUP 2 - CAGE MAPL 4 VISUAL REJECTS LIST OF SPL!CES RADIOGRAPi!ED FRCM G.M. VISUAL REJECT POPULATION Il
1. BV-63 21. BV-828 39. TV-171

2. BV-133 22. BV-837 40. TV-235

3. BV-236 23. BV-911 41. TV-339

4. BV-350 24. BV-920 42. TV-341 l
~~. 5. BV-356 25. BV-ll22 43. TV-343 5~~
6. BV-377 44. TV-358

7. BV-485 26. TH-23 45. TV-360 E

8. BV-488 27. Ti!-26 46. TV-366 5

9. BV- 5 39 28. TH-28 47. TV-370

10. BV-605 29. TH-43 48. TV-440

11. BV-665 49. TV-454 g

12. BV-670 30. TV-41 50. TV-729 3

13. BV-755 31. TV-51 51. TV-777

14. BV-757 32. TV-55 52. TV-959 E

15. BV-759 33. TV-73 53. TV-1017 g

16. BV-766 34. TV-75 54. TV-1029

17. BV-816 35. TV-77 55. TV-1052

18. BV-820 36. TV-79 56. TV-ll31 $

19. BV-823 37. Tv-82 57. TV-ll33 5

20. DV-827 38. TV-85 58. TV-ll34 Note: 1. 58 splices radiographed for 959 reliability with 95% confidence factor. Only 54 required for population of 390.
Note: 2. Three gage mark visual rcjects did not pass the radiography procedure and were tensile tested with results as follows: Splice I.D. Tensile Strength Type of Failure TV-777 76,500 Pullout TV-ll31 89,750 Pullout TV-1133 97,750 Bar Failure E' l I' E m g
I . . . . . . _ _ . _ _ _ . _ _ . _ __. _. ._. ..__ _._ . _.. .__ ._ _ E- _ TEST GROUP 3 - WORST CASES OF PHYSICAL REJECTS
~~,g The following splices were tensile tested based on the worse 3 cases in Appendices B, C, D, E, F 5 G in Car PC 0602.~~
~~Solice I.D. Tensile Strength Tvoe of Failure i 1. BV-68 99,750 Bar Failure~~
g 2. BV-242 100,641 Bar Failure i g 3. BV-541 105,000 Bar Failurc
~~. 4. BV-626 101,000 Bar Failure~~
) 5. BV-635 100,000 Sleeve Failure-l 6. BV-742 92,564 Pullout i
7. BV-757 94,872 Weld Broke

s. BV-796 102,308 Pullout
~~<g 9. BV-ll39 97,500 Pullout g 10. TV-68 99,591 Bar Failure~~
11. TV-80 102,205 Bar Failure i 12. TV-87 109,764 Bar Failure

13. TV-91 102,835 Bar Failure
~~.I 14. TV-153 100,787 Bar Failure~~
15. TV-174 87,402 Pullout

16. TV-285 84,445 Pullout

17. TV-408 92,444 Pullout

18. TV-433 99,556 Pullout

19. TV-434 89,333 Pullout

20. TV-729 95,500 Bar Failure i 21. TV-890 97,500 Bar Failure

22. MU-2 97,000 Bar Fei)nre I
~~I I I I I 5 E I.11~~
~~~ . . . . - . . - - . - . . ....- - .... - -- . - .. - . - . . .- -~~
~~I l~~
~~SUMMARY~~
TENSILE TESTING - Splice Tensile Type of IdentificsLion Strength Failure Remarks
1. BV-68 99,750 Bar Failure

2. BV-242 100,641 Bar Failure

3. BV-541 105,000 Bar Failure

4. BV-626 101,000 Bar Failure

5. Dv-635 100,000 Sleeve Failure g

6. BV-742 92,564 Pullout E

7. BV-757 94,872 Weld Broke Weld of " Butted sleeves

8. BV-796 102,308 Pullout

9. BV-ll39 97,500 Pullout

10. TV-68 99,591 Bar Failure ,

11. TV-70 95,276 Bar Failure g

12. TV-80 102,205 Bar Failure g

13. TV-87 109,764 Bar Failure

14. TV-91 102,835 Bar Failure

15. TV-153 100,787 Bar Failure l

16. TV-155** 103,937 Bar Failure W l 17. TV-174 87,402 Pullout Weld metal did not fail sheared deformations cff bar corner of bar fractured a

18. TV-285 84,445 Pullout " " " " ' E

19. TV-408 92,444 Pullout

20. TV-433 99,556 Pullout

21. TV-434 89,333 Pullout I
~~Sheared deformations off tar 5~~
22. TV-506* 99,250 Sleeve Failure

23. TV-560 97,500 Bar Failure g

24. TV-654' 99,250 Pullout

25. TV-729 95,500 Bar Failure 5

26. TV-777* 76,500 Pullout Sheared deformaticas off bar 27.
~~28. TV-845* TV-890 99,000 97,500 Bar Failure g Bar Failure 3~~
29. TV-ll31* 89,750 Pullout Sheared deformaticns off bar

30. TV-1133* 97,750 Bar Failure

31. M U- 2 97,000 Bar Failure I
~~Worst cases gage mark failure~~
*
~~TV-155 f rom randem 59 nu:nbers Page 1 of 2 I~~
I e I
4 1 . _ . . . . _ . _ . _ _ . . . _ _ _ . . . . . __ _ _ ___ _ _ _.. _. _ ..__. . _ __ . _ _, . .. . _ __. j E-1 l Of the 30 production splices pulled out and tested: f The types of failures broke down as follows:
~~2 Sleeve Failures ;~~
, 16 Bar Failures { 11 Pullouts (Bar pulled out of sleeve) i 1 Butt Weld Failure , ul
5
~
~~30 Total Of the 11 pullouts:~~
)
1 I 6 Pulled out at above 90,000 psi i ! 5 Pulled out due to deformations shearing off bar j j 0 Fulled out due to lack of or f ailure of filler metal ! 11 Total i j J I j Page 2 of 2 i I i 1 ' ll !I i !,E
~~= ~ " ~ * . .e-..-- ,~~
,5 s
I 6(A) . PRODUCTI0il AtiD SISTER SPLICE TF,ST FESULTS g C0tiTAlfitiEllT #1 6_PRODuCTIOtt 185 SISTER g C0flTAlflMEitT #2 14 PRODuCTIOri 166 SISTER TOTALS 10 PRODUCT!0it' 351' SISTER I
~~Il0TE 1. ALL PRODUCTIOff At;D SISTER SPLICES PASSED THE MINIMUM A!;D AVERAGE STRESS CRITERIA.~~
~~Il0TE 2. SEE ATTACHMEtiT PAGE 6(3) FCR PDCDUCTIO!;, SISTER AtlD QUALIFICATI0t; TEST RESULT DISTRIBUTIOff. I I I 3: Il~~
~
i a; t I'I
M M M W W W W W W M M m M M M mM W W I t i . l 6 l CADWELD IN-PROCESS TICNSILE TESTS "lSULTS - Cadwold' Splice? TV-18 Tit-11 DV-11 TV-10 11V-18 TV10-18 TV14-18 TV11-10 Til-8 Tii-9 ; i 4 i Number of Tor.ts 407 201 26 84 0 24 40 11 9 2 2 ; [,[.h nsi) 102.93 100,98 103.52 107.35 100.47 98.50 106.13 100.93 104.14 106.58 99.60 5.99 4.45 5.23 7.12 2.59 4.34 5.14 4.48 6.64 - - n (ksi) er ir 1 5.82 4.40 5.05 6.63 2.57 4.40 4.84 4.44 6.18 - - _ . _ . . . _ _ _ _ _ - _ i lange Iksil 29.94 18.25 24.35 27.05 7.71 12.25 15.59 16.44 19.10 4.55 0 ; l in. Strcnoth tksi) 87.11 91.25 92.43 90.00 96.53 92.74 93.38 87.11 95.64 104.30 99.60
! . n1 ro le o f Failure P DP DF Br DF llP P P DP DF P 1 .vax. Strenoth (ksi) 117.05 109.50 116.79 117.05 104.25 105.00 108.97 103.55 114.74 10 8 . f' 6 99.60 aral PuJe a f ra i lu re Dr im IT IW Sr Dr Dr 4r b" br P P 18 4 7 0 1 O 1 3 0 0 2 ,
~~9 SP 8 4 2 0 2 0 0 C 0 0 0~~
s. u t-------- -~ {
O
$ If 381 193 17 84 5 24 39 8 9 2 0 '
80 - 00 1 0 0 1 0 0 0 0 0 0 0 TOTAL 408 201 2G 85 8 24 40 11 9 2 2 - Probability of ab ab ab strength exceed- .9842 .9931 .9951 .9925 .9975 .9740 .9991 . 9 fs 2 5 .9750 - - inq 90 ksi t' r o b , of aver. sura 13 b b b ab b b ab a of 15 connecutive tests exceeding 9999997 .9999997 .9999997 .9999997 .9999997 .9999997 .9999997 .9999997 .999975 - - 90 kni Notes: 2.o t.a t i o n a - t-studes.t. distribution M 1, - larner th.in t!.e numt.cr nhwn DF - Dar railurn s c - rejecte.I by the lab t,cc..use o f slag at tag
~~hola P = Pull out of the bar~~
~~?,r . !,leeve f.talt.re~~
I - l SIMILARITIES BETWEEN EMBEDDED E ACCESSIBLE CADWELDS TOTAL TOTAL SPLICE SHOTS TYPE REJECT /0PERATORS* ALL OPERATORS REJECTS /0PERATORS* TOTALS
& SIZE UNIT 1 UNIT 2 UNIT 2 F G L S X JJ KK CC 18-18V 570 532 1104 67 35 16 0 1 32 0 0 151 18-14V 327 173 300 15 11 13 0 0 0 0 0 39 18-10V 481 433 914 32 0 0 40 4 73 0 0 149 BV-11 912 862 1774 28 0 50 0 0 18 38 1 134 142 46 79 40 5 123 38 1 473**
~~TOTAL REJECTS 154 46 79 40 5 130 39 1~~
~~28 QUALIFIED CADHELD OPERATORS, CNLY EIGHT SHOT REJECTS IDENTIFIED UDDER SPP-6 PROGRAM.~~
~~(NOTE: REJECTS HERE ARE INDIVIDUAL SPLICES)~~
** 473 0F 502 INDIVIDUAL SPLICE REJECTS (94%) SHOT BY 8 OPERATORS OH ONLY 4 TYPES OF SPLICE.
5 E E E E E E E E E W W E E M M E M M W
l I SIMILAP.ITIES'AMONG OPERATORS FEJECT DISTRIBUTION BY CATEGORY I OPERATOR BAR GAGE MARK EXC. REC. POROSITY OTHERS CASES SIZE & REJECT VCIDS E SLArg i I TYPE CASES
CASES

CASES F #18-TV 111 1.0 18 1
~~#11-BV 18 10 3 0 OTHERS 7 0 2 2 G #18-TV 50 1 0 0~~
~~!l #11-BV 0 0 0 0 OTHERS 0 0 0 0 ,g L #18-TV~~
~~#11-BV 32 21 0~~
~~24 2 4 0 1 OTHERS 0 0 0 0 >l S #18-TV 33 16 0 0~~
~~#11-BV 0 0 0 0 OTHERS 0 0 0 0 l~~
~~X #18-TV 5 1 0 0 'g~~
~~#11-BV OTHERS 0~~
~~0 0 0 0 0 0 0 JJ #18-TV 96 20 9 1 l #11-BV OTHERS 2 4 15 2 1 0 0 1 'g KK #18-TV~~
~~#11-BV 0~~
~~29 11 0 0 0 i 1 0~~
~~! CC OTHERS #18-TV 1~~
~~0 0 0 0 0 0 0~~
~~#11-BV 1 0 0 0~~
l OTHERS 0 0 0 0 Sua- #18-TV 327 48 29 2

I m ALS gy1_BV 71 60 9 1 cTHERS 12 2- 2 3 TOTALS 410 110 40 6 = 566**
~~NOTE: CASES ARE INDIVIDUAL TYPES OF REJECTION.~~
~~SOME INDIVIDUAL SPLICES HAVE MULTIPLE CASES OF REJECTION.~~
**THIS NUFEER EXCLUDES HORIZONTAL SPLICES WHICH DO NOT HAVE GAGE EARKS.
~~g 41 -~~
~~-w , - . -y.- _-. .--w%~~
~~I: ! I: OPERATOR DISTRIBUTI)N 3 ! 4. l t~~
1. 2. 3. 5.*** 6.***
l Statistical Probability For Rejects In Unit 1 ll 5 l i i Physical i ! Unit 1 Unit 2 Unit 2 All Categories 3 ! Operator Actual Actual Rejects Categories Only 5! JJ 258 579 130 58 17 j P 648 650 154 154 44 i S G 37 287 132 203 40 46 11 65 3 19 I! ! j
?
X 98 39 5 12 3 j L 240 396 79 48 14 ; l KK 178 457 39 15 4 LL 398 16 1 25 7 [ Totals 2,144 2,472 494** 388* 111 Ir Il l l
~~Statistical probability of cadweld splice rejects in Unit 1 3' ,~~
~~based on percentage of operator rejects from accessible splices (SPP-6) from Unit 2. 5 ! t~~
** Horizontal splices not included in this total. *** Column 5 is derived by dividing Column 4 by Column 3 and multiplying the !
resultant percentage by column 2. Column 6 is derived by multiplying g l Column 5 by the percentage of physical visual rejects to total visual rejects; 144 divided by 502. g [j 1 1 I ue g,
I I l i INSPECTOR DISTRIBUTION 1 I UNITS 1 AND 2
1. 2. 3. 4. 5.** 6.***
iI Statistical Probability For Rejects in Unit 1 , Unit 1 Unit 2 Unit 2 Physical l Cadwelds Cadwelds Rejects All Categories
~~Inspector (Actual) (Actual) (Actual) Categories Only~~
#1 98 1,242 289 23 7 l #2 1,880 1,405 117 157 45 #3 48 299 60 10 3 l #4 109 92 14 17 5 1
~~, #5 510 200 12 31 9 ii6 346 35 6 59 17~~
~~#7 880 366 4 10 3 il I~~
~~i Subtotals 3,781 3,639 502 307 89~~
~~#8-11 590 633 0 0 0 Totals 4,461 4,272 502* 307 89 i~~
~~Does not include splices BV-1087 and BV-1101, with two tap holes.~~
** Column 5 is derived by dividing Column 4 by Column 3 and multiplying the resultant percentage by Column 2.
,' *** Column 6 is derived by multiplying Column 5 by the percentage of physical visual rejects to total visual rejects, 144 divided by 502. r l I i 49 I
p .. CADWl:1.0 ':l'T. ICE DISTit,II:UTf 0N Nuniber of Rejects tiu. 61>cr o f Sho t.s Ope rator y.gti_c,c Tyge Cont. 42 Cont. Gl Co n ' . #2 Total Shots
,' JJ 18/18V 32 ' 7 130 137 JJ 18/lGV 73 2 136 188 JJ 11 BV 16 249 174 423 . JJ 18 BV 7 0 89 29 F 18/18V 67 197 184 381 } P 18/14V 15 13 85 103 J P 1H/11V 3 0 32 32 P 18/10V 32 187 99 286 l P 18 Ilv 9 120 ' 72 192 1 P 11 DV 28 126 178 304 S 18/10V 40 37 132 169 G 18/lav 35 222 137 359 G 18/14V 11 , 65 66 131 ,i X 18/18V 1 18 !
~~23 41~~
; X 18/10V 4 80 16 96 L 18/18V 16 126 58 184 ;
l L 18/14V 13 36 22 58 L 11 BV 50 78 316 l 394 j I KK 18 BV 1 24 101 125 i KK 11 BV 38 154 356 510 ; CC 11 BV 1 398 16 414 i Total 494 2,144 2,472 4,616 i se m e aus em seu uns uns aus gun m uma e m aus- M M M W
Spli::es With Multiple Def ects - 66 X Splices With 1 Physical & 1 G.M. Defect -2 3
~~Splices With 3 Defects i~~
~~I 1. BV-378 X 23. TV-87 X 45. TV-473 i~~
2. DV-541 24. TV-93 * - 46. TV-533 l 1

3. BV-720 X 25. TV-97 *

47. TV-607 I

4. BV-724 X 26. TV-110 X 48. TV-632

5. BV-742 27. TV-153 j 49. TV-684 X 1

6. BV-757 X 28. TV-155 X 50. TV-729
i
7. TV-18 29. TV-134 ! 51. TV-773

8. TV-40 30. TV-192 52. TV-777

9. TV-46 31. TV-230 X 53. TV-840 I 10. TV-50 X 32. TV-339 54. TV-863 X I 11.
12. TV-55 TV-59 *
33. TV-351

34. TV-354

55. TV-869

56. TV-890 X

13. TV-65 X 35. TV-356 X 57. TV-914

14. TV-66 X 36. TV-370 l .l 58. TV-926 X I
~~i -~~
~~'15. TV-68 X 37. TV-401 X , 59. TV-940 I~~
16. TV-70 38. TV-403 I X ' 60. TV-959 l

17. TV-73 X 39. TV-433

61. Tv-967 18.
I TV-77 *
~~40. TV-434 62. TV-971~~
~~-19 . TV-78 X 41. TV-437~~
63. TV-983 X

20. TV-79 *

42. TV-440 64. TV-1025

21. TV-80 X 43. TV-446 l 65. TV-1064

22. TV-82 44. TV-459 66. TV-ll34 I Individual Splices 2 Casos 504 66 3 Cases 6 576 5 .
51 5
DISTRIBUTION OF REJECTS BY TYPE / SIZE AND VTSUAL REJECT CATEGORY .' 9 ; CAR PC 0602 Appendix
~~ ! Cadweld Type / Size A B C_ . D E F G II J K L Totals 67 0 6 0 61 7 23 0 169 I L la-18TV 1 3 1 18-14TV 15 2 0 2 9 0 0 10 0 9 0 47 ; ~
18-llTV O O O O O 0 3 0 0 0 3 f O i i .__ LH-10TV 39 38 7 5 4 0 1 37 3 53 0 187 ,
, 13-nv 10 2 0 0 2 1 0 0 1 0 3 19 ll-nv 61 60 0 4 5 1 0 0 7 3 0 141 ll-Til 8 0 0 0 0 0 0 0 0 0 0 8 0 0 0 0 0 0 0 0 0 0 2 9-Tl! 2 l ~~~
, ) I e Totals 202 103 7 14 26 3 1 111 18 88 3 576 a l 1 1 ,! Key: Appendix A No Gage Marks 11 Sleeve Not Centered B Excessive Voids J Gage Marks Exceed Tolerance C 1:xcessive Recess K Gage Marks Less Than D Porosity at Sleeve Ends or Tap !! ole Tolerance E Slag at Sleeve Ends or Tap liole L Indetermanent - 2TII in F Tap !! ole Burnout and 2GM G No l' iller Metal Visible
I f . m, CADWCLD SAMPLI!;G t. TESTING FRETCF.NCIES i HO P.IZ ONTAL, VERTICAL DIAGONAL (For Each Grade & Size) , 1P From ist 10 - 7 1P From Splices x 3S 11-100 1P From Each :- :- ! I or 1.S Subsequent Group of 33 l l 1 l I
~~; g Notes: 1. Samples from curved bar production shall be g straight sister splices~~
2. Samples from B-type producticn shall be sister splices I. 3. Selection of samples shall be from recognized methods of randem sampling

4. For back to back sister samples:
~~g 1S From ist 20 l 3 2S From Splices 11-100~~
~~; 1S From Each Subsequc:tt Group of 33 I.:~~
I ? 1 I; I: ! i I? 3 I- . _ . - . . . _ _ , ._. . _ . . _ . . . _ . . . . .. .... _ . . _ ,
~~. ~ . .~~
_ . . _ ~ ~ . . . . . _ . . . . , . . . . . . . . . . _ _ . - _ . . . . . . _ _ _ _ - . - - O' - 9 " _
^ f-3/ "16RECESS ( 3/ l6" RECESS *D=2(3/8)
~~TAP HOLE +- -- ( SLEEVE v'~~
- A M,.$. / ( / wM i ~T ~ r 7 - r y n p 'N 'N v a-%
~~YMM / Nf~~
~~.---w // /M/~~
~~v v v7 h i \~~
" l8 *D=3/16+ 2(3/8)+3/ 16 =9d'/ (IF THERE IS NO RECESS AND VOIDS WITHIN ALLOWABLE ) ' ENDS OF THE BARS SHALL BE WITHIN THE DIAMETER D.
RADIOGRAPHIC EXAMINATION ACCEPTANCE CRITERIA FOR OFF . CENTERED BAR ENDS , W m !llEs e e mm mm W W W m W W W W W W W
I DISTRIBUTION OF VISUAL REJECTS I SPLICES C1.SES 328 Individual Splices, only 1 G.M. Defect 328 23 Individual Splices, only 1 G.M. Cefect & 1 Phy. Defect 23 29 Individual Splices, only 2 G.M. Defects 58 I 4 Individual Splices, only 2 G.M. Defects & 1Phy. Defect 8 2 Individual Splices, only 1 G.M. Defect & 2 Phy. Defects 2 Individual Splice, with 2 G.M. Defects 1 1 Subtotal-Individual Splices with at least 420 387 1 G.M. Defect Individual Splices, only 1 Phy. Defect 109 109 Individual Splices, only 1 Phy. Defect & 1 G.M. Defcet 23 I 23 8 4 2 Individual Splices, only 2 Phy. Defects Individual Splices, 1 Phy. Defect & 2 G.M. Defects Individual Splices, 2 Phy. Defects & 1 G.M. Defect 16 4 4 Subtotal-Individual Splices with at least 1 146 Phy. Defect 156 CASES SPLICES 437 Splices with cne Defect 437 46 Splices with 1 G.M. & 1 Phy. Defect 23 58 Splicts with 2 G.M. Rejects 29 16 Splices with 2 Phy. Defects 8 I 12 Splices with 1 Phy. & 2 G.M. Defects 4 6 Splices with 2 Phy. & 1 G.M. Defects 2 1 Splice with 2 G. Marks 1 576 504 5 I I R-I 55 I .
.I I 7.0 P5{YSICAL INSPECTION AND Ve.RIFICATION OF PREVIOUSLY ACCEPTED PURCHASED ITEMS I 7.1 ABSTRACT This section describes the results of the physical reinspection of hardware by Public Service Company of Indiana, Inc. (PSI) and a review of corresponding documentation by PSI and Sargent & Lundy Engineers (S&L) of materials accepted by PSI Receipt Inspection I prior to August 7, 1979. This section also describes the actions taken and planned to correct identified deficiencies and to preclude recurrence of such deficiencies.
The program consisted of visual and dimensional reinspectior.s of a statistical sarale of hardware utilizing checklists prepared by PSI Qr.ality Engineering and performed by PSI Inspection personnel I trained in the requirements of an approved procedure, SPP-7. The purpose of this Material Verification Program is to assess the I validity of prior receipt inspection activities and to determine the acceptability for construction of such previously accepted items. Similarly, previously reviewed and accepted documentation supporting the identified hardware was reviewed utilizing personnel from PSI's Consulting Engineers, (SSL). Based on the results of this program, sample sizes were increased I where necessary and hardware deficiencies were documented on Nonconformance Reports and submitted to Project Engineering for technical disposition. In addition, results of the sample review of documentation led to a 100% review of documentation packages for I those specifications where deficiencies were identified. The results of this reinspection identified hardware and I documentation deficiencies that will require correction prior to use, but established the fact that the majority of previously receipt inspected items are acceptable for use in construction and the remainder are correctable for such use. I
~~7.2 INTRODUCTION~~
7.2.1 Commitre nts As part of the commitment to the Nuclear Regulatory Commission (NRC) in Artic] 'II-A-1 of the " Description of Licensee Activities I Addressing Ord : Jonfirming Suspension of Construction", PSI undertook a reinspection of a statistically based sample of hardware and documentation that had been received and inspected [ l prior to August 7, 1979. This program had two objectives: to l 5 assess the validity of prior receipt inspections and to determine i the acceptability of hardware for construction The scope of this reinspection included 19 different procurement specifications I involving over 42,000 pieces of which over 4,300 were physically inspected. I I 7.2.2 Procedure Outline The steps taken to perform the Material Verification Program consisted of the following:
1. Preparation and approval of a Special Process Procedure, SPP-7, for physical inspection of Category I, PSI purchased hardware and review of required documentation on a statiscically valid sampling basis to provide results with 95% reliability with a 95% confidence factor.

2. Selection and qualification of personnel to perform reinspection and document reviews.

3. A physical inventory of components received, inspected, and accepted prior to August 7, 1979 and a rar'em selection of components from this inventory to provide a representative sample of components frcm each specification.

4. Review of checklists prepared and drawings utilized prior to August 7,1979 to assure adequecy of requirements and the l preparation and approv?1 of supplementary checklists, as 5 necessary, to assure 4 representative evaluation of prior receipt inspections, and to address the effects of subsequent g engineering changes and long-term storage on the acceptability of such purchased material and components. 5

5. Physical inspection of representative samples of PSI Category I l stored material from each Purchase Specification receipt 5 inspected prior to August 7, 1979 and a review for adequacy and completeness of documentation. Sample sizes were increased as indicated by the SPP sampling tables where deficiencies relating to the original receipt inspection were identified.
~~Inspections of installed items for like deficiencies were conducted where applicable.~~
~~6. Preparation of Nonconformance Reports (NCRs) for hardware deficiencies, Requests for Correction and NCRs for documentation deficiencies.~~
~~7.3 DISCUSSION 7.3.1 Procedure A Special Process Procedure, SPP-7, Attachment 7.6.8 entitled~~
" Procedure for Physical Inspection and Verification of Previously Accepted Purchased Items," was prepared by PSI and approved by the PSI Project Engineering Manager and the PSI Quality Assurance Manager. This procedure provided written instructions for the review of drawings and checklists used for the original inspection of items received prior to August 7, 1979, the guidelines for supplementary checklists were required to assure an adequate g evaluation of prior inspections and of the suitability of the g 1
E
I hardware for construction. This procedure also included the assessment of the possible degradation of qua' aty due to unplanned, long term storage. Activities relating to SPP-7 were f.riormed in two separate phases: (1) Material Verification including reinspection of hardware, and I (2) Evaluation of Documentation supporting the acceptance of hardware. The two phases are reported separately in Subsections 7.3.2 and 7.3.3 of this section. In addition, Site Contractors who had performed Category I Receipt Inspection prior to August 7, I 1979, were required to develop and implement equivalent procedures for verifying the quality of such material. Reports of these activities are furnished as attachments to this section. 7.3.2 Establishment of Teams - Material Verification 7.3.2.1 PSI Quality Assurance personnel were selected from Receipt I Inspection, Construction Surveillance and Construction Field Engineering personnel to perform the Material Verification Program. Individuals were qualified in the appropriate discipline I as a Level I or II Inspector per the PSI Quality Assurance Manual and ANSI N45.2.6 (1973) and were indoctrinated and trained in the requirements of SPP-7. Where Level I personnel were used, they worked in conjunccion with Level II Inspectors. 7.3.2.2 Prior to beginning the Material Verification Program, individual components were randomly selected by component identification I numbers, except for cable trays, which do not carry individual identifiers. The identified items were then relocated within the storage yard or warehouse for ready access to inspection. Items I identified for inspection are listed by Specification and Sampling Plan as indicated in SPP-7. Cable trays were randomly selected from various locations within the various stacks of material. I 7.3.2.3 Inspection of individual items was conducted utilizing approved checklists based upon the original receipt inspection checklists. Exceptions were made relative to some inspections normally performed by Source Surveillance or Inspections that required the removal of protective coatings which might otherwise jeopardize the quality of the items. I 7.3.2.4 Physical inspections were performed on identified parts and components defined by the 19 Procurement Specifications. The inspections were performed in accordance with a sampling plan I designed to determine the acceptability of the items with 95% reliability and with a 95% confidence factor. Under this plan, items on site with quantities less than 38 were inspected 100%. Larger quantities were inspected based on a randomly selected I statistical sample that was automatically increased in size if defects were found. The results of the reinspection disclosed that 14 of the 19 Procurement Specifications required no increase in l I sample size. Further, the results of 100% inspection of items from the specifications having quantities of less than 38 on-site showed one to have no NCRs originated for any reason. Four specifications I I which were sampled disclosed nonconformances requiring an increase in the sample size. One such specification required 100% inspection. Two specifications had no deficiencies reported. Nonconformance Reports documenting those specifications requiring either an increase in sample size or 100% inspection totalled 965. Of these, the majority (over 60%) were written against g Specification Y-2735, Structural Steel, and are attributable to one Supplier. Nonconformances required 100% inspection of E approximately 3100 structural steel members. The majority of the nonconformances are minor dimensional deviations from the American l Institute of Structural Steel fabrication standards and/or W architectural drawings and have been determined to have no degrading effect on the integrity of the structure since correction g for these deficiencies is normally accomplished as a matter of construction practice during ficup and erection. 5 7.3.2.5 Nonconformances were evaluated to determine whether the condition l adversely affected the functional adequacy of the item. If so, a W program was defined and initiated to investigate installed items for like nonconformances. In the case of structural steel members, g erected structural steel was subjected to a physical inspection in g accordance with SPP-3 and the results are separately reported in Section 3 of the Construction and Material Verification Final Report entitled, " Category I Structural Steel." 7.3.2.6 The latest approved Contractor drawings as of August 7, 1979 were the basis for the inspections. That revision was verified against g the latest issue of S&L's Foreign (Supplier / Contractor) Drawing g Status List, to determine the appropriate revision for use. A list of the drawings utilized and their revisions is given in g Attachment 7.6.3. Other reference material includes standards such g as the American Institute of Steel Construction (AISC), " Manual of Steel Construction", 7th Edition, in order to verify the sizes and shapes of the various rolled members and similar relevant data. g Wolding inspection was performed to the latest applicable American E Welding Scciety ( AWS) Manual and American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code. The inspections were performed between April, 1980 and September, 1980. 7.3.2.7 The results of the material verification inspection were recorded under the direction of a PSI Level II Inspector as follows: Each piece selected was inspected in accordance with approved checklists g incorporating or referencing the applicable drawing requirements- g and industry standards. Items to be checked, special tools, and instructions were indicated on the checklists and results recorded thereon. Nonconformance Reports were originated for deficient conditions noted and were submitted through Quality Engineering to l W Project Engineering for technical review and disposition. Items I inspected during this program were marked to provide identification of the specific items selected for a sample. l 1 I I
I I 7.3.2.8 Discussion of Physical Inspection Results Inspection to determine the validity of the original receipt I inspection determined that of the 19 specifications involved, there were nonconformances reported during reinspection as follows: I 7.3.2.9 Specification Y-2735, Structural Steel - 720 Nonconformance Reports were written affecting approximately 3100 items and required inspection of 100% of the structural steel items received prior to R August 7, 1979, that were not erected. R 1091 structural members had no identified deficiencies. Of the nonconformances, 65% were dispositioned "Use-As-Is". Many were I con idered to be matters of Code or Specification interpretation. The identified deficiencies include: Percent
1. Incorrect Cope 38

2. Dimensional Tolerances 23 I 3.
4. 5. Hole Patterns Incorrect Missing, Illegible Welder's Stamps Improper Paint Pattern 13 12 4 I 6. 7. 8. Attachments Missing or Incorrect Illegible Identification No2conformance to AISC Manual 4 2 2
9. Insuf ficient Bending of Embedment Studs 1 I 10. AWS Code, Weld Cracks and Workmanship 1 In addition, inspection disclosed a general condition of rusting of I unpainted surfaces due to extended storage which will require correction. Other nonconformances relating to storage and handling include nicks, dings, gouges, bends, dents and twisting of main pieces and attachments which will be corrected as required during I erection in accordance with approved procedures.
~~Deficiencies in nonconforming structural steel were evaluated by PSI Project Engineering and S&L and were dispositioned as follows: Percent~~
1. Use-As-Is 65.0

2. Rework / Repair 34.9

3. Replace 0.1 Erected structural steel was inspected per SPP-3 and is separately reported. That inspection did not address the possibility of I attachment clips being less than the specified thickness. Because some undersized clips were identified during material verification, an inspection was made- of installed clips in four areas representing different erection periods. 100% of the clips (a total of 234) were physically reinspected on August 8, 1980 from I
~~~'~~~
I
I these four areas. No deficiencies in installed clips were identified. 7.3.2.10 Specification Y-2721 Embedments - 59 post-tensioning system trumplates, sheathing and funnels were inspected. An additiona' 5 trumplates were inspected at the request of Prc. ject Engineerinr. R Drawings used for these inspections are listed in Attachment 7.6.3. One deficiency (NCR PC0068) was identified relative to sheathing and was generic to the bundles on site. The original g receipt inspection checklist required identification tags to include (1) the destination, (2) Ccatract Number, and (3) Diameter g and Length. It was determined that this information is unnecessary since the sheathing ie of the same di eeter, and standard lengths are cut to fit at erection. Other nonconformances related to l W storage and handling included surface rust on trumplates, sheathing and funnels, and gouges on bearing plates as follows: NCR PC0070N - Surf ace rust on 64 trumplates, 59 pieces of sheathing and 59 funnels NCR PC0069N - Gouges in bearing plate NCR PC1010N - Gouges in bearing plates 7.3.2.11 Specification Y-2725, Embedments - 59 items were inspected under this specification including 18 crane rails, 22 mounting brackets and 19 plates. Conditions not documented on earlier inspections included minor variations in crane rail length (NCR PC0067N) and egg-shaped bolt holes (NCR PC0066N). Both of these conditions are normal to this type of erection, the egg-shaped holes allow for alignment and the crane rails are trimmed to length at erection. l 3 It was determined that there was no need to increase the sample size. Other conditions noted were due to long term storage and are documented as follows: NCR PC0067N - Crane Rails - identification becoming illegible NCR PC0065N - Mounting Bracket Assemblies and Plates - light surface rust Marble Hill Unit 1 assemblies have been installed, but await final s3t and alignment at which time normal inspection will note any nonconforming condition. Unit 2 -asemblies were inspected as a part of the Material Verification Program. 7.3.2.12 Specification Y-2766, Embedments - This specificat on included material for the stainless steel liner for the spent fuel pool. g There were no deficiencies identified reflecting on the validity of g the original receipt inspection. Six Nonconformance Reports were initiated; four were attributable to handling and storage; one NCR (PC0073N) has since been determined to be within specified I tolerances. One NCR (PC0076N) identified three instances of poor " workmanship in weld bevel preparations not previously identified in l I ! i the original checklist for inspection upon receipt. This was because the material is for a " furnish and erect" contract not normally subject to PSI inspection upon receipt and corrected as I necessary during erection. Nonconformance Reports relating to this specification are as follows: NCR PC0076N - Poorly prepared weld bevels NCR PC0073N - Weld bevel angles Weld bevels have been dispositioned "Use-As-Is" as they will be corrected during ficup. NCR PC0074N - Missing hex nuts NCR PC0071N, PC0072N and PC0075N - Storage deterioration Conditions noted are identified with " Retain" tags and will be corrected in the process of normal construction when work is resumed. 7.3.2.13 Specifications Y-2797 NSSS Support Steel - There were no deficiencies noted reflecting on the validity of prior receipt 59 pieces were randomly selected. Components with I inspections. nonconformances are documented as follows: NCR # DEFICIENCY DISPOSITION PC0152N - 19 support columns, Rework deteriorating protective coating PC0156N - Four supports having dimensional Rework variations previously identified by Supplier before shipment. PC0151N - Eight anchor bolts and nuts Rework deteriorating protective coating PC0154N - Eight links, machined surfaces Use-As-Is not coated and rusting. Minor dimensional deficiencies. PC0153N - Pipe restraints, protective coating Rework chipped; light surface rust. In additioc, 16 coolant pump boxes were reinspected with no deficiencies noted. It should be noted that the dimensions reported as deficient under NCR PC0154N are normally reworked to fit at final alignment and adjustment of the steel frame and were not required to be accurately measured at the original receipt inspection. I I 1
r B l The general condition of deterioration due to handling and storage l has been identified in a generic NCR PC0617N and will be corrected R W l on the balance of the items as a result of the overall storage and I maintenance program and will be corrected prior to installation. 7.3.2.14 Specification Y-2744, Shop Fabricated Tanks - 100% inspected. No nonconformances reflected on prior receipt inspection. NCR PC0157N documented a long term storage condition concerning surface rust and chipping paint. The item is tagged and will be corrected prior to use. 7.3.2.15 Specification Y-2756, Main Steam Isolation Valves - 100% inspected. Six Nonconformance Reports were written. Dimensional discrepancies in I.D. and 0.D. measurements were recorded and have g been dispositioned "Use-As-Is". Most deficiencies related to long 5 term storage conditions and will be corrected prior to installation. 7.3.2.16 Specification Y-2771, Hangers -59 hangers were inspe:ted. No l Nonconformance Reports were written relating to prior receipt er inspections. NCR PC0129N written relative to long term storage condition. This condition will be corrected in the course of the storage and maintenance program. 7.3.2.17 Specification Y-2787A, Containment Piping Penetrations - 100% inspection conducted. NCR PC0128N documents a marking deficiency. There was no c- ir deficiency reflecting on prior receipt
inspections. NCR PC0128N also documents long term storage condition as do NCR PC0126N and NCR PC0127N. Storage problems will g be addressed and corrected as a part of the storage and maintenance g program.
7.3.2.18 Specification Y-2787B, Containment Piping Penetrations - 100% inspection was conducted (42 pieces) after failure of the original sample. Eight Nonconformance Reports were written that reflect on the adequacy of prior receipt inspection as follows: NCR# DEFICIENCY DISPOSITION PC0078N No 100 Compound Angle on Weld Bevel Rework PC0079N No 100 Transition Angle or. I.D. Rework PC0080N .ield Prep Bevel 320 vs 37 1/20 2. 2 1/20 Rework PC0081N Se il Plate Diameter Undersize. Invalid Finding. Use-As-Is PC0137N Wall Thickness. Invalid Finding. Use-As-Is PC0143N Diameter Out of Spec. Invalid Finding. Use-As-Is PC0145N No Machined Surface on Pipe I.D. Use-As-Is 1 I I l I
I 1 PC0145N Was " Accepted-As-Is" on the 5 asis that machining the Pipe I.D. is not necessarily required by design where 250 RMS is obtained by the fabrication process. PC0150N Weld Preps Incorrect. Rework In addition, NCRs 0142N, 0144N, 0146N, Ol76N,and 0177N were written against storage condition. I These conditions will be addressed and corrected as part of the overall storage and maintenance program and will be corrected prior to installation of the piping. 7.3.2.19 Specification Y-2794A (Valves 21/2" and larger) - five valves were inspected. No nonconforming condition reflected against prior receipt inspection. Two Nonconformance Reports (NCRs PC0148N and I PC0149N) were written against long term storage conditions. These will be addressed as a part of the overall storage and maintenance program and corrected prior to installation. 7.3.2.20 Specification Y-2795, Diaphragm Valves - 100% inspection (88 pieces) conducted after failure of the sample inspection of 43. R NCR PCC091N identifies no evidence of a position indicator. I R Further investigation showed the valve stems had position indicators. Disposition was "Use-As-Is" due to the invalid original finding. I la addition, Nonconformance Reports PC0105N and PC0106N describe deficiencies in long term storage conditions. NCR PC0105N was dispositioned "Use-As Is" on the basis that the checklist stated a I requirement not specified. There is no need to apply primary coating to bolts. NCR PC106N required " Rework" to mark the container with required information. 7.3.2.21 Specification Y-2865, Embedded Piping - 100% inspection conducted (52 pieces). I NCR PC0090N describes dimensional deficiencies that required an increase in sample size from the original sample and which reflect against the original receipt inspection; however, the engineering disposition is to
~~" Accept-As-Is" on the basis that the defined error is within the accuracy of the measurement technique used.~~
In addition, NCRs PC0101N, PC0102N, PC0104N, PCl233N and PCl234N R I were written against identification and long term storage conditions and PC0103N was written against marking requirements not a part of the original inspection. I , I l I I These canditions sill be corrected as required prior to installation. NCR PC010lN was dispositioned "Use-As-Is" based on required cleaning of loose rust on seld preparation prior to g welding. NCR PC0102N dispositioned "Use-As-Is" on basis that g identification is positively e.cablished by heat numbers and by unique configuration and tags. This condition has been previously identified and disposed of in NCR-SMH47. NCR's PC0104N, PC1375N, R E PCl376, PCl377, PC1378 require rework to clean the I.D and R 3 0.D., verify wall thickness af ter cleaning, and apply protective coatings. 7.3.2.22 Specification Y-2900, Cubicle Coolers - 100% inspection conducted. Two nonconformances were writton relating to adequacy of prior inspections as follows: NCRd DEFICIENCY DISPOSITION PC0186N Inlet and Outlet not as shown on drawing Use-As-Is PC0187N No corrosion preventive compound on Rework flange faces PC0186N was dispositioned on the basis that the slight mislocation (1/4" - 1/2") will be accommodated at installation. In addition, g Nonconformance Reports PC0188N and PC0189N were written against g long term storage conditions and the items will be reworked prior to use. 7.3.2.23 Specification Y-2702, Westinghouse (W) NSSS Components - 1550 items such as heat exchangers, tanks valves, detectors and pumps were receipt inspected and accepted by PSI Receipt Inspection prior to August 7, 1979. In order to take a sample providing a l a representative cross-section of the component designs and manufacturing processes utilized in fabrication of these items, the sample size was increased and the following 68 items were selected:
~~a. Specification Y-2702, RHR and Letdown Heat Exchanger -~~
Inspection conducted on five units. There were no l nonconformances reported that reflected in prior receipt 5 inspections. NCR# DEFICIENCY DISPOSITION PC0173N Storage condition. Surface rust on shell support bracketing bolts. Rework PC0174N Overpressure Purge Use-As-Is PC0175N Slight Oversize 0.D. Use-As-Is* PC0174N Nonconformance does not exist. Purge Invalid pressure complies with SSM Y-2712, Finding Rev. 2 Use-As-Is = PC0175N Nozzles are 8" pipe. 0.D. is within Use-As-Is g tolerance of 8" pipe. g
*This was not a required inspection on original receipt.
I
b. Specification Y-2702, Spent Fuel Fool Heat Exchanger - One heat exchanger was inspected. No nonconformance reflected on prior receipt inspection; however, NCRs PC0ll5N, PC0ll6N, R I PC0ll7H, PC0ll8N, PC0119N, PC0120N and PC0121N describe nonconformances including small dimensional deficiencies not a part of the original inspection, as well as overpurge pressure R
and long term storage conditions. Nonconformance Reports I PC0119N and PC0120N were written against long term storage conditions. R NCR# DEFICIENCY DISPOSITION PC0115N Overall length is 31'1" Use-As-Is R S/B 31'1 7/8" PC0116N Shell side inlet / outlet nozzles Use-As-Is R Are: Inlet-18.025', outlet 18.095 I S/B - 18" Nozzles are 18" pipe and within pipe tolerances. I PC0117N Tube side inlet / outlet nozzles Are: Inlet - 15.944, " Outlet 15.930" S/B 16" Nozzles are fabricated from 16" Use-As-Is R pipe and are within pipe tolerances. PC0118N Outside Shell Diameter is Use-As-Is R 48.008". S/B 48.00" diameter is within T.E.M.A. tolerances. Pc6119N No evidence of lubricant Rework R on head to shell bolting. PC0120N Areas of carbon contamination Rework R on stainless steel head PC0121N Nitrogen purge readings are 7.5 Use"As-Is R and 7.0 psig, S/B 6 psig. Purge is in accordance with Rev. 2 of Y-2702-014.
c. Specification Y-2702, Seal Water Heat Exchanger - One unit was inspected. No nonconformances were written that reflect on I the validity of prior inspections. Nonconformances were written against minor dimensional deficiencies not addressed in the original inspection as well as overpurge and long term g storage conditions. NCRs PC0111N and PC0ll4N were written R g against long term storage condition which will be corrected as a part of the overall storage and maintenance program. NCR PC0112N was found to be within prescribed pressure of a later R i
I specification revision. The minor dimensional errors were considered to be within the potential measurement error for the method used. I I I l l l
I NCR# DEFICIENCY DISP 0SITION PC0111N No evidence of lubrication on head Rework R to shell bolting. g PC0ll2N Purge on interior non-corrosion Use-As-Is Rg resistant surfaces is in excess of 6 psig. Purge is in accordance with g Rev. 2 of Y-2702-014 PC0ll3N Shop Primer on external carbon steel Rework R E surfaces is flaking PC0ll4N Carbon contamination on the stainless steel head and on the stainless Use-As-Is RlS inlet flange PC0122N outside shell diameter is 20.046 Use-As-Is Rg "S/B 20.0" Diameter is within g T.E.M.A. tolerances PC0123N Tube side inlet /outside nozzles art: Use-As-Is R
" Inlet 4. 525" Ou' .e t 4.537 S/B 4.0 PC0124N bhell side inletroutlet nozzles ate: Use-As-Is R " Inlet 6.666" Outlet 6.646" S/B f.0 PC0125N overall length is 13" 8 1/2" S/B 13' 8 7/16" Use-As-Is R
~~d. Specification Y-2702, Accumulator Tank - Four tanks were inspected. No nonconformances were written reflecting on original receipt inspection. One Nonconformance Report was written as follows:~~
NCR# DEFICIENCY DIS POS ITION PC0155N Distance between shell heads is + 1" Use-As-Is oversize. " Accepted-As-Is" on the basis that the dimension has no importance after tank fabrication.
e. Specification Y-2702, Diaphragm Valves - A quantity of five valves were inspected. No nonconformances were written reflecting on original receipt inspection; however, NCR PC0162N was written against a characteristic not identified on tne checklist relative to a nameplate on the actuator. It was subsequently determined that this is not a design l requirement. Therefore, no action is required. W

