ML20010H700
| ML20010H700 | |
| Person / Time | |
|---|---|
| Site: | Columbia  |
| Issue date: | 12/06/1979 |
| From: | Engelken R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V) |
| To: | Thornburg H NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
| Shared Package | |
| ML17272A975 | List: |
| References | |
| FOIA-81-223 NUDOCS 8109290146 | |
| Download: ML20010H700 (8) | |
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- El Qq NUCLEAR REGULATORY COMMISSION
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.y 0 6 DEC 1979 9:y/f n
. j. (MEMORANDUM FOR:
H.- D. -Thornburg, Director.- Division of Reactor Construction Inspection, IE
- FROM:-
LR. HL Engelken. Director,. Region V -
SUBJECT:
WASHINGTON NUCLEAR PROJECT NO. 2 (WNP-2) SACRIFICIAL
,o SHIELD WALL, PIPE WHIP RESTRAINTS, AND RELATED STRUCTURES (AITS NO. F05030004)'
NRC:RV has recently-issued two-Immediate Action Letters (IAL) to Washington Public Power Supply System relating to the stoppage of work on;the WNP-2 sacrificial shield wall and certain pipe whip restraints.
The sacrificiai. shield wall surrounds the reactor vessel providing
< biological shielding and. functions as an anchor point for structural steel platforms supporting the main ste'am, feedwater, and recirculation
' lines. The pipe whip restraints are ' attached to the sacrificial' shield wall and the related structural steel, providing whip restraints for
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M syste_ms including main steam and feedwater. The sacrificial shield wall and the. pipe whip restraints were fabricated by the same company.
TheLIALs were issued because the nature and scope of the problems identified:with the sacrificial shield wall, pipe whip restraint, and related-structural steel and concerns about the licensee's corrective actions. To date, RV'has identified fourteen concerns in the areas Lof question. These concerns are sumnarized in the enclosure.
Six of the' concerns relate to the sacrificial shield wal, six to the pipe whip rectraints,:and;two concerns apply to the related structural steel.
It.should be noted that investigations are still-in progress and may result in additional concerns.
lit is anticipated that the licensee's corrective action program will
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result-in changes from the original design and may involve some deviations from the Structural Welding Code (AWS Dl.1).
One concern
-(No. 14) relates to long term temperature controls for the structural steel.- Although this is not a new concern, it has been included in the Llisting'so that the problems of the sacrificial shield wall, pipe whip restraints, and related steel can be considered as one structural system.
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-H. D. Thornburg. Because of the safety significance of these structures and the magnitude of the concerns it is extremely important that a meeting be scheduled at IE:HQ to allow licensee ' representatives the opportunity to present their proposed corrective action program prior to any implementation of the program.
It is strongly recommended that the Office of Nuclear Reactor Regulation be included in this meeting, and that transfer of lead respons~ibility be given to NRR-for those items which reflect s
des _ign changes, deviations from the structural welding code, and
_ p6tentially effect operating license reviews.
Region V:will coordinate the meeting dates with the licensee.
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R. H. Engelken Director
Enclosure:
As stated e
cc: G. W. Reinmuth,IE
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D.N. 50-397 AND RELATED STRUCTURES PROBLEM CONCERN
-ACTION /RMKS-l1.
(SSW) Ring 3 and ring 4 of the SSW The installation of a partial Suggest structural experts in NRR are not welded together as shown penetration weld reflects a change review design change.
on the design dwgs.
Numerous from the original. design.
welds were made to shims between Original design was submitted to the rings, in lieu of actually NRR in WPPSS Rpt. No. WPPSS-74-R2 welding the rings together.
The of March 1974 A
A/E, tentatively, intends to install a 2" partial penetration weld around the circumference of the SSW to structurally join ring 3 to ring 4.
2.
(SSW) Voids in the concrete have Voids, if not repaired, would allow Require WPPSS to assure all' voids are been identified in the SSN.
The radiation streaming inside the located and filled; or have NRR experts voids recently identified may containment during plant operation, examine any plans of partial repairs effect the previously accepted a potential hazard to equipment or use of the operating plant to-corrective action plan, due to and personnel.
detect voids.
the potential increase in magni-tude of the voiding problem.
