ML20024F646
| ML20024F646 | |
| Person / Time | |
|---|---|
| Site: | Clinton  |
| Issue date: | 08/31/1983 |
| From: | Hall D ILLINOIS POWER CO. |
| To: | James Keppler NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| References | |
| 10CFR-050.55E, 10CFR-50.55E, 1605-L, 83-06, 83-6, U-10085, NUDOCS 8309090547 | |
| Download: ML20024F646 (4) | |
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9 5 lLLIN018 POWER COMPANY CLINTON POWER STATION. P.O. BOX 678. CLINTON. ILLINOIS 61727 Docket No. 50-461 August 31, 1983 Mr. James G. Keppler Regional Administrator Region III.
U.S. Nuclear Regulatory Commission 799 Roosevelt Road Glen Ellyn, Illinois 60137 Subj ect :
Potential Deficiency 83-06 10CFR50.55(e)
Structural Steel Welds by Rockwell Engineering
Dear Mr. Keppler:
On April 27, 1983, Illinois Power Company verbally notified Mr. F. Jablonski, U. S.-NRC Region III, (ref: IP memorandum Y-17046, 1605-L, dated April 27, 1983) of a potentially report-able deficiency per 10CFR50.55(e) concerning vendor shop welding deficiencies on certain structural steel members supplied by Rockwell Engineering. 'This initial notification was followed by one interim report (Ref: IP letter U-10060, D. P. Hall to J. G.
Keppler dated May 31, 1983, 1605-L).
Our investigation of this matter continues, and this letter represents an interim report in accordance with 10CFR50.55(e).
Statement of Potentially Reportable Deficiency Vendor shop welding deficiencies were identified on certain structural steel members supplied by Rockwell Engineering (structural steel fabricator) to Baldwin Associates (CPS contractor) for installation at Clinton Power Station (CPS).
The structural steel members in question are columns used to provide lateral support for concrete block walls at CPS.
An evaluation is being performed to determine the extent of the condition and the potential for adverse impact on the safety of operatiens of CPS.
Background / Investigation Results During on-site modifications to a block wall support column by Baldwin Associates, a deficient weld was found that was made by the structural steel fabricator.
The deficient weld was one of three used to attach a connection angle to the column.
The column was being modified per a Field Change Request (FCR 17033) which, in part, required removal of the connection angle.
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Mr. James G. Kcppler Page 2 August 31, 1983 Inspection of the deficient weld revealed that there was no fusion with the base metal.
An investigation was initiated to determine the scope of this problem.
A review of the applicable purchase order was performed and those columns received with unmodified welded connections were identified.
This review identified fifty-eight (58) columns.
An inspection by Baldwin Associates Technical Services was performed and found that fifty-seven (57) columns contained welding deficiencies that varied from cosmetic to structurally significant.
Deviation Reports (DR) 5815 and 10303 have been generated to document the welding deficiencies identified by the inspection.
To evaluate the root causes of potential welding deficiencies, and to eliminate cosmetic deficiencies from the evaluation, the welds on twenty-two (22) erected columns were field ground to sound metal, and another inspection was performed.
This second inspection provided detailed information and sketches of the remaining welds for on-site evaluation.
The thirty-five (35) columns that were not installed were returned for evaluation and repair in the vendor's shop.
The evaluations indicated a trend in inadeguate connection welds parallel to the column flanges on 6" and 8' columns.
This trend is believed to be caused by lack of accessibility to properly position the electrode during welding of the connection angles.
As a result of this adverse trend, the scope of the investigation is being increased to address all safety-related blockwall columns to assure adequacy in meeting design requirements.
In parallel to the above inspection effort, an inspection of a random sample of accessible assemblies welded by the fabricator under other purchase orders was performed. The results of this inspection reinforced the conclusions of the aforementioned inspection and did not indicate any additional adverse trends.
However, several isolated cases of deficient welding were identified.
As a result, an additional sample of safety related structural steel members shop-welded by the fabricator will be inspected to further investigate this condition and assure structural integrity.
Corrective Action (Interim) 1.
In-process installation work on the subj ect blockwall columns was ceased until further investigation into this potential deficiency was performed and repairs made to the columns.
2.
Blockwall columns that were not installed were returned to the vendor for repair in accordance with approved welding procedures.
Baldwin Associates Vendor Surveillance
' s Mr.? James G. Keppler; Page 3 August 31,_ 1983 personnel witnessed.a representative sample of column weld
= inspections and repairs.
For columns that were installed,
-Baldwin Associates repaired the welds in accordance with
~ approved welding procedures.
-3.
Welding deficiencies noted during.the random inspection have been documented on Nonconformance Reports (NCRs) and the members will be reworked to the original designer's requirements.
4.
TWhere possible, Illinois Power and Baldwin Associates have
-constrained future orders of structural steel to stock material.
Fabrication of required members will generally be l
performed on-site by Baldwin Associates using the stock material.
This' action has resulted in minimum purchases of d
shop-fabricated structural steel assemblies.
5.-
Structural steel vendors performing work or supplying material for CPS (past and present) wcre notified, advising i
and stressing.that_they have responsibility for their work.
This includes' correctness of design, proper completion of work, implementation of QA/QC programs, and reportability in i-accordance with the Code of Federal Regulations.
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6.
Enhancements have been made to the Baldwin Associates vendor surveillance program since the affected members were
. received.
These enhancements include the following:
i a.
intensified in-shop vendor surveillances in both scope.
and number.
a reevaluation of Baldwin Associates vendor b.
surveillance inspection points was performed, with more hold points established.
1 c.
a reorganization of the vendor surveillance department from thef. Quality Control to the Quality Assurance Department was made, to increase overall program effectiveness.
i Safety Implications / Significance i -
Illinois Power Company's investigation of this potentially reportable. deficiency is continuing.
The safety implications and significance of the concerns will be assessed after inspection results'are obtained and an engineering evaluation is completed.
It is anticipated that approximately ninety (90) days will be
- necessary to' file a final report on the matter.
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'O Mr. James G. Keppler Page 4 August 31, 1983 We-trust that this interim report provides you sufficient
. background information to perform a general assessment of this potentially reportable deficiency, and adequately describes our overall approach to resolve the problem.
Sincerely yours, D. P. Hall Vice President REC /j f cc:
Manager - Quality Assurance NRC Resident Inspector Director - Office of I&E, USNRC, Washington, DC 20555 Illinois Department of Nuclear Safety INPO Records Center
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