f. Spccification Y-2702, Nozzle Type Relief Valve -16 valves were inspected. Nonconformances do not relate to original inspection. NCR PC0147N describes a dimensional deficiency not addwessed on the original checklist and which was dispositioned "Use-As-Is" on the basis that the small dimensional deficiency would be accommodated at fitup. NCR l
IN PC0108 was written against long term storage conditions and was dispositioned "Use-As-Is" on the basis that light g corrosion in the uutlet surface would not be detrimental and g humidity indicators used in the storage and maintenance program would monitor the storage condition. 1 I' 1 l I 1 l
l
~~g. Specification Y-2702, Air Operated Valve Assemblies - 26 Valves !~~
were inspected. There were no deficiencies reflecting on prior receipt inspection. NCRs were written as follows: NCR PC 0107N - Long term storage condition dispositioned "Use-As-Is" on the basis that described condition is not detrimental. NCR PC 0138N - Invalid finding because written against a reference dimension. NCR PC 0139N - Long term storage condition dispositioned "Use-As-Is" on the basis that the described condition is not detrimental. NCR4 DEFICIENCY DISPOSITION PC0140N Lack of Dessicant. Use-As-Is Dessicant is not required when stored as Level B. PC0141N Lack of Coating on Bolt Heads. Use-As-Is Prime coats not required.
~~h. Specification Y-2702, RHR Pumps - Inspection was conduc*.ed on two pumps. Nonconformances did not relate to the origir.al receipt inspection; however, one nonconformance (NCR PC0100N)~~
I was written against a dimension not required to be checked originally, but checked during this Material Verification Program. The deficiency is an excess thickness of up to 1/4" in I the baseplate. The NCR has been dispositioned "Use-As-Is". will include an inspection for this characteristic for future receipt inspections. In addition, NCR PC0159N was written PS I against long tem storage conditions, and was dispositioned I "Use-Ar-Is" on the basis that storage condition per PMP 6.03 was not violaced. I i. Specification Y-2702, Neutron Detector Positioning Device - Eight devices were inspected. Protective coating was damaged, however, this condition was addressed on a previously initiated CAR PC-0002 dated March 7, 1980. No nonconformances were generated reflecting on the original receipt inspection. 7.3.2.24 Specification Y-2720 - Containment Cranes. It was determined that I this material had not been receipt inspected prior to August 7, 1979 and it was deleted from the Material Verification Program. 7.3.2.25 Specification Y-2741 - Piping Subassemblies Inspection af a sample of 59 piping subassemblies discicsed a nonconformane in weld bevel angles resulting in increasing the I I sample size to 208. In addition, fourteen Nonconformance Reports R were written against long term storage conditions: PC1011N, PC1015N, PC1016N, PC1017N, PC1023N, PC1024N, PC1025N, PC1026N, g PC1043N, PC1044N, PC1045N, PC1046N, PC1050N and PC1051N. The other nonconformances are as follows: 5 NCR# DEFICIENCY DISPOSITION PC0099N Weld Bevels are - 2 1/20 Use-As-Is R 1019N to + 60 from 37 1/20 g 1027N + 2 1/20 requirement. g 1047N PC1012N No wrap on pipe Use-As-Is R l 1018N W PC1020N Item damaged / gauge in Repair R g 1049N flange end weld g 1013N 1014N PC1021N Identification Rework R 1022N 1042N PC1048N Dimensional Use-As-Is R The weld bevels will be inspected and corrected as necessary at g fitup as a part of the Piping Contractor's standard practice. The storage conditions will be corrected as a part of PSI's storage and 5 maintenance program. 7.3.2.26 Specification Y-2804, Containment Electrical Penetrations The entire inventory (38 pieces) was inspected. No deficiency ' reflecting on prior rece: t inspection was reported. Four R Nonconformance Reports vete written as a result of this inspection as follows: NCR# DEFICIENCY DISPOSITION PC0011N No identification on flanges. Use-As-Is g Flanges are interchangeable. g l PC0169N Low purge pressure Rework i PC0170N Broken gauge Replace Gauge / l Re pressurize PC0172N Identification Rework All penetrations were reinspected to verify "N" Stamp on Code R Nameplate. This action was completed 11-08-80. 7.3.2.27 The following specifications had no nonconformances reported: Specification Y-2815, Cable Pans and, Y-2718C, Carbon Steel Valves. I 7.3.2.28 Corrective Action for Hardware Nonconformances Individual nonconformance reports define the engineering actions to I i be taken to correct nonconforming conditions that cannot be l accepted without rework to design requirements, repaired to an l acceptable condition or replaced. Of the several thousand items I inspected, seven items were identified to be replaced. In many instances nonconforming structural steel members were dispositioned to be reworked as necessary at erection. This is a common erection practice permitted by the AISC Code of Practice referenced in the I 7.3.2.29 specification. Action to Prevent Recurrence A program is being initiated to inform PSI Receiving Inspectors and Source Surveillance personnel of the kinds of nonconforming conditions identified and inspection checklists and surveillance I plans are being revised to assure that attention is directed to such conditions in the future. An analysis is being made of reported conditions identifying generic problems requiring I corrective action on future shipments. Suppliers of such items will be required to furnish a response to identify actions they will take to prevent such problems in the future. Supplier I representatives are being brought in to review the results of this program to assure their understanding of the problem. In the case of structural steel, it appears that a revision of design documents and the industry standards they reference, must be addressed, since I many dimensional tolerancer specified appear to be more stringent than the fabrication process is capable of meeting. Structural steel members 30 feet and more in length are not fabricated, I erected, inspected or used in temperature controlled environments, yet tolerances are specified that are practically unattainable without such controls. PSI Quality Engineers, Inspection and Source Surveillance personnel are being reinstructed in the appropriate inspection methods to assure adharence to drawing and specification requirements and documentation of nonconforming conditions. An overall program addressing storage conditions and maintenarce is underway and will address and correct deficient conditions. 7.3.3 Documentation Review I 7.3.3.1 Documentation supporting the receipt of items inspected under the Material Verification Program was reviewed in accordance with the same statistical sampling plan as for the hardware. Except for NSSS documentation, the review was conducted for PSI by S&L personnel in accordance with their procedures approved by PSI. I I Where S&L identified documentation deficiencies they originated Requests for Correction with direct transmittal to the Suppliers R of the documentation. Documentation supplied by the NSSS supplier was reviewed by PSI in accordance with the requirements of SPP-7. Nonconformance Reports relating tu documentation were prepared by PSI Quality Assurance for instances in which the required correct documentation could not be furnished by a Supplier or manuf acturer. g The nonconformance reports resulted in obtaining correct 5 documentation. R Such Nonconformance Reports were reviewed and dispositioned by PSI l Engineering and Quality Assurance. m The conduct and results of the documentation review portion for the g Material Verification Program is described in the following g sections. 7.3.3.2 Sargent & Lundy and PSI document reviewers were evaluated by PSI l Quality Assurance to assure that qualification requirements of PSI E Project Managrent Procedures 3.01 and 3.16 were met as appropriate. S&L personnel were trained in the purpose and use of Special Process Procedure, SPP-7. 7.3.3.3 Documents selected for review correspond to the specifications R and items identified for material verification. Available docu- = mentation packages were submitted for S&L to review. R Some documentation was reviewed by S&L at Supplier's offices. Most of the Radiographs were reviewed by S&L. 7.3.3.4 Documents were reviewed using standard S&L checklists and/ g or procedures approved by PSI Quality Assurance. Where specia checklists were required, they were prepared by S&L and R B approved by PSI. 7.3.3.5 Except for documents relating to Specification Y-2721, deficiencies were found in the document packages of all specifications, resulting in 100% review. Deficiencies were first documented by g S&L on their form " Request for Correction", in accordance with g their Procedure QCP-MH-8.4. When corrected or completed and docu-l mentatica could not be readily furnished, the deficiency was docu- R l mented by PSI on Nonconformance Reports, which identified the l l specific documentation problems. These were submitted to Project e l Engineering for review and disposition. Documentation inspection resulted in initiating Nonconformance Reports (NCRs) to identify g discrepancies based on checklist criteria. Where review resulted g in identifying signi ficant Suppliers' programmatic deficiences, Corrective Action Requests were generated addressing generic R nonconformances. The results of the documentation review for l completeness, accuracy and technical sdequacy are reported for each = specification in the following paragraphs. I I
I 7.3.3.6 Specification Y-2766, Stainless Steel Liner A total of 33 Requests for Correction were originated by S&L and I forwarded to Suppliers. Responses to Requests for Correction are being processed by S&L; however Nonconformance Reports relating to this specification have been initiated by PSI and dispositioned as follows:
~~- NCR PC1074N - Illegible, incomplete and incorrectly filled out Quality Verification Records. Use of unapproved materials.~~
I - NCR PC1075N - Missing CMTRs I Conditions noted have been dispositioned as " Rework" on the basis that the Supplier will furnish adequate documentation. 7.3.3.7 Specification Y-2804, Electrical Penetrations Review of documentation for electrical penetrations resulted in 37 Requests for Correction, identifying the following discrepancies:
- Documentation package does not contain Certificate of Compliance for SA and ASTM materials for bolts, nuts, midlock ferrule, midlock cap, etc. - Weld procedure, weld rod certification, and NDE Reports for name plate welds are missing in the package. - Bolts, nuts, and weld neck flange are not listed on the N-2 data form.
Requested documentation was subsequently furnished by the Supplier. 7.3.3.8 Specification Y-2720, containment Cranes It was determined that the Containment Crane had not been receipt inspected prior to August 7, 1979 and it was not inspected under I the Material Verification Program. However, documentation was reviewed by S&L prior to this determination. A Request for Correction was initiated identifying one minor deficiency. Resolution of this deficiency, incorrect posting of an Equipment Number, has been completed. 7.3.3.9 Specification Y-2702, Westinghouse NSSS PSI, in its review of documentation for 68 items, initiated 46 Nonconformance Reporcs as follows: 33 Nonconformance Reports which have been dispositioned by W, found acceptable by PSI and require no further action for proper close out. These are: PC0041N, 42N. 43N, 46N, 47N, 49N, 50N, 52N, 54N, 55N, 56N, 182N, I 204N, 207N. 59N, 82N, 83N, 85N, 86N, 88N, 89N, 45N, 58N, 60N, 62N, 64N, 84N, 87N, 92N, 93N, 179N, 180N and 206N. I I
I 13 nonconformances, PC0044N, 46N, SIN, 57N, 61N, 63N, 94N, 95N, 181N, 183N, 184N,185N and 208N, have been dispositioned by E and found acceptable by PSI. However, due to the nature of the discrepancies (documentation either missing, incorrect or g incomplete), the nonconformances will remain open until E provides g PSI with hard copy evidence of the subject documentation. Hard copy evidence is being reviewed from E, all but 6 NCRs have been acceptably closed. It was determined that it was unnecessary R to increase the size of the sample based on the following:
a. The NCRs generated reflect differences in Quality Assurance Programs as opposed to a deficiency in either.