This pla;. may involve use of the operating plant to detect addi-tional voids.
Voids also exist between rings 3 and 4 of the SSW (see1,above).
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WNP-2 DEFICIENCIES IN SACRIFICIAL SHIELD, PIPE WHIP RESTRAINTS D.N. 50-397-AND RELATED STRUCTURES i
PROBLEM CONCERN ACTION /RMKS 3.
(SSW) Numerous deficiencies in The' licensee's corrective action Require WPPSS to perform a structural weld quality have been plan presented to the NRC in reinspection of all accessible identified on the SSW structure.
October 1979 was found deficient.
welds. Make an assessment, The deficiencies were identified The plan included a plotting of following reinspection, of the in welds which were supposedly known deficiencies on a drawing of need to remove skin plates and inspected and accepted.
Defi-the wall, an extrapolation of the concrete to reinspect internal ciencies include cracks, undercut, deficiencies to the currently welds.
Have experts in NRR overlap and slag on welds inaccessible areas of the wall, review any rationale associated (indicating inspections could and an rnalysis, based on the with acceptance of non-reinspectable-not have been properly performed).
extrapolation, of the structural welds (i.e., extrapolation acceptability.
The licensee had methodology) not reinspected the accessible surfaces of the wall to accumulate a sound data base for extrapo-lation.
Information was not available to provide evidence that the extrapolation method was statistically sound.
The NRC RV questions the validity of the inspection records.
4.
(SSW)NDErecordsassociated The potential for records falsifi-Investigate potential falisfication with the SSW contain photocopied cation exists.
Many of the welds aspects of records generation. NRR inspector's UT/PT acceptance are now inaccessible., making or IE initially evaluate licensee's signatures.
(See item 7 for a reinspection / examination difficult.
rationale for accepting any related item on pipe whip non-reinspectable welds.
Other action restraints) as warranted by investigation results.
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WNP-2 DEFICIENCIES IN SACRIFICIAL SHIELD, PIPE WHIP' RESTRAINTS
.D.N. 50-397 AND RELATED STRUCTURES U
PROBLEM CONCERN LACTION/RMKS 5.
(SSW) NDE qualification records NDE examiner may not have'been Require WPPSS to reinspect all cannot be located for one properly qualified.
Nondestruc-related' weld joints; or have individual who performed ultra-tive-examinations may not have NRR/IE critically evaluate sonic testing on the SSW.
been properly performed.
rationale for accepting any Individual is no longer employed non-reinspectable welds, by the subcontractor.
6.
(SSW) No procedures were generated No records / procedures are available Require WPPSS to accumulate-or records maintained of fonning to enable assessment of the forming available information addressing of the ctrved plates used in the process.
the forming process and present-SSW.
Note: The NRC RV has received an this information to the NRC'for allegation in this area. The examination.
alleger, who was not familiar with the forming process, feels the curved plates may have been im; coperly formed as evidenced by metal discoloration on the inside surfaces of the curved sections.
These surfaces are m-longer accessible for inspection.
7.
(PWR) Pipe ~ whip restraints of the PWR's provided under 215 contract Require licensee to provide rationale same or similar design were may not have received sufficient for the inconsistency of NDE (and provided under two contracts.
One examination.
(Also 215 PWR's may lack of post weld heat treatment, if contract (#90) required NDE and not have.been properly stress determinedapplicable).
Provide PWHTofwelds,theother(#215) relieved - further reviews are rationale to NRR/IE for examination.
required only visual inspectica necessary to determine if post of welds.
(215 PWR's may not have weld heat-treatment was specified been PWHT'd).
and performed on 215 PWRs.
Contract 90 PWRs were stress relieved.)
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WNP DEFICIENCIES IN SACRIFICIAL SHIELD, PIPE WHIP RESTRAINTS D.N. 50-397 AND RELATED STRUCTURES PROBLEM CONCERN ACTION /RMKS 8.
(PWR) NDE records associated with The potential for records. falsi-Investigate potential falsification pipe whip restraints (PWR) contain fication exists.
aspects of record generat'
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photocopied inspector's acceptance Require re-examination of signatures for ultrasonic and inspections. involving photocopied magnetic particle testing.
(See signatures.
Other action as item 4 for a related item on the warranted by investigation results.
SSW) 9.
