ML20024D171

Interim Deficiency Rept Re Nonconforming Weld Repair of Beam Cope Burn Cuts.Initially Reported on 830624.Cause & Extent of Burn Cuts & Nonconforming Weld Problem Investigated.Final Rept Scheduled for 840215

ML20024D171
Person / Time
Site:	Satsop
Issue date:	07/22/1983
From:	Dobson D WASHINGTON PUBLIC POWER SUPPLY SYSTEM
To:	Sternberg D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V)
References
10CFR-050.55E, 10CFR-50.55E, GO3-83-583, NUDOCS 8308030258
Download: ML20024D171 (3)

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Washington Public Power Supply System D Box 1223 Elma, Washington 98541 (206)482-4428 3U ffp ,

8 .. 7 7 July 22, 1983 7't' o.

G03-83-583 U. S. Nuclear Regulatory Commission, Region V Office of Inspection and Enforcement 1450 Maria Lane, Suite 260 Walnut Creek, California 94596-5368 Attention: Mr. D. M. Sternberg, Chief Reactor Projects Branch No. 1

Subject:

POTENTIAL 10CFR50.55(e) DEFICIENCY NONCONFORMING WELD REPAIR OF BEAM COPE BURN CUTS (D/N NO. 49)

On June 24, 1983 the Supply System notified your office of a potential 10CFR50.55(e) Deficiency concerning the subject condition. An investiga-tion is in progress and insufficient data exists to determine the safety significance at this time. Attached is a Supply System approved Interim Report that describes the problem and provides a proposed resolution.

It is anticipated that a final report will be provided to your office by February 15, 1984. Should you have any questions or desire further infor-mation, please contact me directly. ~

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D. E. obson (760)

Acting Program Director, WNP-3/5 JAV:nj Attachments cc: J. Adams - NESCO D. Smithpeter - BPA Ebasco - New York WNP-3 Files - Richland R. D. Hill - Puget Sound Power & Light Company P. Inman - Washington Water Power Company B. D. Withers - Portland General Electric Company L. D. Weislogel - Pacific Power & Light Company 8308030258 830722 PDR ADOCK 05000 S

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WASHINGTON NUCLEAR PROJECT NO. 3 (DOCKET NO. 50-508)

POTENTIAL 10CFR50.55(e) DEFICIENCY INTERIM REPORT NONCONFORMING WELD REPAIR OF BEAM COPE BURN CUTS (D/N NO. 49) l Description of Deficiency

A potential problem in weld repair of burn cuts which were formed during the coping of rolled beams used for floor framing in the Reactor Building was identified. This steel was supplied by Chicago Bridge and Iron under Contract WPPS-3240-ll3. The burn cuts were covered by a seal pass weld instead of a full penetration weld repair as required by CB&I procedure.

The deficiency in repair may result in failure of the beams to function as designed.

Corrective Actions The following actions have been/are being taken to resolve the problem:

1) CB&I has undertaken an in-house investigation to determine the cause and extent of the subject burn cuts and nonconforming repair weld pro-blem. CB&I has compiled a list of all the beams fabricated under Contract WPPS-3240-ll3 and categorized these beams by the methods and shop location of the fabrication. CB&I also started radiographing copes of installed beams inside the Reactor Building to identify the extent to which the deficient beams have been installed.

To facilitate an evaluction and a disposition seven categories were established as follows:

Category 1: Void (this category not being used)

Category 2: Copes prepared by hand burning Category 3: Copes examined and repaired by CB&I Category 4: Copes of beams which have bent plate clips extending beyond the cope Category 5: Cope depth greater than the burn cut Category 6: All copes which are not covered by Categories 2 through 5 and 7 Category 7: Copes of those beams which were fabricated by Mark Steel Corporation

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POTENTIAL 10CFR50.55(e) DEFICIENCY INTERIM REPORT NONCONFORMING WELD REPAIR OF BEAM COPE BURN CUTS (D/N NO. 49)

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2) The status of the investigations on the seven categories are as follows:

Category 1: Items previously included in Category 1 have been dis-tributed to other six categories and this category is voided.

Category 2: Copes in this category were prepared by hand burning. It has been determined by CB&I that the burn cuts are not formed in the hand burning process.

Category 3: Items have been repaired.

Category 4: Items are in the process of being evaluated through design analysis.

Category 5: Inventory of Category 5 items is not complete at this time. CB&I has submitted test results to substantiate the "use as is" disposition for this category. The results of these tests are being evaluated by the Engineer.

Category 6: Investigation of Category 6 items is in progress. CB&I is radiographing all the copes in this category. As of July 12, 1983 a total of 134 beams consisting of approxi-mately 236 copes have been examined. One hundred and thirteen (113) of these beams have been installed.

Forty-nine (49) copes in 28 beams, out of 134 beams examined, were found to have potentially nonconforming weld repairs.

Category 7: CB&I audited Mark Steel procedures and methods of fabri-cation and concluded that the burn cuts were not pro-blems in the process of fabrication which was followed by Mark Steel. CB&I issued a letter to this effect.

The Engineer is evaluating CB&I's disposition of these items along with the information which supports these conclusions.

3) CB&I is actively pursuing the in-house investigation to pinpoint the cause of the problem, through extensive personnel interviews, fabrica-tion documentation verifications and in-house quality assurance pro-gram reviews.

Reason Why The Final Report Will Be Delayed CB&I's investigation is not complete at this time. Until all the data and reports are forwarded, an engineering evaluation and analysis cannot be completed. It is anticipated that a final report will be provided by February 15, 1984.

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