b. The E Quality Assurance Records Management Program has provided PSI with the neeusary confidence level that documents are available.

c. E is contractually responsible for retaining the applicable Code-related records for PSI.
7.3.3.10 Specification Y-2718C, Carbon Steel Valves In the review of documentation fc: four valves, two Requests for Correction containing one or more discrepancies were initiated for l each valve. The following major discrepancies were noted: EW Some of the records identify valves as Class 3 rather than Class 2 as required by the specification.
~~- NDE personnel qualifications levels are not shown on test reports.~~
~~Studs and nuts (pressure retaining parts) not listed on the Code Data Report. Also, CMTRs were not supplied for these parts.~~
~~- Heat Treat Chart was not included in documentation packages.~~
Requested documentation was subsequently furnished by the Supplier. No Nonconformance Reports were initiated. 7.3.3.11 Specification Y-2725, Containment Liner In the review of the entire lot size of packages 27 Requests for Correction were initiated with resolutions now being processed by g S&L. The NCR relating to this specification is as follows: l 5 1
~~- NCR PC1072N - Illegible, incomplete, and incorrectly filled out Quality Verification Records.~~
Conditions noted have been dispositioned by the Supplier furnishing adequate documentation. R I I
I 7.3.3.12 Specification Y-2744, Shop Fabricated Tanks In the review of the entire lot of six packages, four Requests for Correction were initiated identifying the following discrepancies:
- Material used in fabrication was not listed as an acceptable material in the specification. l - Material Suppliers ASME Quality System Certificate number and I expiration date was not shown on CMTR.
Requested documentation was subsequently furnished by the Supplier. 7.3.3.13 Specification Y-2756, Main Steam Isolation Valves In the review of packages for the entire lot of four, one Request for Correction was initiated containing one or more discrepancies I for each valve. The discrepancies are:
~~- Material Suppliers ASME Quality System certificate number and expiration date not shown on CMTRs. - lieat Treat Charts or statement not included on some of the CMTRs.~~
Requested documentation was subsequently furn'shed by the Supplier. 7.3.3.14 Specification Y-2794, Stainless Steel Valves In the review of the entire lot of documentation (five valves), two Requests for Correction were initiated identifying the following discrepancies: Most of the CMTRs do not show the material Supplier's ASME Certificate Number and expiration date.
~~- Wrong pressure rating shown in data package for two valves.~~
Requested Documentation was subsequently furnished by the Supplier. 7.3.3.15 Specification Y-2795, Diaphragm Valves I In the review of the entire lot, four Requests for Correction were initiated with resolutions now being processed by S6L. 36 Nonconformance Reports relating to this specification were A total of initiated as follows: NCR PC0925 and PC0926 - No Hydro Test Pressure shown on Code Data Report.
~~- NCR PC0944N through PC0951N - CMTRs require Quality System NCR PC0917N through PC0943N Certification Number ..J NCR PC1003N Expiration date.~~
1 I I l
I Conditions noted have been dispositioned as either " Rework" or l "Use-As-Is" by Projec t Engineering. W 7.3.3.16 Specification Y-2771, Hangers, Supports, Snubbers As a result of the review of the entire lot of 2490 document packages, 271 Requests for Correction, were originated. Two Nonconformance Reports were originated as follows:
- NCR PC0915N and PC0916N - Illegible, missing, incomplete, and incorrectly filled out Quality Verification Records. Use of unapproved procedures. - Conditions noted have been dispositioned as " Rework" and the Supplier has furnished adequate documentation.
7.3.3.17 Specification Y-2900, Cubicle Coolers Review of the entire lot (24 coolers) resulted in initiating 24 Requests for Correction. S&L is resolving Supplier responses, however, PSI has initiated 24 Nonconformance Reports. The Nonconformance Reports are as follows: NCR PC0300 through PC0823N
~~- Wrong leak test pressure used, 150 PSI versus 170 PSI required.~~
~~No traceability for tube sheets or baf fle plates.~~
~~- No revisions or identification of welding procedures used in ,~~
~~fabrication.~~
- No material Suppliers, ASME Certification Number and expiration date shown on CMTRs. - CMTRs do not show heat treat conditions. "U-Bend" brazing map not included in documentation package.
Conditions noted have been dispositioned as " Rework" and the Supplier is to furnish adequate documentation from shop records. 7.3.3.18 Specification Y-2735, Fabricated Steel Review of documentation packages for the entire lot of 6997 pieces g (some of which had been erected) for documentation accuracy and g
<chnical adequacy, required initiation of Request for Correction sdentifying the following discrepancies. - Documents were copied with information either lef t of f, or the copy was illegible. - The grades of the materials were not shown. - Material results were out of the specified chemical range.
I I
l I l NCR# DEFICIENCY DIS POS ITION PC1053N Category 11 material used as Use-As-Is I Category I. Material meets chemical and physical requirements of Category I material. PC1054N No fabrication drawings furnished. Use-As-Is Supplier to obtain fabrication drawings. PC1055N Plate thickness oversized. Use-As-Is Thickness acceptable to design criteria. PC1056N Did not reference DCR. Use-As-Is Supplier to furnish DCR. PC1058N Incorrect material supplied. Use-As-Is Higher grade material used. Requested docutrentation is now being processed and resolved by S&L. NCR PC1073N has been originated to document missing, illegible and incomplete Quality Verification Records and has been I dispositioned " Rework" and Supplier is to provide correct Quality Verification Records. All RCs have now been closed. R 7.3.3.19 Specification Y-2741, Piping Material and Fabrication In the review of the entire lot size, 1699 Requests for Correction were initiated identifying the following discrepancies:
~~- Examination and documentation checklist is not complete nor accurate. - Certificate of Compliance incorrectly identified.~~
NDE Reports not complete. Illegible, missing, incomplete and incorrectly filled out Quality Verification Records. Requested documentation was subsequently furnished by the Supplier. NCR PCO218 describes an illegible data plate rubbing. ! I This is dispositioned "Use-As-Is". requirement (Ref. ECN M-236). The rubbing is not a Code 7.3.3.20 Specification Y-2797, NSSS Support Steel In the review of the entire lot size, 79 Requests for Correction were written containing one or more discrepancies as follows: I l I I
I Some procedures are missing the revision numbers and some procedure revisions are shown for which there is 1o record of S&L approval. Drawing numbers were missing. Weld procedures were missing.
~~- A OtTR was missing.~~
Documentation was missing weld material and heat number h* identification. Weld Identification was incorrect. A shipping checklist was missing. The Requests for Correction have been responded to providing the necessary information. 7.3.3.21 Specification Y-2787A, Containment Piping Penetrations In the review of the lot size, one Request for Correction identifying one minor discrepancy was initiated. This discrepancy was an incorrect listing of an ultrasonic procedure number. The requested documentation noted has been subsequently furnished by the Supplier. No PSI Nonconformance Reports were initiated. , 7.3.3.22 Specification Y-2787B, Penetrations In the review of the entire lot size, 29 Requests for Correction were written covering one or more discrepancies on each penetration. The following discrepancies were identified: Weld procedures not submitted to S&L for approval. Missing nameplate rubbings and Code Data Reports.
~~- Missing weld records. - Errors found in CMTBs Requested documentation was subsequently furnished by the Supplier. No PSI Nonconformance Reports were initiated.~~
~~7.3.3.23 Specification Y-2865, Essential Service Water lieaders in the review of lot size, 46 Requests for Correction were initiated identifying the following discrepancies:~~
~~- No actual chemical / physical properties on CITR I~~
I
I No ASME certificate number and expiration date on CMTR.
~~- It..orrect or missing code addenda on the CMTR and MT report.~~
Unapproved weld procedures. Six Nonconformance Reports were initiated (NCR PC0004, 05, 07 through NCR PC0010) based on a Supplier furnishing " typical" rather than actual properties for his material certification report. This resulted in an ASME Section III Code interpretation to "Use-As-Is" I on Class 3 items where actual results of chemical and physical properties are not required on Class 3 items. I There was also an instance of two different certifications assigned the same heat number. The Supplier was requested to clarify the R matter. The material was placed on hold until the matter was R resolved acceptably. R 7.3.3.24 Specification Y-2815, Cable Pans and Hangers In the review of the entire lot size (documentation repre:enting 'I 4244 items), 19 Requests for Correction were initiated identifying the following discrepancies:
~~- Missing CMTRs. - Lack of traceability of CMTRs to hangers.~~
The requested documentation was subsequently furnished by the Supplier. No PSI Nonconformance Reports were initiated. I 7.3.3.25 Documentation found to be acceptable by S&L was stamped as approved. Incomplete documentation packages are being withheld at S&L until resolution of discrepant documents are received via S&L's document status program. A program has been initiated to review and verify on a sampling basis the returned S&L accepted documentation packages for I accuracy, completeness, technical adequacy, and for PSI acceptance of resolved deficiencies. I 7.3.3.26 Corrective Action In general, missing or incomplete documentation has been made available upon request. Where documentation is not available, an I NCR was written on an individual basis and submitted for review and technical disposition. R 7.3.3. Action to Prevent Recurrence Improved definition of documentation requirements has been made the responsibility of Quality Engineering based on review of applicable
. Codes, Drawings and Specifications. These requirements are being provided and included in surveillance plans and checklists. Review of documentation at Suppliers' plants prior to shipment is being instituted where practical to identify problems earlier at s ot:rce .
I
/
~~I Skill requirements for document reviewers have been identified and personnel have been formally trained and qualified to meet these requirements.~~
~~7.4 CONCLUSION~~
S The Material Verification Program substantiated that for most specifications, the physical receiving inspection of hardware has I 3 been satisfactorily performed. Where deficiencies were found, they have generally been determined to not adversely af fect the usability of the material. Most of the deficiencies are minor in nature. Some will require rework or repair to meet acceptance requirements. It was determined that more errors and omissions existed in documentation than in the related hardware. Material verification and documentation review deficiencies have been dispositioned by Project Engineering and Quality Assurance. g Many of the characteristics identified would be better assessed at the Suppliers' facilities than at receipt inspection. 5 Consequently, surveillance plans and inspection checklists will be improved to provide better and more timely correlation of l inspection results. W The program also demonstrated that improvements made since g August 7, 1979 in the qualification and training of personnel have resulted in improving the effectiveness of inspection. Further 5 upgrading of checklists, continued formal and on-the-job training and qualification of personnel will enhance these results. PSI has l initiated an extensive program to accomplish these objectives. W
~~7.5 REFERENCES~~
7.5.1 AISC " Manual of Steel Construction" 7th Edition. 7.5.2 ANSI N45.2.6 (1973) " Qualification of Nuclear Power Plant Inspection, Examination and Testing = Personnel". 7.5.3 AWS - D.l.1 Structural Welding Code - Steel. 7.5.4 Document Review Work Instruction I 7.5.5 Document Review Material Dictionary I 7.5.6 Document Review Quality Control Requirements Dictionary 7.6 ATTACRMENTS 7.6.1 Cherne Contracting Corporation Report on Receipt Inspection R Verification Program. 7.6.2 Newberg-Marble Hill Report on Material Verification Program. R I I
I 7.6.3 List of Drawings and Revisions Utilized. R 7.6.4 Receiving Inspection Checklist / Report (Specimen). l 7.6.5 Quality Assurance Checklist (Specimen). 7.6.6 Document Review Checklist (Specimen). 7.6.7 List of Nonconformance Reports. R I 7.6.8 SPP-7 " Physical Inspection and Verification of Previously Accepted Purchased Items." .I I i l 1 I I I I I I I l I 'I 1I l . . . _ .. . - . . . - - - - _ _ _ _ - . - . - . _ . . .
I ATTACHMENT 7.6.1 CHERNE CONTRACTING CORPORATION RECEIPT INSPECTION REVERIFICATION PROGRAM 1.0 ABSTRACT I This report describes the program to reinspect Category I materials received and inspected by Cherne Contracting Corporation (Cherne) and its subcontractors at the Public Service Company Indiana, Inc., (PSI) Marble Hill Site prior to August 7, 1979. The program was g entered into by Cherne upon the request of PSI as a part of its g response to Item 1 of th NRC Order confirming PSI's voluntary cessation of Safety-Related construction activities. Except for three items, the program confirmed the effectiveness of prior receipt inspections. Two of the three items were found to fall within acceptance limits when the sample size was increased. One item, Auxiliary Steel, required 100% inspection.
~~2.0 INTRODUCTION~~
2.1 Commitments As part of PSI's commitment to the Nuclear Regulatory Commission in l Article III-A.1 of the " Description of Licensee Activities Address- R W ing Order Confirming Suspension of Construction," Cherne was requested to perform a verification of the quality of items it had receipt inspected prior to August 7, 1979. 2.2 Procedure Outline Steps taken to conduct the Receipt Inspection Verification Program included the following: 2.2.1 Preparation and approval of a procedure RVP-001 Receipt Inspection Verification Program, including a sampling plan and tables to provide results with a 95% reliability with a 95% confidence factor. 2.2.2 Selection and training qualification of personnel to perform the verification. 2.2.3 Physical inventory of items received, inspected and accepted prior to August 7, 1979. . 2.2.4 Physical inspection of randomly selected samples of Category I stored materials. 2.2.5 Evaluation of results and preparation of necessary Nonconformances l Reports and Corrective Action Requests. W 3.0 DISCUSSION 3.1 Procedure Procedure RVP-001 entitled " Receipt Inspection Reverification l Program" was prepared by Cherne and approved by PSI Quality W Assurance Management. I I Tne procedure provides written instructions for reviewing documents, selecting samples, preparing checklists and conducting I the inspections. Tne enecklists were required to include or reference acenptance criteria for the inspections. The procedure required inspections to be conducted with an approved I sampling plan giving sample sizes based on Cherne's inventory of purchased items received, inspected and accepted prior to August 7, 1979. The plan required increasing the sample size if deficiencies I were detected such that a reliability of 95% with a confidence factor of 95% would be maintained. 3.2 Establishment of Teams - Material Verification Prior to performing the Receipt Inspection Reverification Activity, Cnerne's QC personnel were trained in the requirements of the Reverification Program and Cherne's Procedure RVP-001. In order to determine the items that were to be included in the Reverification Program, all Cherne Receiving Inspection Reports, which were completed prior to August 7, 1979, were reviewed. Items were accumulated by generic category such as 450 elbows (2" and under), 900 elbows (2" and under) couplings 2" and under, or weld I material (Reference 1). The total quantity in each category was subtocated by purchase order number. After selection of the sample size from PSI's 95% Confidence and Reliability Statistical Sampling Program for each category, a sample for each purchase order was selected based on the percentage of items covered by that particular purchase order. Random samples were sele-ted to represent the various item numbers referenced on each purchase order in each of the general categories. Physical inspections and documentation reviews were I conducted on each item in accordance with the appropriate checklists. Special checklists covering the various categories of items were I prepared to perform the Receipt Inspection Reverification. The program was conducted under the direct supervision of a Cherne individual qualified to ANSI N45.2.6 (1973) Level II. Every step was witnessed by PSI QA Receipt Inspection personnel. As shown in Reference 1, separate Receiving Inspection Report Numbers were assigned for each purchase order under the main I categories. Weld material is an exception where one RIR number covers more than one purchase order number. Nonconformances were evaluated to determine whether the conditions adversely affected the functional adequacy. I I 3.3 DISCUSSION OF PHYSICAL INSPECTION RESULTS The results of the Material Verification Program are summarized below. RIR No. RVP001 and 002 900 elbows 2" and under Sample 93 Sample was increased to 93. Refer to NCR 6.199. RIR No. RVP003 and 004 450 elbows 2" and under Sample 59 R*R No. RVP005, 006 and 007 Couplings 2" and under Sample 59 RIR No. RVP008 and 009 Tees 2" and under Sample 124 Sample was increased to L24. Refer to n'. 6.201 and 6.202 RIR No. RVP010, 011 and 012 Reducing inserts 2" and under Sample 59 RIR No. RVP01'8 and 014 Caps 2" and under Sample 59 RIR No. RVP015 and 016 Pipe 2" and under Sample 60 RIR No. RVP0l7 and 018 Pipe over 2" Sample O No items were inspected because the individual pieces were installed. Since the sample for the small bore pipe was totally acceptable and the same receipt practices were used for both small and large bore pipe, the large bore pipe was not inspected. RIR No. RVP019 Flanges over 2" Sample 21 Physical inspection was performed on 21 flanges out of 32. The remaining 11 flanges were installed. Documentation review was conducted on 32 of the g flanges. Since all flanges inspe:ted were acceptable, the 11 installed g items were not physically inspected. RIR No. RVP020 Boits Sample 24 24 bolts were inspected and found to be acceptable. The remaining bolts were installed and were not physically hspected; however, a 100% documentation review was conducted. RIR No. RVP021 f 4.- Sample 48 48 nuts were inspected and .,~y 4 ' f feceptable. The remaining nuts were installed and were not physixtly agected. However, a 100% documentation review was conducted. RIR No. RVP022 through 29 Weld Material Sample 63 RIR No. RVP030 Aux Steel Sample 59 Out of the initial sample of 59, 38 items were shown a have deficiencies which are addressed on NCR 6.204. With the 38 deficience 2s in the initial sample, Cherne elected to perform a 100% inspection of welded auxiliary steel received on loads 1 throe m 25 for quality of welding. The 100% inspection has been completed and deficient items have been identified. I
~~.E =~~
I
~~4.0 CONCLUSION~~
S Items, either with the initial sample size or the increased sample size, were found to be acceptable with the exception of RIR No. RVP030 covering auxiliary steel. The deficient items found during the 100% inspection will be documented on Cherne's NC2s and will be reworked as soon as Cherne is released to perform receipt inspection. I The results of the Material Verification Program disclosed that the present qualification of personnel and the completeness of checklists are adequate to identify deficiencies in procured materials and hardware. Deficiencies identified in the Mceerial Verification Program will be the basic for assuring strengt.ening of future inspection practices when Cherne is released to perform receipt inspection.
~~5.0 REFERENCES~~
5.1 Cherne Procedure RVP-001, " Receipt Inspection Reverification Program" I 5.2 NCR 6.199 NCR 6.200 NCR 6.201 4 g NCR 6.202 g NCR 6.203 NCR 6.204 5.3 PSI - SPP-7 " Procedure for Physical Inspection and Verification of Previously Accepted Purchased Items" I 5.4 Cherne Contraccing Corporation letter dated August 22, 1980, A. Dolgaard to J. Marcella "Results of Cherne's Receipt Inspection Reverification Program" 6.0 ATTACRMENTS 6.1 None i 1 Il Il ! il II l
I AITACHMENT 7.6.2 NEWBERG-MARBLE HILL' S REPORT MATERIAL VERIFICATION PROGRAM i ( l.0 MATERIAL VERIFICATION PROGRAM l.1 ABSTRACT This section describes the results of the physical reinspection by Newberg-Marble Hill (N-MH) of hardware and documentation that had g been previously accepted by N-MM and its Subcontractor's Receipt g
~~- ispection prior to August 7, 1979. This section also describes the actions taken and planned to correct identified deficiencies and to preclude recurrence of such deficiencies.~~
The program consisted of visual and dimensional reinspection of a statistical sample of hardware utilizing checklists preesred by N-MH Quality Control personnel trained in the requiremento of an approved procedure, QCP 10.0L-01, to assure an evaluation of prior receipt inspection activities and to determine the acceptability g for construction of such previously accepted items. Similarly-previously reviewed and accepted documentation supporting the 5 identified hardware was reviewed utilizing personnel from Public Service Company of Indiana, Inc., (PSI) and N-MH. Based on the results of this program, sample sizes were increased where necessary and hardware deficiencies were documented on g Nonconformance Reports and submitted to PS1 for technical g disposition. The results of this reinspection identified hardware and documentation deficiencies that will require correction prior to hN use, but established the fact that the previously receipt inspected I items are acceptable for use in construction. l
~~1.2 INTRODUCTION~~
1.2.L Commitments As part of PSI's commitment to the Nuclear Regulatory Commission in Article III-A-1 of the " Description of Licensee Activities Address- g ing Order Confirming Suspension of Construction", N-MH at the g request of PSI, undertook a reinspection of a statistically based sample of hardware and documentation that had been received aad inspected prior to August 7, 1979 by N-MH and its l Subcontractors. This program had two objectives; (a) to assess the " validity of prior receipt inspections and (b) to determine the acceptability of hardware for construction. The scope of this
~~-L-I~~
reinspection included one procurement specification involving 31,792 items of which over 510 were physically inspected. To accomplisn this program, the following measures were taken. 1.2.2 Procedure Outline The steps taken to perform the Material Verification Program consisted of the following:
1. Preparation and approval of QCP 10.01-01 for physical inspection of Category I purchased hardware and review of required documentation on a statistically valid sampling basis to provide results with 95% reliability and with a 95%
~~confidence factor.~~
2. Selection and qualification of personnel to perform reinspection and document reviews.