(PWR) NDE qualification records NDE examiners may not have been Require WPPSS to re-examine all cannot be found for one, or properly qualified.
Examinations related weld joints; or have NRR/IE possibly two, individuals who may not have been properly evaluate rationale for accepting any performed UT and MT on the PWRs.
perfomed.
nonreinspected welds.
Contractor'.s qualification procedure is not in full accord with SNT-TC-1A.
10.
(PWR) The electroslag welding Welds made with the improperly Require requalification of the weld procedure used in the welding of qualified welding procedure may-procedure.
Assess acceptability of PWRs was not qualified using not meet Charpy impact test welds based on requalification results.
post weld heat treatment as requirements.
required by the code (AWS Dl.1).
11.
(PWR) Approximately 90 typical Welds may not perform their Require licensee to provide fillet joint configurations specified intended function. 'The licensee welds, sized in accordance with code on design drawings for the PWR has considered accepting the under-requirements; or have NRR/IE evaluate use fillets which are smaller sized fillet welds based on compu-rationale for accepting welds smaller than the minimum fillet weld tations which indicate the smaller than code requirements.
size specified in the applicable welds provide required strength,
- code, and they passed visual inspection criteria.
Quality record ques-tions, identified elsewhere in this summary, raise concerns about the validity of the inspections performed.
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- WNP-2 DEFICIENCIES IN SACRIFICIALISillELD, PIPL WHIP RESTRAINTS' ' '
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PROBLEM-CONCERN ACTION /RMKS:
1 12.
(PWR) Nurserous record irregular-Records do not provide clearly -
Require licensee to< reinspect any; ities and inconsistencies exist traceable evidence of welders.and -
welds which are supported by.
between weld maps, manufacturing inspectors involved and assurance '
inconsistent qdality. records; or -
orders-(M.0.),welderand that all required. inspectior.s were have NRR/IE evaluate rationale for.
inspection records associated with
' performed. -In some cases the, accepting welds supported by the PWRs.
Inconsistencies contractor recently provided irregular / inconsistent records.
include:
conflicting inspection missing inspection data using
-dates; changes.in inspector.I.D.
information contained on the weld nLQ1bers Without Clarifying map. The weld map, however, does information; records indicate not have any signatures or some inspections were performed inspection s. tamps attesting to its by an individual at a time he accuracy. This, in conjunction was not working for the company; with the. erasure marks, and cross-inspections following stress outs on the we'd maps (with no relieving are dated with dates clarifying information) make it which precede stress relieving; questionable whether the. weld' map welder I.D. Nos. ano electrode should be relied upon to. provide-I.D. Nos. haw been changed with-evidence of satitfactory out clarifying information; NDE inspection.
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records list wrong AWS UT legend number; weld procedure Nos.
have been changed with no i
explanation; different. signatures
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for one welder qualifier; missing inspection results.
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. DEFICIENCIES IN SACRIFICIAL'SilIELD, PIPE WHIP RESTRAINTS J.* - ' '
D.N. 50-397 AND RELATED STRUCTURES
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PROBLEM CONCERN ACTION /RMKS 13.
(RS) The generic procedure used Laminations may exist in weld Require' licensee to comply with to repair laminations in' the zones which could jeopardize the AWS Code requirements relating to weld zone of SSW related integrity of.the welds.
removal of laminations; or have structures (RS) requires grinding NRR/IE evaluate technical of the laminations to a maximum '
rationale for not meeting code depth of 3/8", followed by requi remen ts.
rewelding.
This falls short of the AWS code, w'ich requires grinding to depths of 1" with supplementary ultrasonic tests as required (if laminations are longer than 1 inch).
14.
(RS) Steel structures bridging NRR may want to consider the need AITS Ho. F50012P1, issued frcm RV from the SSW to the containment for long term temperature controls on November 7. 1978 requested wall have undergone significant in the operating licensee review.
cesideratta of transfer of lead weld repairs in the past two responisbility in this area.
years.
Licensee consultants have detennined a need to main-(Note:
For control purposes tain some minimum temperature AITS F50012H1 is hereby cancelled.
of weld joints to ensure adequate This item is now included in nil-ductility transition tempera-AITS No. F05030004) ture characteristics of the structural welds.
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