3. Physical inventory of items received, inspected, and accepted prior te August 7, 1979 and random selectioa of items from this inventory to provide a representative sample of items from each N-MH specification.

4. Review of Field Change Requests, Engineering Change Notices and Specification Amendments issued since August 7, 1979 to assure adequacy of requirements and effects of the changes on the acceptability of purchased material.

5. Physical inspection of representative samples of Category I stored material receipt inspected prior to August 7, 1979 and a review for adequacy and completeness of documentation. Sample sizes were increased as indicated by the procedure sampling tables where deficiencies relating to the original receipt inspection were identified.

6. Preparation of Nonconformance Reports (NCRs) for item deficiencies and Deviation Reports for documentation and storage deficiencies.
1.3 DISCUSSION 1.3.1 Procedure A Quality Control Procedure, QCP 10.01-01, was prepared by N-MH entitled "N-MH Material Verification Program", and approved by tne PSI Procedure Review Committee. This procedure provided written instructions for the preparation and use of chenklists to assure an adequate evaluation of prior inspections and of the suitability of the itera for construction. This included consideration of I engineering changes, field change requests and specification amendments that sight adversely affect such use and the possibility of degradation of quality due to unplanned long-term storage. The procedure required both visual and dimensional inspections to an approved sampling plan utilizing specially prepared tables to assure that results would be 95% reliable with a 95% confidence factor. The tabl s required increasing the sample size in the evei.t of conditions found nonconforming on characteristics addressed by prior receipt inspections. Activities relating to QCP 10.0L-0L were performed in two phases: (1) Material verification including reinspection of items, and (2) Evaluation of documentation supporting the acceptance of the items. 1.3.2 Establishment of Teams - Material Verification 1.3.2.1 N-MH Quality Control personnat were selected to perform the Material Verification Program. Individuals were qualified in the appropriate discipline as a Level I or II Inspector per ANSI N45.2.6 and indoctrinated in the requirements of QCP 10.0L-OL. g Where Level I personnel were used, they worked in conjunction with g Level II Inspectors. In addition, PSI Level II personnel were used to monitor and assist N-MH in the Verification Program. L.3.2.2 Prior to beginning the Material Verification Program, individual items were randomly selected by item identification numbers and from various locations within the various stacks of material in the storage areas. Inspection of individual items were conducted utilizing approved checklists. The items identified for inspection are listed in the checklists included in the Attachments. L.3.2.3 Physical inspections were performed on identified items defined by ten checklists for Procurement Specification Y-2722. The inspections were performed in accordance with a sampling plan designed to determine the acceptability of the items with 95% reliability and with a 95% confidence factor. Under this plan, items on hand with quantities less than 28 were inspected 100%. Larger quantities were inspected based on a randomly selected statistical sample that was increased in size if any defects were found. The results of the reinspection disclosed that nine of ten checklists required no increase in sample size. Further, the l results of 100% inspection of two items having quantities of less E than 28 showed all to be acceptable. However, one checklist disclosed a nonconformance requiring an increase in the sample size. A 100% inspection of the items on this checklist was not required.
I 1.3.1.4 Nonconformances were evaluated to determine whether the condition adversely affected the functional adequacy of the item. The disposition of all NCRs was "Use-As-Is", except for one NCR dispositioned as " Rework". L.3.2.5 The latest approved Subcontractor (Supplier) drawings were the basis of the inspections. The drawings utilized is given in each checklist. Welding inspection was performed visually to the latest applicable American Welding Society (AWS) Manual. The inspections were performed during September, 1980. The results of the Material Verification Inspection were recorded under the direction of a N-MH Level II Inspector as follows: Each piece sampled was inspected against the latest drawings approved I for use by N-MH. Items to be checked with special tools and instructions were indicated in the checklist. PSI personnel were present during all verification activities and signed off on the checklists as having witnessed the activities. 1.3.2.6 Results of item inspections were documented on the checklists furnished for the program. Nonconformance Reports were originated I for deficient conditions noted and were submitted to PSI for review and disposition. 1.3.3 Discussion of Physical Inspection Results Inspection to determine the validity of the original receipt inspection determined that of the ten checklists involved, there were nonconformances reported during reinspection as follows: 1.3.3.1 Checklist 01 - Angles, Frames and Nosings A sample of 59 angles and frames were inspected. No nosings were inspected since they are identified as Category II items. Two I Nonconformance Reports affecting two items were written. NCR #833 was for a frame evidencing a side with a shorter dimension than shown on the Design Drawing. NCR #891 was for the mislocation of anchor studs in two locations on the frame member. Both NCRs were dispositioned "Use-As-Is". The deficiencies had no adverse effect on their function. The sample size was not increased. In addition, the inspection disclosed a general condition of poor I drainage in the storage area which will require correction. The area is scheduled for reconditioning by PSI within the next month. I I l.3.3.2 Checklist 02 - Concrete Reinforcement Bar - 51 Bar Lists were originally inspected. There was one deficiency R noted reflecting on the validity of the original receipt R inspection. Sample size was increased to 78 with no further R discrepancies noted. Nonconformance #838 was written on the transposition of an approved Heat Number on the Bar List and Bundle Tag. A corrected Bar List was furnished and the rebar bundle l retagged with the proper Heat Number, m 1.3.3.3 Checklist 03 - Cadweld Sleeves 57 Cadweld sleeves were inspected. There were no deficiencies noted reflecting on the validity of the original receipt inspection. 1.3.3.4 Checklist 04 - Cadweld Filler Metal Cartridges 62 Cadweld filler metal cartridges were inspected. There were no deficiencies noted reflecting on the validity of the original receipt inspection. 1.3.3.5 Checklist 05 - Embedded Steel Plates 59 steel plates for embedment were inspected. There were no deficiencies noted reflecting on the validity of the original receipt inspection. The inspection did disclose a general condition of poor drainage in the storage area which will require correction. The area is scheduled for reconditioning by PSI within the next month. In addition, the inspection disclosed a general condition of l rusting of unpainted surfaces and anchor studs due to extended E storage which will require correction prior to erection. l.3.3.6 Checklist 06 - Anchor Bolts 59 anchor bolts were inspected. There were no deficiencies noted reflecting on the validity of the original receipt inspection. The inspection did disclose a general condition of poor drainage in the storage area which will require correction. The area is E scheduled for reconditioning by PSI within the next montn. g l l l l I I l l l
I 1.3.3.7 Checklist 07 - Welding Material 56 welding electrode containers and 41 backing rings were I inspected. There were no deficiencies noted reflecting on the validity of the original receipt inspection. l.3.3.8 Checklist 08 - Piping Subassemblies 31 piping subassemblies were inspected. This was a 100% inspection of the items. There were no deficiencies noted reflecting on the. I validity of the original receipt inspection. NCR #892 -as written on the size of the ring lug and bar lug being interchanged. Disposition is " Accept-As-Is". The inspection did disclose a general condition of pooc drainage, housekeeping, and storage conditions which will require correction. NCR (146 identifies this problem requiring the rework of the entire storage area. In addition, the inspection disclosed a general condition of rusting of unpainted surfaces due to extended storage which will I require correction prior to erection. Due to the rusting, the Code Data Stamp was not discernible on the piping subassemblies. However, the items were identified by their piece mark applied with a paint stick. All items measured agreed with the design requirements on the drawings. NCR #846 identifies
~~'g the missing identification and is dispositioned " Rework" to require 3 the Contractor to re-apply the appropriate Code Stamp.~~
1.3.3.9 Checklist 09 - Piping and Tubing 21 piping and tubing items were inspected. This was a 100% 1 inspection of the items. There were no deficiencies noted I reflecting on the validity of the original receipt inspection. The inspection did disclose a general condition of poor drainage, l housekeeping, and storage conditions which will require I correction. NCR #846 describes this condition and requires the rework of the entire storage area. I In addition, the inspection disclosed a general condition of rusting of unpainted surfaces due to extended storage which will require correction prior to erection. 1.3.3.10 Checklist 10 - Welding Electrodes 37 welding electrode containers were inspected. This was a 100% I inspection of the items. There were no deficiencies noted reflecting on the validity of the original receipt inspection. I I -e-I
I 1.3.4 Action to Prevent Recurrence N-MH's Receiving Inspectors have been made aware of the kinds of nonconforming conditions identified and inspection checklists are being revised to assure that attention is dirceted to such conditions in the future. All N-MH Quality Control personnel are being reindoctrinated in the appropriate inspection methods to assure adherence to drawing and specification requirements and documentation of nonconforming conditions. 1.4 DISCUSSION OF DOCUMENTATION REVIEW RESULTS A review of documentation supporting the receipt of items inspected under the Material Verification Program was performed on those items inspected per the statistical sampling plan. The reviews g were conducted by N-Mi Quality Control personnel and PSI Level II g personnel in accordance with procedure QCP 10.01 1. A R Nonconformance Report relating to documentation was prepared by R N-MH Quality Control for the instance in which the required R g correct documentation had not been supplied by the Manufacturer or W Supplier. This Nonconformance Report was reviewed and dispositioned by PSI. Certifications supporting weld filler R g materials consumed in construction prior to August 7, 1979 were R E reviewed and were found in conformance to specified requirements. R
~~1.5 CONCLUSION~~
Based upon the results of this material verification program it can be determined that all hardware and documentation previously accepted by E receipt inspection prior to August 7, 1979 evidence no deficiencies that g reflect adversely on the validity of the original receipt inspections. Concrete materials and N-MH welding electrodes received prior to August 7, 1979 have since been consumed in Category II work. A review of = concrete material receiving logs and the volume of concrete produced since August 7, 1979 verifies the use of previously received concrete g materials. A review of the weld rod receiving reports and the weld rod g issue logs verifies the use of weld rod in storage as of August 7, 1979. The N-MH Project Engineer provided a review of Field Change Requests, Engineering Change Notices, and Specification Amendments issued since August 7, 1979 and determined that the hardware and material inspected as part of the Material Verification Program have been unaffected by j such changes. E I I l l l
I With the addition of more qualified quality personnel, an increase in the number of quality personnel and the implementation of new and improved quality procedures, N-MH is confident that receipt I inspection will continue to assure the acceptability of N-MH provided hardware and material for construction.
~~1.6 REFERENCES~~
1. 6.1 QCP - 10.01-01, "N-MH Material Verification Program" 1.6.2 QCP 15.01, "Nonconformance Reports"

1. 6. 3 QCP 15.02, " Deviation Reports"

1. 6. 4 QAP 2.01, " Training of Personnel"

1. 6. 5 QAP 10.01, "QC Personnel Qualification and Certification" I 1.6.6 Sargent & Lundy Specification Y-2722, " Concrete Structures and Site i
Work" l.6.7 SPP-7, " Procedure for Physical Inspection and Verification of Previously Accepted Purchased Items" 1.6.8 Dispositioned NCRs NCR No. 833 l NCR No. 838 5 NCR No. 846 NCR No. 891 NCR No. 892
~~' I l.6.9 QCP 10.01-01, Rev. 2~~
1. 7 ATTACHMENTS

1. 7.1 irification Program Checklist (L sample only)

I I

I I
I I
l
~~.--n 1~~
~~g._--~-- VERIFICATION PT40 GRAM CHECKLIST QCP 10.01-01 4 t M1~~
~~' "( [ M6T '? N i No.: 01 Date: 7-31-80 Page 1 of #~~
~~II i{!~~
~~, 1, ' }3 l[ "J ,!_ ~ ~ ~ ' .~~
O
~~//: Item (s) : Angles, Frames and Nosings ! . \. II kh$.~~
~~I ME _b j Y-2722 Amend 1:~~
~~,g.~~
~~k_' ._. a~~
~~..y__ .i Spec. No.: 8-21-7P.__~~
P.O. No.: 104-F-101 (N-MH) Approved For Use : '~7fdjV. M.su z't'QCr -S - g" p Supplier / Manufacturer: Southwest Ornamental Iron Co. See inspection Quantity: See attached sample plan Part Nos.: sheets Inspection Method: Items isnpected on random basis per statistical samol-ing plan. General storage insp ct/ ion is performed on an area walk-thru basic. / VERIFICATION INSPECTION REQUIRED Idontification @ Document tion General Storage StorageDamageh PRECAUTIONS / PRE-REQUISIT None I POST-INSPECTION A TI N: None i I SAMPLE SELECTION: , Nosings are a Category II. None are to be inspected. Angles and frames are to be selected from the Engineer's log of items received cnd the shipping tickets. Selections shall be made at random from the log of items still in storage. When selecting the samples, obtain as many diverse pieces as possible. Use shipping tickets to identify storage areas for h items sele d.
~~' Witnessed By PSI:~~
~~dM/[' NAME'AND d~~
~~/ "~~
~~O Level /!~~
/
l Inspector: w Au= 9/P//iLo Level // NAME AND DATE R viewed: M][/ 'NAMEMAND DATE ' 9-8 -80 Level g '
/
NOTE: REVIEWER LEVEL II MINIMUM - NOT REQUIRED IF INSPECTOR LEVEL II.
VERIFICATION PROGRAM CHECKLIST - HARDWARE jf CHECKLIST NO.: 01 DATE: 7-31-80 PAGE 2 OF M QUANITY NSPECTED: 5f Moms , SPECIFICATION NO.: Y-2722 AMEND: 8-21-78 INSPECTION ITEM INSPECTION CRITERIA SAT UNSAT* N/A General Storage Area Inspection Drainage Pallets /Durinage
/
~~Accessibility I ntification nspe i n Tags F er ai egre ti n~~
/
a Item Storage Bent wiste/ roka members NcR S33 Inspection Tags / Proper Identification Stored on pallets or dunnage Proper drainage Paint All ferrous material receive a prime coat of paint f Non-Painted Surface Contact surfaces under washers of strength bolts [ Field welded joints - 3" strips on each side of joint non-painted [ , a Galvanized surfaces [
~~LIST NCR NUMBER IF. APPLICABLE OR DR NUMBER~~
VERIFICATION PROGRAM Cl!ECKLIST - DOCUMENTATION j/ CHECKLIST NO.: 01 DATE: 7-31-80 'PAGE 3 OF # QUANITY INSPECTED:__ 87 MCMS , SPECIFICATION NO.: Y-2722 AMEND: 8-21 ~18 REQUIRED DOCUMENTATION COMMENT ** SAT 3AT N/A C mensions i
/ . Length Width /
~~N /~~
~~/} Merber Size Record all dimensions check d TGV S i %c :N Cn /~~
NOTE: and circle the design dimen- / NCR 891 sions on the vendor design drawd ~ ing. Attach dimensional check and drawing to this checklist. f' Welding / Penetration - D S NOT APPLY TO VISUAL INSPECTION Undercut s
/
~~Studs 360 0 full fillet Workmanship~~
/
i LIST NCR NUMBER IF APPLICABLE OR DR NUMBER LIST DATE PE INFORMED OF DOCUMENTATION DISCREPANCIES (SECTION 7.2 of QCP 10.01-011 INSPECTION: ALL DOCUMENTS ARE PRESENT, LEGIB LE ,. SUITABLE FOR REPRODUCTION AND EXHIBIT PROPER SIGNA-MINIMUM TURE OR STAMP. ALL DOCUMENTS COMPLY TO REQUIREMENTS OR HON-CONFORMANCES ARE IDENTIFIED AND RESOLVED W W W M M W W M M M M M M M M M M M
M M M M M p M M M M M M M M M M M W W
"?RIFICATION PROGRAM CIIECKLIST - DOCUMENTATION jf CllECKLIST NO.: 01 DATE: PAGE 4 OF #
7-31-80 QUANITY INSPECTED: 87/b415 ,SPECIFICAL . .i NO. : Y-2722 AMEND: S-21-78 REQUIRED DOCUMENTATION COMMENT ** SAT UNSAT* N/A Certificate of Compliance / Final Shop Inspection Report / Mill Test Report // (D J Required Tensile Test Report 1 N
** LIST NCR NUMBER IF APPLICABLE OR DR NUMBER LIST DATE PE INFORMED OF DOCUMENTATION DISCREPANCIES (SECTION 7.2 of QCP 10.01r01)
INSPECTION: ALL DOCUMENTS ARE PRESENT, LEGIBLE, SUITABLE FOR REPRODUCTION AND EXHIBIT PROPER SIGNA-MINIMUM TURE OR' STAMP. ALL DOCOMENTS COMPLY TO REQUIREMENTS OR HON-CONFORMANCES ARE IDENTIFIED AND RESOLVED
Paga 1 of L3 ATTACHMENT 7.6.3 LIST OF DRAWINGS AND REVISIONS UTILIZED SPEC. # - Y-2702 DWC. # REV. # 1190E21
~~7 C-8X20WDF86X28A l l~~
L216E14 2 3 5874 3 , 593L 5 I SD-C-102872 C l SD-C-102864 C , DS-C-56885 8 DS-C-56884 A ; DS-C-56898 A I l DS-C-56892 A l t DS-C-56895 A t DS-C-56877 8 . I DS-C-56900 A DS-C-56896 A DS-C-56879 A l D-165950 7 l D-165985 7 , l D-L65963 6 E! l D-165956 E-L67329 6 6 5: l E-167328 6 _SP _FC. _# - Y-2718C DWG. # REV. # l, W7820002 A Ii SPEC. # - Y-272l l Ii DWG. # REV. # 170WAC-L 2 Ii L70W50B 6 I I I
Page 2 of 13 SPEC. # - Y-2725 DWG. # REV. # CBI 35L 3 CBI 353 4 ) I CBI 355 1 CBI 356 4 CBI 357 2 CBI 353 1 R SPEC. # - Y-2735 I DWG. # REV. # DWG. # REV. # 5 1031 A 2096 B 1072 0 2114 B I - 1083 LO84 1085 A B 2119 2122 3070 1086 B 4111 0 I 1089 8 8023 A 2041 B 8030 B 2042 C 8031 B I 2049 2054 2076 A A C 8033 8035 9036 C C 0 4040 C 4278 0 I 4126 4130 C 4287 0 ' B 4302 A 4132 C 4304 B I 4146 4162 4213 A A B 4306 5027 608L 0 C D 4206 D 6089 A I 4207 C 7040 B 4212 E 7060 C 4239 D 7077 B 4240 B 8L10 3 4269 A 8111 A 4271 D SPEC. # - Y-2741 I DWG. # REV. # DWG. # REV. # MH-0SX33AA-8-115 L ML-2SX05CB-6-183 0 MH-0SX32AB-8-122 1 ML-2SX05CA-6-167 0 I I
Pega 3 of 13 SPEC. # - Y-274L DWG. # REV. # DWG. # REV. # __ Mll-L AF02Cil-4-149 0 Mil-LSIO9 BB-10-158 0 ML-2SXA9A-6-133 0 MH-1SIO9AB-10-153 4 MH-LSX04EA-3-163 0 Mii-ISIOSCA-8-97 0 MH-LSX07GA-16-192 0 MH-L S IO98 A-10-l L 7 0 Mil-0SX32AB-8-127 0 MH-2CS02AB-10-89 0 g Mll-1SX25AB-6-140 0 MH-LSIO5CA-8-90 0 g Mll-L SX07GA-16-L 97 0 MH-1SIO18-24-6 0 MH-0SX33AB-8-110 1 MH-lSI05CB-8-130 0 M11-1SX28AA-10-246 0 Mll-1CS10AB-6-164 L MH-LSX04DB-6-153 0 MH-1SIO5DC-6-123 L Mll-ISX05CA-6-149 0 ML-2SIO3BA-4-187 0 ML-2SX25AA-6-70 0 MH-IRH02AA-8-10 0 g MH-0SX32AB-8-128 L ML-2SIO8B-4-78 0 g MH-ISX04DB-6-156 0 MH-1CS02AA-in-114 2 ML-2SX07GB-16-119 0 ML-2SIO4A-12-71 0 MH-LAF02DB-4-126 L MH-LCS02AB-10-160 1 Mll-1AF02DG-4-141 1 ML-02-166X 0 ML-2CC07AA-6-126 1 MH-02-2 LOX 0 MH-0SX32AA-8-133 0 ML-02-128X 0 g MH-LSIL88-4-47 0 ML-05-132X 1 m MH-IS105DC-6-125 0 ML-05-77X 0 MH-ISIO5DD-6-85 0 Mil-02-139X 0 g MH-1SIO5DB-6-145 MH-1S103AA-4-L44 0 0 ML-02-182X MH-06-147X 0 1 5 MH-ISIl8AB-4-49 1 MH-02-13tX 0 MH-LSIO2BB-6-131 0 MH-02-160X 0 l Mll-LCS02AB-10-89 0 MH-02-155X 0 W MH-1CS02AA-10-73 0 ML-05-99X 1 MH-1SIA4B-8-166 0 ML-02-104X 0 g Mll-L CS10AA-6-li 7 0 0 ML-05-il5X ML-02-8LX 0 0 5 MH-LSIO5DA-6-105 MH-1SX27DB-10-238 0 ML-02-95X 0 MH-1SX27DB-10-235 0 M18-02-147 X 0 MH-1SX27DA-10-177 0 MH-02-178X 0 Mll-1CC03DB-3-132 0 MH-02-231X 0 MH-LCC038-12-1L8 0 HL-06-12ix 0 E Mll-LCC-07AB-6-15L 0 MH-02-L71X 0 g ML-2SX05CB-6-18L 0 ML-05-62X 0 MH-1SX26AB-10-244 0 MH-09-189X 1 ML-02-83X 2 MH-0SX33AA-8-LL6 0 ML-09-57X 1 MH-1SIO9BB-10-156 0 MH-02-152X 0 MH-0293X 0 MH-09-199X 0 MH-02187X 0 g ML-02-155X 0 ML-0285X 0 3 l ML-09-52X 0 MH-02194X 0 ML-05-110X 0 Mii-02137X 0 ML-09-47X 0 MH-02104X 0 ML-05-147X 0 MH-0220LX 0 I I
Pags 4 of 13 SPEC. # - Y-2741 DWG. # REV. # DWG. # REV. # ML-09-6X 0 ML-0276X 0 I E-02-147X ML-09-6LX ML-02-136X 0 0 0 MH-0570X MH-02107X MH-02169X 2 1 0 MH-07-l12X 2 ML-02146X 0 I MH-02-l86X ML-09-15X ML-2CS02AB-10-92 0 0 0 MH-0555X ML-0657X MH-02196X 2 0 0 I MH-ISIO4D-8-169 MH-1RC37A-3-35 ML-2CS02AB-10-96 0 0 0 MH-06107X MH-0294X ML-0211LX 0 0 0 ML-2CS05AA-3-l16 0 ML-07-108X 1 ML-2CSLOAA-6-114 L ML-07-48X L MH-LSIL8DB-4-196 0 ML-09-200X 0 ML-2SIO5CB-8-139 0 MH-09-150X 1 I ML-2CS12AB-3-147 MH-ISIO9BD-10-109 MH-1SIOSAB-8-59 1 L 0 MH-08-57X ML-07-168X ML-09-155X l 0 0 ML-2SIO2BA-6-20 0 ML-09-60X 0 ML-2SIO9AD-10-106 0 MH-09-63X I ML-2CSL2AB-3-143 0 MH-09-95X 3 1 ML-2CS06AB-6-169 0 MH-08-60X 1 I ML-2CS12AB-6-155 ML-2CS06AA-6-120 ML-2SI18AB-4-49 0 0 0 MH-09-16LX MH-09-29X MH-09-135X 0 0 1
~~' I MH-lRH03AA-8-17 MH-LSX26AA-10-170 MH-1SX26AA-10-168 2~~
0 0 MH-09-48X ML-09-69X MH-09-66X 0 0 0 , ML-2SX27DB-10-107 0 ML-09-150X 0 ML-2CC06DB-6-118 0 ML-09-88X 0 MH-LCC07B-3-152 0 ML-07-44X 1 ML-2CC06DA-6-ll5 0 MH-07-LL3X 2 g ML-2CC-13AB-4-91 0 5 MH-lCCl3AB-4-11L 0 MH-LAF02CG-4-126 1 MH-LAF02CE-4-94 0 I ML-2CC-31B-8-148 MH-1CC3 5 A-6-l69 ML-2SX06AA-16-77 0 0 0 I ML-2CC60A-16-54 MH-1AF02CC-4-32 ML-2AF02CE-4-101 0 0 0 I SPEC. # - Y-2744 DWG. # REV. # D-77-417 I D-77-416 3 3 I
I Pegs 5 of 13 SPEC. # - Y-2756 DWC. # REV. # 94-14805 D 94-14806 D SPEC. # - Y-2766 I DWG. # REV. # DWG. # REV. # 19L 1 370 2 g 354 356 4 2 391 393 3 1 g 364 4 397 2 365 2 450 1 369 2 SPEC. # - Y-2771 DWG. # REV. # DWG. # REV. # 2AF05006R A ISX24001R A 2AF0500dR A 1BR18002X A 2AF05057R A 1CC15015X A ICC02077V A ICC04009X A 2AF05012R A 1CS06013X A 2CS02006R A 1FP06045X A 2CS02014R A ICC13038X A 2CS02019R A ICV 180L3X A 2CS02010R A ICV 44041X A 2CS020L6R A 1BR100LLX A g l iSIO6034R A LCV08017X A g
ISIO6037R B ICV 180L1X A l ICS03027R A LCV47008R A iSX15006X A 2AF02004R A ISIO7007X A 2FP03069R A a ICS03009X A 2FP03087R A 1FP04025X A 2FP03095R A g IFP0500?X A 2CV08007V A 3 IBR30003X A 2CV08009V A ISI15009X A 2CV18001R A LCC02010X A 1CS03003V A ISI18032X A 1FP15024X A ISI18039R A 2CS08010R A LSI18060R A LSX25002R ISI18034R A
E LSI18045R A A 3 1AF07032R A ICSOLO41X A LAF07030X A ICC13018X A LRH04010X A 1CS08004R A I I
Page 6 of 13 SPEC. # - Y-2771 ) DWG. # REV. # DWG. # REV. # LCC03041V A LCCl3029X A 2AF04003V A 2SX24002R A 2FP11015X A I LFPL7030R A 1SX41005R A ISX02023R A I SPEC. # - Y-2787A DWG. # REV. # 1067100 A SPEC. # - Y-2787B
~
DWG. # REV. # 802384-22-BL 2 802384-23-B1 1 I 802384-42-BL 802384-43-Bt 802384-16-BL 1 2 L 802384-9-B1 I 3 802384-4-B1 2 R 802384-4-B1 3 802384-28-BL 3 SPEC. # - Y-2794A DWG. # REV. # I W7820030 W7820031 W7820027 A A A R R I R I I I-
Page 7 of 13 SPEC. # - Y-2795 DWG. # REV. # SD-C-106787 A SD-C-106777 A SD-C-106783 A 3 , SD-C-106786 SD-C-106785 A A E' SD-C-106798 A SD-C-106795 A l SD-C-106793 A l SD-C-106776 A SD-C-106775 SD-C-106778 A A R E< 3 '- SD-C-106792 A R SD-C-106791 A R , SPEC. # - Y-2797 DWG. # REV. # 9182-19 1 9182-45 1 : 9182-15 1 l 9182-15 1 L 9182-12 4 9182-33 5 9182-39 1 ' 9182-28 3 9182-29 3 9182-9 1 9182-30 3 ; SPEC. # - Y-2804 I DWG. # REV. # None None R l SPEC. # - Y-2815 l DWG. # REV. # E-0-3013 lit 116. 3 N/A EB-785 N/A E-0-3013 lit 116.12 N/A g' EB-759 N/A 5 EB-737 N/A EB-757 N/A ' EB-703 N/A EB-704 N/A E-0-3013 HL 116.14 N/A E l
Page 8 of 13 SPEC. # - Y-2865 DWG. # REV. # TF L15 2 R i' I TF 116 TF 117 TF 119 L Initial Issue 1 TF 216 2 R I TF 219 TF 220 TF 222 L Initial Issue 1 I TF 313 TF 3L4 TF 315 L 2 1 TF 316
~~,1 1~~
~~TF 317 L i TF 3L8 Initial Issue TF 319 1 4 g TF 4L4 3~~
~~W TF 418 L i TF 421 1 TF 424 Initial Issue I TF 425 2 l~~
~~TF 426 L TF 427 1 fl' W TF 428 2 TF 429 2 TF 503 1~~
; E TF 506 2 B TF 507 2 TF 508 2 1 TF 605 1 TF 606 1 ', TF 609 1 TF 610 1 i
l I TF 700 TF 702 TF 707 Initial Issue Initial Issue Initial Issue l TF 1015 2 TF 1011 2 TF 1014 1 SPEC. # - Y-2900 DWG. # REV. # E 6000-520L A E 6000-5202 A l E 6000-5203 A W E 6000-5204 A E 6000-5205 A E 6000-5206 I A i E 6000-5207 A i E 6000-5208 A E 6000-5209 A I
Page 9 of 13 SPEC. # - Y-2735 PIECE MARK # REV. # PIECE MARK # REV. # PIECE MARK # REV. # 4007 CL B 4052 Cl B 4075 D5 0 4008 Cl 0 4053 Cl 0 4079 Di G E 4009 CL 0 4054 CL A 4080 Di C 3 4010 Cl A 4055 Cl 0 4081 D1 B 4011 Cl 0 4056 Cl A 4082 DL A 4012 Cl A 4057 CL 0 4083 D1 A, B&D 4013 Cl A 4058 Cl A 4084 BL A 4015 Cl A 4059 Cl A 4085 31 0&D 4025 Cl A 4060 CL B 4086 BL C g 4027 Cl 0 4061 Cl 0 4087 B1 A 5 4035 Cl A 4062 CL 0 4088 BL C 4039 C1 A 4063 Cl B 4089 BL 0 $ 4040 BL C 4064 Cl A 4090 B1 0 g 4041 B1 F 4065 Cl B 4092 B1 B 4042 PL C 4066 Cl B 4093 BL B 4043 81 C 4067 D1 0 4094 BL 0 E 4044 BL 0 4068 DL 0 4095 B1 A&C 5 4045 B1 A 4069 D1 B 4096 B1 0&A 4046 B1 B 4070 DL 0 4097 B1 B g 4047 BL 0 4071 D1 A 4098 B1 A g 4048 B2 0 4072 DL 0 4099 B1 8 4049 B1 0 4073 D1 0&B 4050 Cl A 4074 DL 0&A l 405L Cl A 4075 DL 0 m I i' I' I. I I I 1 ! I
Pegs 10 of 13 SPEC. # - Y-2735 PIECE MARK # REV. # PIECE MARK # REV. # PIECE MARK # REV. # 410L Bl A 4142 DL B 4182 PM1 A&B 4102 B1 A 4143 B1 A 4183 B1 F 4103 BL C 4144 BL A 4184 BL E 4104 B1 B 4L45 B1 0&A 4L85 B1 D I 4105 BL 4106 31 4107 B1 C 0 A&C 4147 BL 4148 BL 4149 B1 B D C 4185 B2 4L86 CCl 4187 CCl D C A&B 4L07 B5 A&C 4L50 B1 A 4188 B1 B 4108 BL C 415L Bl A 4189 BL D 4109 B1 0 4L52 B1 A 4190 B1 D 4110 BL A 4153 BL A&B 4191 B1 A I 4112 B1 41L3 G1 4114 BL B A A 4154 BL 4154 B9 4L54 BLS C, D & A 4L92 B1 C, D & A 4193 B1 C, D & A 4L94 BL B&E A B 4115 B2 A 4155 BL A, B, E&F 4195 Bl A&B 41LS B7 A 4156 B1 B 4L96 B1 B I 2115 B12 A 4157 B3 C 4197 BL C 4116 B1 A 4158 B1 B 4L98 B1 B&C 4117 B1 C 4159 Bt C 4198 B3 S&C I 4LL8 B1 D 4160 B1 A 4L99 B1 C 4118 B5 D 4162 BL A 4194 Bil B 4L19 B1 E&D 4162 B6 A 420L B1 C&D I 4120 Bt C 4163 B1 3 4202 BL A&B 4L20 B8 C 4164 BL A 4203 B1 B 412L BL 0 4165 B1 A 4204 BL A l 4122 BL 0 4L66 B1 D 4205 B1 B W 4123 BL B 4167 BL B 4205 B4 B 4124 B1 B 4168 81 D 4206 B1 A&D I 4125 BL 4L26 B1 4127 B1 A C 0 4169 BL
~~'170 a 4170 B5 A~~
A A 4207 BL 4208 BL 4208 B4 C 0 0 4128 Bl B 4171 B1 0&D 42LO G1 0 4129 BL 0&A 4L71 B3 0&D 421L Bt C I 4131 B1 C 4172 31 0&D 4212 B1 E 4132 BL C 4173 B1 A 4213 B1 A I 4133 BL 4134 BL 4L35 B1 0 B A 4L74 B1 4175 BL 4176 B1 B B C 4214 B1 4215 BL 42L6 G1 B A 0 4136 BL B 4L77 BL 0, B & D 4217 Bl A 4L37 B1 D 4178 B3 8 42L8 B1 A I 4138 Bl A 4179 BL F 4219 BL B 4139 CCl 0 4180 B1 C 4219 B3 3 4140 CCl A 4180 B7 C 4220 B1 A&B 5 4141 CCl B 4181 B1 C 4220 B9 A&B 4142 BL B 4182 Bl A&B 4221 BL A I I I
P:gs 11 of 13 SPEC. # - Y-2735 PIECE HARK # REV. # PIECE MARK # REV. # PIECE HARK # REV. # 4221 88 0 4265 DL A 7005 B1 A 4222 B1 E 4266 B1 0&C 7006 G1 C 4223 BL 0 4266 83 0&C 7007 BL C 3 4224 B1 0 4268 D1 A 7008 81 C E 4225 81 A 4270 Cl A 7009 BL B 4226 Bl A&B 4272 Cl 0 70LO B1 A 4227 BL 0&B 4273 C1 B 7011 BL A ' 4228 G1 B 4274 C1 C 70L2 G1 A W 4229 BL C 4275 CC1 A 7013 DL - 4230 B1 A 4276 BL A 70L4 B1 C g 4230 B4 A 4277 B1 B 7015 81 B g 4231 BL 8 4278 BL 0 70L6 BL - 4232 B1 A 4279 BL 0 7017 B1 C 4233 B1 A 4279 B4 0 70L8 B1 C 4234 BL C 4280 CCl A 7020 D1 A 4235 81 A 428L CCl 0&A 7021 DL B&C 4236 B1 0 4232 B1 A 7021 D4 B&C E 4236 KB2 0 4283 BL B 7022 D1 A W l 4237 BL B 4284 B1 A 7023 D1 A l 4238 81 C 4284 85 A 7024 DL B g 4239 B1 D 4285 B1 B 7025 BL A g 4240 B1 8 4287 ML 0 7026 BL E&F 4240 85 B 4288 CCl C 7027 BL E 424L B1 A 4289 CCl 0 7027 B8 - 4241 85 A 4290 M1 0 7028 BL C 4242 B1 A 4291 M1 0 7029 DL A 4243 BL A 4292 BL E 7031 D1 - g 4247 B1 0 4293 B1 E 7032 DL A g 4248 Bt 0 4293 B8 E 7033 GL D 4249 BL 0 4296 BL 0 7035 D1 B 4252 B1 A 4297 B5 0 7037 81 B l 4253 BL A A298 KBL C 7037 B3 8 m 4253 B5 A 4298 KB4 C 7038 B1 A 4254 B1 B 4299 KBL A&B 7039 BL B g l 4255 BL E 4300 KB1 B&0 7040 D1 704L Di 5 4256 81 0 4301 KB1 B C 4257 CCL 0 4302 Cl A 7042 DL 0 4258 CCl 0 4304 B1 b 7043 D1 A l 4259 CCL 0 4306 B1 0 7044 BL D 4260 CCL 0 4307 B1 B 7045 BL 0 4261 Bl A 7001 BL F 7046 CL 0 g 4262 B1 C 7002 BL F 7047 CL 0 g 4263 CCL 0&D 7003 Bt B 7048 CL A l 4263 CC9 0&D 7003 83 B l 4264 Dt C 7004 Bt B&C ll I I E
Page 12 of 13 8,ec. # - x.2,35 ll PIECE MARK # REV. # PIECE MARK # REV. # PIECE MARK # REV. # !l 7049 C1 C 5019 C1 B 5071 Cl A 7050 C1 B 5020 C1 B 5072 C1 B 5073 Cl I 7052 Cl 7053 Cl 7054 BL B B B 5021 Cl 5022 Cl 5023 Cl A A 0 5074 Cl 5075 Cl 0 A B 7055 31 C 5024 C1 0 5076 Cl 0 I 7056 XGL 7057 GL 7058 BL A C 0 5025 Cl 5026 Cl 5028 DL A A A 5077 Cl 5079 Cl 5080 CL A A 0 i 7058 B5 7059 XB1 7060 XBL 0 B C 5029 D1 5030 B1 5031 CL 0 A 0 5081 Cl 5082 C1 5083 Cl 0 A B - 7061 Bl A 5032 B1 B&D 5084 Cl D 7062 Cl A 5033 Bl A 5085 C1 C 7065 CL C 5034 BL A 5086 Cl B 7066 Cl 0 5035 B1 - 5087 Cl A I 7067 BL 7067 B6 7068 B1 D D A 5036 31 5037 BL 5038 B1 B B 0 5088 CL 5089 Cl 5090 CL A B C 7069 B1 8 5039 B1 5091 C1 A I B 7079 BL B 5040 BL C 5092 Cl B 7081 B1 D 5041 G1 A 5093 Cl B 708L B8 D 5042 BL A 5094 Cl B I 7082 B1 7082 B8 7083 B1 0 0 C 5043 GL 5044 BL 5045 Bl A A 5095 C1 5096 Cl 5097 B1 A 0 C&E 7084 FL 5046 BL 5098 Di I A C A 7085 PL1 A 5047 B1 D 5099 B1 A 7088 BL A 5048 GL A 510L Bt B 7089 81 E 5050 B1 C SLO 2 Bt C I 7090 81 7092 B1 5001 Cl A A 5051 BL 5052 GL 5053 B1 B B C 5103 Bt 5104 B1 5105 GL C A 8 I 5002 Cl 5003 CL 5004 C1 A 0 A 5053 B3 5054 31 5055 BL C B A SLO 7 B1 5L12 GL SL13 B1 B F 5005 Cl B 5056 B1 A 5114 B1 B I 5007 Cl 5008 Cl 5009 Cl A A A 5057 B1 5058 B1 5059 B1 A 0 E 5114 B4 5115 BL SLL6 B1 8 C B 5010 Cl A 5060 BL C 5117 BL C I 501L Cl B 5061 B1 0 SL2L BL A&B l 5012 C1 - 5064 Cl A 5123 DL C 5014 Cl A 5065 Cl 0 SL25 B1 D 5015 Cl B 5068 CL 0 5126 D1 A l 5017 Cl A 5069 CCl B 5127 D1 D l 5018 Cl A 5070 CL A 5127 PL2 D l ll I I
i Page 13 of 13 l SPEC. # - Y-2735 PIECE MARK # REV. # PIECE MARK # REV. # 5128 KB1 C 6089 B10 A SL29 B1 A 6091 HL C 5130 C1 C 6091 F4 C 5132 B1 B 6092 B1 A 5133 B1 A 6093 HAL 0 5134 81 C 6094 B1 0 5137 DL - 6095 Cl A 5143 A 6099 PL1 C 6012 FL A 6100 PLL E 6019 F1 A 6LOS PL1 B 5 6072 B1 A 6109 PLL A 6088 B1 B 6110 PL2 D g 6089 B1 A 6111 B1 0 g 6089 B3 A SPEC. # - Y-2865 DWG. #/ PIECE MARK # DWG. #/ PIECE MARK # S 117 S 417 S 507 S 420 l S 505 S 414 " S 119 S 605 S 319 S 609 E S 429 S 6LO 3 S 217 S 428 S 418A S 707 S 316 S 417A S 317 S 2L9 S 311 S 315 S 318 S 427 S 220 S 419 S 506 S 116 S 508 S 310A g S 222 S 606 S 313 S 702 E S 42L S 426 S 218 S 700 > S 4L8 S 4L6 l S 424 S 422 S 4LS S 3L4 S 312 S 425 , I-I I ;
REPORT NO. ATTACHMENT 7.6.4 PUBLIC RECEIVING INSPECTION SERVICE IDATE INDIANA CHECKLIST / REPORT I
l. AUGUST 5, 1980 I Crane Girder Assembly &l l ITEM NAME: Crane Mounting Bracket AsRECE NO: iSee Attached Listing P.O. NUM BER: 1043-89Q P.O. ITEM NO:
n l SPECIFICATION NO: Y-2725 SIZE & QTY.: HEAT NO: N/A ORAWING NO. i LOT NO: !See Attached Listing VENDOR NAME: C3I i MATERIAL SPEC: See Checklist PMP TITLE & NO: !SPP-7 & PMP 3.07 I l REOMNT ! RECORD ACCEPT / RECMNT RECORO ACCEPT / CHECKITEM R EJECT lA I N/A l NO: l REJECT l CHECK ITEM lA IN/A! NO: Sse Attached Checklist X f ; See Attached List For f Docu- en t a tion X i For Ite=s Checked. l I I I I I l I i I i i I I l l l l I .. l l l l l !I l l l l l l l ! l l I - I I i i I l l 1 1 i ! i ! i ! i I RESULTS: ACCEPT O RE;ECT .-
- NCR b YES LJ NO I.7.3 ACCEPTWITH COMMENTS: _
~~I NCR NO: PC0065N, PC0066N. PC0067N 1 I~~
/ MEASURING & TEST ECutPMENT USED: '"5'5CTED I , 4 g 1"-6" Calipers Q-0402 SY Q-0403 j j/ INSPECTCR
CATI s

25' Tape I r;EVIEWED l
~~,y .~~
9 o 6" Scale kAECElVING INSPEC"CR $1.;PRV. OATE g U ACCEPT TAG NO: I b REJECTTAG NO: RETAIN TAG NO: 37'3-3828
]
ANI CATE CCNDITIONALLY ACCEPT TAG NO: ( UB 85-170 1/80 ( - l
ATTACl! MENT 7.6.5 pusuc OUALITY ASSURANCE CHECKLIST ,,ac 1 op 3 SERVICE MARBLE HILL
'"D'*"^ UNIT 1 as 2 DATE R E V. PREPARE D SY:
CHECKLIST NO. * * * ~ ~ PRI-999 0 SOURCE SURVEILLANCE GENERIC SURVEILLANCE REVIFWED SY: TITLE: HECE RPT INSPECTION X SPP-7 SPECIFIC SURVEILLANCE REVIEWED BY ANI: Steel Liner Work DOCUMENTATION REVIEW OTHER -APPROVED BY: C. T. Warner 5-28-80 IPO NO ISPECIFICATION NO: lHEV. O ISSRmlR/CSR NO. SUPPLIER / CONTRACTOR: CBI Il043-84Q,1043-85b Y-2725 IAMn 4 I UNSAT VERif 8fR ATTRIBUT E/I TEM RESULTSMEM AR KS REFERENCEISI V/W SAT N/A SIGNATUREt OOC. NO, DATE NO DESCRIPTION __ NOTES:
1) Piece mark numbers and drawings listed on attachment

2) See prerequisites ITIM INSPECTION:
~~A) Check received items against the attached applicable detail drawing (s ) for the following: CRANE GIRDER ASSEMill.Y AND CRANE. HOllNTING IIRACKET ASSEMill.Y: V X~~
1) Veri fy t hat the lenP,t h is correct . and Crane Rails varied 2/16" to perform measurements of all accessable 4/16" over required length.
detailed dimensions that comprise the See NCRf PC-0067N member or component as per the att ached CBI drawings.
2) Y Ve ri f y locat ion of hole pat terns, size, X Sc. NCRI PC-0066N. Piece Mark number, and center-to-center distances 356-C-3, 17,.14 & 10 have some of the holes. egg shaped holes exceeding 1-9/16" requirement & allow-

3) Veri fy t hat at tachments called for on th,. X able tolerance.
drawings are with the piece and are attached in t he m mner called for (i.e. welded or hol t ed) . , SWSM* M S M M M M M M M M M N M M M M M M
W M M M M m M M m M M M M M M m M M M cmcKUST NO. i. E V. pusuc OUALITY ASSURANCE CHECKLIST PAGE b OF SERVICE CONTINUATION SHEET 0
'" ' ^ " ^ MARBLE HILL UNITS 1 & 2 PRI-999 UNSAT VE RIFIER ATTRIBUTE / ITEM SIGNATURE / RESULTS/R E M ARKS HE F EH E NCF tS) V/W SAT N/A NO DESCHIPTIoN DOC.NO. DATE
4) Verify that piece identification is y X Crane Rails could not be legible and accurate. identified. See NCRf PC-0067N

5) Physical Conditions: V Verify that no damage has occured to: V -
a) Exposed machined surfaces X No Machined Surfaces h) Packing conditions X c) Protective Coatings X See Item #9. See NCRf PC-0065N AI.S0 Verify none of the following types of V physical damage has occured: X a) bent memhe.s l>) nicks, gouges, deep scratches X c) broken welds X .
6) Verify Ihat contamination of material V X lias not taken place (ie. road salt, oil, grease, mud, rust) also verify that there is no evidence of fire, or t ie down failure.

7) Veri fy t hat ~11 parts that will comprise V X cont act surfaces for holted connect ions are free from scale, chips, or foreign mat erials and the surfaces and edges to be joined are smooth, uniform and free from tears, cracks, poor workmanship, and other ilefects.
I tr 61784 R 7/80
cnEcxtcr NO. .:E
v.
puauc QUALITY ASSURANCE CHECKLIST 3 RAGE _3._ OF SERV;CE CONTINUATBON SHEET
***"^ MAllBLE HILL UNITS 1 & 2 PRI-999 0 UNSAT VtRIFIER ATTRIBU T E /t T E M S4GN ATUREI RESULTS!ft EM AR KS REFEHENCEts) V/W SAT N/A wO DESCRIPTION DOC. NO. DATE
8) Verify ANSI Storage Level "D" require- V X Crane Cirders Not Verified This ments are being met. Also, for the Inspection Per Attached List.
~~Crane Cirder, verify the open ends of girders are sealed, and weld 5cint prep areas are coated with a preservative.~~
9) Verify that coatings are in tact, free V X Coating Deteriorated With Light of rust, chipped areas, etc. Surface Rust In Some Areas On Assembly Numbers 356 Bt>C and 353-4. See NCRf PC-0065N.

10) Check all pieces for conformity to size and shape, by the following:
a) Measure plate and bar thickness X b) Measure rod, tube and anchor bolt X No At t.achments Of This Type. diameters. c) Measure angles, thickness and leg X No Angle Attachments. dimensions.
11) Veri fy nonconf orming items are properly V X r agged and segregated. Verify noncon-turmance report s are writ ten for the attached 1istingu.

12) Veri f y original doc umentat ion packages V X See Cover Sheet lia ve been submitted and reviewed, Quality Documentation Reviewed

iccepted, NCR (If applicable) for the by QA Records Section.
~~.it t ached Iist ings.~~
l M "N M M M M M M M M M M M M M M M M M
I... ATTACIDfENT 7.6.6 TITLE: I;STRUCTIOs FOR 1;o . 200-A Rev. O REVIEW OF P!PI!?G hTEmenanuncae.,
'8 N 1 N I DOCl* M r*
~~TAT I C' Date: 1/23/80 Pt.no 1 of 9 PREPARED BY: Ie REVIEWED BY: . /.* M e' -~~
I 1.0 Scope A Ff'AcvGo Gvm I.O~ bi4,m I This instruction covers the review of ITT Grinnell piping documentation. 2.0 Purpose - I The purpose of this instruction is to establish guidelines to assure a complete and accurate review of piping documentation. 3.0 Summary of Instruction A. Documentation Packages. B. Load Sh6et. -
~~' ~~~
C. Documentation & Examination Checklist. I D. Certificate of Conformance. E. Code Data Report. F. Engineering Shop Sketch. G. Materials Record. II . Certified Material Test Reports (CMTR's). I. Traveler. I J. NDE Reports.
~~K. Code Plate Etching.~~
~~3.1 Documentation Packages Should cont.ai::: 1. E>' amination and Documentation Checklist.~~
~~2. Cortificute of Conformance.~~
I
3 TITLE: INSTRUCTION FOR No. 200-A Rev. O REVIEW OF PIPING SARGEfjTE:LUfjDY Date: 1/23/80 DOCUMENTATION Page 2 of 8 I
~~3. Code Data Report, as applicable.~~
~
4. Engineering Shop Sketch.

5. Materials Record.

6. Traveler. .

7. NDE Reports, as applicable.
I,
~~8. Code Plate Etching, as applicable.~~
3.2 Load Sheet t A load sheet should accompany a set of documentation packages. The load sheet will list register numbers and piece mark numbers. The register numbers which have an X at the end indicates that those packages are included in that load. Verify that the packages are included in the load. 3.3 Documentation and Examination Checklist
~~1. Verify that the following items are correct:~~
~~A. Plant. B. Job. C. Contract No. D. System. E. Nuclear Class. F. Piece Mark. G. Register No. 11 . PSI P.O. No.~~
~~2. All documents on the checklist should be checked as being in package or marked N/A.~~
I I, l l
I
~
~~TITLE: INSTRUCTION FOR No. 200-A Rev. O REVIEW OF PIPING SARGEUTSLUUDY Date: 1/23/80~~
~
DOCUMENTATION Page 3 of 8 I 3. Verify that all documents with a check are actually in the package. l 3.4 Certificate of Conformance I l -
~~1. Verify that the following items are correct: -~~
~~j a. Station Name.~~
b. System.

c. PSI P.O. No.
~~j d. Specification Number.~~
e. Piece Mark and Register Number.

2. The Certificate should be signed by the QC Manager I ,
~~and dated. 3.5 Code Data Reoort , i~~
~~1. Verify the following are correct:~~
~~A. Owner. B. Location of Plant. C. Contract No. D. System. E. Piece Mark No. F. Register No.~~
~~2. Item 6 on the data report should show:~~
~~A. Nuclear Class. B. Edition of ASME Code (1974). C. Applicable Addenda (Summer of 1976). D. Remarks (1) supplemental sheets. (2) items supplied by subcontractor.~~
~
~~I TITLE: INSTRUCTION FOR No. 200-A Rev. SARGEfJTE LUTjDY REVIEW OF PIPING Date: 1/23/80~~
~~. O N G8NOGES ,~~
~~DOCUMENTATION Pace 4 of 8 3.6 Shop Sketch~~
~~', 1. Verify the following are correct:~~
~~A. Contract No. B. Station & Unit. E' 5 l C. Location of Plant. ! D. Nuclear Class. E. Pipe Design Table (refer to PMD Line List) . F. System. G. Piece Mark.~~
~~!! . Register No.~~
~~2. Must have Fabrication Stamp showing:~~
~~, A. Fabricated For (PSI). .~~
~~B. Location (Plainfield). C. PSI P.O. No.~~
~
~~D. System. Stamp must be legible.~~
3. If pipe was hot or cold bond this should be I, indicated on shop sketch.

4. For applicable systems, the shop sketch should indicate Inservice Inspection.
~~3.7 Materials Record~~
~~1. Verify the following are correct:~~
A. Piece Mark No. l B. Register No. - C. Contract No. l l D. Station & Unit. E. Location. g F. System. W G. Nuclear Class. l I l I
l' TITLE: INSTRUCTION FOR REVIEW OF PIPING SAGGEUT?4LUNDY No. 200-A Rev. 0 Date: 1/23/80 I DOCUMENTATION
~~'cuamamar. .~~
~~Page 5 of 8 3 2. Must have a fabrication stamp which is legible 3 - (refer to 3.6.2).~~
~~3. Each item on the materials record should have a description which includes size and material used as well as heat code, heat number and piece no.~~
E 4. Verify that we have CMTR for each heat code 5 shown by referring to appropriate book. I 5. All information on Materials Record must be legible and not obliterated by Inspection stamps. 3.8 CMTR's
1. Should reference ASME Material Specification.

2. Refer to applicable Pipe Design Table to verify that the correct material was used.
~~I .~~
~~3. Description and Material shown on CMTR and Materials Record-should be identical.~~
I 4. Review CMTR against applicable material specification and verify that all chemical properties, mechanical properties and required I . tests are reported and correct.
5. CMTR's must show either the material manufacturer's ASME certificate number and expiration date I or a statement indicating that the supplier had been audited by ITT Grinnell.
~~I 6. Wolded Material-must have a manufacturer's data report attached (Form NM-1) as well as any applicable NDE reports.~~
~~7. CMTR's must be legible. -~~
~~3.9 Traveler~~
~~1. Verify that the following are correct:~~
A. Contract No. B. Station & Unit. l C. Piece Mark No.
\
i* *
=
~~INSTRUCTION FOR r ( TITLE: No. 200-A Rev. 0 l~~
~~' REVIEW OF PIPI.Nn SADGEUTf4LUUDY Date: 1/23/80 'suosmeene. 3 l~~
~~DOCUMENT' ^rION Pace 6 of 8 g D. Register No. E. System.~~
~~, l F. Nuclear Class.~~
~~G. Job Spec. (reviewed and accepted).,~~
~~2. Operations A. Welding should show: '~~
~~(1) Weld ID. (2) Procedure No. I! t (3) Heat No. (4) Heat Code. '~~
~
(5) Welder ID. (6) Date of Inspection. (7) Inspection Stamp for Fit-Up and Final. - B. NDE should show: (1) Inspection Stamp. (2) Date of Inspection. 3.10 NDE Reports 3.10.1 RT Report .
~~1. Verify that the following are correct:~~
A. Station & Unit. B. Location. C. Piece Mark Number. D. Register NumL9r. E. Contract Number. I I!, l
I. . l TITLE: INSTRUCTION FOR No. 200-A Rev. O REVIEW OF PIPING. SAriGEf1TALUf DY Date: 1/23/80 I
~~'ametNesRO .,~~
~~DOCUf1ENTATTON Pace 7 of 8 I 2. Verify that there is an RT report for each butt weld. I '~~
3. RT report should reference procedures for inspection and acceptance-verify that these procedures were reviewed and accepted. *

4. Verify that all shots are acceptable.

5. A weld repair sketch or report should be included as applicable.

6. Verify that the RT report has been accepted by PSI by referring to the acceptance records.

7. Verify that the RT report is signed by the examiner, AI or customer as applicable.
~~3.10.2 UT,MT,PT~~
1. Report should be identified with the name of the company who performed the test.

2. Should reference an inspection procedure and/or I acceptance standard-verify that these procedures have been reviewed and accepted.
~~~ 3. Reports should contain:~~
~~A. Register No. B .. Piece Mark No. C. ID of items tested. D. Results of test. - I 3.10.3~~
~~4. Reports should be signed ,and dated by the examiner.~~
Ferrite Report 1 S UTY.,. t & LZVCL_ I 1. Should reference a procedure-verify that the procedure has been reviewed and accepted. I ".:. Should show piece identification and weld number.
~~3. Should show results of test-verify that the results are acceptable.~~
~~I -~~
..* . l *
3
~~) . . TITLE: INSTRUCTION FOR No. 200-A Rev. O REVIEW OF PIPING SARGErJTT= LUfjDY Date: 1/23/80 DOCUMENTATION Page 8 of 8~~
~~4. Should be signed and dated.~~
~~3.11 Code Plate Etching~~
~~. 1. Must be legible. ,~~
~~2. Must show:~~
A. ITT Grinnell. B. Register No. C. Nuclear Class. D. Year Built. E. Piece Mark No. F. N Stamp I I I I I' I I' I
I Peg 2 L of 7 ATTACibiENT 7.6.7 LIST OF NONCONFORMANCE REPORTS BY SPECIFICATION I Y-2735 PC-0109N PC-0231N PC-0273N PC-0316N PC-0358N PC-0403N PC-0110N PC-0232N PC-0274N PC-0317N PC-0359N PC-0404N PC-0130N PC-0233N PC-0275N PC-0318N PC-0360N PC-0405N I PC-0131N PC-0132N PC-0133N PC-0234N PC-0235N PC-0236N PC-0276N PC-0277N PC-0278N PC-0319N PC-0320N PC-0321N PC-0361N PC-0362N PC-0363N PC-0406N PC-0407N PC-0408N I PC-0134N PC-0135N PC-0136N PC-0237N PC-0238N PC-0239N PC-0279N PC-0280N PC-0281N PC-0322N PC-0323N PC-0324N PC-0364N PC-0365N PC-0366N PC-0409N PC-0410N PC-0411N PC-Ol71N PC-0240N PC-0282N PC-0325N PC-0367N PC-0412N I PC-0178N PC-0190N PC-0191N PC-024LN PC-0242N PC-0243N PC-0283N PC-0284N PC-0285N PC-0326N PC-0327N PC-0328N PC-0368N PC-0369N PC-0370N PC-0413N PC-0414N PC-0415N I PC-0192N PC-0193N PC-Ol94N PC-0244N PC-0245N PC-0246N PC-0286N PC-0287N PC-0288N PC-0329N PC-0330N PC-0331N PC-0371N PC-0372N PC-0373N PC-0416N PC-0417N PC-0418N PC-0195N PC-0247N PC-0289N PC-0332N PC-0374N PC-0419N I PC-0197N PC-0198N PC-0199N PC-024SN PC-0249N PC-0250N PC-0290N PC-0291N PC-0292N PC-0333N PC-0334N PC-0335N PC-0375N PC-0376N PC-0377N PC-0420N PC-042LN PC-0422N I PC-0200N PC-0209N PC-0210N PC-025LN PC-0252N PC-0253N PC-0293N PC-0294N PC-0295N PC-0336N PC-0337N PC-0338N PC-0378N PC-0379N PC-0380N PC-0423N PC-0424N PC-0425N PC-0254N I PC-0211N PC-0296N PC-0339N PC-0381N PC-0426N PC-0212N PC-0255N PC-0297N PC-0340N PC-0382N PC-0417N PC-0213N PC-0256N PC-0298N PC-0341N PC-0383N PC-0428N PC-0214N PC-0257N PC-0299N PC-0342N PC-0384N PC-0429N I PC-0215N PC-0216N PC-0217N PC-0258N PC-0259N PC-0260N PC-0300N PC-0301N PC-0302N PC-0343N PC-0344N PC-0345N PC-0385N PC-0386N PC-0387N PC-0430N PC-0431N PC-0432N I PC-0219N PC-0220N PC-022LN PC-0261N PC-0262N PC-0263N PC-0303N PC-0304N PC-0305N PC-0346N PC-0347N PC-0348N PC-0388N PC-0389N PC-0390N PC-)433N PC-0434N PC-0435N PC-0222N PC-0264N PC-0306N PC-0349N PC-0391N PC-0436N I PC-0223N PC-0224N PC-0225N PC-026SN PC-0266N PC-0267N PC-0307N PC-0309N PC-0310N PC-0350N PC-0351N PC-0352N PC-0392N PC-0393N PC-0397N PC-0437N PC-0438N PC-0439N I PC-0226N PC-0227N PC-0228N PC-0268N PC-0269N PC-0270N PC-0311N PC-0312N PC-0313N PC-0353N PC-0354N PC-0355N PC-0398N PC-0399N PC-0400N PC-0440N PC-0441N PC-0442N l l PC-0229N PC-0271N PC-0314N PC-0356N PC-0401N PC-0443N I PC-0230N PC-0272N PC-0315N PC-0357N PC-0402N PC-0444N
~~Document Review I~~
I
Pega 2 of 7 I Y-2735 PC-0445N PC-0488N PC-0529N PC-0571N PC-0613N I PC-0446N PC-0489N PC-0530N PC-0572N PC-0614N PC-0448N PC-049uN PC-0531N PC-0573N PC-0615N l PC-0449N PC-0491N PC-0532N PC-0574N PC-0616N 5 PC-0450N PC-0492N PC-0533N PC-0575N PC-06L7N PC-0451N PC-0493N PC-0534N PC-0576N PC-0618N PC-0452N PC-0494N PC-0535N PC-0577N PC-06L9N PC-0453N PC-0495N PC-0536N PC-0578N PC-0620N PC-0454N PC-0496N PC-0537N PC-0579N PC-0621N PC-0455N PC-0497N PC-0538N PC-0580N PC-0622N PC-0456N PC-0498N PC-0539N PC-0581N PC-0623N PC-0457N PC-0499N PC-0540N PC-0582N .0-0624N PC-0458N PC-0500N PC-0541N PC-0583N PC-0625N g PC-0459N PC-0460N PC-0501N PC-0502N PC-0542N PC-#543N PC-0584N PC-0585N PC-0626N PC-0627N 5 PC-0461N PC-0503N PC 0544N PC-0586N PC-0628N PC-0462N PC-0504N PC-0545N PC-0587N PC-0629N PC-0463N PC-0505N PC-0546N PC-0588N PC-0630N PC-0464N PC-0506N PC-0547N PC-0589N PC-063tN PC-0465N PC-0507N PC-0548N PC-0590N PC-0632N g PC-0466N PC-0508N PC-0549N PC-059tN PC-0633N g PC-0467N PC-0509N PC-0550N PC-059::G PC-0634N PC-0468N PC-0510N PC-055LN PC-0593i. PC-0635N PC-0469N PC-0511N PC-0552N PC-0594N PC-0636N PC-0470N PC-05L2N PC-0553N PC-0595N PC-0637N PC-0471N PC-0513N PC-0554N PC-0596N PC-0638N PC-0472N PC-05t4N PC-0555N PC-0597N PC-0639N PC-0473N PC-0515N PC-0556N PC-0598N PC-0640N l 3 PC-0474N PC-0516N PC-0557N PC-0599N PC-0641N PC-0475N PC-0517N PC-0558N PC-0600N PC-0642N PC-0476N PC-05t8N PC-0559N PC-060LN PC-0643N PC-0477N PC-0519N PC-0560N PC-0602N PC-0644N PC-0478N PC-0520N PC-056LN PC-0603N PC-0645N PC-0479N PC-0521N PC-0562N PC-0604N l PC-0481N PC-0522N PC-0563N PC-0605N W PC-0482N PC-0523N PC-0564N PC-0606N PC-0483N PC-0524N PC-0565N PC-0607N PC-0484N PC-0525N PC-0566N PC-0608N PC-0485N PC-0526N PC-0567N PC-0609N PC-0486N PC-0527N PC-0568N PC-0610N PC-0487N PC-0528N PC-0569N PC-06LIN PC-0570N PC-0612N
~~Document Review l ll I I I~~
I Pega 3 of 7 I Y-2735 PC-0646N PC-0688N PC-0730N PC-0772N PC-0839N PC-0885N I PC-0647N PC-0648N PC-0649N PC-0689N PC-0690N PC-0691N PC-0731N PC-0732N PC-0733N PC-0773N PC-0774N PC-0775N PC-0840N PC-0841N PC-0842N PC-0886N PC-0887N PC-0888N PC-0650N PC-0692N PC-0734N PC-0776N PC-0843N PC-0889N I PC-0651N PC-0652N PC-0653N PC-0693N PC-0694N PC-0695N PC-0735N PC-0736N PC-0737N PC-0777N PC-0779N PC-0780 PC-0844N PC-0845N PC-0846N PC-0890N PC-0891N PC-0892N I PC-0654N PC-0655N PC-0656N PC-0696N PC-0697N PC-0698N PC-0738N PC-0739N PC-0740N P0-078 PC-078L PC-0783N PC-0848N PC-0849N PC-0850N PC-0893N PC-0894N PC-0895N PC-0657N PC-0699N PC-0741N PC-0784N PC-0851N PC-0896N I PC-0658N PC-0659N PC-0660N PC-0700N PC-0701N PC-0702N PC-0742N PC-0743N PC-0744N PC-0785N PC-0786N PC-0787N PC-0852N PC-0853N PC-0354N PC-0897N PC-0898N PC-0899N I PC-066LN PC-0662N PC-0663N PC-0703N PC-0704N PC-0705N PC-0745N PC-0746N PC-0747N PC-0788N PC-0789N PC-0790N PC-0855N PC-0856N PC-0857N PC-0900N PC-0904N PC-0905N PC-0664N PC-0706N PC-0748N PC-0791N PC-0858N PC-0906N I PC-d665N PC-0666N PC-0667N PC-0707N PC-0708N PC-0709N PC-0749N PC-0750N PC-0751N PC-0792N PC-0793N PC-0794N PC-0859N PC-0860N PC-0861N PC-0907N PC-0908N PC-0909N I PC-0668N PC-0669N PC-0670N PC-0710N PC-0711N PC-0712N PC-0752N PC-0753N PC-0754N PC-0795N PC-0796N PC-0797N PC-0862N PC-0863N PC-0864N PC-0910N PC-1005N PC-1006N I PC-0671N PC-0672N PC-0673N PC-0713N PC-0714N PC-0715N PC-0755N PC-0756N PC-075/N PC-0798N PC-0799N PC-0824N PC-0865N PC-0866N PC-0867N PC-1007N PC-1008N PC-1009N PC-0674N PC-0716N PC-0758N PC-0825N PC-0868N PC-1030N I PC-0675N PC-0676N PC-0677N PC-0717N PC-0718N PC-0719N PC-0759N PC-0760N PC-0761N PC-0826N PC-0827N PC-G828N PC-0869N PC-0870N PC-0871N PC-103tN PC-1032N PC-1033N I PC-0678N PC-0679N PC-0680N PC-0720N PC-072LN PC-0722N PC-0762N PC-0763N PC-0764N PC-0829N PC-0830N PC-083tN PC-0372N PC-0873N PC-0877N PC-1034N PC-1035N PC-1036N PC-0681N PC-0723N ?C-0765N PC-0832N PC-0878N PC-1037N I PC-0682N PC-0683N PC-0684N PC-0724N PC-0725N PC-0726N PC-0766N PC-0767N PC-0768N PC-0833N PC-0834N PC-0835N PC-0879N PC-0880N PC-0881N PC-1038N PC-0026N PC-0028N I PC-0685N PC-0686N PC-0687N PC-0727N PC-0728N PC-0729N PC-0769N PC-0770N PC-0771N PC-0836N PC-0837N PC-0838N PC-0882N PC-0883N PC-0884N PC-0029N PC-0030N PC-1028N PC-1029N
~~Document Review I~~
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*PC-1053N PC-0189N PC-0103N PC-0153N PC-0172N *PC-1054N = PC-0800t3 PC-0104N PC-0154N *PC-1055N *PC-0801N *PC-0004tl PC-0156N *PC-1056N *PC-0802N *PC-0005N PC-1057N *PC-0803N *PC-0007N *PC-1058tl *PC-0804N *PC-0008N g *PC-1073N *PC-0805N *PC-0009N 3 PC-1080N *PC-0806N *PC-0010N PC-1081N *PC-0807N PC-1233N**
~~PC-1093N** *PC-0808N PC-1234N** PC-1094N** *PC-0809N PC-1375N** PC-1095N** *PC-0810tl PC-1376N** PC-1399N** *PC-0811N PC-1377N'* E~~
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** Revision 1 I
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*PC-0917N *PC-0918N
~~l15 PC-0143N PC-0144N PC-0076N~~
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Pege 6 of 7 I I Y-2794A Y-2771 Y-2756 Y-2744 Y-2741 Y-2725 , PC-0148N PC-0129N PC-0163N PC-0157N PC-0096N PC-0065N PC-0149N *PC-0915N PC-0164N PC-0097N PC-0066N g
*PC-0916N PC-0165N PC-0166N PC-0098N PC-0099N PC-0067N *PC-1072N 3
PC-0167N PC-0100N PC-0163N *PC-0218N PC-0874N PC-090lN PC-0902N g PC-0903N g PC-10llN PC-1012N g PC-1013N PC-1014N g PC-1015N PC-1016N l PC-1017N 5 PC-1018N PC-1019N g PC-1020N g PC-1021N PC-1022N PC-1023N l PC-1024N W PC-1025N PC-1026N g PC-1027N g PC-1042N PC-1043N PC-1044N l PC-1045N 85 PC-1046N PC-1047N g PC-1048N g PC-1049N PC-1050N PC-105LN I I
~~Document Review I~~
I
I Page 7 of 7 I Y-2721 Y-2702 Y-2702 Measurement Equipraent PC-0068N *PC-004LN PC-Oll6N PC-0035N PC-0069N *PC-0042N PC-Oll7N PC-0036N I PC-0070N *PC-0043N PC-Oll8N PC-0037N PC-LOLON *PC-0044N PC-0119N PC-0038N
*PC-0045N PC-0120N PC-0039N I *PC-0046N *PC-0047N *PC-0048N PC-0121N PC-OL22N PC-0123N *PC-0049N PC-0124N I *PC-0050N *PC-005LN *PC-0052N PC-0125N PC-0138N PC-Ol39N I *PC-0054N *PC-0055N *PC-0056N PC-0140N PC-014LN PC-0147N g *PC-0057N PC-0155N g *PC-0058N *PC-0059N PC-0159N PC-0160N *PC-0060N PC-0162N *PC-0061N PC-0173N l = *PC-0062N PC-OL74N *PC-0063N PC-0175N i g *PC-0064N *PC-0179N g *PC-0082N *PC-0180N *PC-0083N *PC-018tN *PC-0084N *PC-0182N I *PC-0085N *PC-0086N *PC-0087N *PC-0183N *PC-0184N *PC-0185N I *PC-0088N *PC-0089N *PC-0092N *PC-0204N *PC-0206N *PC-0207N *PC-0093N *PC-0208N *PC-0094N *PC-0095N PC-Ol07N I PC-0108N PC-Oll1N PC-0112N PC-Oll3N I PC-01l4N PC-0115N !
~~Document Review I~~
~~I l I~~
~~SUMMARY~~
~~OF REVISIONS PROC. NO $UBJECT 3 pp 7 PROCEDURE FOR PliYSICAL INSPECTI0tl AND VERIFICATI0t3~~
=
OF PREVIOURLY ACCFPTED PURCHARED ITEMR REV5ON REVIslON DESCRIPTION I 3 Revised Attachment 6 g Added Paragraph 4.7.5 , g Attachment 4 Updated I I I I I & I I I REVISION AUTHORIZATION REVISION NUMBEn 3 g DATE E ISSUE o 08-15-80 l PREPAHED ,,p u tssdb) OY N! IJ ' * } CHECKED BY b/ gAhfs:.psQ _ l APPROVED M8M'w . I SECTION MGR dW8% _ l APPHOVED 1 N O A. MGR -;
'ggg*g APPROVE 0' l PROJ OtR, l Putu.c Service te%sne ATTACHMENT 7.6.8 m- ._ --m ae .
~~I i~~
iI .PUBLIC MARBLE HILL GENERATING STATION SPECIAL PROCESS PROCEDURE Date Revision 08.-14-80 3 SERVICE [ l INDIANA 7,u,. SPP-7 PROCEDURE FOR PHYSICAL INSPECTION AND VERIFICATION OF FREVIOUSLY ACCEPTED 'I PURCHASED ITEMS l !I j TABLE OF CONTENTS SECTION TITLE l 1.0 PURPOSE ll 2.0 APPLICABILITY 3.0 DEFINITIONS ,l
~~= 4.0 INSTRUCTIONS~~
~~5.0 REFERENCES~~
~~! 6.0 ATTACH!ENTS~~
~~I iI ,~~
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~~'I lI~~
.I I I!e , a ' IEa ,
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MARBLE HILL GENERATING STATION Date 08-14-80 l Mov e n 3 e PUBLIC SPECIAL PROCESS PROCEDURE Page 3 of 21 SERVICE Title. INDIANA SPP-7 PROCEDURE FOR PHYSICAL INSPECTION AND VERIFICATION OF PREVIOUSLY ACCEPTED PURCHASED ITEMS 1.0 PURPOSE This document establishes the procedure for physical inspection and document verification of previously accepted purchased items to validate the adequacy of prior receipt inspections. 2.0 APPLICABILITY This procedure shall apply to Category I items purchased and receipt inspected by Public Service Indiana prior to August 7, 1979 and may be g applied to contractor and subcontractor Category I items purchased and rece ipt inspected prior to that date. 5 3.0 DEFINITIONS i 3.1 Receipt Inspection - Inspections or tests performed upon receipt to determine whether quality requirements of purchasing documents have g, been met and whether there has been damage or deterioration aue to shipping or handling 5 3.2 Source Surveillance - Activities conducted by the purchaser at a supplier's plant to assure that requirements of the purchase order have been, or are being met. Source Surveillance and Receipt Inspections are generally complementary functions intending to provide overall assurance of the quality of a purchased item. 4.0 INSTRUCTI0t'S 4.1 Statistical Sampling Method 4.1.1 A statistical sampling program has been developed to provide a 95% reliability at a 95% confidence factor of its E 3 l results as to the validity of prior receiving inspections. ) The statistical basis for this program and tables for its use are included as Attachments to this procedure. 4.1.2 A Sampling Plan shall identify previously received. l inspected, and accepted items; the quantities available; E the minimum sample size; and the number of rejects 5 permissible for that sample sin to maintain a 95% reliability at a 95% confidence factor. Attachment 6 is g the sampling plan for PSI Category I items accepted prior g i to August 8, 1979. Refer to Attachment 2 for lot sices in excess of 700, and to Attachment 3 for lot sizes below 700. The Attachments show the increase in sample size l g necessary to be inspected and the maximum quantity 5 m rejectable to maintain the 95% confidence factor. R Is 5
I l 08-15-80 I i MARBLE HILL GENERATING STATION osse I Redelon 3
~~'PUBLIC SPECIAL PROCESS PROCEDURE p*e 4 of 21 SERVICE I INDIANA~~
~~Title:~~
SPP-7 PROCEDURE FOR PHYSICAL INSPECTION AND VERIFICATION OF PREVIOUSLY ACCEPTED I PURCHASED ITEMS i If the number of rejects exceeds the minimum quantity allowed by Attachments 2 or 3, the discipline Quality Engineer shall be notified and shall review results before the lot is accepted by using larger sample size. 4.2 Preparation of Checklists 4.2.1 The discipline Quality Assurance Engineer shall prepare / approve checklists identifying the physical characteristics and documentation to be verified during I this activity. These checklists shali be prepared based upon: (a) a review of the inspection and documents reviewed during the original inspection, (b) areas of concern related to known product experience including latest design I, changes and verifiable upon ~ receipt, and (c) areas of e :=tble damage or deterioration due to handling or storage
~~;ince receipt at Marble Hill. They shall identify the~~
'l packaging and preservation required by the procurement 5 documents, and the required preservation and packaging condition prior to storage in accordance with instructions provided by the Materials Manager. 4.2.2 The validity of prior inspections shall be based entirely upon the results of inspections of characteristics shown I under (a) above. Identification of discrepancies associated with (b) and (c) above is for the purpose of correcting conditions which do not reflect on the validity of prior Receipt Inspections. 4.2.3 Checklists shall clearly categorize the characteristics falling under each of the above groups. Characteristics idt.ntified as having been inspected at the original Receipt Inspection, may not require repeating during the verification activity if it is impractical or potentially I injurious to the item to do so. Any such exceptions and the basis for such shall be documented on the checklist and shall be approved by the Manager Quality Engineering. I 4.2.4 Checklists shall identify the item by name and part number, specification number and revision, the purchase order number, Supplier and/or Manufacturer, and quantity. The l I checklist shall identify each characteristic to be inspected, and shall furnish the accept / reject criteria, prescribe the inspection method, and provide space for identifying the inspector, his supervisor, and their {I h qualification levels per ANSI N45.2.6. The checklist shall E l m E l l 2 l 1
I paw 08-14-80 MARBLE HILL GENERATING STATION SPECIAL PROCESS PROCEDURE M widen
~~.PUBLIC Page 5o 21 SERVICE~~
~~Title:~~
g INDIANA SPP-7 PROCEDURE FOR PilYSICAL INSPECTION AND g VERIFICATION OF PREVIOUSLY ACCEPfED PURCllASED ITEMS identify all necessary precautions, pre-requisites to starting inspect. ions, and actions necessary to restore the item to a l safe, or preserved, status af ter inspection. The checklist a shall provide for identification of the Nonconformance Report (Attachment 4) written against any discrepant charactetistic. g The checklist shall include a delineation of required quality documentation based upon the procurement documents, drawing or 5 specification, and provide space for indicating the acceptance status of such documentation including radiographs and reports l of nondestructive examination C ere applicable. W 4.2.5 Prior to release tr Inspection for use, checklists shall be g approved by the Qus 'ty Engineering Discipline g Superintendent, who shall, at least, qualify as a Level II Inspector per ANSI N45.2.6. Checklists shall have been demonstrated in the presence of a designee of the Inspection or Quality Systems Superintendent as appropriate = as being suitable te the items to be verified. Such de.nonstration is intended to eliminate any ambiguities or E
.aisunderstandings as to checklist requirements. The 3 appropriate Superintendent or Supervisor shall sign the master copy of the checklis:, indicating acceptance and understanding of the checklist requirements. Attachment 5 is a Typical Receiving Inspection Checklist.
4.3 Sample Selection 4.3.1 Samples of the applicable items shall be selected based on Attachments 2 and 3 dependent upon population size. 4.3.2 Where quantity of any one item is less than thirty-eight (38), and therefore insufficient to allow valid sampling, the entire quantity shall be inspected. 4.3.3 When a specification or shipment contains a large quantity of unlike items, each item should be treated as a separate g l population anu sampled accordingly. g 4.3.4 Cenerally, the process of manufacturing, loading, unloading, receiving, and storing items introduces sufficient randomness to permit sampling. Methods of l W taking random samples vill be identified in the Receiving Inspection Checklists prepared for this verification activ.ty.
~~~ 5 U~~
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I Det* I -PUBLIC MARBLE HILL GENERATING STATION SPECIAL PROCESS PROCEDURE Rm Page 08-14-80 3 6 of 21 SERVICE I INDIANA
~~Title:~~
SPP-7 PROCEDURE FOR PHYSICAL INSPECTION AND VERIFICATION OF PREVIOUSLY ACCEPTED PURCHASED ITEMS 4.3.5 Because all characteristics identified in the Receiving Inspection Checklists cannot be verified on installed items, the verification activity will be first directed to I purchased items in the warehouses and laydown areas. discrepancies are identified in such items, the installed items shall be evaluated to determine required corrective If action. I 4.4 Personnel Qualifications I 4.4.1 Personnel preparing or approving checklists for this verification activity, or interpreting their results, shall be qualified as Level II or III in accordance with , g requirements of ANSI N45.2.6 (1973) except Level I persons 5 may determine the acceptability of inspection results that clearly fall within the boundaries of acceptance criteria. I 4.4.2 Personnel performing inspections under this verification program shall be a minimum of Level II per ANSI N45.2.6 (1973), unless directly supervised by a Level II, who I reviews and is re spons ible for his work; in which case, a Level I Inspector may be used. Where a Level I and Level II are responsible for the work, both shall sign the checklist atterting to its completeness and correctness. 4.4.3 Personnel performing inspection under this procedure shall have had documented training in its purpose and use. 4.4.4 Personnel reviewing and accepting documentation under this procedure shall be qualified as in 4.4.1 and 4.4.2 for the specific functions of this SPP as a minimum. 4.5 Physical Inspection I 4.5.1 Inspector shall use checklists prepared in accordance with 4.2. 4.5.2 Inspector shall:
~~a. Review checklist completely before starting work.~~
I b. Assure all pre-requisite conditions are met prior to starting inspection. Obtain any identified tools, gauges, fixtures, lights I c. or accessories, assure that they function properly, and {@ have a current calibration status as applicable. II
Il MARBLE HILL GENERATING STATION Dew 08-14-80 gI Re,wn 3 g
~~.PUBLIC SPF.CIAL PROCESS PROCEDURE "". f 21 SERVICE~~
~~Title:~~
~~3 INDIANA SPP-7 PROCEDURE FOR PHYSICAL INSPECTION AND 3 VERIFICATION OF PREVIOUSLY ACCEPTED PURCHASED ITEMS~~
d. Prepare or utilize a space suitable for the inapection to be performed including reasonable access to all identified features, protection f rom damage of materials parts, components, equipment and relevant documents and records. Large components may be inspected in place Discipline Quality Engineers shall assist, as required, g in determining the suitability of an inspection area. 3

e. Perform inspections as specified and document results g on the checklist and on a Nonconformance Report, if g discrepant. Initial each line, as completed. Sign the completed report and obtain necessary Level II review and approval,

f. Initiate action to restore the inspected item to a safe or preserved condition (e.g. , re-establishment of purge g gas environment, preserystion coatings, silical ge installation, application of humidity indicators).
5
g. Verify action is complete. Initial the completed form l for this activity. Em 4.6 Documentation Review 4.6.1 Reviewers of Quality Verification Records shall be qualified and trained in accordance with 4.4.3 and 4.4.4 I
~~4.6.2 Documentation shall be reviewed against checklists prepared by the discipline Quality Engineers and shall include the following as a minimum:~~
a. That required documents are present,

b. That they are legible and suitable for reproduction.

c. They exhibit proper and required signatures or stamps. ,

d. That documents conform to specifications, codes or drawings, as applicable, or nonconforming conditions have been identified and properly dispositioned.
4.6.3 Discrepancies identified and not correctable during review of documentation shall be documented on a Nonconformance Report. , lg 4.6.4 Outside organizations may be utilized to perform document reviews. When this is done, it shall be to procedures
~~; reviewed and approved by PSI. 3 e~~
g l
l I i osu 08-14-80 I PUBLIC MARBLE HILL GENERATING STATION SPECIAL PROCESS PROCEDURE Rahlon Page 3 8 of 21 SERVICE I INDIANA
~~Title:~~
SPP-7 PROCEDURE FOR PHYSICAL INSPECTION AND VERIFICATION OF PREVIOUSLY ACCEPTED i l PURCHASED ITEMS 4.7 Control of Nonconforming Items 4.7.1 Nonconformances on hardware, or documentation shall be documented on a Nonconformance Report and shall be disposed I of in accoruance with approved procedures. In addition, the discipline Quality Engineer shall be promptly informed and shall determine the possible effect of the nonconformance on installed hardware and the balance of the lot. Documentation discrepancies may be corrected by obtaining corrected copies from the Supplier. If such are not available, a technical I review by Engineering or Quality Assurance shall be made to determine what action should be taken to determine the acceptability of the item. 4.7.2 Hardware discrepancies that can be corrected to the drawing or specification may be disposed of by the discipline Quality Engineer after contact with the Supplier, and coordination I with Material Control and the Contract Administrator. Documentation discrepancies that can be corrected by replacement of an incorrect or missing document may be dispositioned by the Document Review Supervisor. 4.7.3 Decisions to accept a nonconforming condition as is, or after repair, requires a technical review in coordination with the I Project Engineering Manager, who shall prescribe and approve such action, and with the Contract Administrator so as to levy repair costs back to the Supplier. 4.7.4 Decisions to reject a purchased item requires coordination with the Manager Material Control in order to assure inventory replacement, and with the Contract Administrator to obtain credit for return of the rejected item. 4.7.5 Processing of Nonconformance Reports a) NCR Dispositions Are Classified As:
" Rework" - The process by which a nonconforming item is made to conform to a prior specified requirement. " Repair" - The process of restoring a nonconforming I characteristic to a condition such that the capability of an item to function reliably and safely is unimpaired, even though that item still may not conform to the original requirements.
Ie{ r "Use-As-Is" - A disposition which may be imposed for a nonconformance when it can be established that the nonconformance will result in no adverse conoitions and
08-15-80 I MARBLE HILI, GENERATING STATION Date 3 SPECIAL PROCESS PROCEDURE Reshion 9 of 21
.PUBLIC ""*
~~SERVICE~~
~~Title:~~
g INDIANA SPP-7 PRCCEDURE FOR PilYSICAL INSPECTION AND g VERIFICATION OF PREVIOUSLY ACCEPTED PURCllASED ITEMS that the item under consideration will continue to meet I engineering functional requirements including pe r f o rmanc e , maintainability and safety. b) NCRs mav be initiated which include "Use-As-Is,"
~~" Rework" and/or " Repair" dispositions.~~
c) Completed NCRs - NCRs closed out by Receiving Inspection removing referenced retain tags and applying signature in " Inspector" Block. d) Partial Completed NCRs - Prior to initiation of rework / repair dispositions "Use-As-Is" dispositions can l be processed by sign-of f and dating adjacent to the item " being cleared and removal of applicable retain tags. NCR will remair open pending completion of remaining _spositions. e) Inspection Superintendents office will maintain status g of SPP-7 NCRs and provide Construction Coordinator with open NCRs. 5 4.8 Corrective Action 4.8.1 Nonconformances encountered during this verificatit.. activity shall be evaluated by the discipline Quality Engineer as to the action to be taken on:
a. Installed items,

b. The balance of the lot from which the sample is taken, l

c. Received, but uninspected items f rom other lots, and 5

d. Work-in-process at Supplier's plants.
The cause of the condition shall be determined. The , discipline Quality Engineer is responsible for determining tne scope of the problem, the extent to which corrective action is necessary, and the action, if any, to eliminate its cause, and prevent re cu r re nc e . 4.9 Records 4.9.1 Completed Checklists, Personnel Qualifications, reviewed Document Packages, Nonconformance Reports, and Corrective Action Requests shall be handled in accordance with = procedures established for Quality Verification Records. 8 ! n 4.9.2 In addition to the normal transmittal of such documei.ta co 3 { record files, a concise file of documents relating to this
~~quality verification shall be maintained in a separate i~~
~~I 08-14-80 I MARBLE HILL GENERATING STATION Date Reelslon 3~~
~~.PUBLIC SPECIAL PROCESS PROCEDURE ee 2 f 21 SERVICE~~
~~Title:~~
INDIANA SPP-7 PROCEDU'2 FOR PHYSICAi, INSPECTION t.ND VERIFICATION OF PREVIOUSLY ACCEPTED PURCHASED ITEMS location to assist in the review, audit, and validation of l I this activity until authorization to proceed with normal receipt inspection is received. j l
~~5.0 REFERENCES~~
~~5.1 Evaluation of In-Place Concrete, Marble Hill Nuclear Generating~~
~~'g Station, Units 1 and 2, Report SL-3753 prepared by Sargent & Lundy~~
!E Engineers, November 20, 1979. 5.2 H.S. Ang and W.H. Tang, Probability Concept in Engineering, Planning, I and Design, Volume 1, " Basic Principles" John Wiley & Sons, Inc., New York, New York, 1975, p. 361. 6.0 ATTACHMENTS ,I Attachment 1 - Statistical Basis for Sampling Program Attachment 2 - Sampling Program for Large Size Lots Attachment 3 - Sampling Program for Small Size Lots Attachment 4 - Nonconformance lieport i Attachment 5 - Typical Reinspection Checklist Attachment 6 - Sampling Plan for Category I Items I I I I E I: j
i MARBLE HILL GENERATING STATION Date 08,14-80 Revluion 3
~~'PUBLIC SPECIAL PROCESS PROCEDURE Pge 11 of 21 SERVICE i~~
i Tm.: e INDIANA SPP-7 PROCEDURE FOR PHYSICAL INSPICTION AND 5 VERIFICATION OF PREVIOUSLY ICCEPTED PURCHASED ITEMS ATTACHMENT 1 STATISTICAL BASIS FOR SAMPLING PROGRAM A. Methodology A statistical sampling program has been established to perform the g reinspection of all the items received and accepted prior to August 7, g 1979. The quality of the entire population of items in each specification is determined by inspecting a number of random samples. The statistical program for this type of inspection is known as " sampling by attributes." The size of sample units depends upon the population size and other , variable parameters. Each sample unit will be classified as acceptable or defective at the end of inepection process. The methodology being used E l here for determining the sample size required to qualify the population g has been previously used in evaluation of in place concrete in Marble Hill Units 1 and 2 (Reference 5.1). Depending on the natore and significance ' of the deficiency, the sample will be classified as acceptable or defective. The appropriate number (n) of samples to be inspected depends on the size l of the population (N), the confidence level (C), and the acceptable 3 maximum fraction of defectives (p) in the population. By testing a number of random samples (n out of population N), we can establish with g confidence C that the maximum fraction defective is p if the observed g' number of defectives is r, u.Ing the following equation (Reference 5.2). r Np Nq c=1- E * "-* x=0 N (n) (1) E g l In the above equation, q=1 p and the permutation symbol N means N! . l n n!(N-4! W l l In this inspection program, the .alues of p, C, and N are given and he ! equation is solved for n. l l If n is small relative to N, equation (1) can ce approximated by C=1- h ( *" ) px qn-x I: x2 E 8 m E g (2) b
l I MARBLE HILL GENERATING STATION Date 08-14-80 Revision 3
~~.PUBLIC SPECIAL PROCESS PROCEDURE e.oe 12 f 21 SERVICE~~
~~Title:~~
I- INDIANA SPP-7 PROCEDURE FOR PHYSICAL INSPECTION AND VERIFICATION OF PREVIOUSLY ACCEPTED PURCHASED ITEMS ATTACHMENT 1 (Cont'd) The fallcwing statistical sampling program is developed to establish with I 95% reliability and 95% confidence level, that the population quality meets the design requirements. Using equation (1) or (2) and the above parameter values, the number of samples, n, required to establish the quality of population has been calculated. As an example, for large value I of N, with C = 0.95 and p=0.05, n is calculated as 59 for r=0. As a first step, for large value of N, a sample of 59 units is to be I tested. In order to establish with a confidence level of 95% that no more than 5% of the population is defective (i.e., reliability of 95%), none of the samples should fail the inspection. The sampling program is I sequential in that if a defective unit is encountered in the first 59 samples, the sample size is increased to a total of 93. In this larger , sample, there should be no more than the defective sample. Attachments 2 and 3 give the sampling programs for large value of N and relatively smaller value of N respectively. B. Overall Quality of Population
~~.'.11 the items involved in each specification are qualified by inspection of randomly selected samples by the method discussed in previous section.~~
For population size greater than 700, the sainple size for establishing with 95% confidence that no more than 5% of the population is defective is given in Atte.chment 2. Attachment 3 provides the sample size required for establishing with 95% confidence that no more than 5% of the population is I defective for smaller population size. The inspection procedure is as follows: Identify and inspect at least the number of Units required by Attachments 2 or 3 corresponding to the population size of concern. If there is no defective unit observed, stop further inspection in that population. If one defective unit is observed, increase the sample size to next
~~_ higher number of sample size for that population. .~~
1 If no further defective units are observed in this increased sample, stop further inspection. I If more defective units are observed, further testing of random samples must be done according to the sizes shown in Attachment 2 or 3.
~
IE I
I \ i MARBLE HILL GENERATING STATION oses 08,14 8o Revinnon 3
~~'PUBLIC SPECIAL PROCESS PROCEDURE %. I f 2i SERVICE~~
~~Title:~~
INDIANA SPP-7 PROCEDURE FOR PHYSICAL INSPECTION AND VERIFICATION OF PREVIOUSLY ACCEPTED PURCHASED ITEMS ATTACllMENT 1 (Cont'd) C. Selection of Sample It should be emphasized that this method is applicable only when the selection of sample is completely random. Sampling selection procedures shall be established prior to starting of actual inspection to avoid any bias introduced during inspection. D. Acceptance Criteria from a Statistical Standpoint The statistical sampling program adooted for inspection of all population is aimed to ensure with 95% reliability and 95% confidence level that the population meets the requ i reme n t . By inspecting the number of samples g shown in Attachment 2 or Attachment 3 and satisfying the maximum failure g criteria, we can establish wi.th 95% confidence that no more than 5% of the population should be defective in the entire population under investigation, hence the entire population is judged to be acceptable. I I I' I I I
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n 5 b 1 l - - . - . _ __. . ..
MARBLE HILL GENERATING STATION ow -0 Revision SPECIAL PROCESS PROCEDURE
~~.PUBLIC "*** 2' " "~~
~~SERVICE~~
~~Title:~~
lI i INDIANA SPP-7 PROCEDURE FOR PHYSICAL INSPECTION AND VERIFICATION OF PREVIOUSLY ACCEPTED PURCHASED ITFMS i il ATTACHMENT 2 SAMPLING PROGRAM FOR LARGE SIZE LOTS i !I Maximum Number ! of De fectives Sample Size
l 0 59 l 1 93 2 124 Ig 3 153 4 181
~~!g i 5 208 6 234~~
~~; 7 260 8 286~~
{ 9 311 !- 10 336 4 4his table is applicable to all the lots whose population size is larger than 700, for 95% reliability wit's 95% confidence level. 4 l. l e I5 i \. -. - _ _ - . ..
l MARBLE HILL GENERATING STATION Date 08-14-80 Revianon 3 SPECI AL PROCESS PROCEDURE
~~'PUBLIC Page 15 of 21 SERVICE~~
~~Title:~~
INDIANA SPP-7 PROCEDURE FOR PHYSICAL INSPECTION AND VERIFICATION OF PREVIOUSLY ACCEPTED PURCHASED ITEMS ATTACHMENT 3 SAMPLING PROGRAM FOR SMALL SIZE LOTS Maximum Number g De fec tive 0 1 2 3 4 g Lot Size 114 46 68 05 98 107 I-88 43 63 76 I 79 42 60 71 38 30 Note: For lot size less than 38, all items should be inspected. This table is applicable for 95% reliability and 95% confidence. l1 5 I Il
~~? -~~
e 6 I
l MARBLE HILL GENERATING STATION Date 08-14-80 l_. /"L L,
/
~~PUBLIC SERVICE~~
~~Title:~~
SPECIAL PROCESS PROCEDURE Revision eat. 16 of 3 21 ( // INDIANA SPP-7 i I PROCEDURE FOR PHYSICAL INSPECTION AND VERIFICATION OF PREVIOUSLY ACCEPTED PURCHASED ITEMS B ATTACHMENT 4 I pusuC SERVICE NONCONFORMANCE REPORT NONCONFORMANCE REPORT MARBLE HILL PROJECT DATg NCR NO. _ f INOiANA PACE OP I EQuePMENT NAME/CEsCRIPTION ITEM /EOulP/lNsTALLATION NO. R E SPONSisLE ORGAN 62A TION Pse SPEC NO. SLOG.GOCE OswGsTMAvELLER I -E - O . . . .- E ,. . O -. Ms = =E= s:,,,- C sAPETY RELATEo O NON.sAPErv RELATEo O NON Asa.E CEsCRiPTION OP NONCONPORMANCE g g OlsPOstTION INSTRUCTIONS /JusTIFiCAT10N e z 3 3 E f $ s E 2, E' f i i w O INITIATOR DATE I sw Me. - e - p.r to CPR21 or 10 CPRSO.55 4.L NRC O vts O NC oisPOsitiONEo ev oATE I QvAL4TY ENG4NEERING OATE ' OISPCslTION APPROV AL$sREMARKs i I AE ACCEPTANCE CCRRECTlvt ACTION REQUEST REOutREQ DATE O NO PROJECT ENGINE ERING O vEs CAR NO. OATE i
\
CLo point INSTRUCTIONS I-l 1 ( @E OU ALITY FNGINE ERiNG DATE ant (A5ast ONLYS DATE i i DisPostTION k.- COMPLETE.ANO ACC.PTA u R %.. c. AN,wMEO., o. i,-,.,,E,,, om
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MARBLE HILL GENERATING STATION Date 08-14-80 RevWon 3
'r7 PUBLIC SPECIAL PROCESS PROCEDURE Page 17 of E /f 21 u
SERVICE .i.tle: {. SPP-7 PROCEDURE FOR PHYSICAL INSPECTION AND E VERIFICATION OF PREVIOUSLY ACCEPTED g PURCHASED ITEMS ATTACHMENT 5 TYPICAL REINSPECTION CHECKLIST
~~.c..~~
MLC RECEIVING I?.;P ECTIC J i Skav6Ct - omit IN@ AN A CH E CK LIST,R EPO R T l lElectraeal Equareent l l at tw eeA'AE- IM.ngers and tesvs I Pt?Ct NO: t P o. arf. st a- P O. situ No. SPEC 6F4C a?60N %O: bit & QTY.: Mtaf NO; OA AngG NO Re li sh te Sheet **.tt al . LOf AO; vtNCO84 N A9t-pup f titt & r.o.
~~' MAf t Ai&L SPf t:~~
8EOMNI REC 3AO aCCEPYtl { atOt*NT 'Rf CO8L3 ACCitte f CNICK situ , l ,,al No- , et.ECT . CMECK litM lg ' ,g,, g " NO. 6 A E.E CT l See At tached Cseckttst l l l l l l I !
~~l l l l l l l t 5~~
! I i l l i I I I I I I I I l l t i i i l I I l l l i l i i i I l I I I I l l 1 I I I I I l l l l l 1 I i MTSULT$. ACCEPT RIJICT NCR Yt3 NO O ACC Pr wiTN CoqutNrs NCR NQ;
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l 1 l MARBLE HILL GENERATING STATION Date 08-14-80
~~4. ?~~
~~PUBLIC SPECIAL PROCESS PROCEDURE RevWon Pase 3 8 or 21~~
', 7 j SERVICE y ,,. /-E - INDIANA SPP-7 PROCEDURE FOR PHYSICAL INSPECTION AND VERIFICATION OF PREVIOUSLY ACCEPTED PURCHASED ITEMS I
~~ATTACHMENT 5 (Cont'd) I . I I~~
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MARBLE HILL GENERATING STATION cate 08-14-80 Revision 3 PUBLIC SPECIAL PROCESS PROCEDURE a
~~#..: /f SERVICE Pase e 21 / / /~~
~~Title:~~
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I MARBLE HILL GENERATING STATION Date 08-14-80 Revkion PUBLIC SPECIAL PROCESS PROCEDURE ,
~~-'[~~
~~SERVICE~~
~~Title:~~
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MARBLE HILL GENERATING STATION oss. 08-14-80 SPECIAL PROCESS PROCEDURE Rwk 3
~~.PUBLIC P.2 21 or 2i SERVICE~~
~~Title:~~
INDIANA g SPP-7 PROCEDURE FOR PHYSICAL INSPECTION AND VERIFICATION OF PREVIOUSLY ACCEPTED PURCHASED ITEMS ATTACHMENT 6 SAMPLING PLAN FOR CATEGORY I ITEMS SPECIFICATION MAXIMUM NUMBER TITLE LOT SAMPLE REJECT Y-2766 Stainless Steet Liner 3885 59 0 Y-2804 Electrical Penetrations 38 30 0 Y-2720 Containment Crancs 4 4 -- Y-2815 Cable Pans 4244 59 0 Y-2702 W NSSS 1550 59 0 Y-2718C Carbon Steel Valves 4 4 -- Y-2725 Containment Liner 1205 59 -- Y-2744 Shop Fabrication Tanks 6 6 -- Y-2756 Main Steam Isolation Valves 4 4 -- Y-2794 Stainless Stect valves 5 5 -- Y-2795 Diaphragm Valves 88 43 0 I Y-2721 Containment Post Tensioning Erection 19401 59 0 Y-2771; llangers, Supports, Snubbers 2490 59 0 Y-2900 Cubicle Coolers 24 24 0 Y-2735 Fabricated Steel 6997 59 0 Y-2741 Piping Material and Fabrication 1695 59 0 Y-2797 NSSS Support Steel 773 59 0 Y-2787A Containment Piping Penetrations 4 4 -- Y-2787B Penetrations 78 42 0 g Y-2865 Embedded Piping Essential 122 46 0 g c; lleaders E R 3 Y-2725 Containment Liner 1205 59 0
I 8.0 IN-PLACE CATEGORY I BURIED AND EMBEDDED PIPING 8.1 ABSTRACT This section describes the findings and results of a physical inspection and verification program conducted by Public Service Company of Indiana, Inc. (PSI) and Stewart Mechanical Enterprises, Inc. (SME), a Subcontractor to Newberg-Marble Hill (N-MH), on 5 In-Place Category I Buried and Embedded Piping which was accessible at the Marble Hill Nuclear Generating Station. The section also describes the results and conclusions of the inspection and the I proposed follow-up actions to be taken in assuring the appropriate corrective actions are implemented. This program consisted of documented visual inspection conducted by a qualified and trained team in accordance with the Special Process Procedure, SPP-8. The visual inspection consisted of 100% inspection of accessible In-Place pipe and pipe field welds. Based on the results of these examinations, PSI will take measures to assure that appropriate repairs are conducted upon restart of I Category I construction activities.
~~8.2 INTRODUCTION~~
This report summarizes the measures taken to perform inspection and identify discrepancies of In-Place Category I Buried and Embedded Piping and to determine the necessary corrective measures at the I Marble Hill Nuclear Generating Station. The program included the following items: 8.2.1 Preparation and approval of a Special Process Procedure (SPP-8) for physical inspection and verification of In-Place Category I Buried and Embedded Piping. 8.2.2 Establishment and qualification / training of a Physical Survey Team. 8.2.3 Compilation of survey data (see Paragraph 8.3.3). 1 I 8.2.4 Examination of traveller packages to assure inclusion of documents ) required (a detail review of documents included in the traveller I packages is being performed as part of Special Process Procedure SPP-12). Physical inspe.ction of Category I In-r.', ace accessible pipe and pipe l I 8.2.5 field welds. 8.2.6 Documentation of inspection results on the appropriate forms. 8.2.7 Physical flagging with a " fail ribbon" of In-Place pipe not conforming to design configuration. 8.2.8 Preparation of Corrective Action Requests (CARS) to procedurally identify discrepancies and/or nonconformities to establish corrective actions and actions to prevent recurrence. I 8.3 DISCUSSION Special Process Procedure SPP-8 (" Physical Inspection and Verification of In-Place Category I Buried and Embedded Piping") g was prepared by S&L, reviewed and approved by the P31 Project g Engineering Manager and the PSI Quality Assurance Manager. This procedure establishes written criteria and instructions for: 8.3.1.1 Physically verifying that traveller packages for In-Place pipe I contain the specified documents. G.3.1.2 Physically inspecting In-Place Category I accessible piping for correctness of the installed configuration. 8.3.1.3 Visually examining 100% of accessible Category I Pipe Field Welds. 8.3.1.4 Identifying locations of items requiring corrective actions. 8.3.2 ESTABLISHMENT OF THE PHYSICAL SURVEY TEAMS The Physical Survey Team (PST) was established by the PSI g Construction Manager with the concurrence of the PSI Project g Engineering and Quality Assurance Managers. The Physical Survey Team performed the inspection under the supervision of the Team Lesder. The Team Leader was a PSI Construction Engineer h experienced in piping related work. The Physical Survey Team membership consisted of: 8.3.2.1 The Team Leader with a B.S. degree and one year of experience in piping related work or a high school gradiate with five years experience in piping related work. 8.3.2.2 At least one PSI Quality Assurance (QA) Engineer / Inspector qualified as a Level II Mechanical Welding Inspector under ANSI N45.2.6. 8.3.2.3 A Stewart Mechanical QA Engineer qualified to Level I ( ANSI N45.2.6). In addition each member of the Physical Survey Team attended a documented training session which dealt specifically with the SPP-8 Procedure. 8.3.3 COMPILATION OF SURVEY DATA In addition to documents outlined in SPP-8. the following Sargent & Lundy letters were used by the PST during the inspection: l l 8.3.3.1 S&L letter dated 5/15/80 documenting S&L review and acceptance of l the attached SME Weld Procedure / Pipe Design Table Cross Reference w List, marked " Attachment 8.6.2". I I I
I 8.3.3.2 S&L letter dated 5/13/80 regarding clarification of relevant are strikes. 8.3.4 PHYSICAL INSPECTION The PST performed the Physical Inspection between May 12, 1980 and May 28, 1980. The Inspection included the following: 8.3.4.1 Configuration and cleanliness inspection of accessible In-Place Category I Piping. 8.3.4.2 Visual examination of exposed and accessible Category I piping welds performed by SME. 8.3.4.3 Verification that SME Traveller Packages contain specified documents. 8.3.5 INSPECTION RESULTS AND DOCUMENTATION The results of the inspections were recorded under the direction of I the PSI Level II Quality Assurance Engineer / Inspector team member. The results were recorded as follows: 8.3.5.1 The inspection of Pipe Traveller Packages was documented on a unique Form SPP-8-4.2.2-1 and the pipe line number is being used as I a unique document identification. A sample Form SPP-8-4.2.2-1 is attached and marked " Attachment 8.6.3". In performing the I Traveller Packages Review, two discrepancies were noted and CARS were issued. Of the two discrepancies, one was subsequently determined not to be a discrepancy. 8.3.5.2 In-Place Category I Pipe inspected for correct configuration and cleanliness was documented on Form SPP-8-4.2.3.1-1 with discrepancies noted. The pipe line number was used as a unique document identification. A sample Form SPP-8-4.2.3.1-1 is attached I and marked, " Attachment 8.6.4". A generic pipe cleanliness problem was identified and addressed by the SPP-8 team on a Corrective Action Request (CAR). It should also be noted that no piping I configuration discrepancies were found. 8.3.5.3 The documents used (i.e., ASME Section III, drawings, Procurement I Specifications, etc.) to inspect Category I In-Place Piping as well as visual examination of pipe field welds were documented in Form SPP-8-4.2.3.2-1 which is attached and marked " Attachment 8.6.5". 8.3.5.4 Pipe field welds inspected were documented on Form SPP-8-4.3.1-1. Discrepancies and exact locations of discrepancies were noted on the form. The pipe line number was used as a unique document identification. A sample Form SPP-8-4.3.1-1 is attached and marked 8 " Attachment 8.' 6". It should be noted that pipe field welds were l examined to cr. Jria as outlined in Attachment 8.6.6. Namely, l undercuts, cracks, linear indications, excessive-reinforcement, lack of fusion, lack of penetration (ID), weld type, size and location, are strikes and gauges, and welder ID. I I
l I' Out of 126 pipe welds inspected, 10 welds require corrective g actions in the following categories: undercuts (2), linear indications (2), excessive-reinforcement (1), lack of fusion (2), 51 weld size (1), arc strikes (3), welder ID missing (4). No discrepancies were found in the other categories specified in j Attachment 8.6.6. (Note: some welds registered discrepancies in B more than one category.) 8.3.6 PHYSICAL MARKINGS Concurrent with the recording activity, Category I In-Place Pipe inspected for configuration was flagged with a " pass ribbon" or
~~= " fail ribbon".~~
8.3.7 PREPARATION OF CORRECTIVE ACTION REQUEST (CARS) Using documentation obtained during the inspections, PSI has generated eleven (11) CARS (PC-0339, 0346, 0385, thru 0392, and 0578) to identify noncoaformances, establish action required to prevent recurrence, probable cause, and action taken to assure the quality of items af fected prior to discovery of adverse condition. Proposed corrective actions were reviewed and approved by Sargent & Lundy, PSI and PSI Authorized Nuclear Inspector, where required. The CARS written may be divided into three (3) groups involving traveller packages, pipe welds and pipe cleanliness. Two CARS involved traveller packages discrepancies, namely the use of white-out on traveller documents and a missing document (FIT-UP l SHEET) which was subsequently found. W Eight CARS involved pipe welds. The CARS were written by category B of weld problem as discussed in Paragraph 8.3.5. The CARS wtitten 5 involve a total of ten (10) welds requiring corrective action. The welds will be repaired per approved procedures. Note that of the ten (10) welds, three (3) welds merely required stamping the welder l ID next to the weld. The welder ID was documented in the traveller
~~documents.~~
One CAR was written to identify a generic pipe cleanliness problem. The Contractor will clean foreign matter from inside of installed piping, and install end caps. The Contractor will also increase training and surveillance of pipe cleanliness requirements. 8.3.8 ENGINEERING ANALYSIS An engineering analysis was performed by Sargent & Lundy on all the welda requiring corrective action other chan welds lacking welder ID only (a total of 7 welds), considering that pipe which is l embedded in concrete will not be subject to bending moments, cyclic ! or otherwise. The engineering analysis determined that with the exception of the lack of fusion identified on weld 4, line ICCD9AB2-2", CAR-PC0391, the observed weld defects would not cause j a failure of the piping system joint in question. 5 I
I I To support the engineering analysis, once safety-related work commences, further investigation of the lack of fusion on weld 4, line ICCD9AB2-2" is required.
~~8.4 CONCLUSION~~
Of the four categories examined (i.e., Traveller Packages, Piping Configuration, Pipe Cleanliness, Pipe Field Welds), a generic 8 discrepancy was found only on pipe cleanliness. The majority of other discrepanies were found in pipe field welds. The applicable
.E CARS address the corrective actions required, and recommended g action to prevent recurrence is additional training to be conducted for Welding Inspectors, Foremen, Pipefitters and Welders.
I In summary, Category 1 In-Place Buried and Embedded Piping, and Pipe Field Welds were inspected where accessible. Discrepancies were documented on CARS with corrective actions agreed on. These future corrective actions will assure that presently accessible Category I In-Place Pipe and Pipe Field Welds installed to date will meet the req.:irements of the applicable specifications, codes I and standards. 4 Based on the above inspection results, the Engineering Analysis performed, the fact that the four lines containing defective welds I have been successfully hydrostatically tested, and providing that furti:er investigation of weld number 4, line ICCD9AB2-2" will indic.'te no unacceptable lack of fusion, it can be concluded that 1 the Ca tegory I In-Place Pipe and Pipe Field Welds which are Buried and Emtedded or are otherwise unaccessible will meet the operating design requirements specified.
~~l NOTE: .'SI has transferred code related work from SME to CCC via R iW E ngineering Change Notices (ECN's) S-285 and M-376.~~
8.5 REFERENCIS 8.5.1 SPP-8, F)ysical Inspection and Verification of In-Place Safety Categor: I Buried and Embeddad Piping, Revision 2, Special Process Procedu es, Marble Hill Nuclear Generating Station, Public Service I Company of Indiana, Inc. I 8.6 8.6.1 ATTACHMENTS SPP-8, Revision 2 8.6.2 Sargent & Lundy Letter of May 15, 1980 8.6.3 Traveller Package Worksheet 8.6.4 Spool Verification Wotksheet I I l
~~/. - - - -~~
i l I 8.6.5 Documentation Used Work Sheet 8.6.6 Pipiag Weld Inspection Worksheet 8.6.7 List of S&L Drawings used for Inspection (SPP-8) ' 8 I I ( l l I' l I I I' I I I I I , I I 1 I
~~---- -. - . _ _ _ _ _ _ _ _ _ - 1~~
~~J -~~
~~SUMMARY~~
OF REVISIONS I PROC.NO. SPP-8' SUSJECT PHYSICAL INSPECTION & VERIFICATION OF IN-PLACE SAFETY CATEGORY I BURIED & EMBEDDED PIPING REVISION DESCRIPTION N E l I I 1 Major Revision to all pages. 2 (1.) Added definitions on relevant are strike and piping design table. (2.) Added note to paragraph 4.2.2 b. (3.) Added section i to paragraph 4.2.3.3. (4.) Revised paragraph 4.3.1 h. I I I E . I ATTACHMENT 8.6.1
~~, REVISION AUTHORIZATION REVISION l 2~~
~~I NUMBER DATE M ED 05-07-80 05-12-80 m , , , , I '""^"' h" Ghiv c"'.c ' LU M ili/wL I .E=:: %LagA_~~
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I, MARBLE HILL GENERATING STATION Date 05-12-80 g
~~.PUBLIC SPECIAL PROCESS PROCEDURE Revision 2 g SERVICE 73,, ;~~
INDIANA see-8 PiivSicAL INSPECTION AND VERIFICATION OF IH-PLACE SAFETY CATECORY I ) BURIED AND EMBEDDED PIPING g l 5' I TABLE OF CUN1ENTS I SECTION TITLE 1.0 PURPOSE 2.0 APPLICABILITY l 3.0 DEFINITIIONS 4.0 INSTRUCTIONS 5.0 FLOWCHART
~~6.0 REFERENCES~~
ATTACilMENT A EXCESSIVE REINFORCEMENT ASME SECTION 111, NB 4426, NC 4426 AND ND l E 4426. I I I I I l e I i g 3 l 1- . -- ___ - __. - . . ._.
I I -PUBLIC MARBLE HILL GENERATING STATION SPECIAL PROCESS PROCEDURE Date Revision Page 05-12-80 2 3 of 9 3 SERVICE
~~Title:~~
5 INDIANA SPP-8 PHYSICAL INSPECTION AND VERIFICATION OF IN-PLACE SAFETY CATEGORY I BURIED AND EMBEDDED PIPING 8 l 1.0 PURPOSE This document establishes the method for the physical inspection of in place Safety Category I buried and embedded piping, which is or will I be buried or embedded, for agreement with the latest design requirements; or, where discrepancies exist, to document the deviations in accordance with existing PSI procedures. Dimensions of piping and hangers as well as relative location in the
= building, are not included in the Scope of SPP-8. Piping is generally adjusted during installation, and these in place adjusted conditions are I taken into account in the development of a final drawing. Therefore, verification of location and dimensions shall be performed during normal construction activities.
2.0 APPLICABILITY This procedure is applicable to the work performed by Stewart Mechanical Enterprises, Inc. as subcontracted by Newberg-Marble Hill. 2.0 DEFINITIONS Traveller Packages - Assembled documentation containing Isometric Drawing, Isometric Data Sheet, Traveller Forms, Fit-up Checklist, Final Pass Checklist, Nuclear Welding Material Log Sheet, NDE Report, and I llyd ro tes t Report assembled in accordance with Section 6 of Stewart Mechanical's Quality Assurance Manual. In-Place Pipe - Any Safety Category I pipe placed temporarily or I permanently in its intended location. Exposed Pipe - Any in place pipe not yet buried, embedded or coated and wrapped. Pass Ribbon - A ribbon of a green color which denotes that the flagged j item was inspected and found to be acceptable. I Fail Ribbon - A ribbon of a white color which denotes that the flagged item was inspected and found to be questionable or rejected. PDT - S&L Piping Design Table g - Quality Assurance. Latest S&L Design Drawings - Latest as of April 14, 1980. I 1 l f PST - Physical Survey Team R PSI - Public Service Indiana I$
j _ I MARBLE HILL GENERATING STATION osis 05-12-80 Revision 2
~~~PUBLIC SPECIAL PROCESS PROCEDURE SERVICE Titls:~~
INDIANA SPP-8 PHYSICAL INSPECTION AND VERIFICATION OF IN-PLACE SAFETY CATECORY I Relevant Arc Strike - (a) An Arc Strike pit whose depth is 1/32" or greater. (b) An Arc Strike on the internal surface of stainless steel piping. (c) An Arc Strike which results in cracking. S&L - Sargent 6 Lundy Engineers SM - Stewart Mechanical Enterprises, Inc. 4.0 INSTRUCTIONS 4.1 Establishment of Physical Survey Teams The establishment of the Physical Survey Team shall be the responsibility of the Public Service Indiana (PSI) Construction Manager with the concurrence of the PSI Project Engineering and Quality Assurance Managers. The team shall consist of a PSI Quality Assurance Engineer / Inspector, a Stewart Mechanical Quality Assurance Engineer and/or a Newberg Quality Control Engineer, and a PSI Construction Engineer who will serve as a Team Leader. The Team Leader shall have at least a B.S. degree and one year of experience in piping related work or five years experience in piping related work. The Quali ty Assurance Engineer / Inspector f rom PSI shall be a qualified Level II Mechanical Welding Inspector under ANSI N45.2.6 (Reference 6.2) The Stewart Mechanical Quality Assurance Engineer and/or Newberg Quality Control Engineer shall be qualified to Level I as a minimum. Note: Additional PSI Level II Quality Assurance Engineera/ Inspectors may be used to support the Physical Survey Teams. Each Team Leader shall be under the supervision of the PSI Construction Area Manager for the performance of the physical survey in his area, who in turn is re s pons ib le to the Construction Manager for the overall performance of work. The PSI Project Engineering Manager is res pons ible for providing technical support to the entire program. The recording of data , shall be under the direction of the PSI Level II Quality Assurance Engineer / Inspector. 4.2 Physical Survey Team Verification and Inspection Activities 4.2.1 The Physical Survey Team shall obtain a list of Safety Category I in place pipes and a list of all Safety Category I $ exposed pipes. The Physical Survey Team shall organize the { list by elevation and system, and establish a schedule for .- completing the verification and inspection based on a 100% G 5 B I E
I MARBLE HILL GENERATING STATION ost. 05.-12-80 I .PUBLIC SPECIAL PROCESS PROCEDURE Revision 2 SERVICE
~~Title:~~
I INDIANA SPP-8 PHYSICAL INSPECTION AND VERIFICATION OF IN-PLACE SAFETY CATECORY I BURIED AND EMBEDDED PIPING 8 review of all exposed pipes and internal examination of 42" diameter and over in place pipe. Only the latest issue of S&L drawings shall be used. 4.2.2 The Stewart Mechanical Traveller Packages or documents herein for in place pipe to be inspected, shall be examined by the Physical Survey Team for the items listed below. Note: The Physical Survey Team may, at their option, call on Quality I Engineering personnel for assistance. I
~~a. Verification that all documentation required to be in the Traveller Package in accordance with Stewart Mechanical's Quality Assurance Manual, Section 6.0.~~
I b. Verification that the weld procedure indicated for each weld is the correct procedure based on S&L's piping design tables and that the correct piping design tables are used. S&L Piping and Instrumentation Diagrams (P & ' I ids) shall be used for verification of correct piping design tables. I Note: S&L shall review cross reference lists supplied by Stewart Mechanical for concurrence that the correct weld proceduresg are used in conjunction with the correct piping design tables. The Physical Survey Team shall use Form SPP-8-4.2.2-1 to document the inspection of each Traveller Package Documents. 4.2.3 A physical inspecton of the exposed pipes and 42" diameter and over in place pipe shall be conducted by the Physical I Survey Team based on the latest S&L drawing, and the l associated Traveller Package Documents examined in Paragraph 4.2.2. 4.2.3.1 The Physical Survey Team shall inspect each exposed . pipe to insure that the correct configuration is as shown on the latest S&L drawings. Each pipe I correctly installed shall be flagged with a "pau ribbon". Any pipes found to be incorrectly I installed shall be flagged with a " fail ribbon". Form SPP-8-4.2.3.1-1 shall be used by the Physical Survey Team to indicate which spools have been inspected atid any discrepancies observel. I@; E 4.2.3.2 The Physical Survey Team shall list all documents and drawings used in the physical .nspection and G verification on Form SPP-8-4.2.3.2-1. i
o.m 05-12-80 I MARBLE HILL GENERATING STATION l
~~'PUBLIC SPECIAL PROCESS PROCEDURE Revision 2 E~~
~~g p, 6 of 9 SERVICE~~
~~Title:~~
INDIANA SPe-8 PaYSICAL INSPECTION AuD veR1F1 CATION l OF IN-PLACE SAFETY CATEGORY I BURIED AND EMBEDDED PIPING 4.2.3.3 The following documents will be required by the Physical Survey Team in order to perform the activities in 4.2:
a. S&L's Latest Drawings

1. Outdoor piping

2. Embedded piping (M-334)

3. S-1077

4. P& ids

b. SM's Isometric Drawings (Weld ID)

c. SM's Traveller Packages

d. SM's Procedures 4.0, 6.0, 7.0 and 13.0

e. Vendor Drawings (SX System)

f. S&L Line List

g. S&L Specification Y-2722 and appropriate ECNs

h. Field Change Requests

i. An S&L Letter approving SM Weld /PDT Cross-Reference List.
4.2.4 The Physical Survey Team shall sign-off each Form used in the physical inspection and forward all Forms, grouped by l w elevation, to the Project Engineering Manater for input to l the final report. 4.3 Visual Field Weld Inspection The PSI Level II Mechanical Welding Inspector, qualified under ANSI N45.2.6-1973 shall inspect all pipe welds on exposed pipe and the " l internal weld surface of all accessible 42" diameter and larger in place SX pipe. When the surface condition of the weld precludes meaningful visual examinatica, cicaning shall be performed. Acceptable methods of cleaning include solvent cleaning and brushing. The method of ' cleaning shall be recorded in the remark column of Form, SPP-8-4.3.1-1. Note: Grinding and polishing of the welds i;
~~! prohibited. Welds which have been coated and wrapped shall not be j~~
{ visually examined except for internal weld surface as outlined above. W e I
05-12-80 I MARBLE HILL GENERATING STATION Date PUBLIC SPECIAL PROCESS PROCEDURE Revision 2 SERVICE
~~Title:~~
I INDIANA SPP-8 PHYSICAL INSPECTION AND VERIFICATION OF IN-PLACE SAFETY CATEGORY I BURIED AND EMBEDDED PIPING I 4.3.1 The WeMing Inspector shall visually inspect each ASME Section III weld for the following items:
a. Undercut: 1;o t to exceed 1/32" at any point.

b. Cracks: Are not acceptable.

c. Linear Indications: Not'to exceed 1/16".

d. Excessive Reinforcement: (See Attachment A).

e. Lack of Fusion: Not acceptable.

f. For pipe 42" diameter and larger, check pipe ID for weld defects as stated in a I unacceptable.
~~e and h. Lack of penetration is If weld surface is not accessible, it shall be documented as such.~~
~~g. Weld Type Size (Leg & Throat) and Location. Note:~~
~~I Minimum throat & leg size is per ASME Section III. No maximum. Throat size is cosine of leg. 4~~
~~h. Following cleaning and brushing of area to be inspected, gouges and relevant arc strikes are not acceptable.~~
I Each weld examined shall be documented pass or fail for each of the above items on Forms SPP-8-4.3.1-1 for piping. The acceptance criteria shall be as stated in "a" through "h" above. Where a weld defect is identified, the exact location of the defect along the circumference of the pipe shall be identified by the Time Clock Method. When facing the clock, I the Inspector shall be facing Plant North, Plant West or up. I 4.3.2 Upon completion of the inspection, the Welding Inspector shall sign each form used to document the weld inspection and forward them to the Team Leader for input to the final report for the Safety-Category I Piping. I 4.4 Verification of Installation Cleanliness l I The Physical Survey Team shall visually inspect for cleanliness, the internal surface of each accessible exposed pipe and each in place 42" diameter and larger. For size 42" diameter and larger, the inspection shall include the complete length of the pipe which is Q accessible. I$
I' MARBLE HILL GENERATING STATION ost. 05,-12-80 SPECI AL PROCESS PROCEDURE Revision 2 g
~~'PUBLIC p'" 8 of 9 m SERVICE~~
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INDIANA SPP-8 PaYSICAL INSeECTION AND VERIFICATION - OF IN-PLACE SAFETY CATEGORY I BURIED AND EMBEDDED PIPING For pipe smaller than 42" diameter, the inspection shall include only that section of pipe which can be visually inspected without crawling inside the pipe. Eaamplas of items to be checked are weld g splatter, oil, grease, paint, slag, chalk abrasive carbon deposits, g coatings, and other foreign matter. Should the PST determine at the conclusion of the verification program that a generic cleanliness problem exists, a generic = nonconformance will be initiated to address all cicanliness problems. The cleanliness shall be documented for each pipe checked by the PST on the Spool Verification Worksheet, Form SPP-8-4.2.3.1-1. 4.5 Processing of Nonconformances It shall be the responsibility of the PST to originate any deficiencies with design requirements in accordance with PMP 1.07 on a Corrective Action Request (CAR). The PSI Level II Inspectors are responsible for assuring that the nonconformances are documented l W accurately with the findings of the PST and are responsible for signing the signature block labeled " Initiator". NOTE: For SPT 8 g deficiencies, it shall be noted in the " Method of Discovery" birck on the CAR Form that the deficiencies were discovered by SPP-8 PUT. 5 The control of the nonconformances (CARS) shall be in accordance with PMP 1.07 af ter the origination of the CAR by the PST. Numbers l for the CARS shall be obtained by the PSI Superintendent of Civil N Quality Engineering from the Nonconformance Computer Coordinator. 4.6 Record 3 Checklists and marked-up drawings for this irlpec tion are quality records. In addition to their being maintaiaed as quality l documents, the complete set shall be maintained separately until the = results of the reinspection have been evaluated and authorization for construction has been received. t 5.0 FLOWCHART Figure 1 is a Flowchart for the inspection and verification of piping and hangers. , Figure 2 is a Flowchart for the visual inspection of piping and hanger I attachment welds.
~~6.0 REFERENCES~~
~~l l 6.1 PMP 5.16, "Special Process Procedures", Rev. O, March 5, 1980.~~
~~@ 6.2 ANSI N45.2.6-1973, " Qualifications of Inspection, Examination, and l~~
~~{ Testing Personnel for rhe Construction Phase of Nuclear Power M~~
~~.- Plants,"ASME, New York, New York.~~
G l 5 6.3 PMP 1.07, " Control of Nonconformance", Rev.0, March 6, 1980
I 05-12-80 I .PUBLIC MARBLE HILL GENERATING STATION SPECIAL PROCESS PROCEDURE ost. Revlolon 2 SERVICE
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